BOMBARDIER 2006 outlander max 400 Operator's Manual
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BOMBARDIER 2006 outlander max 400 Operator's Manual

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  • Page 2 TTI™ Printed in Canada. (vmo2006-008 DR) ®™ and the BRP loge are trademarks of Bombardier Recreational Products Inc. or its affiliates. ©2005 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved. * Trademark of Bombardier Inc. used under license.
  • Page 3 SAE experience problems which cannot be U.S. equivalent in parenthesis. Where resolved by an authorized Bombardier precise accuracy is not required, some ATV dealer. conversions are rounded off for easier use.

  • 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 in- jury or death. NOTICE................7 INTRODUCTION ..
  • Page 5 Expected Results ............. . . 66 SECTION II – BOMBARDIER 2-UP VEHICLE SAFETY VIDEOCASSETTE . . 67 Objective.
  • Page 6 22) Radiator Cap ..............99 23) Fuses ..
  • Page 7 TROUBLESHOOTING ............115 SPECIFICATIONS .
  • Page 8 Vehicle Cleaning and Protection..........148 WARRANTY BRP LIMITED WARRANTY NORTH AMERICA: 2006 BOMBARDIER †...

  • Page 9: Notice

    NOTICE This Operator's Guide has been pre- pared to acquaint the owner/operator of a new vehicle with the various ve- hicle controls, maintenance and safe operating instructions. It is indispens- able for the proper use of the product. This Operator's Guide uses the follow- ing symbols.

  • Page 10: Introduction

    INTRODUCTION Your dealer should have provided you with some basic information on the partic- ular 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 Video- cassette that came with this vehicle.

  • Page 11: Safety Information

    SAFETY INFORMATION ____________ ____________ SAFETY INFORMATION...
  • Page 12 WARNING Operator: • A person under 16 years old should never operate this vehicle. • Never carry more than one (1) passenger on this vehicle. • Passenger must be seated on the designated passenger's seat and hold on to the grab handles at all times. •...

  • Page 13: Special Safety Messages

    Never operate this vehicle without proper instruction. Take a training course offered by BRP. All operator should receive training from a certified instructor. See your authorized Bombardier ATV dealer for more informations. Always follow this age recommendation: A person under 16 years old should never operate this vehicle.
  • Page 14 Always inspect your vehicle each time you use it to make sure it is in safe op- erating condition. Always follow the inspection and maintenance procedures and schedules described in this Operator's Guide. The operator and the passenger must always keep both hands on the han- dlebars or grab handles and both feet on the footrests of the vehicle during operation.
  • Page 15 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use proper gear and maintain a steady speed when climb- ing a hill. If you stall or roll backwards, follow the special procedure for braking described in this Operator's Guide.

  • Page 16: Operation Warnings

    OPERATION WARNINGS While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. NOTE: The following illustrations are general representations only. Your model may differ. WARNING V00A0AQ POTENTIAL HAZARD Operating this vehicle without proper instruction.
  • Page 17 WARNING V00A1AQ POTENTIAL HAZARD Failure to follow the age recommendations for this vehicle. 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 18 WARNING V00A1BQ POTENTIAL HAZARD Failure to follow the age recommendations for the passenger. WHAT CAN HAPPEN A child, under 12, may not have the ability needed to ride safely and may be involved in a serious accident. HOW TO AVOID THE HAZARD No one under 12 should be riding on this vehicle.
  • Page 19 WARNING V00A1CQ POTENTIAL HAZARD Carrying more than one (1) passenger on this vehicle. WHAT CAN HAPPEN Carrying more than one (1) passenger reduces your ability to balance and control this vehicle. Could cause an accident, resulting in harm to you and/or your passengers. HOW TO AVOID THE HAZARD Never carry more than one (1) passenger.
  • Page 20 WARNING V00A2DQ POTENTIAL HAZARD Allowing passenger to sit in a location other than the designated passenger seat. WHAT CAN HAPPEN Passenger seated in a location other than the designated passenger seat could : – impair vehicle stability which could lead to a loss of control –...
  • Page 21 WARNING V00A1DQ POTENTIAL HAZARD Operating this vehicle on paved surfaces. WHAT CAN HAPPEN The tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Never operate this vehicle on any paved surfaces, including sidewalks, driveways, parking lots and streets.
  • Page 22 WARNING V00A1EQ POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, even a dirt or gravel one.
  • Page 23 WARNING V00A1FQ POTENTIAL HAZARD Riding this vehicle without wearing an approved helmet, eye protection and protective clothing. Passenger should also have an approved helmet with a rigid chin guard. WHAT CAN HAPPEN The following items concern the operator and the passenger: –...
  • Page 24 WARNING V00A07Q POTENTIAL HAZARD Riding this vehicle after consuming alcohol or drugs. WHAT CAN HAPPEN Could cause the passenger to fall off. 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 of passenger and/or operator.
  • Page 25 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 op- erating conditions, and your experience.
  • Page 26 WARNING V00A1GQ POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, for the operator and the passenger, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Do not try to show off. ___________ ___________ SAFETY INFORMATION...
  • Page 27 WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the 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 28 WARNING V00A1HQ POTENTIAL HAZARD Removing hands from handlebars for the operator and from grab handles for the passenger, 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.
  • Page 29 WARNING V00A1IQ 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, passenger ejection or loss of con- trol.
  • Page 30 WARNING V00A1JQ 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 or passenger ejection. 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 this vehicle on...
  • Page 31 WARNING V00A1KQ POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Vehicle could go out of control, causing a collision, an overturn or a pas- senger ejection. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described further in this Operator's Guide.
  • Page 32 WARNING V00A1LQ 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 this vehicle on hills too steep for the vehicle or for your abil- ities.
  • Page 33 WARNING V00A1MQ POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control, passenger ejection or cause vehicle to over- turn. 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.
  • Page 34 WARNING V00A1NQ POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control, passenger ejection or cause vehicle to over- turn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described further in this Operator's Guide.
  • Page 35 WARNING V00A1OQ POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control, passenger ejection or cause vehicle to over- turn. HOW TO AVOID THE HAZARD Never attempt this maneuver when the passenger is on board. Always disembark him before executing.
  • Page 36 WARNING V00A1PQ 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: Operator and passenger must keep their weight uphill.
  • Page 37 WARNING V00A1QQ POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control, passenger ejection or a collision. Could cause the vehicle to overturn. HOW TO AVOID THE HAZARD The operator is responsible for the safety of his passenger. In doubt, disem- bark him before riding over obstacles.
  • Page 38 WARNING V00A1RQ 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 or passenger ejection. HOW TO AVOID THE HAZARD Never slide or skid with passenger. Always remember that the vehicle han- dling and stability may be affected when riding with a passenger.
  • Page 39 WARNING V00A1SQ 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 40 WARNING V00A1TQ 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 41 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 im- proper or uneven tire pressure, may cause loss of control, and increases the risk of an accident.
  • Page 42 All parts and accessories added to this vehicle should be approved by BRP and should be installed and used according to instructions. If you have questions, consult an authorized Bombardier ATV dealer. Do not install passenger seat or use the racks to carry more than one (1) passenger.
  • Page 43 WARNING V00A1UQ 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 and passenger, as well as other loads and added accessories.
  • Page 44 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 in- jury or death.

  • Page 45: 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 46: Pre-Operation Check

    • Check for oil leaks on the en- Correct any problem you may have gine/transmission and drive train found before riding. See an autho- components. rized Bombardier ATV dealer as nec- • Ensure fuel valve is in fully open essary. position (ON). • Clean headlamps and taillight.

  • Page 47: Clothing

    Clothing Actual weather conditions should help you decide how to dress. However, it is important that the operator and the passenger always wear the appropriate protective clothing and apparel, including an approved helmet, eye protection, boots, gloves, long sleeved shirt and pants. The passenger should have an ap- proved helmet including a rigid chin guard.

  • Page 48: Carrying Loads/Passenger

    Your vehicle can help you perform a number of different LIGHT tasks ranging from snow removal to pulling wood or carrying cargo. A variety of accessories are available from your authorized Bombardier ATV dealer. However, always re- spect the load and capacities of the vehicle. Overloading of the vehicle can over- stress the components and cause failure.

  • Page 49: 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.

  • Page 50: Design Limitation

    Design Limitation Although the vehicle is exceptionally rugged for its class, it is still a light vehicle by definition and its operation must be restricted to its proper purpose. The addition of weight to any part of the vehicle changes its gravitational stability and modifies its performance.

  • Page 51: Uphill Driving

    Uphill Driving Due to configuration, this vehicle has excellent climbing ability, so much so that tipover is possible before traction is lost. For example, its common to encounter terrain situations where the top of the hill has eroded to a point that the hill peak rises very sharply.

  • Page 52: Riding Techniques

    Riding Techniques Riding your vehicle too fast for the conditions may result in injury. Apply only enough throttle to proceed safely. Statistics show that high speed turns usually result in mishaps and injury. Always remember that this vehicle is heavy! Its pure weight alone may entrap you should it fall and pin you down.
  • Page 53 This vehicle is not designed for riding on roads or highways. (In most places it is an illegal practice). Riding your vehicle on roads or highways could cause a collision to occur with another vehicle. The tires of this vehicle are not suited for paved road use.
  • Page 54 Mud or marsh lands may be encountered near water. Be prepared for sudden “holes” or changes in depth. Similarly so, be watchful of hazards such as rocks, logs, etc., partially covered by vegetation. If your trip crosses frozen waterways, make sure that the ice is thick enough and sound enough to support the total weight of yourself, your passenger, the vehicle and its load.
  • Page 55 V00A1WL If you do get into a slide or skid, it may help to turn the handlebar into the direction of the skid until you regain control. Never jam the brakes and lock the wheels. Respect and follow all posted trail signs. They are there to help you and others. Obstacles in the “trail”...
  • Page 56 Uphill Do not forget, the operator is responsible for the safety of the passenger. In doubt, disembark him before climbing hill. Always remember that the vehicle handling, stability and braking distance may be affected when riding with a pas- senger. If you decide to keep your passenger, he must synchronize his movements with yours.
  • Page 57 Downhill Do not forget, the operator is responsible for the safety of the passenger. In doubt, disembark him before going down the hill. Always remember that the vehicle handling, stability and braking distance may be affected when riding with a passenger. If you decide to keep your passenger, he must synchronize his movements with yours.
  • Page 58 Side Hilling Do not forget, the operator is responsible for the safety of the passenger. In doubt, disembark him before proceeding. Always remember that the vehicle handling, stability and braking distance may be affected when riding with a pas- senger. If you decide to keep your passenger, he must synchronize his movements with yours.

  • Page 59: Routine Maintenance

    Part of your responsibility towards safety is to respect the contents of this Op- erator's Guide. It provides valuable advice on how to properly take care of your vehicle. If further assistance is required your authorized Bombardier ATV dealer is always willing to help.

  • Page 60: Hang Tag

    HANG TAG This vehicle comes with a hang tag and labels containing important safety infor- mation. Any person who rides this vehicle should read and understand this information before riding. V00M0BL 704901107 vmo2006-005-009_en ___________ ___________ SAFETY INFORMATION...

  • Page 61: Location Of The Important Labels

    The following labels are on your vehicle and they should be considered perma- nent parts of the vehicle. 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 representation only.
  • Page 62 vmo2006-005-007_a vmo2006-008-002_a LABEL 1 LABEL 2 V01M0RY LABEL 3 V00M0CY V07M06Y ___________ ___________ SAFETY INFORMATION...
  • Page 63 LABEL 4 LABEL 8 V07M0YY XT MODELS LABEL 9 V07M07Y LABEL 5 vmo2006-008-003_aen LABEL 6 vmo2006-008-004_aen LABEL 10 V00M05Y vmo2006-005-011 INTERNATIONAL MODELS ONLY LABEL 7 vmo2006-005-010_en ____________ ___________ SAFETY INFORMATION...
  • Page 64 LABEL 11 vmo2006-005-012 While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. ___________ ___________ SAFETY INFORMATION...

  • Page 65: Safety Training

    SAFETY TRAINING _____________ ____________ SAFETY TRAINING...

  • Page 66: Introduction

    INTRODUCTION Objective The objective of this course is to give the Bombardier 2-UP vehicle owner the information required to operate a 2-UP vehicle safely. The course will be offered to all 2-UP vehicle buyers, and members of their immediate fam- ilies.

  • Page 67: Section I - General Safety Information

    Safety Commission) Injury and ers of ATVs during the last 5 years Death Statistics. (January 1997-December 2001): c) Discuss Bombardier's age and 1. 417,200 ATV-related injuries size recommendation. 2. 1,463 ATV-related deaths. d) Discuss what protective clothing...

  • Page 68: Expected Results

    E) Riding with a Passenger – Before riding with a passenger, the operator should first become highly familiar with the operation of the 2-UP vehicle. – Once ready, the operator should be- gin riding with a passenger at very low speed and on familiar terrain. F) ATV-Related Local, State and Federal Laws –...

  • Page 69: Section Ii - Bombardier 2-Up Vehicle Safety Videocassette

    SECTION II – BOMBARDIER 2-UP VEHICLE SAFETY VIDEOCASSETTE Objective Body Posture The purpose of this section is to: You and your passenger must position your body weight to lessen the hazard a) Indicate guidelines prior to view- of tipping over. You and your pas-...

  • Page 70: Expected Results

    4. Make sure fuel and oil caps are tight. 5. Secure front and rear of vehicle. Law Observance Refer to section I. C) Recap – Questions and answers. – Review of the CPSC injury and death data. – Review of safety messages, such as wearing protective head gear and clothing.

  • Page 71: Section Iii - Operator's Guide Review

    SECTION III – OPERATOR'S GUIDE REVIEW Objective – Know the meaning of the warning and caution symbols in the Opera- The purpose of this section is to: tor's Guide and what they refer to. a) Emphasize the importance of ob- –...

  • Page 72: Section Iv - Hands-On Riding

    SECTION IV – HANDS-ON RIDING Objective 3. Dealer representative checks off the scoring chart when you The purpose of this section is to: have completed the maneu- a) Familiarize you with the pre-oper- vers satisfactorily. ation check. 4. Dealer representative and you b) Remind you about the protective continue with the maneuvers clothing that should be worn by...

  • Page 73: Driving Maneuver List

    DRIVING MANEUVER LIST Hands-on riding practice should incorporate the maneuvers described below. Trainees are required to perform a minimum number of repetitions of each of the eight driving maneuvers. The person giving the training must demonstrate each maneuver and then have the trainee repeat the following minimum number of repetitions.
  • Page 74 Maneuver #3 Maneuver #4 Sharp turns less than 90 - left and Slalom (minimum repetition: three right. Corners 90 degrees and less times). than 90 degrees (minimum repetition: two clockwise and two counterclock- FINISH wise). START START FINISH V01A4IY TYPICAL V01A4HY 1.
  • Page 75 Maneuver #5 Maneuver #6 Quick stop: large oval with panic Riding over obstacle (minimum rep- maneuver (minimum repetition: two etition: once with left wheels, once times). with right wheels, and once with both wheels). FINISH START START 1.5 m (5’) 1.2 m (4’) 1.8 m (6’) FINISH...
  • Page 76 Maneuver #7 Maneuver #8 Traversing hills (minimum repetition: U-turn and K-turn (minimum repeti- once each direction). tion: one time). 9 m (30’) 2.4 m Uphill (8’) START FINISH V01A5SY TYPICAL — U-TURN Uphill START FINISH V01A4LY 2.4 m TYPICAL (8’) 1.

  • Page 77: Instructor's Check List

    • Failure to perform the required training may constitute a violation of the Bombardier ATV dealer agreement. • If you would like further information on the 2-UP vehicle safety training course, please contact BRP at (715) 848–4957 in the US or at (819) 566–3366 in Canada.
  • Page 78 Section II: Bombardier 2-Up Vehicle Safety Videocassette Review the Bombardier 2-UP vehicle Safety Videocassette with your trainee. Make sure to answer any questions your trainee may have. Section III: Operator's Guide Review Review the Operator's Guide with your trainee. Emphasize the need for periodic and frequent reviews of the guide.
  • Page 79 5) Quick Stop Quick stop as used in article I above. Large oval with panic maneuver (minimum repetition: two times). 6) Riding Over Obstacles Riding over obstacles – 4 x 4 pieces of wood should be placed in vehicle's path so rider can drive over them (minimum repetition: once with left wheels, once with right wheels, and once with both wheels).
  • Page 80 Trainee's Scoring Chart EXERCISE PASS FAIL 1. Starting and stopping 2. Turning 3. Sharp turns 4. Slalom 5. Quick stops 6. Riding over obstacles 7. Traversing hills (if there is no hill available, make sure to review the description of the maneuver in the Operator's Guide with the trainee) 8.

  • Page 81: Vehicle Information

    VEHICLE INFORMATION _____________________...

  • Page 82: How To Identify Your Atv

    These numbers are required by the authorized Bombardier ATV dealer to complete war- ranty claims properly. No warranty will be allowed by BRP if the engine identifica- tion number (EIN) or vehicle identification number (VIN) is removed or mutilated in any way.

  • Page 83: Compliance Label

    Compliance Label This label indicates vehicle's compliance in many countries. LABEL LOCATION Under seat, on the upper bar of frame. Outlander MAX V00M02Y U.S.A. AND CANADA V00M03Y OTHER COUNTRIES IN THE WORLD _____________________...

  • Page 84: Emission Requirements

    EMISSION REQUIREMENTS The California Air Resources Board (CARB) requires that your ATV comply with applicable exhaust emissions standards during its useful life, when operated and maintained according to the instructions supplied. A noncompliance Red Label (as well as a Green Label) is obtained annually during California Vehicle registration.

  • Page 85: Controls/Instruments/Equipment

    CONTROLS/INSTRUMENTS/EQUIPMENT NOTE: Some controls/instruments/equipment are optional. 22,23 vmo2006-008-006_a _____________________...
  • Page 86 13 25 11 10 vmo2006-008-007_a While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. ______________________...

  • Page 87: Throttle Lever

    NOTE: This section gives basic func- tions of the various controls of your ATV. For more details of how to op- erate one control in conjunction with some others, refer to OPERATING IN- STRUCTIONS further in this section. 1) Throttle Lever Located on the right side of handlebar.

  • Page 88: Brake Lever Lock

    4) Brake Lever Lock To release mechanism: Squeeze brake lever. Lever lock should auto- Located on left side of handlebar on matically return to its original position. the brake lever. When applied, it pre- Brake lever should return to rest posi- vents the vehicle from moving.

  • Page 89: Multi-Function Switch

    Headlamp Switch WARNING Located on the top of multi-function Before moving vehicle in reverse, switch. Place headlamp switch to LO ensure the path behind is clear of for the low beam and taillight. Place obstacles or bystanders. Remain headlamp switch to HI for the high seated.
  • Page 90 Engine Stop Switch Located at the middle of multi-function switch. The engine will turn over but will not start if the engine stop switch is turned to OFF position. V07I06Y TYPICAL 1. Start button 2. Engine stop switch To start engine, place the engine stop switch to RUN.

  • Page 91: Speedometer

    This button is used to override the re- verse speed limiter system and while power backing up. To do this, press the override button. WARNING Never activate the override button while throttle is open as loss of control may result, causing severe personal injury or death.
  • Page 92 vmo2006-005-015_a 1. Lift to release locking tab 2. Turn clockwise to release speedometer vmo2006-005-014_a TYPICAL 1. Display selector button 2. 4WD system display 3. Transmission position display 4. Vehicle speed display 5. Multi-function display 6. Unit display 7. Oil pressure indicator lamp 8.
  • Page 93 Multi-Function Display regulator. Odometer (ODO) Check voltage regulator connection or contact an authorized Bombardier ATV Odometer records the total distance dealer for voltage regulator replace- travelled either in miles or kilometers. ment. Trip Meter (TRIP 1/TRIP 2)

  • Page 94: 12-Volt Power Outlet

    4-Wheel Drive System wires are hidden in the wiring harness at the rear of vehicle. See an autho- When this indicator is ON, it rized Bombardier ATV dealer for more indicates the 4WD system is details. activated. 9) Ignition Switch...

  • Page 95: Fuel Tank Cap

    The ON with lights position, turns on all lights with either the engine run- ning or not. Remember that having the lights on without the engine run- ning discharges the battery. Always turn ignition to OFF after engine has been stopped. NOTE: While engine can be stopped by turning ignition key OFF, we recom- mend the engine be stopped by the...

  • Page 96: Fuel Valve

    12) Fuel Valve RES (reserve) Located on left side panel under con- When fuel is exhausted in the fuel tank sole. This is a 3-position rotary valve: when in the ON position, an emergen- OFF, ON, RES. Rotate the knob to align cy supply of fuel is available by turn- its pointer with ON, OFF or RES.

  • Page 97: Footpeg

    vmo2006-008-008_a 1. Grab handles 2. Passenger's seat V07K0SY The grab handles must be used by the passenger to hold on firmly during ve- 1. Brake pedal hicle operation. 14) Footpeg WARNING Located on footrest. Use this area to keep your feet and the passenger's Never hold on to the operator.
  • Page 98 Passenger's Seat Installation WARNING – Insert passenger's seat position- Without its passenger's seat, the ing tubes into rear fender provided vehicle becomes a one-rider vehi- holes. cle and NO PASSENGER must be allowed on vehicle. NEVER carry passenger on storage box. Passenger's Seat Removal –...

  • Page 99: Operator's Seat

    Storage Box Installation Pull seat rearward. Continue lifting movement until you can release the – Position storage box onto rear fend- front retaining device then completely remove seat. – When storage box rests in its posi- tion, firmly push down to latch. Seat Installation –...

  • Page 100: Rear Storage Compartment

    vmo2006-005-026_a vmo2006-008-013_a 1. Access panel 1. Rear storage compartment cover 2. Front rack 2. Seat 3. Latch 3. Rear racks 4. Latch This panel allows an easier access to the service compartment. The ser- WARNING vice compartment contains different When engine is running, always maintenance items like rear brake engage the PARK position on the fluid reservoir, radiator cap, coolant...

  • Page 101: Trailer Hitch

    21) Trailer Hitch Located near rear axle. Convenient hitch to install a ball to tow a trailer or other equipment. Install the prop- er ball size as per trailer manufacturer recommendations. Refer to SPECIFI- CATIONS for carrying loads and tow- ing recommendations.

  • Page 102: Rewind Starter Handle

    26) Dipstick The tools included in the tool box are: – pliers (1) Located on the right side of engine. – screwdriver (1) Allow to check the oil level in the en- gine. – open wrench 10/13 mm (1) – open wrench 15/17 mm (1) –...

  • Page 103: Winch Control Switch

    28) Winch Control Switch 29) Fairlead XT Models XT Models Located on the left side of the handle- Located on the front of skid plate. bar. The fairlead is used to prevent the To take out wire rope from winch, damages to the vehicle and guide the press the left side of switch.

  • Page 104: Liquids

    LIQUIDS While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. NOTE: This section specifies the rec- Fuel Level ommended liquids and procedures to WARNING check their levels. Refer to MAINTE- NANCE for procedures to replace the Always stop engine before refu- liquids.
  • Page 105 However, during the hottest days of the summer and bitter cold days of the winter, refer to the following chart to select the proper viscosity. NOTE: For improved overall perfor- mance and wear protection use XP-S 5W40 synthetic 4-stroke oil (P/N 293 600 039).

  • Page 106: Engine Coolant

    NOTE: A cooling system that fre- quently requires coolant is the indica- tion of leaks or engine problems. See an authorized Bombardier ATV dealer. Coolant Replacement Refer to MAINTENANCE section. _____________________...

  • Page 107: Brake Fluid

    NOTE: A low level may indicate leaks or worn brake pads. See an autho- rized Bombardier ATV dealer. Brake Lever Fluid Reservoir Turn steering in the straight-ahead position to ensure reservoir is level.

  • Page 108: Break-In Period

    BREAK-IN PERIOD Engine Belt A break-in period of 10 operating hours A new belt requires a break-in period is required before running the vehicle of 50 km (30 miles). Avoid strong ac- at sustained full throttle. celeration/deceleration, pulling a load or high speed cruising.

  • Page 109: Operating Instructions

    OPERATING INSTRUCTIONS General • Activate the brake lever and brake pedal to make sure the brakes fully The transmission lever must be on apply. Lever and pedal must fully PARK or NEUTRAL to allow engine to return when released. start. •...

  • Page 110: Initial Cold Starting

    Correct any problem you may have NOTE: The throttle can be used found before riding. See an autho- to help starting the engine faster. rized Bombardier ATV dealer as nec- Press the throttle lever slightly; If it is essary. pressed too much, the choke system will not be activated.

  • Page 111: Warm Engine Starting

    Warm Engine Starting Set transmission lever in PARK posi- tion. Start the engine as explained above but without the choke. If the engine Push the engine stop switch in OFF does not start after two 5-second at- position. tempts with the electric starter, pull Turn key in ignition switch to OFF.

  • Page 112: Winch Operation

    CAUTION: The vehicle must be stopped to engage or disengage 2WD/4WD selector. Mechanical damage may occur if selector is en- gaged or disengaged while driving. CAUTION: If the rear wheels are spinning, release the throttle and wait engine return to the idle before selecting the 4WD mode.

  • Page 113: Special Procedures

    Clean the spark plug cap area then re- engine is hot. move it. Remove the spark plug (tools are supplied in tool box). See an authorized Bombardier ATV WARNING dealer as soon as possible. Always wear eye protector and Post-Operation Care gloves when cleaning the spark plug hole.

  • Page 114: Turn Over

    Before starting engine, check engine oil level and refill if necessary. If the oil pressure light stays ON after starting engine, stop engine and see an autho- rized Bombardier ATV dealer as soon as possible. ATV Immersion Should the ATV become immersed, it...

  • Page 115: 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 in- jury or death. Cargo WARNING The vehicle handling, stability and braking distance are affected when load- ing racks and using the vehicle.

  • Page 116: 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 recommended. WARNING V07A0EY TYPICAL Rear Location V00A174 Never tip this vehicle on end for transporting. We recommend that you carry the vehicle in its nor- mal operating position (on all four wheels).

  • Page 117: Troubleshooting

    – Check connections and terminals condition. – Have the battery checked. – Contact an authorized Bombardier ATV dealer. ENGINE TURNS OVER BUT FAILS TO START 1. Engine stop switch. – Make sure that engine stop switch is in ON position.
  • Page 118 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 119 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 120: Specifications

    SPECIFICATIONS OUTLANDER™ 400 H.O. VEHICLE MODEL MAX XT ENGINE Bombardier -Rotax 4-TEC, 4-stroke. ® Type Over Head Camshaft (OHC) 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 121 OUTLANDER™ 400 H.O. VEHICLE MODEL MAX XT ELECTRICAL Make Denso Magneto generator Type 400 W @ 6000 RPM Ignition type CDI (Capacitor Discharge Ignition) Ignition timing Not adjustable Engine RPM limiter 8000 RPM (any gear in forward) Vehicle speed limiter 15 km/h (9 MPH) in reverse Make Spark plug...
  • Page 122 OUTLANDER™ 400 H.O. VEHICLE MODEL MAX XT DRIVE TRAIN Shaft driven/single auto-lock differential Front differential (shear pump) Rear axle Shaft driven Turning radius 2 m (79 in) SUSPENSION Independent suspension Type MacPherson type Front Travel 178 mm (7 in) Type TTI independent™...
  • Page 123 OUTLANDER™ 400 H.O. VEHICLE MODEL MAX XT LOADING CAPACITY Front racks 45 kg (100 lb) 90 kg (200 lb) Rear racks includes tongue load Rear storage box 10 kg (22 lb) 235 kg (517 lb) includes operator Total vehicle load allowed and passenger, all other loads and added accessories.
  • Page 124 VEHICLE MODEL MAX XT LIQUIDS and GREASES SAE 5W30, 4-stroke mineral-based. API Engine oil type classification SG, SH or SJ or Bombardier (engine and transmission) synthetic oil 5W40. Refer to OIL VISCOSITY CHART for other grade Ethylene-glycol/water mix (50% coolant, 50% distilled water).

  • Page 125: Maintenance Information

    MAINTENANCE INFORMATION _____________________...

  • Page 126: Maintenance Chart

    MAINTENANCE CHART The maintenance is very important, if you are not familiar with safe service prac- tices and adjustment procedures, see your authorized Bombardier ATV dealer. PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 300 KM (185 mi) (To be performed by an authorized BRP ATV dealer.
  • Page 127 PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 300 KM (185 mi) (To be performed by an authorized BRP ATV dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST C: CLEAN 25 H OR 750 KM (470 mi) I: INSPECT 50 H OR 1500 KM (930 mi) L: LUBRICATE...
  • Page 128 PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 300 KM (185 mi) (To be performed by an authorized BRP ATV dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST C: CLEAN 25 H OR 750 KM (470 mi) I: INSPECT 50 H OR 1500 KM (930 mi) L: LUBRICATE...
  • Page 129 PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 300 KM (185 mi) (To be performed by an authorized BRP ATV dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST C: CLEAN 25 H OR 750 KM (470 mi) I: INSPECT 50 H OR 1500 KM (930 mi) L: LUBRICATE...

  • Page 130: General

    GENERAL While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. WARNING Unless otherwise specified, engine should not be running for all main- tenance procedures. Before performing any service or inspection operation on the vehi- cle, wait until the engine and ex- haust have cooled down to avoid...

  • Page 131: Engine/Transmission

    ENGINE/TRANSMISSION Oil Change and Oil Filter Replacement Oil and filter are to be replaced at the same time. Oil change should be done with a warm engine. WARNING The engine oil can be very hot. In order to avoid potential burns, do not remove the engine drain plug or the filter cover if the engine is hot.

  • Page 132: Oil Strainer Cleaning

    Oil Strainer Cleaning The oil strainer must be cleaned every 200 hours or every 2 years or every 6000 km (3730 mi). Contact an authorized Bombardier ATV dealer. Coolant Replacement WARNING In order to avoid potential burns, V07C06Y do not remove the radiator cap or loosen the coolant drain plug if the 1.

  • Page 133: Drive Belt

    1. Bleeding screw 2. Engine temperature sensor Drive Belt Drain the system completely and rein- See an authorized Bombardier ATV stall the coolant drain plug. dealer to check the width and the con- dition of drive belt. Pinch hose between radiator and ther-...
  • Page 134 Stop engine and allow muffler to cool. LOW PRESSURE ONLY, NEVER USE Reinstall the clean-out plug. A HIGH PRESSURE WASHER. See an authorized Bombardier ATV Radiator dealer to check the performance of Periodically check the radiator area for the cooling system.

  • Page 135: Carburetor

    CARBURETOR See an authorized Bombardier ATV dealer each year to verify and clean the fuel system. _____________________...

  • Page 136: Air Intake System

    AIR INTAKE SYSTEM Air Filter Box Draining Air Filter Removal Periodically inspect air filter box drain CAUTION: Never remove or modify tube for liquids water or deposits. any component in the air box. Oth- erwise, engine performance degra- dation or damage can occur. The engine carburetion is calibrated to operate specifically with these com- ponents.

  • Page 137: Air Filter Cleaning

    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 cleaning solution disappears. Then, let the filter dry completely.

  • Page 138: Electrical

    ELECTRICAL Removal WARNING Disconnect BLACK (-) cable first then Unless otherwise indicated, al- RED (+) cable. ways turn ignition switch to the OFF position before performing WARNING any maintenance or repair on elec- trical system. Always respect this order for dis- assembly;...

  • Page 139: Fuses

    Fuses To remove fuse from holder, remove the fuse holder cover then pull fuse WARNING out. Check if filament is melted. Always turn the ignition switch off before replacing a defective fuse. If a fuse is damaged, replace it by one of the same rating.
  • Page 140 NOTE: Concerning the following illus- trations, the front fascia has been re- moved from the vehicle for a better comprehension. Press the spindle then push it on the side to unlock headlamp bulb. vmo2006-005-043_a 1. Screws 2. Holder Remove rubber protector over head- lamp housing.
  • Page 141 Beam Aiming Adjustment Push the bulb in and hold while turning counterclockwise to release. Adjust beam aiming as follows: Install the new bulb by first pushing in Turn knobs to adjust beam height and while turning clockwise. side orientation to your convenience. Adjust both headlamps evenly.

  • Page 142: Drive Train

    Wheel Bearing Condition Push and pull the wheels from the upper edge to feel the play. See an authorized Bombardier ATV dealer if there is any play. V07H01Y FRONT OF VEHICLE 1. Drive shaft protector 2.

  • Page 143: Tires/Wheels

    Tires/Wheels TIRE PRESSURE FRONT REAR WARNING MAX. When the tires are replaced, nev- UP to 34 kPa 34 kPa 235 kg (5 PSI) (5 PSI) er install a bias tire with a radial (517 lb) tire. Such a combination could 31 kPa 31 kPa create handling and/or stability...
  • Page 144 V07H04Y 1. Taper side of nut CAUTION: Always use the recom- mended wheel nuts (P/N 250 100 039). Using a different nut could cause damages to the rim. _____________________...

  • Page 145: Steering System

    STEERING SYSTEM Throttle Cable Lubrication Lubrication The throttle cable must be lubricated with cable lubricant (P/N 293 600 041) or an equivalent. WARNING Always use a silicone-based lubri- cant. Using another lubricant (like a water-based lubricant) could V07I0GY cause the throttle lever/cable stick- 1.

  • Page 146: Throttle Lever Adjustment

    V07I0JY NOTE: Place a rag around the throttle V07I0IY cable adjuster to prevent the lubricant Remove the carburetor side cover. from splashing. Add lubricant until it runs out at carbu- retor end of the throttle cable. Reinstall and adjust the cable. Throttle Lever Adjustment Slide rubber protector back to expose throttle cable adjuster.
  • Page 147 With the transmission lever on PARK position, start the engine. Check if the throttle cable is adjusted correctly by turning handlebar fully right then ful- ly left. If the engine RPM increases, readjust the throttle lever free play. _____________________...

  • Page 148: Suspension

    Bombardier ATV dealer as necessary. Trailing Arms Check trailing arms for distortion, cracks or bending. See an authorized V07J01Y Bombardier ATV dealer if any problem is detected. 1. Adjusting cams 2. Smooth adjustment 3. Hard adjustment A-Arms Check A-arms for cracks, bending or other damages.

  • Page 149: Brake

    4.3 mm (.170 in) Rear disc thickness Maximum discs 0.2 mm (.010 in) warpage See your authorized Bombardier ATV dealer if a problem is detected con- cerning the brake system. Brake Fluid Replacement WARNING The brake fluid replacement or...

  • Page 150: Body/Frame

    BODY/FRAME Engine Area Seat Fasteners Check engine area for any damage Remove seat(s) and/or storage box and leaks. Ensure all hose clamps and check latch mechanisms and pins are properly secured and no hose is for wear. See an authorized Bom- cracked, kinked or otherwise dam- bardier ATV dealer for parts replace- aged.

  • Page 151: Warranty

    WARRANTY _____________________...

  • Page 152: Brp Limited Warranty North America: 2006 Bombardier

    Carlisle‡ tires and Warn††† winches installed as original equipment on ATVs are warranted separately by the tire and winch manufacturer. If such tire or winch are installed on your Bombardier ATV, please contact the manufacturer or ask your authorized Bombardier ATV dealer for warranty coverage and assistance.
  • Page 153 3) CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on 2006 Bombardier ATVs purchased as new and unused by its first owner from a Bombardier dealer authorized to distrib- ute Bombardier ATV products in the country in which the sale occurred (“Bom- bardier ATV dealer”), and then only after the BRP specified predelivery inspection...
  • Page 154 BRP’s obligations under this warranty are limited to, at its sole discretion, repair- ing parts found defective under normal use, maintenance and service, or replac- ing such parts with new genuine Bombardier parts without charge for parts and labor, at any authorized Bombardier ATV dealer during the warranty coverage pe- riod.
  • Page 155 Bombardier ATV dealer and gives the coordinates of the new owner; or b) BRP or an authorized Bombardier ATV dealer receives a proof that the former owner agreed to the transfer of ownership, in addition to the coordinates of the new owner.

  • Page 156: Brp International Limited Warranty: 2006 Bombardier Atv

    Bombardier ATV distributor/dealer. Moreover, this warranty cover- age is only available if the Bombardier ATV is purchased in the country in which the purchaser resides. BRP will not honor this limited warranty to any private use owner or commercial use owner if the preceding conditions have not been met.
  • Page 157 BRP’s obligations under this warranty are limited to, at its sole discretion, repair- ing parts found defective under normal use, maintenance and service; or replac- ing such parts with new genuine Bombardier parts without charge for parts and labour, at any authorized Bombardier distributor/dealer.
  • Page 158 BOMBARDIER RECREATIONAL PRODUCTS INC. BOMBARDIER ATV CONSUMER SERVICES GROUP VALCOURT QC J0E 2L0 TEL : +1-819-566-3366 © 2005 Bombardier Recreational Products Inc. All rights reserved. † Bombardier is a trademark of Bombardier Inc. used under license. _____________________...

  • Page 159: 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 Inc. Warranty Department 75 J.A. Bombardier Street Sherbrooke, Québec J1L 1W3...
  • Page 160 _____________________...

  • Page 161: Change Of Address/Ownership

    STOLEN UNITS: If your personal ATV is stolen, you should notify BRP or an au- thorized 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 162 AFFIX PROPER POSTAGE Bombardier Recreational Products Inc. WARRANTY DEPARTMENT 75, J.-A. Bombardier Street Sherbrooke, Québec Canada J1L 1W3 V00A2G _____________________...
  • Page 163 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.

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