Covers all Bombardier Outlander models including: Outlander The service manual fully covers the and models listed below. It is the OEM factory full service manual with almost additional pages that were never included in the overpriced paper manual that your dealer charges over a hundred and fifty dollars for.
BRP did not make an all new manual for so I have combined the base manual with the supplemental manuals into one easy to use manual. At assembly, the rub- Start engine and allow it to warm then adjust idle ber flanges must be perfectly matched with the speed to specifications by turning idle speed air box, carburetor and engine or severe engine screw clockwise to increase engine speed or Page Throttle Lever Side Remove both screws on throttle housing.
Remove throttle cable. The engine carburation is calibrated to operate specifically with these components. Otherwise, engine performance degradation or damage can occur. Remove LH and RH side covers to get access to the air box no. Remove air box no. NOTE: Air box no. Installation Properly reinstall removed parts in the reverse order of their removal.
The voltage is also regulated to a systems where some are inter-related: maximum of The ignition system is made up of the follow- tem, the engine RPM limiter and the vehicle speed ing components: limiter. Make sure that can cause severe damage.
Waterproof Connector Housing — Loose or bad Check wiring and connections. Use a load testing device that has an burns or destroys organic tissues by chemical adjustable load. Battery caps do not have vent holes. Make sure Perform the following operations anytime a new that vent tube is not obstructed. Connect a 2 A battery charger for until the bat- tery is fully charged. Ignition switch is in the OFF position. Turn switch in the ON position. Burnt fuse. Check main fuse and wiring condition.
Transmission is not set on Neutral. Set transmission in Neutral or use the override mode. Tighten any loose cables. If wiring and connectors are good, check the elec- tric starter. See below. After one item has been checked and it is found not to be the problem, continue with the next item: 1. Check that main fuse is not burned and if battery is fully-charged before diagnosing.
Check ignition system connector for poor connections. Voltage leak can occur at high voltage level which is not detectable with For checking the resistance of secondary wind- an ohmmeter. It runs hotter and burns off combustion de- posits which might tend to foul the plug during prolonged idle or low speed operation. Do not place tools on battery. Scribe a line at this height on test surface wall Properly reinstall removed parts in the reverse order or screen.
Light beam center should be mm of their removal. Bulb Replacement Unscrew lens screws to expose bulb. Switch connector Installation For the installation, reverse the removal procedure. Lens 2. The obtained value should be between 12 and Test Unplug indicator light connector.
NOTE: Do not brush chain. For installation, use the torque values and Loctite Lubricate only with an approved O-ring chain lubri- products from the exploded views. The bottom part of the chain Lift rear of vehicle and install jack stands under the should be taught during adjustment. NOTE: The drive pinion must be installed with the lip toward the outside of vehicle.
Pull out the rear axle with rear sprocket no. Both ends of cotter pins must be folded. Removal Install both rear wheels. Lift rear of vehicle and install jack stands under the Put vehicle back on the ground. Install the rear wheel hubs. See the procedure above.
Remove O-ring no. Press the bearing into the chain tensioner. Pry out drive axle seals no. Remove slide-shoe no. Installation Installation takes place in the reverse order of re- moval.
Place vehicle on level surface. Check that handlebar is straight. Check pressure in each tires. Always follow recom- mended pressure. Frame support 2. The connectors are locat- — throttle clip screws. Remove handlebar grip. Remove cable brake screw. Rubber cap 2. Throttle cable 3. Adjustment screw 4.
Throttle cable housing 1. Multi-switch 2. Remove RH handle brake. RH handle brake screws Separate handle brake no. On some vehicles, unplug connectors under steer- ing cover and cut locking tie. Adjust the handle horizontal position by changing the position of the clevis pin.
At installation, use torque values and Loctite products from the exploded view. Do not torque yet. To check bushing wear, use the following procedure: — Lift front of vehicle until front wheels are out of ground. NOTE: Move the tire and check if the knuckle moves with the wheel at the same time. Remove spring stopper and cap then release handle. Loosen chain tensioner lock bolts. Renew if any faults are present. Installation Assembly and installation are essentially the re- verse of disassembly and removal procedures.
Install the swing arm bolt no. Brake disc 2. Swing arm bolt 3. Chain roller 4. Clean threads be- Always use brake fluid meeting the specification fore using Loctite product when installing screws.
DOT 4 only. A contaminated brake disc or pad reduces stop- Install a tube to bleed valve. Discard contaminated pads and Open bleeder. Position cylinder holding bracket with the UP mark upward. Install bolts and tighten loosely. With the handlebar in straight ahead position, po- sition cylinder reservoir parallel to the ground.
Remove boot kit no. Place rag over piston. Place caliper body with piston down and apply small squirts of air pressure to the fluid inlet to re- move piston. Refer to BODY for re- moval procedure. Remove bolts no. Installation Remove rear brake pads no. Front Brake Pads Push caliper pistons inward before installing brake pads. Front Brake Disc Inspection Remove cotter pin and unscrew nut. Front brake discs no. Page Front Brake Lever Unhook brake pedal spring no. Lubrication Remove stop nut no.
Remove cable barrel no. Remove cable from hand lever. To ease this opera- Remove cable no. Clean threads be- fore using Loctite product when installing screws. Plastic Rivet Plastic rivets no. To remove front bumper no. Front fascia 2. Screws 1. Front luggage rack 2. Front fascia Installation 3. Screws 4. Plastic rivets Installation is the reverse order of removal. Remove screws no. Remove plastic rivets no. Pull out the RH side footwell by detaching the grommet no. Clean surface with isopropyl alcohol.
To clean use a soft clean cloth and either soapy Using a pencil and the decal as a template, mark water or isopropyl alcohol. For installation, use the torque values and Loctite products from exploded views. Print page 1 Print document pages.
Rename the bookmark. Delete bookmark? Cancel Delete. Delete from my manuals? Sign In OR. Don't have an account? Sign up! Restore password. Upload manual. Spark plug defective — Change spark plug.
Ignition system defective — Check the ignition coil. Check the CDI controller. Check the spark plug connector. Check the ignition pulse generator. Engine does not speed up Carburetor running over because float needle dirty or worn. Faults Possible cause Action Engine has too little power Fuel feed interrupted — Check the fuel tank breather.
Air filter very dirty — Clean the air filter. Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer Check exhaust system for damage. Change glass fiber yarn filling of main silencer. Valve clearance too little — Adjust the valve clearance. Fill up with fuel. Engine takes in bad air — Check rubber sleeves and carburetor for tightness. Engine overheats Too little coolant in cooling system — Check the cooling system for leakage. Check the coolant level. Too little air stream — Switch off engine when standing.
Radiator fins very dirty — Clean radiator fins. Foam formation in cooling system — Drain the coolant. Refill the coolant.
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