Can am 400 2006-2009 Factory Service Repair Manual – PDF Download

Description

Can am 400 2006-2009 Factory Service Repair Manual

FILE DETAILS:

Can am 400 2006-2009 Factory Service Repair Manual

FILE TYPE:PDF
DOWNLOADABLE:YES
MANUAL LANGUAGE:ENGLISH
PAGES:527

DESCRIPTION:

Can am 400 2006-2009 Factory Service Repair Manual

• This manual has been prepared as a guide to correctly service and repair 2006 Outlander’M and Out- landerTM MAX Series ATVs as describe in the model list in the INTRODUCTION. This edition was primarily published to be used by mechanical technicians who are already familiar with all service procedures relating to BRP products.
• Mechanical technicians should attend training courses given by BRP Training Dept. Please note that the instructions will apply only if proper hand tools and special service tools are used. This Vehicle Shop Manual uses technical terms which may be slightly different from the ones used in the PARTS CATALOG.
• It is understood that this manual may be translated into another language. In the event of any discrepanCy. the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser- vice and Warranty Bulletins may be published to update the content of this manual.
• Make sure to read and understand these. It does not include dealer modifications, whether authorized or not by BRP, after manufacturing the product. In addition, the sole purpose of the illustrations throughout the manual. is to assist identification of the general configuration of the parts.
• They are not to be interpreted as technical drawings or exact replicas of the parts. The use of BRP parts is most strongly recommended when considering replacement of any component. Dealer and/or distributor assistance should be sought in case of doubt.

TABLE OF CONTENTS:

Can am 400 2006-2009 Factory Service Repair Manual

SAFETY NOTICE
INTRODUCTION
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN)
ENGINE IDENTIFICATION NUMBER (E I N )
ARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES
ENGINE EMISSIONS INFORMATION
SELF-LOCKING FASTENERS PROCEDURE
LOCTITE APPLICATION PROCEDURE
TIGHTENINGTOROUES
01 MAINTENANCE
01- MAINTENANCE CHART
NOISE EMISSIONCONTROLSYSTEM REGULATION
MAINTENANCE CHART
02- PRESEASON PREPARATION
03- STORAGE PROCEDURES
VEHICLE CLEANING
ENGINE LUBRICATION
RAGSINSTALLATION
DRIVEAND DRIVEN PULLEYSPROTECTION
VEHICLE PROTECTION
04— SPECIAL PROCEDURES
02 TROUBLESHOOTING
01 — TROUBLESHOOTING CHART
OUTLANDER4OOSERIES
MAGNETOSYSTEM
CYLINDERAND HEAD
CRANKSHAFTAND BALANCER SHAFT
02- TROUBLESHOOTING CHART
OUTLANDERBOOSERIES
CYLINDERANDHEAD
03 ENGINE SYSTEM
01- AIRINTAKESILENCER 55
OUTLANDER4OOSERIES 56
PROCEDURES
AIR FILTER BOXCLEANING/DRAINING
AIR FILTER BOX
OUTLANDER 800 SERIES
PROCEDURES
AIR FILTER BOX
02- LUBRICATION SYSTEM
OUTLANDER 400 SERIES
PROCEDURES
OIL LEVELCHECK
OILCHANGE
OUTLANDER 800 SERIES
PROCEDURES
OIL LEVELCHECK
OILCHANGE
03- COOLING SYSTEM
PROCEDURES
COOLING SYSTEMLEAKTEST
COOLANTREPLACEMENT
THERMOSTAT
RADIATORCAP
RADIATORFAN
COOLANTTEMPERATURESENSOR(CTS)
FANACTIVATION SWITCH IFAS)
04- EXHAUSTSYSTEM
OUTLANDER 400 SERIES
PROCEDURES
EXHAUSTPIPE
HEATSHIELD
MUFFLER SUPPORT
RUBBER BUSHING
OUTLANDER 800 SERIES
PROCEDURES
FRONTEXHAUSTPIPE
“Y” EXHAUSTPIPE
FUELTANK PROTECTOR
HEATSHIELD
MUFFLER SUPPORT
RUBBER BUSHING
05 – ENGINE REMOVAL AND INSTALLATION
OUTLANDER 400 SERIES
ENGINE REMOVAL
ENGINE MOUNT REPLACEMENT
ENGINE INSTALLATION
OUTLANDERBOD SERIES
ENGINE REMOVAL
ENGINE MOUNTREPLACEMENT
ENGINEINSTALLATION
04 ENGINE MANAGEMENT IV-810)
OPERATING PRINCIPLE
ELECTRICALSYSTEM
ENGINE MANAGEMENTSYSTEM
ELECTRONICFUEL INJECTION
OTHER ENGINE MANAGEMENTFUNCTIONS
ENGINE MANAGEMENTSYSTEM FLOWCHART
02- DIAGNOSTIC PROCEDURE
COMMUNICATIONTOOLS
ELECTRICALCONNECTIONS
COMMUNICATION PROCEDURES
TAULTCODETABLE
O3 – COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT
ELECTRICALSYSTEM
IGNITIONTIMING
ENGINE CONTROL MODULE IECM)
THROTTLE POSITIONSENSOR(TPSI
IDLE BYPASSVALVI‘
CRANKSHAFTPOSITIONSENSORICPSI
CAMSHAFTPOSITIONSENSOR (CAPS)
MANIFOLD AIR PRESSURE AND TEMPERATURE SENSOR [MAPTSI
COOLANTTEMPERATURESENSORICTSI
OILPRESSURE SWITCHIOPS)
05 FUEL SYSTEM
01 – FUEL TANK AND FUEL PUMP
OUTLANDER 400 SERIES
GENERAL
PROCEDURES
FUEL TANK PRESSURIZATION
FUELGAUGE
FUELTANKPROTECTORS
FUELTANK
FUELTANKSTRAINER
FUELVALVE
FUELPUMP
OUTLANDER 800 SERIES
FUEL DELIVERY SYSTEM DIAGNOSTIC FLO\
PROCEDURES
FUELTANKPRESSURIZATION
lN-LINEFUELFILTER
FUELTANK
FUELPUMP
FUELLEVELSENDER
02— CARBURETOR
OUTLANDER 400 SERIES
GENERAL
PROCEDURES
CARBURETOR
THROTTLECABLE
CHOKECABLE
06 ELECTRICAL SYSTEM
01- CHARGING SYSTEM
GENERAL
PROCEDURES
VOLTAGE REGULATOR/RECTIFIER
02— IGNITION SYSTEM
OUTLANDER 400 SERIES
PROCEDURES
MAINFUSECONDITION
SPARKOCCURRENCE
BATTERYCONDITION
IGNITIONSWITCH
CRANKSHAFT POSITION SENSOR
IGNITIONCOIL
ELECTRONIC MODULE ICDII
IGNITIONTIMING
SPARK PLUG
OUTLANDER 800 SERIES
GENERAL
PROCEDURES
IGNITION SWITCH
MULTl-FUNCTION SWITCH (RUN/STOP)
IGNITIONCOIL
IGNITIONTIMING
IGNITION COIL
IGNITION TIMING
SPARK PLUG
03 — STARTING SYSTEM
OUTLANDER 400 SERIES
STARTING SYSTEM TROUBLESHOOTING
IGNITION SWITCH
ENGINESTOPSINITCH
STARTSWITCH
STARTINGSOLENOID
ELECTRICAL CABLES OR CONNECTIONS
ELECTRICSTARTER
ELECTRONIC MODULE
PARTREPLACEMENT
ELECTRICSTARTER
OUTLANDER 800 SERIES
STARTING SYSTEM TROUBLESHOOTING
ELECTRICAL CABLES OR CONNECTIONS
ECMINITIALIZATION
ELECTRICSTARTER
IGNITION SWITCH
ENGINE STOPSWITCH
STARTSWITCH
STARTING SOLENOID
PARTREPLACEMENT
ELECTRICSTARTER
04 – DIGITALLY ENCODED SECURITY SYSTEM
KEYPROGRAMMING
05 – LIGHTS, INSTRUMENTS AND ACCESSORIES
SPEEDOMETERFUNCTIONS
PROCEDURES
SPEEDOMETER
VEHICLE SPEED SENSOR (VSSI
FUELLEVELSENDER
MULTl-FUNCTIONSWITCH
I2»VOLTAUXILIARYPOWEROUTLET
IZ-VOLTPOWEROUTLET
TAILLIGHT
WINCHCONTROLSWITCH
07 TRANSMISSION
01- CONTINUOUSLY VARIABLETRANSMISSION ICVTI
OUTLANDER 400 SERIES
DRIVENPULLEY
OUTLANDER 800 SERIES
GENERAL
PROCEDURES
DRIVE BELT
DRIVE PULLEY
DRIVEN PULLEY
CVTAIRGUIDE
02 – GEARBOX AND 4X4 COUPLING UNIT
OUTLANDER 800 SERIES
GENERAL
MAINTENANCE
OILCHANGE
PROCEDURES
SHIFTING INDICATOR SWITCH
OILSEALS
ACTUATOR
OUTPUT SHAFT AND COUPLING MECHANISIV
ENGINE DRIVE SHAFT
03- TRANSMISSION LINKAGE
OUTLANDER400 SERIES
GENERAL
PROCEDURES
TRANSMISSION LEVER HANDLE
TRANSMISSIONLEVER
SHIFTING PLATE
OUTLANDER 800 SERIES
GENERAL
PROCEDURES
TRANSMISSION LEVER
SHIFTING PLATE
3 DRIVETRAIN
01 – 4X4 COUPLING UNIT
OUTLANDER 400 SERIES
GENERAL
PROCEDURES
ACTUATOR
2WD/IIWDSWITCH
COUPLING UNIT
02- FRONT DRIVE
GENERAL
PROCEDURES
TIRES AND wHEELS
WhEEL—TUB
FRONT DRIVESHAFT
FRONT DIFFERENTIAL
FRONT PROPELLER SHAFT
DIFFERENTIAL PROTECTOR
DRIVE SHAFT
DRIVE SHAFTBOOT
REAR PROPELLERSHAFT
REARPROPELLERSHAFTU-JOINT
REARDIFFERENTIAL
09 STEERING SYSTEM
01 – STEERING SYSTEM
TIRESANDWHEELS
PROCEDURES
HANDLEBARGRIP
HANDLEBAR COVER
STEERINGCOLUMN
STEERINGCOLUMN BEARING
WHEELBEARING
MULTI-FUNCTIONSWITCH
THROTTLE HANDLE
HANDLE BRAKE
ADJUSTMENT
STEERING ALIGNMENT
1O SUSPENSION
01- FRONTSUSPENSION
PROCEDURES
TIRES AND WHEELS
SHOCK ABSORBERAND SPRING
LOWER SUSPENSION ARMPROTECTOR
LOWER SUSPENSIONARM
LOWER BALLJOINT
UPPER SUSPENSIONARM
UPPER SUSPENSIONARM BRACKET
UPPER BALLJOINT
02- REAR SUSPENSION
PROCEDURES
TIRES AND WHEELS
TORSION BAR
TRAILING ARM
TRAILIN GARM BEARINGS
REAR MASTERCYLINDER
12 BODY/FRAME
CENTRAL PANEL
HEAVY DUTY BUMPER
FRONT BUMPER/FRONT SKID PLATE/FRONT FASCIA
FUELVALVESUPPORT
FENDERSUPPORT
DECALSREPLACEMENT
HITCH/TRAILER BALL
PLASTICMAINTENANCE
PLASTICREPAIR
FOOTRESTSUPPORT
BATTERYSUPPORT
13 TECHNICAL SPECIFICATIONS
01 – OUTLANDER SERIES
14 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS
01- ELECTRICAL CONNECTORS
DEUTSCH CONNECTORS
ECMCONNECTORS
MULTI-FUNCTIONSPEEDOMETER CONNECTOR
02- WIRING DIAGRAMS
WIRING CONNECTORSCODING
WIRECOLORS
WIREGAUCE
CONNECTORHOUSINGAREA
CONNECTOR IDENTIFICATION
WIRE LOCATION INCONNECTOR

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CAN AM 400 2006-2009 FACTORY SERVICE REPAIR MANUAL – PDF DOWNLOAD:

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