To troubleshoot a Bombardier Outlander 400 that is stuck in 4-wheel drive:

1. Ensure the vehicle is completely stopped before changing the 2WD/4WD mode.
2. Release the throttle and allow the engine to return to idle before switching modes.
3. If the rear wheels are spinning, wait until they stop before switching to 2WD.
4. Push the 2WD/4WD selector upward to disengage 4WD.

Engaging or disengaging 4WD while driving or with spinning wheels can cause mechanical damage.

This answer is automatically generated

Summary of Contents for BOMBARDIER Outlander 400

Page 2 All content of the Safety Information section should be interpreted by the reader as a warning which, if not followed, may result in injury including the possibility of death. The following are trademarks of Bombardier Recreational Products Inc. or its subsidiaries: Outlander ™...
Page 3 It is backed scriptions contained in this document are cor- by the BRP warranty and a network of autho- rect at the time of publication. Bombardier rized Bombardier ATV dealers ready to pro- Recreational Products Inc. however, main-...
Page 4: Table Of Contents
TABLE OF CONTENTS While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death. NOTICE ....................... European Community................INTRODUCTION ....................SAFETY INFORMATION SPECIAL SAFETY MESSAGES................. OPERATION WARNINGS................... SAFETY WARNING .................... Clothing ....................
Page 5 8) Direction Indicator Switch..............9) Horn Button ..................10) Hazard Warning Button..............11) Speedometer..................12) 12-Volt Power Outlet ................ 13) Ignition Switch .................. 14) Fuel Tank Cap.................. 15) Fuel Gauge ..................16) Fuel Valve ..................17) Brake Pedal..................18) Footpeg .................... 19) Access Panel ...................
Page 6 SPECIAL PROCEDURES................... Flooded Engine ..................Engine Overheat..................Post-Operation Care................Turn Over ....................ATV Immersion..................Storage and Preseason Preparation ............CARGO AND TRANSPORTATION ..............Cargo....................... Transportation ..................TROUBLESHOOTING ..................SPECIFICATIONS....................MAINTENANCE INFORMATION MAINTENANCE CHART..................102 GENERAL ......................105 ENGINE/TRANSMISSION................... 106 Oil Change and Oil Filter Replacement ........... 106 Oil Strainer Cleaning ................
Page 7 Engine Area .................... 124 Hitch/Trailer Ball Condition ..............124 Chassis Fasteners .................. 124 Seat Fasteners ..................124 Vehicle Cleaning and Protection............. 124 WARRANTY BRP INTERNATIONAL LIMITED WARRANTY: 2006 BOMBARDIER ATV PRODUCTS ....................126 PRIVACY OBLIGATION/DISCLAIMER ............... 129 CHANGE OF ADDRESS/OWNERSHIP .............. 131...
Page 9: Notice
NOTICE European Community This Operator’s Guide has been prepared to acquaint the owner/operator of a new vehicle This warning applies only in the European with the various vehicle controls, mainte- Countries where on road usage is allowed. nance and safe operating instructions. It is in- dispensable for the proper use of the product.
Page 10: Introduction
INTRODUCTION Your dealer should have provided you with some basic information on the particular controls and features of your new vehicle. Please take the time to study this Operator’s Guide and all on- product warning labels as well as the Safety Videocassette that came with this vehicle. They more completely describe what you should know about this vehicle before riding it.
Page 11: Safety Information
SAFETY INFORMATION...
Page 12: Special Safety Messages
Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Bombardier ATV dealer to find out about the available training course nearest you. Always follow this age recommendation: A person under 16 years old should never operate this vehicle.
Page 13 Operator’s Guide for carrying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, contact an authorized Bombardier ATV dealer to find out about the available training courses nearest you.
Page 14: Operation Warnings
Beginning and inexperienced operators should complete the training course offered by BRP. They should then regularly practice the skills learned in the course and the operating tech- niques described further in this Operator’s Guide. For more information about the training course, contact an authorized Bombardier ATV dealer.
Page 15 WARNING V00A01Q POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN A lack of respect for this age recommendation can lead to severe injury or death of the child. Even though a child may be within the age group for which this vehicle is recommended, he may not have the skills, abilities, or judgment needed to operate this vehicle safely and may be involved in a serious accident.
Page 16 WARNING V00A02Q POTENTIAL HAZARD Carrying a passenger on this vehicle. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this vehicle. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
Page 17 WARNING V00A04Q POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. Paved surfaces may seriously affect handling and con- trol of this vehicle, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD If an on-road usage is allowed in your area, operate your vehicle on paved surface only for short distance and for the only purpose of moving the vehicle from an off-road usage to...
Page 18 WARNING V00A06Q POTENTIAL HAZARD Riding this vehicle without wearing an approved helmet, eye protection and protective cloth- ing. WHAT CAN HAPPEN The following items concern all ATV's operator: – riding without an approved helmet increases the chances of a severe head injury or death in the event of an accident.
Page 19 WARNING V00A07Q POTENTIAL HAZARD Riding this vehicle after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident or death. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while riding this vehicle.
Page 20 WARNING V00A08Q POTENTIAL HAZARD Operating this vehicle at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the vehicle, which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating conditions, and your experience.
Page 21 WARNING V00A09Q POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Do not try to show off.
Page 22 WARNING POTENTIAL HAZARD Failure to inspect this vehicle before operating. Failure to properly maintain this vehicle. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition.
Page 23 WARNING V00A0BQ POTENTIAL HAZARD Removing hands from handlebar or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the vehicle or could cause you to lose your balance and fall off the vehicle. If you remove a foot from the footrests, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.
Page 24 WARNING V00A0CQ POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the vehicle overturning or loss of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain.
Page 25 WARNING V00A0DQ POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the vehicle on such terrain.
Page 26 WARNING V00A0EQ POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Vehicle could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described further in this Operator’s Guide. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
Page 27 WARNING V00A0QQ POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills.
Page 28 WARNING V00A0FQ POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described further in this Operator’s Guide. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
Page 29 WARNING V00A0GQ POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described further in this Operator’s Guide.
Page 30 WARNING V00A0HQ POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the vehicle around on any hill until you have mastered the turning technique as described further in this Operator’s Guide on level ground.
Page 31 WARNING V00A0IQ POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in vehicle overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Keep your weight uphill.
Page 32 WARNING V00A0JQ POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the vehicle to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described further in this Operator’s Guide.
Page 33 WARNING V00A0KQ POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this vehicle. You may also regain traction unexpectedly, which may cause the vehicle to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain.
Page 34 WARNING V00A0LQ POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this vehicle in fast flowing water or in water deeper than that specified further in this Operator’s Guide.
Page 35 WARNING V00A0MQ POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind the vehicle, resulting in serious injury. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no obstacles or people behind the vehicle.
Page 36 WARNING V00A0OQ POTENTIAL HAZARD Operating this vehicle with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this vehicle, or operation of this vehicle with improper or uneven tire pressure, may cause loss of control, and increases the risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type of tires specified further in this Operator’s Guide for this vehicle.
Page 37 Never modify this vehicle through improper installation or use of accessories. All parts and accessories added to this vehicle should be approved by BRP and used according to instruc- tions. If you have questions, consult an authorized Bombardier ATV dealer. Do not install passenger seat or use the racks to carry a passenger.
Page 38 WARNING V00A0PQ POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle including operator, as well as other loads and added accessories.
Page 39 WARNING V03M01Q POTENTIAL HAZARD Transporting inflammable or dangerous material can lead to explosions. WHAT CAN HAPPEN This can cause serious injury or death. HOW TO AVOID THE HAZARD Never transport inflammable or dangerous material. While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death.
Page 40: Safety Warning
SAFETY WARNING To fully appreciate the pleasures and excitement of riding this vehicle, there are some basic rules and tips that you should follow. Some may be new to you while others may be common sense or obvious. Irrespective, we ask that you take a few minutes to read this Operator’s Guide completely before you operate this vehicle.
Page 41 Correct any problem you may have found be- i) Ensure transmission lever is working then fore riding. See an authorized Bombardier reset in PARK position. ATV dealer as necessary. j) Check fuel, oil and coolant levels.
Page 42: Clothing
Clothing Actual weather conditions should help you decide how to dress. However, it is important that the operator always wears the appropriate protective clothing and apparel, including an approved helmet, eye protection, boots, gloves, long sleeved shirt and pants. This type of clothing will provide you protection from some of the minor hazards you may encounter en route.
Page 43: Carrying Loads
A variety of accessories are available from your authorized Bombardier ATV dealer. However, always respect the load and capacities of the vehicle. Over- loading of the vehicle can overstress the components and cause failure. To prevent possible injury, it is equally important to follow the instructions and warnings that accompany the acces- sory.
Page 44: Recreational Riding
Recreational Riding Respect the rights and limitations of others. Stay away from areas designated for other types of off road use. This includes snowmobile trails, equestrian trails, cross country ski trails, mountain bike trails etc. Never assume there are no other users on the trail. Always stay to the complete right of the trail and do not zig zag to one side of the trail then the other.
Page 45: Off-Highway Operation
Off-Highway Operation The very nature of off-highway operation is dangerous. Any terrain, which has not been specially prepared to carry vehicles, presents an inherent danger where angularity, terrain substance and exact steepness are unpredictable. The terrain itself presents a continual element of danger, which must be knowingly accepted by anyone venturing over it.
Page 46: Downhill Driving
Downhill Driving This vehicle can climb slopes that are steeper than it can safely descend. Therefore, it is essen- tial to assure that a safe route exists to descend a slope before you climb it. Decelerating while negotiating a slippery downhill slope could “toboggan” the vehicle. Maintain steady speed and/or accelerate slightly to regain control.
Page 47 V00A0UL Even though there is an adequate suspensions system on this vehicle there are “washboard” or rough terrain conditions that will make you feel uncomfortable and even cause back injury. “Post- ing” or riding in a crouched position will often be required. Slow down and allow your flexed legs to absorb impact.
Page 48 V00A0VL Water will affect the braking ability of your vehicle. Make sure you dry the brakes by applying them several times after the vehicle leaves the water. Mud or marsh lands may be encountered near water. Be prepared for sudden “holes” or changes in depth.
Page 49 Riding on loose stones or gravel is very similar to riding on ice. They will affect the steering of this vehicle… possibly causing it to slide and tipover, especially at high speeds. In addition, braking distance may be affected. Remember that “gunning” the throttle or sliding may cause loose stones to be ejected rearwards, into another ATV rider’s way.
Page 50 Uphill Keep your body weight forward towards the top of the hill. Keep your feet on the footpegs and shift into low gear then accelerate and when necessary, change gear quickly as you climb. Do not overspeed since this may cause the front of the vehicle to lift from the ground and fall back on you.
Page 51 Downhill Keep your body weight rearwards. Apply the brake gradually to prevent skidding. Do not “coast” down the slope using solely engine compression or in neutral gear. V00A0YL While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death.
Page 52: Routine Maintenance
If further assistance is required your authorized Bombardier ATV dealer is always willing to help. Modification of the vehicle to increase speed and performance may violate the terms and con- ditions of your vehicle limited warranty.
Page 53: Hang Tag
HANG TAG This vehicle comes with a hang tag and labels containing important safety information. Any person who rides this vehicle should read and understand this information before riding. WARNING RECREATIONAL MODEL Improper ATV use can result in SEVERE injury or DEATH. THIS ATV IS FOR RECREATIONAL USE.
Page 54: Location Of The Important Labels
If missing or damaged, they can be replaced free of charge. See an authorized Bombardier ATV dealer. NOTE: The following illustrations used in this Operator’s Guide are a general representa- tion only. Your model may differ.
Page 56 Label 1 Label 3 WARNING CAUTION Improper ATV use can result in SEVERE INJURY or DEATH. • ATV MUST be stopped before shifting lever. • Always apply foot brake to ALWAYS USE NEVER CARRY NEVER USE NEVER USE PASSENGERS. WITH DRUGS AN APPROVED ON PUBLIC shift from Park (P) and...
Page 57 Label 6 WARNING Improper loading of a trailer may cause loss of vehicle control, resulting in severe injury or death. • Maximum towing weight: 135 kg (298 lb). • Maximum tongue weight: 14 kg (30 lb). Label 7 WARNING • NEVER carry a passenger on this carrier •...
Page 58 Label 10 Label 11 LOCATED UNDER SEAT...
Page 59 Label 12 WARNING This warning applies only in European Countries where on road usage is allowed. On Road Use This ATV is built for “OFF ROAD” purposes only. It may be used for short distances on paved surfaces at reduced speed, in order to move the vehicle from an off road location to another.
Page 61: Vehicle Information
VEHICLE INFORMATION...
Page 62: How To Identify Your Atv
It may sometimes become necessary to locate these numbers for warranty purposes or to trace your vehicle in the event of loss. These numbers are required by the authorized Bombardier ATV dealer to complete warranty claims properly. No warranty will be allowed by BRP Inc. if the engine identification number (EIN) or vehicle identification number (VIN) is removed or mutilated in any way.
Page 63: Compliance Label
Compliance Label This label indicates vehicle’s compliance European community countries. LABEL LOCATION All Outlander Under seat, on the upper bar of frame. V00M0FY EUROPEAN COMMUNITY COUNTRIES...
Page 64: Controls/Instruments/Equipment
CONTROLS/INSTRUMENTS/EQUIPMENT NOTE: Some controls/instruments/equipment are optional.
Page 65 TYPICAL...
Page 66: Throttle Lever
While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death. 3) Brake Lever NOTE: This section gives basic functions of the various controls of your ATV. For more de- Located on the left side of handlebar.
Page 67: Brake Lever Lock
4) Brake Lever Lock To release mechanism: Squeeze brake le- ver. Lever lock should automatically return to Located on left side of handlebar on the brake its original position. Brake lever should return lever. When applied, it prevents the vehicle to rest position.
Page 68: Vehicle Lock
P l e a s e , c h e c k w i t h y o u r a u t h o r i z e d Bombardier ATV distributor/dealer to know which model you must use with your vehicle.
Page 69: Start Button
NOTE: Place ignition switch to ON “without This switch can be used to stop engine and light” position to close the headlamp. as an emergency control. NOTE: While engine can be stopped by turn- ing ignition key OFF, we recommend the en- gine be stopped by the engine stop switch.
Page 70: Override Button
Override Button Choke Lever Located below engine stop switch. Located at bottom of multifunction switch. This device features a variable lever to ease cold start. Position OFF is for normal use with a warm engine. V07I08Y V07I07Y CHOKE LEVER IN THE OFF POSITION TYPICAL 1.
Page 71: Direction Indicator Switch
Direction Indicator Switch 10) Hazard Warning Button This switch is located on the left side of han- This button is located on the left side of con- dlebar. sole. V07G24Y TYPICAL TYPICAL 1. Hazard warning button 1. Horn button 2. Direction indicator switch Device fitted to the vehicle that operates a si- multaneous flashing of all direction indicators, To activate the direction indicator lamps, push...
Page 72: Speedometer
11) Speedometer Change from One Unit to the Other This vehicle is equipped with an electronic The speedometer is factory preset in miles speedometer. It indicates the speed of vehicle but it is possible to change it to kilometer read- either in MPH or km/h.
Page 73 18 volts in the electrical sys- tem, caused by a disconnected or defective 1. Selector button voltage regulator. Check voltage regulator connection or con- tact an authorized Bombardier ATV dealer for voltage regulator replacement.
Page 74: 12-Volt Power Outlet
Hourmeter after engine starting, stop engine. Check en- gine oil level. Refill if necessary. If the oil level is good, see an authorized Bombardier ATV dealer. Do not use the vehicle until repaired. Engine Temperature (RED) The hourmeter records engine running time in hours and minutes.
Page 75: Ignition Switch
13) Ignition Switch 14) Fuel Tank Cap Located on the console. The fuel tank cap is located on the left side of the rear fender. Key-operated, 3-position switch: OFF, ON with lights and ON without lights. CAUTION: Never place anything over fuel tank cap because the vent hole on the top of fuel tank cap can be blocked and the engine could misfire.
Page 76: Fuel Gauge
15) Fuel Gauge Stops fuel supply to carburetor. Located on the left side of the rear fender near CAUTION: Turn valve to OFF position when fuel tank cap, the gauge shows an approxi- vehicle is not being operated or when trans- mate amount of the fuel in tank.
Page 77: Brake Pedal
17) Brake Pedal 19) Access Panel Located on the right footrest. When pressed The access panel is located on the front fend- down, the rear brake is applied. When re- er, between front racks. To open the panel, leased, the brake pedal should return to its unlatch, lift then remove it completely.
Page 78: Rear Storage Compartment
20) Rear Storage Compartment 21) Seat Latch Located in rear of vehicle. Convenient loca- Located underneath the rear end of seat. It tion to carry personal articles such as a spare allows the removal of seat to give access to spark plugs, first aid kit, etc.
Page 79: Cargo Rack
Seat Installation Refer to SPECIFICATIONS for carrying loads and cargo weight distribution recommenda- Insert front tabs of seat into frame hook. tions. When seat rests in its position, firmly push seat down to latch. 23) Trailer Hitch NOTE: A distinctive snap will be felt. Double Located near rear axle.
Page 80: Radiator Cap
24) Radiator Cap 25) Fuses Located in service compartment, under ac- The electrical system is protected with fuses. cess panel. Refer to MAINTENANCE for details. The fuse holders are located in the service WARNING compartment. In order to avoid getting burned do not re- move the radiator cap when the engine is hot.
Page 81: Rewind Starter Handle
27) Rewind Starter Handle 29) Winch The rewind starter handle is provided as an XT Models emergency starting device. Located at the front of vehicle behind front Follow the usual starting procedure; but use skid plate. the rewind starter instead of the electric start- Located on right side of vehicle.
Page 82: Winch Control Switch
30) Winch Control Switch 31) Fairlead XT Models XT Models Located on the left side of the handlebar, over Located on the front of skid plate. direction indicator switch. The fairlead is used to prevent the damages To take out wire rope from winch, press the to the vehicle and guide the wire rope into the left side of switch.
Page 83: Liquids
LIQUIDS While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death. NOTE: Fuel Level This section specifies the recommend- ed liquids and procedures to check their levels. Refer to MAINTENANCE for procedures to re- WARNING place the liquids.
Page 84: Oil Level
Oil Viscosity SAE 5W30 or XP-S 10W40 4-stroke oil (P/N 219 700 346) is recommended for all seasons. However, during the hottest days of the sum- mer and bitter cold days of the winter, refer to the following chart to select the proper viscos- ity.
Page 85: Engine Coolant
C o o l i n g s y s t e m m u s t b e f i l l e d w i t h Bombardier premixed coolant (P/N 219 700 In order to avoid getting burned, do not re- 362) or with distilled water and antifreeze so- move the radiator cap if the engine is hot.
Page 86: Battery
NOTE: A low level may indicate leaks or worn Refer to MAINTENANCE to removal/installa- brake pads. See an authorized Bombardier tion instructions. ATV dealer. Brake Lever Fluid Reservoir Turn steering in the straight-ahead position to ensure reservoir is level.
Page 87: Break-In Period
10 hours, 300 km (185 mi) or 30 days after the accelerations, prolonged cruising speeds and purchase, whichever comes first, your vehicle engine overheating are detrimental during the be inspected by an authorized Bombardier break-in period. ATV dealer. This inspection will give you the opportunity to discuss the unanswered ques- tions you may have encountered during the first hours of operation.
Page 88: Operating Instructions
. S e e a n a u t h o r i z e d • Apply parking brake and check if it oper- Bombardier ATV dealer as necessary. ates properly. •...
Page 89: Initial Cold Starting
Initial Cold Starting After a few seconds, move the choke lever from full choke position to an intermediate po- Insert key in ignition switch and turn to ON. sition until the best engine RPM is achieved. Place the engine stop switch to RUN. NOTE: Over using the choke may flood the In cold weather, under 0°C (32°F), place the engine and make it hard to start.
Page 90: Warm Engine Starting
Warm Engine Starting Shifting the Transmission Start the engine as explained above but with- Let engine idle to warm up. out the choke. If the engine does not start af- Apply brakes and select the desired gear ter two 5-second attempts with the electric range H or L.
Page 91: Special Procedures
Never refill cooling system when engine is Start engine as explained above. If engine hot. continues to flood, see an authorized Bombardier ATV dealer. See an authorized Bombardier ATV dealer as soon as possible.
Page 92: Post-Operation Care
(beach area, launching/loading boats necessary to take it to an authorized etc.), rinsing the vehicle with fresh water is Bombardier ATV dealer as soon as possible. necessary to preserve vehicle and its compo- DO NOT START THE ENGINE! Immersion of nents.
Page 93: Cargo And Transportation
CARGO AND TRANSPORTATION While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death. Cargo WARNING The vehicle handling, stability and braking distance are affected when loading racks and using the vehicle.
Page 94: Transportation
Transportation Front Location When transporting a vehicle, secure vehicle to trailer or in pickup box with suitable tie- downs. Using ordinary ropes is not recom- mended. WARNING V07A0EY TYPICAL Rear Location V00A174 Never tip this vehicle on end for transport- ing.
Page 95: Troubleshooting
– Start engine with spark plugs grounded to the engine away from spark plug holes. If no spark appears, replace spark plugs. – If trouble persists, contact an authorized Bombardier ATV dealer. 6. Engine compression. – As the engine is pulled over with the rewind starter, “cycles” of resistance should be felt as piston goes past top dead center.
Page 96 – Contact an authorized Bombardier ATV dealer. 4. Engine is overheating. – Check ENGINE OVERHEATING in SPECIAL PROCEDURES. – If overheating persists, contact an authorized Bombardier ATV dealer. 5. Air filter/box plugged or dirty. – Check air filter and clean if necessary.
Page 97 – Check the position of the air intake tube. 4. CVT dirty or worn-out. – Contact an authorized Bombardier ATV dealer. Transmission lever is hard to move 1. Transmission gears are in a position that prevents the transmission lever to work.
Page 98: Specifications
SPECIFICATIONS OUTLANDER 400 H.O. ™ VEHICLE MODEL STANDARD ENGINE BOMBARDIER-ROTAX ® 4-TEC, 4-stroke. Type Single Over Head Camshaft (SOHC) Number of cylinder Single cylinder Number of valves 4 valves with mechanical lifters (adjustable) Displacement 400 cc (24.4 cu. in) Bore Standard 91 mm (3.58 in)
Page 99 OUTLANDER 400 H.O. ™ VEHICLE MODEL STANDARD Make Spark plug Type DCPR8E 0.6 to 0.7 mm (0.024 to 0.027 in) Number of spark plug Type Dry type battery Battery Volt 12 volts, 18 Ah. Electric start and manual rewind starter. Starting system Start on P, R, N, H or L position (with brake applied) Headlamp bulb...
Page 100 Engine oil type (engine and XP-S 5W40 synthetic 4-stroke oil. transmission) Refer to OIL VISCOSITY CHART for proper grade. Ethylene-glycol/water mix (50% coolant, 50% distilled water). Use Bombardier premixed coolant Coolant or a coolant specially designed for aluminum engines Type...
Page 101 OUTLANDER 400 H.O. ™ VEHICLE MODEL STANDARD Front Bombardier differential oil or Synthetic polyester oil Differential 75W90 (API GL-5) Rear Brake Brake fluid, DOT 4 Propeller shaft joint grease Suspension synthetic grease (P/N 293 550 033) CAPACITIES 16 L (4.2 U.S. gal) including an approximate reserve Fuel tank of 2 L (0.5 U.S.
Page 103: Maintenance Information
MAINTENANCE INFORMATION...
Page 104: Maintenance Chart
Bombardier ATV dealer. PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 300 KM (185 mi) (To be performed by an authorized Bombardier BRP ATV dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST...
Page 105: Periodic Maintenance Chart
PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 300 KM (185 mi) (To be performed by an authorized Bombardier BRP ATV dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST 25 H OR 750 KM (470 mi)
Page 106 PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 300 KM (185 mi) (To be performed by an authorized Bombardier BRP ATV dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST 25 H OR 750 KM (470 mi)
Page 107: General
Other items found in maintenance chart mu s t b e p erf orm e d by a n a u th or iz ed Bombardier ATV dealer. NOTE: Among other things, this section gives the procedures to replace the liquids. Refer to LIQUIDS for procedures to check levels and refill.
Page 108: Engine/Transmission
ENGINE/TRANSMISSION Oil Change and Oil Filter Allow enough time for oil to flow out of oil filter. Remove the right engine cover. Replacement Unscrew the oil filter cover. Oil and filter are to be replaced at the same time. Oil change should be done with a warm engine.
Page 109: Oil Strainer Cleaning
The oil strainer must be cleaned every 200 hours or every 2 years or every 6000 km (3730 m.). Contact an authorized Bombardier ATV dealer. Coolant Replacement WARNING In order to avoid getting burned, do not re- move the radiator cap or loosen the cool- ant drain plug if the engine is hot.
Page 110: Valve Adjustment
Install radiator cap. Inspect all connections for leaks and check coolant level in the reservoir. Valve Adjustment See an authorized Bombardier ATV dealer for valves adjustment. Insufficient clearance will cause loss of power V07C09Y and possibly damage the valves. Excessive 1.
Page 111: Radiator
ONLY. NEVER USE A HIGH PRESSURE 1. Cleanout plug WASHER. 2. Muffler See an authorized Bombardier ATV dealer to check the performance of the cooling system. Block the end of the muffler with a shop rag and start engine. Drive belt...
Page 112: Air Intake System
AIR INTAKE SYSTEM Air Filter Box Draining NOTE: If vehicle is used in dusty area, in- spect more frequently than specified in MAIN- Periodically inspect air filter box drain tube for TENANCE CHART. liquids or deposits. If liquids/deposits are found, squeeze and re- move the clamp.
Page 113: Air Filter Cleaning
Loosen clamp and remove air filter. V07C0HY 1. Clamp 2. Air filter Air Filter Cleaning Pour cleaning solution (P/N 219 700 341 or an equivalent) into a bucket. Put the filter in to soak. While filter soaks, clean inside the air box. Rinse the filter with warm water until all clean- ing solution disappears.
Page 114: Electrical
ELECTRICAL Remove the holding strap then pull the bat- tery out of frame. WARNING Unless otherwise indicated, always turn ignition switch to the OFF position before performing any maintenance or repair on electrical system. Spark plug Removal Unplug the spark plug cable. Unscrew the spark plug one turn.
Page 115: Fuses
Fuses To remove fuse from holder, remove the fuse holder cover then pull fuse out. Check if fila- If a fuse is damaged, replace it by one of the ment is melted. same rating. CAUTION: Do not use a higher rated fuse as this can cause severe damage.
Page 116: Bulb Replacement
Bulb Replacement Unplug connector from headlamp. NOTE: Use small locking tab to unlock connec- WARNING tor then pull on connector. Always turn the ignition switch OFF before replacing a defective bulb. Always check light operation after replace- ment. Headlamps CAUTION: Never touch glass portion of an halogen bulb with bare fingers, it shortens its operating life.
Page 117 1. Position lamp socket 2. Headlamp housing V06G0SY Push bulb in and hold while turning counter- clockwise to release. TYPICAL Install the new bulb by first pushing in while turning clockwise. Properly reinstall removed parts in the re- verse order of their removal. Put back the position lamp socket in the head- lamp housing, turn clockwise to lock in place Beam Aiming Adjustment...
Page 118 Reinstall the lens. Indicator Light If one LED is burnt in the cluster, see an au- thorized Bombardier ATV dealer for the clus- ter replacement. Speedometer The speedometer is lighted with LEDs. If one LED burns, replace the speedometer. The...
Page 119: Drive Train
Push and pull the wheels from the upper edge t o f e e l t h e p l a y. S e e a n a u t h o r i z e d Bombardier ATV dealer if there is any play. V07H01Y FRONT OF VEHICLE 1.
Page 120: Tires/Wheels
Tires/Wheels Do not rotate tires. The front and rear tires have a different size. The tires are directional and their rotation must be kept in a specific WARNING direction for proper operation. Wheel Removal When the tires are replaced, never install Loosen nuts then lift vehicle.
Page 121: Steering System
STEERING SYSTEM Throttle Cable Lubrication Separate the housing. Slide rubber protector back to expose throttle cable adjuster. Lubrication The throttle cable must be lubricated with sil- icone lubricant (P/N 293 600 041) or an equiv- alent. WARNING Always use a silicone-based lubricant. Us- ing another lubricant (like a water-based lubricant) could cause the throttle lever/ca- ble sticking or stiffness.
Page 122 V07I0JY NOTE: Place a rag around the throttle cable V07I0IY adjuster to prevent the lubricant from splash- ing. Remove the carburetor side cover. Add lubricant until it runs out at carburetor end of the throttle cable. Reinstall and adjust the cable. V07F04Y Insert the needle of lubricant can in the end of throttle cable adjuster.
Page 123: Throttle Lever Adjustment
Throttle Lever Adjustment Slide rubber protector back to expose throttle cable adjuster. Loosen lock nut then turn the adjuster to ob- tain correct throttle lever free play. NOTE: Measure throttle free play at the tip of throttle lever. Tighten lock nut and reinstall protector. V07I010 1.
Page 124: Suspension
Front Suspension Inspect the McPherson struts for oil leaks or other damages. Check tightness of fasteners. See an authorized Bombardier ATV dealer as necessary. Rear Suspension Inspect shock absorber for oil leaks and fas- teners for tightness.
Page 125: Brake
Rear disc 4.3 mm (0.170 in) thickness Maximum discs 0.2 mm (0.010 in) warpage See your authorized Bombardier ATV dealer if a problem is detected concerning the brake system. Brake Fluid Replacement WARNING The brake fluid replacement or any brake system repairs should be performed by an authorized Bombardier ATV dealer.
Page 126: Body/Frame
S e e a n a u th o ri z ed secured and no hose is cracked, kinked or Bombardier ATV dealer for parts replacement otherwise damaged. if damaged.
Page 127: Warranty
WARRANTY...
Page 128: Brp International Limited Warranty: 2006 Bombardier Atv Products
All genuine Bombardier parts and accessories, installed by an authorized Bombardier distribu- tor/dealer (as hereinafter defined) at the time of delivery of the 2006 Bombardier ATV product, carry the same warranty as that of the ATV.
Page 129 WARRANTY GIVES YOU SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM COUNTRY TO COUNTRY. Neither the distributor, any Bombardier ATV dealer nor any other person has been authorized to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against BRP.
Page 130 BRP or an authorized Bombardier ATV distributor/dealer receives a proof that the former owner agreed to the transfer of ownership, in addition to the coordinates of the new owner. The distrib- utor will then forward this information directly to BRP.
Page 131: Privacy Obligation/Disclaimer
If you prefer not to have your name and address released, please let us know by writing to the address below: Bombardier Recreational Products Europe N.V. Customer Service...
Page 133: Change Of Address/Ownership
BRP. STOLEN UNITS: If your personal ATV is stolen, you should notify BRP or an authorized Bombardier ATV dealer. We will ask you to provide your name, address, phone number, the vehicle identification number and the date it was stolen.
Page 134 AFFIX PROPER POSTAGE Bombardier Recreational Products Europe N.V. Customer Service Guldensporenpark 83, building I B-9820 Merelbeke, Belgium...
Page 135 BRP. STOLEN UNITS: If your personal ATV is stolen, you should notify BRP or an authorized Bombardier ATV dealer. We will ask you to provide your name, address, phone number, the vehicle identification number and the date it was stolen.
Page 136 AFFIX PROPER POSTAGE Bombardier Recreational Products Europe N.V. Customer Service Guldensporenpark 83, building I B-9820 Merelbeke, Belgium...
Page 137 ATV MODEL No. VEHICLE IDENTIFICATION NUMBER (V.I.N.) ENGINE IDENTIFICATION NUMBER (E.I.N.) Owner: ________________________________________________________ NAME ________________________________________________________ STREET ________________________________________________________ CITY STATE/PROVINCE ZIP/POSTAL CODE Purchase Date YEAR MONTH Warranty Expiry Date YEAR MONTH To be completed by the dealer at the time of the sale. DEALER IMPRINT AREA Please verify with your dealer to ensure your vehicle has been registered with BRP.

BOMBARDIER Outlander 400 Operator's Manual

1 Throttle Lever

2 WD/4WD Selector

3 Brake Lever

4 Brake Lever Lock

5 Transmission Lever

6 Vehicle Lock

7 Multifunction Switch

8 Direction Indicator Switch

9 Horn Button

10 Hazard Warning Button

11 Speedometer

12 Volt Power Outlet

13 Ignition Switch

14 Fuel Tank Cap

15 Fuel Gauge

16 Fuel Valve

17 Brake Pedal

18 Footpeg

19 Access Panel

20 Rear Storage Compartment

21 Seat Latch

22 Cargo Rack

23 Trailer Hitch

24 Radiator Cap

25 Fuses

26 Tool Kit

27 Rewind Starter Handle

28 Dipstick

29 Winch

30 Winch Control Switch

31 Fairlead

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