Textron Motors MPE 850 OFF-ROAD Service Manual
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Textron Motors MPE 850 OFF-ROAD Service Manual

4-stroke engine
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SERVICE MANUAL
4-Stroke Engine
MPE 850 OFF-ROAD
This service manual is valid for the following engine models:
– 409135 I2 846 UTV NA-80
TD409135_SHB
Rev A
03.08.2015
en_English
Read this service manual thoroughly before operating the engine
for the first time.

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  • Page 1 SERVICE MANUAL 4-Stroke Engine MPE 850 OFF-ROAD This service manual is valid for the following engine models: – 409135 I2 846 UTV NA-80 TD409135_SHB Rev A Read this service manual thoroughly before operating the engine 03.08.2015 for the first time.
  • Page 3 Textron Motors GmbH strives to make continual improvements as part of the ongoing technical development of its products. All documentation is therefore subject to technical modifications. Reprints and translations, in whole or in part, require written permission from Textron Motors GmbH.

  • Page 4: Table Of Contents

    Table of contents Table of contents 1 About this document 1.1 Meaning of symbols and signal words......... . . 6 2 Safety 2.1 Meaning of safety alert symbol and signal words .
  • Page 5 Table of contents 8 Service tasks in the workshop 8.1 Safety messages workshop..........32 8.2 Tools and accessories .

  • Page 6: About This Document

    1 About this document 1.1 Meaning of symbols and signal words 1 About this document This service manual was designed to help you operating the engine safely and reliably. Observe the following references: – Read this service manual thoroughly before operating the engine for the first time. –...

  • Page 7: Safety

    2 Safety 2.1 Meaning of safety alert symbol and signal words 2 Safety This engine is state-of-the-art and built according to recognized safety technical and emission regulations. Ignoring the information in this service manual may result in personal injury or property damage. Read and observe the following safety messages carefully before operating the engine for the first time.

  • Page 8: Important Safety Messages

    All the components in your engine have been carefully tested and fulfill strict quality and safety requirements. ► Textron Motors offers spare parts to the highest quality. Ensure that equivalent spare parts corresponds with this quality requirements. Engine modifications may pose a safety risk to persons.
  • Page 9 2 Safety 2.2 Important safety messages Engine exhaust gases contain carbon monoxide (CO). Inhalation of Engine exhaust gases carbon monoxide can deprive the body of oxygen and result in organ damage or death by asphyxiation. ► Never operate the engine in enclosed spaces. Fuel, engine oil and coolant Engine fluids pose a health risk.

  • Page 10: Description

    The engine models I2 846 UTV has been designed for powering off-road vehicles. Any other use is not permissible. All specifications in this service manual are only valid for the unmodified engine delivered by Textron Motors. Engine modifications are not permissible and in addition, may void the warranty or violate federal laws.

  • Page 11: Fuel

    3 Description 3.3 Fuel | 3.4 Engine oil 3.3 Fuel Engine models I2 846 UTV NA-80 Fuel Unleaded gasoline Recommended fuel quality 95 ROZ or 85 MOZ USA ʺPremium 91ʺ Minimum requirement The minimum requirement is only suitable for using from start of series production.

  • Page 12: Coolant

    3 Description 3.5 Coolant 3.5 Coolant Engine models I2 846 UTV NA-80 Coolant additive Coolant additive based on ethylene glycol, silicate- and nitrite- free, suitable for aluminium engines. Suggested coolant additives NOTICE! Insufficient cooling due to incompatibilities of coolant. Combining different coolant additives may trigger a chemical reaction and they may lose their effectiveness.

  • Page 13: Engine Components And Information

    3 Description 3.6 Engine components and information 3.6 Engine components and information Engine models I2 846 UTV NA-80 – 1st cylinder – Sensor camshaft 2nd cylinder – Fuel supply – Throttle body / Air intake – Intake Manifold / Intake side –...
  • Page 14 3 Description 3.6 Engine components and information – Permanent vent coolant circuit – Exhaust ports / Exhaust side – Engine rotation direction – Stub shaft / Power take off – Crankcase vent / Engine oil return SHB MPE850 Rev A | 409135 |...

  • Page 15: Protective Functions

    3 Description 3.7 Protective functions 3.7 Protective functions The engine has an engine diagnostics, which monitors various operating parameters. The protection functions described in this chapter are intended for your protection and to protect your engine when the operating parameters exceed defined limits. Protective function Description Coolant temperature...
  • Page 16 WARNING! Risk of accident. Faults at the pedal value sensor and electronic throttle system (drive-by-wire) can affect the vehicle operation substantially. Contact immediately a qualified workshop. All Textron Motors authorized workshops are qualified to repair your engine. – 4500 min [rpm] Fault at the pedal value sensor –...

  • Page 17: Technical Specifications

    3 Description 3.8 Technical specifications 3.8 Technical specifications Engine models I2 846 UTV NA-80 Calibration Type 4-stroke gasoline engine, parallel twin with balance shaft and single overhead camshaft (SOHC) Displacement 846 cm³ Number of cylinders Bore x stroke 89 x 68 mm [3.5 x 2.7 in]w Compression ratio 11,5 : 1 Engine power SAE J1349...

  • Page 18: Supported Vehicle Equipment

    ► The required service tasks must be performed in a qualified workshop. All Textron Motors authorized workshops are qualified to service your engine. Observe that only the regular operating hours intervals will be indicated.
  • Page 19 NOTICE! Engine damage caused by overheating. An empty expansion tank may be an indication of a leaking cooling system. Immediately inspect the cause and repair possible faults by a qualified workshop. All Textron Motors authorized workshops are qualified to repair your engine. ►...

  • Page 20: Operation

    The following service tasks require special technical knowledge of this engine. These service tasks must be performed in a qualified workshop. All Textron Motors authorized workshops are qualified to service your engine. All activities are described in chapter 8 Service tasks in the workshop.

  • Page 21: Operation During The Break-In Period

    4 Operation 4.2 Operation during the break-in period 4.2 Operation during the break-in period The way you operate the engine is a major factor in determining engine performance and useful life. This affects the way you operate in the – first 5 hours of operation. –...

  • Page 22: Operating Engine

    4.3 Operating engine 4.3.1 Checking coolant level The following procedure is the practice with a Textron Motors expansion tank. However, the expansion tank is not always in scope of supply of the engine. If the vehicle equipment is different, observe strictly the vehicle manufacturer's documentation.

  • Page 23: Put The Engine Into Operation

    4 Operation 4.3 Operating engine 4.3.2 Put the engine into operation The following procedure is not a complete description of the commissioning, it describes only the engine- specific requirements. Observe strictly the vehicle manufacturer's documentation. ► Put the shift control lever in neutral position. ►...

  • Page 24: Checking Oil Level

    4.3.3 Checking oil level The following procedure is the practice with a Textron Motors oil tank. However, the oil tank is not always in scope of supply of the engine. If the vehicle equipment is different, observe strictly the vehicle manufacturer's documentation.
  • Page 25 4 Operation 4.3 Operating engine Refilling engine oil NOTICE! Engine damage caused by too much engine oil. Refill engine oil in small quantities with repeatedly checking. The difference between the MIN-marking and the MAX-marking approximately 0,5 liter [0.5 qt (US)] engine oil. ►...

  • Page 26: Take The Engine Out Of Operation

    4 Operation 4.3 Operating engine 4.3.4 Take the engine out of operation The following procedure is not a complete description of the decommissioning, it describes only the engine- specific requirements. Observe strictly the vehicle manufacturer's documentation. ► Actuate the brake pedal. ►...

  • Page 27: Transport And Storage Of The Vehicle

    4 Operation 4.3 Operating engine 4.3.5 Transport and storage of the vehicle If you intend to transport or place the vehicle in storage, read the following instructions: ► If you do not intend to operate the engine for 90 days or more, prepare the engine for storage. (See chapter 5.1 Engine storage for more than 90 days.) ►...

  • Page 28: Special Scenarios

    Preparation for storage requires special technical knowledge of this engine. These tasks must be performed in a qualified workshop. All Textron Motors authorized workshops are qualified to prepare your engine for storage. SHB MPE850 Rev A | 409135 |...

  • Page 29: Malfunctions

    6 Malfunctions 6.1 Malfunctions table Follow the remedy guidance or contact a qualified workshop if you cannot correct a malfunction yourself. All Textron Motors authorized workshops are qualified to repair your engine. Observe the chapter 3.9.1 Lights in vehicle. Possible cause...
  • Page 30 Fill up fuel. (See the vehicle manufacturer‘s documentation.) The battery has been discharged or Contact a qualified workshop. is defective. All Textron Motors authorized workshops are qualified to repair your engine. The engine stalls, but can Lack of fuel. Fill up fuel. (See the vehicle be started again.

  • Page 31: Dealer And Servicing Network

    Visit our web site www.weber-motor.com for a list of all authorized Textron Motors workshops. 7.2 Tools and parts Textron Motors offers a selection of accessories to prepare you for the most important situations. Visit your local vehicle dealer or our web site www.weber-motor.com for more information. 7.3 Repairs Repairs require special technical knowledge of this engine.

  • Page 32: Service Tasks In The Workshop

    ► Ensure your workshop is qualified to service your engine. ► All Textron Motors authorized workshops are qualified to service your engine. Service manual Before reading chapter 8 Service tasks in the workshop, you must have read and understood all other information in the service manual.

  • Page 33: Tools And Accessories

    8 Service tasks in the workshop 8.2 Tools and accessories 8.2 Tools and accessories 8.2.1 Service parts Textron Motors offers a service case that contains the following service parts. Visit your local vehicle dealer or our web site www.weber-motor.com for more information. Figure Description...

  • Page 34: Equipment Workshop

    8 Service tasks in the workshop 8.2 Tools and accessories 8.2.3 Equipment workshop In addition to the service case, you will require the following tools and accessories for service tasks. The figures are only examples of suitable tools. All tools and accessories are available from specialist retailers. Figure Description Figure...

  • Page 35: Supplies

    8 Service tasks in the workshop 8.2 Tools and accessories 8.2.4 Supplies You will require the following supplies or equivalents to perform service tasks. Unless otherwise specified, use the products as directed by the manufacturer. Supplies Recommended products Anti-Seize assembly paste for lubricating threaded –...

  • Page 36: Changing Engine Oil And Oil Filter

    8.3 Changing engine oil and oil filter The following procedure is the practice with a Textron Motors oil tank. However, the oil tank is not always in scope of supply of the engine. If the vehicle equipment is different, observe strictly the vehicle manufacturer's documentation.
  • Page 37 8 Service tasks in the workshop 8.3 Changing engine oil and oil filter The remaining engine oil will be pumped out with the suction pump in the dry sump. ► Disconnect the power supply of the ignition coils and injectors. (See the vehicle manufacturer‘s documentation.) When the starter is operated, the engine cranks, but will not start.
  • Page 38 ► Check the oil level. (See chapter 4.3.3 Checking oil level.) ► Update the engine control unit calibration. (See the Textron Motors Diagnostic Tool manual.) ► Clear the service counter for service light. (See the Textron Motors Diagnostic Tool manual.) ►...

  • Page 39: Checking And Adjusting Valve Lash

    8 Service tasks in the workshop 8.4 Checking and adjusting valve lash 8.4 Checking and adjusting valve lash 8.4.1 Checking valve lash Check valve lash with a cold engine. WARNING! Danger of serious cuts from the gear on the camshaft when the engine is started.
  • Page 40 8 Service tasks in the workshop 8.4 Checking and adjusting valve lash Inf or ma t ion ! The camshaft is turned by turning the crankshaft. Read the vehicle manufacturer‘s documentation for instructions. Always turn the crankshaft in the same direction as the engine rotates. (See chapter 3.6 Engine components and information.) Two rotations of the crankshaft correspond to one rotation of the camshaft.
  • Page 41 8 Service tasks in the workshop 8.4 Checking and adjusting valve lash Checking valve lash on the 2nd cylinder ► Turn the crankshaft in the same direction as the engine rotates until the position of the camshaft is as illustrated. (See the vehicle manufacturer‘s documentation.) The camshaft is marked at the 1st cylinder end only.
  • Page 42 Connect the wire harness connectors to the ignition coils and sensor camshaft ► Update the engine control unit calibration. (See the Textron Motors Diagnostic Tool manual.) ► Clear the service counter to reset service light. (See the Textron Motors Diagnostic Tool manual.)

  • Page 43: Adjusting Valve Lash With Valve Adjustment Kit

    8 Service tasks in the workshop 8.4 Checking and adjusting valve lash 8.4.2 Adjusting valve lash with valve adjustment kit I nf orm a t i o n ! The camshaft is turned by turning the crankshaft. Read the vehicle manufacturer‘s documentation for instructions.
  • Page 44 8 Service tasks in the workshop 8.4 Checking and adjusting valve lash Replacing valve adjustment shim NOTICE! Engine damage from small components in the engine or cylinder head. Operating the engine when there are small components in the crankcase and cylinder head can result in serious damage and cause the crank drive to seize.
  • Page 45 8 Service tasks in the workshop 8.4 Checking and adjusting valve lash ► Remove the valve adjustment shim using a bar magnet. ► Measure the valve adjustment shim using a caliper. ► Insert the new valve adjustment shim. ► Hold the rocker arm pusher in position.

  • Page 46: Adjusting Valve Lash Without Special Tool

    8 Service tasks in the workshop 8.4 Checking and adjusting valve lash 8.4.3 Adjusting valve lash without special tool Inf or ma t ion ! The camshaft is turned by turning the crankshaft. Read the vehicle manufacturer‘s documentation for instructions. Always turn the crankshaft in the same direction as the engine rotates. (See chapter 3.6 Engine components and information.) Two rotations of the crankshaft correspond to one rotation of the camshaft.
  • Page 47 8 Service tasks in the workshop 8.4 Checking and adjusting valve lash Replacing valve adjustment shim NOTICE! Engine damage from small components in the engine or cylinder head. Operating the engine when there are small components in the crankcase and cylinder head can result in serious damage and cause the crank drive to seize.
  • Page 48 8 Service tasks in the workshop 8.4 Checking and adjusting valve lash ► Hold the rocker arm in position. ► Check if the circlip is installed. ► Slide in the rocker axle ► Remove the cover from the chain channel. NOTICE! Valve breakage due to insufficient valve lash.

  • Page 49: Replacing Spark Plugs

    8 Service tasks in the workshop 8.5 Replacing spark plugs 8.5 Replacing spark plugs Remove spark plugs with a cold engine. ► Disconnect the wire harness connectors from the ignition coils ► Unscrew bolts ► Unplug ignition coils ► Unscrew the spark plugs using a spark plug wrench.
  • Page 50 8 Service tasks in the workshop 8.5 Replacing spark plugs ► Insert the ignition coils ► Replace serrated lock washers Assemble the bolts , washers serrated lock washers as illustrated. Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ►...

  • Page 51: Checking Spark Plugs

    8 Service tasks in the workshop 8.6 Checking spark plugs 8.6 Checking spark plugs Remove spark plugs with a cold engine. ► Disconnect the wire harness connectors from the ignition coils ► Unscrew bolts ► Unplug ignition coils ► Unscrew the spark plugs using a spark plug wrench.
  • Page 52 8 Servicearbeiten in der Werkstatt 8.6 Zündkerzen prüfen ► If the electrodes are extremely sooty, clean carefully using a spark plug brush. ► Check the spark plug gap using a feeler gauge. Required spark plug gap: 0,69 – 0,84 mm [0.028 – 0.032 in] ►...
  • Page 53 8 Servicearbeiten in der Werkstatt 8.6 Zündkerzen prüfen ► Connect the wire harness connectors to the ignition coils ► Test-drive the vehicle. SHB MPE850 Rev A | 409135 |...

  • Page 54: Changing Coolant

    8.7 Changing coolant 8.7 Changing coolant The following procedure is the practice with a Textron Motors expansion tank. However, the expansion tank is not always in scope of supply of the engine. If the vehicle equipment is different, observe strictly the vehicle manufacturer's documentation.
  • Page 55 When the MAX-marking is exceeded, pump out excessive coolant with a suction pump. ► Update the engine control unit calibration. (See the Textron Motors Diagnostic Tool manual.) ► Clear the service counter for service light. (See the Textron Motors Diagnostic Tool manual.)

  • Page 56: Replacing Fuel Filter

    8 Service tasks in the workshop 8.8 Replacing fuel filter 8.8 Replacing fuel filter See the vehicle manufacturer's documentation. SHB MPE850 Rev A | 409135 |...

  • Page 57: Preparing The Engine For Storage

    8 Service tasks in the workshop 8.9 Preparing the engine for storage 8.9 Preparing the engine for storage ► Change engine oil and oil filter (See chapter 8.3 Changing engine oil and oil filter.) ► Fill up the fuel tank. Add a fuel stabilizer according to the manufacturer's instructions. ►...

  • Page 58: Disposal

    8 Service tasks in the workshop 8.10 Disposal 8.10 Disposal When disposing of engine fluids, replaced parts or the whole engine, always comply with the relevant applicable national laws and guidelines. SHB MPE850 Rev A | 409135 |...

  • Page 59: Confirmation Of Service Tasks

    9 Confirmation of service tasks 9 Confirmation of service tasks Have the workshop personnel provide certification confirming that your engine was serviced. You can use the following documents. _________________ _________________ Engine model (6-digit) Date of initial registration _________________ Serial number (10-digit) Work carried out: Work carried out: ...
  • Page 60 9 Confirmation of service tasks Work carried out: Work carried out:  Engine oil and oil filter changed  Engine oil and oil filter changed  Valve lash checked  Valve lash checked Date: Date:  Spark plugs replaced  Spark plugs replaced ...

  • Page 61: Appendix

    Appendix Engine manufacturer Appendix Engine manufacturer Engine manufacturer Textron Motors GmbH Kautexstraße 52 53229 Bonn Germany www.weber-motor.com SHB MPE850 Rev A | 409135 |...

  • Page 62: Index

    Index Index Oil pressure light 18 Break-in period, engine 21 Part number, engine 10 Protection functions, engine 15 Components, engine 13 Coolant, change 54 Coolant level, check 22 Repairs 31 Coolant, refill 22 Roll over detection 15 Coolant, specification 12 Cylinder definition, engine 13 Serial number, engine 10 Service case, overview 33...

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409135 i2 846 utv na-80

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