User Manuals: Can-Am Renegade 1000R 2016 ATV

Manuals and User Guides for Can-Am Renegade 1000R 2016 ATV. We have 1 Can-Am Renegade 1000R 2016 ATV manual available for free PDF download: Service Manual

Can-Am Renegade 1000R 2016 Service Manual

Can-Am Renegade 1000R 2016 Service Manual (535 pages)

Brand: Can-Am | Category: Offroad Vehicle | Size: 65.8 MB

Table of Contents

Safety Notice
2
Vehicle Information
3
Vehicle Identification Number (VIN)
3
Engine Identification Number (EIN)
3
VIN Decal Description
3
Engine Emissions Information
4
Emission Regulations
4
Manual Layout
5
Typical Page
6
Tightening Torque
8
Fastener Information
9
Self-Locking Fastener Procedure
9
Loctite Threadlocker Application Procedure
9
Threadlocker Application for Uncovered Holes (Bolts and Nuts)
9
Threadlocker Application for Stud Installation in Blind Holes
10
Threadlocker Application for Pre-Assembled Parts
10
Threadlocker Application for an Adjustment Screw
10
Application for Stripped Thread Repair
11
Gasket Compound Application
11
Standard Thread Repair
11
Threadlocker Application for Mounting on a Shaft
12
Threadlocker Application for Case-In Components (Metallic Gaskets)
12
Periodic Maintenance Schedule
13
Sever Dusty Conditions
13
Maintenance Schedule Legend
13
Maintenance Schedule
13
Periodic Maintenance Procedures
16
Air Intake System
16
Engine Air Filter Maintenance Guideline
16
Removing the Engine Air Filter
16
Draining and Inspecting the Engine Air Filter Housing
17
Cleaning the Paper Filter
17
Cleaning the Foam Filter
18
Oiling the Foam Filter
18
Installing the Engine Air Filter
18
Exhaust System
19
Lubrication System
19
Cleaning and Inspecting the Muffler Spark Arrester
19
Recommended Engine Oil
19
Verifying the Engine Oil Level
20
Changing the Engine Oil
20
Replacing the Engine Oil Filter
21
Removing the Engine Oil Filter
21
Installing the Engine Oil Filter
21
Cooling System
22
Recommended Engine Coolant
22
Verifying the Engine Coolant Level
22
Checking the Engine Coolant Specific Gravity
22
Replacing the Engine Coolant
23
Cooling System Leak Test
23
Cylinder Head
25
Inspecting and Adjusting Engine Valve Clearance
25
Valve Clearance
25
Recommended Gearbox Oil
26
Verifying the Gearbox Oil Level
26
Replacing the Gearbox Oil
26
Continuously Variable Transmission (CVT)
27
Inspecting the Gearbox Input and Output Shafts Oil Seals
27
Cleaning the Vehicle Speed Sensor
27
Cleaning the CVT Air Inlet / Outlet
27
Inspecting the Drive Belt
28
Drive Pulley, Driven Pulley and One-Way Bearing Maintenance
28
Inspecting and Cleaning the Throttle Body
28
Lubricating the Throttle Cable
28
Electrical System
30
Replacing the Fuel Tank Vent Breather Filter
30
Inspecting the Fuel System
30
Inspecting the Battery
30
Drive System
31
Replacing the Spark Plugs
31
Verifying the Front Differential Oil Level
31
Replacing the Front Differential Oil
31
Inspecting the Front Differential Oil Seals
32
Verifying the Rear Final Drive Oil Level
32
Replacing the Rear Final Drive Oil
32
Wheels and Tires
33
Steering System
33
Inspecting the Rear Final Drive Oil Seals
33
Inspecting the Drive Shaft Boot and Protector
33
Suspension
34
Inspecting the Shock Absorber
34
Lubricating the Shock Absorber Spherical Bearing
34
Lubricating the Front Suspension Arm
34
Brakes
35
Inspecting the Front Suspension Arm
35
Inspecting the Rear Suspension Arm
35
Inspecting and Lubricating the Rear Stabilizer Bar Bushings
35
Verifying the Brake Fluid Reservoir Level
36
Adding Brake Fluid
36
Inspecting and Cleaning the Brake System
36
Replacing the Brake Fluid
37
Brake Fluid Filling
37
Draining the Brake Fluid
37
Bleeding the Brake System
38
Storage Procedure
39
Fuel System Protection
39
Engine Internal Lubrication
39
Engine Air Intake System
39
Chassis
40
Battery Removal
40
Vehicle Cleaning
40
Tire Pressure
40
Vehicle Protection
41
Recommended Product for Plastic Parts
41
Recommended Product for Vinyl Parts
41
Recommended Rust Protection
41
Preseason Preparation
42
Special Procedures
43
What to Do if Water Is in the CVT
43
What to Do if Water Is in the Air Filter Housing
43
What to Do if Vehicle Is Turned over
43
What to Do if Vehicle Is Immersed in Water
44
Engine Removal and Installation
45
Engine Removal
46
Engine Lifting
49
Engine Installation
51
Engine Mounts Replacement
51
Engine Mount Removal
51
Engine Mount Installation
51
Air Filter Housing
52
Air Filter Housing Removal
53
Air Filter Housing Inspection
56
Air Filter Housing Installation
56
Spark Arrester
58
Muffler Removal
58
Muffler Inspection
58
Muffler Installation
58
Heat Shield Removal
59
Heat Shield Installation
59
Y-Exhaust Pipe Removal
59
Y-Exhaust Pipe Inspection
60
Y-Exhaust Pipe Installation
60
Front Head Pipe Removal
60
Front Head Pipe Installation
60
Exhaust System Tightening System Sequence
61
Lubrication System Components
63
570 Engine
63
850 And 1000R Engines
64
Engine Lubrication Circuit
65
Troubleshooting
66
Testing the Engine Oil Pressure
66
Low or no Oil Pressure
66
Oil Contamination
66
High Oil Consumption
67
Oil Cooler Location
67
Removing the Oil Cooler
67
Installing the Oil Cooler
67
Oil Pressure Switch Access
68
Oil Pressure Switch Activation
68
Testing the Oil Pressure Switch Resistance
68
Installing the Oil Pressure Switch
68
Oil Pressure Regulator Location
69
Removing the Oil Pressure Regulator
69
Oil Pump Location
69
Removing the Oil Pump
69
Inspecting the Oil Pump
70
Installing the Oil Pump
71
Clearance of Inner and Outer Rotor
71
Oil Pump Axial Clearance
71
Engine Oil Strainer
72
Testing the Oil Pump Function
72
Removing the Oil Strainer
72
Cleaning and Inspecting the Oil Strainer
72
Reed Valve
72
Removing the Reed Valve
73
Inspecting the Reed Valve
73
Installing the Reed Valve
73
Radiator
75
Water Pump
78
Thermostat Location
79
Removing the Thermostat
79
Testing the Thermostat
80
Installing the Thermostat
80
Inspecting the Radiator
80
Removing the Radiator
80
Coolant Temperature Sensor (CTS)
81
Installing the Radiator
81
Radiator Cooling Fan Operation
81
Radiator Cooling Fan Fuse Location
81
Testing the Radiator Cooling Fan
82
Troubleshooting the Radiator Cooling Fan
82
Removing the Radiator Cooling Fan
82
Radiator Cooling Fan Relay (R1)
83
Water Pump Housing
83
Installing the Radiator Cooling Fan
83
Relay Location (Radiator Cooling Fan)
83
Water Pump Impeller
84
Water Pump Shaft and Seals
84
Installing the Water Pump Housing
84
Water Pump Seals Replacement
84
Water Pump Shaft and Seals Replacement
89
Water Pump Shaft and Seals Installation
90
Water Pump Gears Identification
91
Inspecting the Water Pump Gears
91
Water Pump Gear
91
Water Pump Intermediate Drive Gear
91
Removing the Water Pump Gears
92
Installing the Water Pump Gears
92
Magneto and Starter
94
Subsection XX
95
Magneto Cover Access
96
Removing the Magneto Cover
96
Inspecting and Cleaning the Magneto Cover
96
Installing the Magneto Cover
97
Stator Connector Access
97
Testing the Stator Static Continuity
97
Testing the Stator Insulation
98
Removing the Stator
98
Inspecting the Stator
98
Installing the Stator
98
Removing the Rotor
99
Inspecting the Rotor
99
Installing the Rotor
100
Removing the Sprag Clutch
101
Inspecting the Sprag Clutch
101
Installing the Sprag Clutch
101
Removing the Sprag Clutch Gear
102
Inspecting the Sprag Clutch Gear
102
Installing the Sprag Clutch Gear
102
Starter Drive Gear Location
102
Electric Starter
103
Inspecting the Starter Drive Gear
103
Testing the Starter Operation
103
Removing the Starter
103
Installing the Starter
104
Starter O-Ring and Mating Surface
104
Intake Manifold
105
Intake Manifold Access
106
Removing the Intake Manifold
106
Inspecting the Intake Manifold
107
Installing the Intake Manifold
107
Top End
108
Cylinder Head No. 1
109
Cylinder Head No. 2
110
Cylinders and Pistons
111
Leak Test
112
Preparing the Leak Test
112
Diagnosis
113
Valve Cover Access
114
Removing the Valve Cover
114
Inspecting the Valve Cover
114
Removing the Rocker Arm
114
Inspecting the Rocker Arm
115
Rocker Arm Bore Diameter
115
Installing the Rocker Arm
116
Removing the Camshaft
116
Rocker Arm Shaft Diameter
116
Inspecting the Camshaft
117
Camshaft Lobe (Intake)
117
Installing the Camshaft
118
Cylinder Head Access
118
Removing the Cylinder Head
118
Inspecting the Cylinder Head
119
Installing the Cylinder Head
120
Camshaft Bearing
120
Removing the Valve Spring
121
Cylinder Head Screw Identification
121
Inspecting the Valve Spring
122
Installing the Valve Spring
122
Valve Spring Free Length
122
Removing the Valve
123
Inspecting the Valve
123
Inspecting the Valve Stem
123
Inspecting the Valve Face and Seat
124
Installing the Valve
124
Valve Stem Diameter
124
Valve Seat Contact Width
124
Inspecting the Valve Guide
125
Removing the Valve Guide
125
Installing the Valve Guide
125
Removing the Cylinder
126
Valve Guide (Measurement A)
126
Inspecting the Cylinder
127
Installing the Cylinder
127
Cylinder Taper Measurements
127
Cylinder Taper Specifications
127
Removing the Piston
128
Inspecting the Piston
128
Piston/Cylinder Clearance
129
Piston Measurement
129
Connecting Rod/Piston Pin Clearance
130
Piston Pin Diameter
130
Installing the Piston
130
Removing the Piston Rings
132
Inspecting the Piston Rings
132
Installing the Piston Rings
132
Ring End Gap
132
Timing Chain
134
Unusual Engine Noise or Vibration
135
Engine Lacks Acceleration or Power
135
Timing Chain Tensioner Location
135
Timing Chain Tensioner Access
135
Inspecting the Timing Chain Tensioner
136
Installing the Timing Chain Tensioner
136
Timing Chain Tensioner Adjustment
136
Removing the Camshaft Timing Gear
137
Inspecting the Camshaft Timing Gear
138
Installing the Camshaft Timing Gear
138
Camshaft Timing
139
Crankshaft TDC Position Tool Installation
141
Timing Chain Location
142
Removing the Timing Chain
142
Inspecting the Timing Chain
143
Timing Chain Guide (Tensioner Side)
144
Installing the Timing Chain
144
Removing the Timing Chain Guide (Tensioner Side)
144
Inspecting the Timing Chain Guide
144
Bottom End
145
Crankcase and PTO Cover
146
Crankshaft
147
Engine Drive Shaft
148
Removing the Engine Drive Shaft
148
Inspecting the Engine Drive Shaft
148
Installing the Engine Drive Shaft
149
Installing the Rear Bearing Cover
149
Installing the Front Bearing Cover
150
Replacing the Front Oil Seal (Engine Drive Shaft)
150
Replacing the Rear Oil Seal (Engine Drive Shaft)
150
Removing the PTO Oil Seal
151
Inspecting the PTO Oil Seal
152
Installing the PTO Oil Seal
152
Removing the PTO Cover
152
Inspecting the PTO Cover
152
Replacing the Plain Bearing (PTO Cover)
153
Installing the Plain Bearing
153
Plain Bearing Inside Diameter (PTO Cover)
153
Installing the PTO Cover
154
Drive Gears Location
154
Removing the Drive Gears
155
Inspecting the Drive Gears
155
Installing the Drive Gears
155
Disassembling the Crankcase
156
Models Without Oil Cooler
156
Models with Oil Cooler
157
Cleaning the Crankcase
157
Inspecting the Crankcase
158
Replacing the Plain Bearing (Main)
158
Main Bearing Inside Diameter (PTO/MAG)
158
Assembling the Crankcase
159
Crankshaft Locking Procedure
161
Removing the Crankshaft
162
Inspecting the Crankshaft
162
Connecting Rod Big End Radial Play
163
Connecting Rod Big End Axial Play
163
Crankshaft Axial Play
163
Crankshaft Radial Play MAG/PTO Side
164
Crank Pin Diameter
164
Connecting Rod Big End Diameter
164
Connecting Rod Big End Radial Clearance
164
Crankshaft Radial Play (PTO Cover Bearing)
165
Assembling the Crankshaft
165
Crankshaft Journal Diameter (PTO Cover Bearing)
165
Installing the Crankshaft
166
Continuously Variable Transmission (CVT) (570/850)
168
CVT Cover Access
171
Draining the CVT Cover
171
Removing the CVT Cover
171
Installing the CVT Cover
171
Removing the Drive Belt
172
Installing the Drive Belt
172
Removing the Drive Pulley
172
Disassembling the Drive Pulley
174
Governor Cup
174
Sliding Sheave
175
Fixed Sheave
175
Cleaning the Drive Pulley
176
Inspecting the Drive Pulley
176
Bushings
176
Centrifugal Lever Pivot Bolt
177
Centrifugal Lever
177
Centrifugal Lever Pivot Bolt Bore Diameter
178
Sliding Sheave Large Bushing
178
Sliding Sheave Small Bushing
178
Assembling the Drive Pulley
179
One-Way Clutch
179
Friction Washer
179
Installing the Drive Pulley
180
Removing the Driven Pulley
181
Disassembling the Driven Pulley
181
Cleaning the Driven Pulley
182
Inspecting the Driven Pulley
183
Bushing Inner Diameter
184
Wear on Teeth
184
Width on Top Surface
184
Wear on Contact Surface
184
Assembling the Driven Pulley
185
Installing the Driven Pulley
185
Spring Free Length
185
Clutch Spring Squareness
185
Removing the CVT Air Guide
189
Inspecting the CVT Air Guide
189
Tightening Sequence (Driven Pulley Screw)
189
Installing the CVT Air Guide
190
Gearbox and 4X4 Coupling Unit (with External Switches)
191
Gearbox Components and 4X4 Coupling Mechanism
192
Gearbox Components and 4X4 Actuator Unit
193
Gearbox Identification
194
Gearbox Troubleshooting
194
Gearbox with External Switches
194
Unusual Gearbox Noise And/Or Vibrations
194
Vehicle Speed Sensor (VSS)
195
VSS Location
195
VSS Access
195
VSS Connector Access
195
VSS Circuit Protection
196
Testing the VSS Input Voltage
196
Testing the VSS Signal
196
Removing the VSS
196
Gearbox Position Indicator Switch Access
197
Testing the Gearbox Position Indicator Switch Continuity
197
Installing the VSS
197
VSS O-Ring
197
Removing the Gearbox Position Indicator Switch
198
Installing the Gearbox Position Indicator Switch
198
4WD Indicator Switch Access
198
Removing the 4WD Indicator Switch
198
Installing the 4WD Indicator Switch
199
4WD Actuator Access
199
Testing the 4WD Actuator
199
Removing the 4WD Actuator
199
Replacing the Gearbox Oil Seals
201
Lubricating the Oil Seal
201
Countershaft Oil Seal
201
Shift Shaft Oil Seal
202
Output Shaft Oil Seal
202
Output Shaft and Coupling Mechanism
203
Output Shaft Backlash Procedure
203
Removing the Output Shaft and Coupling Mechanism
204
Output Shaft Backlash
204
Inspecting the Output Shaft and Coupling Mechanism
205
Installing the Output Shaft and Coupling Mechanism
206
Coupling Sleeve Groove Width
206
Removing the Gearbox
208
Disassembling the Gearbox
208
Bevel Gear Axial Clearance
209
Removing the Bearings
212
Inspecting the Gearbox
212
Shift Forks
213
Shift Drum
213
Levers
213
Gears
213
Width of Shift Fork Engagement Groove (High Gear Shifting)
214
Width of Shift Fork Engagement Groove (Low/Reverse Gear Shifting)
214
Diameter Free Pinion
214
Intermediate Gear Shaft
214
Adjusting the Gearbox
215
Bevel Gear Shaft
215
Bevel Gear Backlash Procedure
216
Bevel Gear Axial Clearance Procedure
217
Assembling the Gearbox
218
Installing the Bearings
218
Installing the Gearbox
223
Gearbox and 4X4 Coupling Unit (with GBPS)
225
Shift Shaft and Shift Drum
249
Shifter (Gearbox with External Switches)
252
Handle Removal
253
Handle Installation
253
Shift Lever Access
253
Shift Lever Removal
253
Shift Lever Inspection
254
Shift Lever Installation
254
Shift Rod Adjustment
255
Shift Plate Removal
256
Shift Plate Inspection
256
Shift Plate Installation
256
Shifter (Gearbox with GBPS)
258
Engine Management System (EMS)
263
Engine with Gearbox Using External Switches
263
Engine with Gearbox Using GBPS
265
Engine RPM Limiter
268
Vehicle Speed Limiter
268
Drowned Mode (Flooded Engine)
268
Monitoring System
268
Controller Area Network (CAN)
269
Communication Tools and B.U.D.S.
270
Diagnostic Tips
270
Multi-Purpose Interface Card Connection Troubleshooting
270
MPI Status Lights
270
Multi-Purpose Interface Card (MPI-2 or MPI-3)
271
Communication Problems When Using B.U.D.S.
271
MPI Card Power
271
Diagnostic Connector Location
271
B.U.D.S. Software
272
Connecting the PC to the Vehicle
272
Reading the Electronic Control Units Using B.U.D.S. Software
272
Updating Electronic Module (ECU) Software
273
Saving Changes to an ECU
274
Diagnostic and Fault Codes
276
Pilot Lamps for Problematic Conditions
276
Limp Home Mode
276
Monitoring System
276
Fault Code Categories
277
Fault Code States
277
How to Display Fault Codes in the Multifunction Gauge
277
How to Read Fault Codes Using B.U.D.S.
278
Fault Code Diagnostic
280
How to Clear Fault Codes Using B.U.D.S.
280
Missing Module
280
General Guidelines to Solve Fault Codes
281
Fault Code Table
283
How to Find Fault Code Descriptions
283
Electronic Fuel Injection (EFI)
310
ECM (Electronic Control Module)
310
EFI Sensors
310
Throttle Body
310
Idle Speed Adjustment
311
Fuel Rail
311
Fuel Injectors
311
Fuel Pump
311
Closed Throttle and Idle Actuator Reset
312
Engine Control Module (ECM)
313
Electrical Related Problems
313
Quick Test to Validate ECM Operation
313
ECM Connector
313
Testing the ECM Power Supply
314
Testing the Continuity of ECM Ground Circuits
314
Testing the CAN Resistor
314
Removing the ECM
315
Installing the ECM
315
Replacing the ECM
315
ECM Data Transfer
315
Fuel Injector Leak Test
317
Testing the Fuel Injector Input Voltage
317
Testing the Injector Power Circuit Resistance
318
Testing the Fuel Injector Resistance
318
Testing the Injector Ground Circuit Resistance
318
Installing the Fuel Injector
318
Replacing the Fuel Rail
319
Installing the Fuel Rail
319
Injector O-Rings
319
Removing the Throttle Cable
320
Installing the Throttle Cable
320
Adjusting the Throttle Cable
320
Throttle Body Description
321
Throttle Body Access
321
Inspecting the Throttle Body
321
Cleaning the Throttle Body
321
Installing the Throttle Body
322
Throttle Position Sensor (TPS)
323
TPS Access
323
Testing the TPS Wear
324
Testing the TPS Resistance
324
Testing the TPS Input Voltage
324
Idle Air Control Valve (IACV)
325
Replacing the TPS
325
IACV Access
325
Testing the IACV Resistance
325
Crankshaft Position Sensor (CPS)
326
Inspecting the IACV Visual
326
IACV Calibration
326
CPS Access
326
Manifold Absolute Pressure and Temperature Sensor (MAPTS)
327
Replacing the CPS
327
MAPTS Access
327
MAPTS Pressure Function
327
MAPTS Temperature Function
328
MAPTS Pressure Function Quick Test
328
MAPTS Circuit Continuity Test (Pressure Function)
328
MAPTS Connector
328
Replacing the MAPTS
329
ECM Adapter
329
MAPTS Temperature Sensor Test Results
329
MAPTS Circuit Continuity Test (Temperature Function)
329
CTS (Coolant Temperature Sensor)
330
CTS Access
330
Testing the CTS Resistance
330
Testing the CTS Circuit Continuity
330
Fuel Tank and Fuel Pump
332
Fuel Tank Vent System
334
Fuel Tank Vent Breather Filter
334
Fuel Tank Leak Test
335
Fuel Pump Module
335
Fuel Filters
335
Fuel Pump Pressure Regulator
335
Fuel System Pressure Test
336
Test Conclusion
336
Slow Pressure Drop
337
Fuel System Diagnostic Flow Chart
338
Fuel Hose and Oetiker Clamps
339
Disconnecting a Fuel Pressure Hose
339
Fuel Hose Replacement
339
Fuel Tank Draining
339
Fuel Tank Inspection
341
Fuel Tank Installation
341
Fuel Pump Pressure Test
342
Fuel Pump Quick Test
342
Fuel Pump Connector Access
342
Fuel Pump Input Voltage Test
342
Fuel Pump Resistance Test
343
Fuel Pump Access
343
Fuel System Pressure Release
343
Fuel Pump Removal
343
Fuel Pump Installation
344
Fuel Pump Pre-Filter Replacement
346
Fuel Level Sender
348
Fuel Level Sender Resistance Test (Fuel Pump Module Installed)
348
Fuel Level Sender Resistance Test (at Fuel Pump Connector)
348
Fuel Level Sender Input Voltage Test
348
Fuel Level Sender Replacement
349
Fuel Tank Vent Valve Test
349
Inlet Check Valve Test
349
Fuel Tank Vent Valve Installation
350
Inlet Check Valve Installation
350
Pressure Relief Valve Installation
350
Power Distribution Diagram
351
Fuse Box 1
352
Fuse Links and Fuse Box 2
353
Grounds
353
Testing a Fuse Link
353
Replacing a Fuse Link
353
Wiring Harness and Connectors
355
Connector Abbreviation Description
355
Wiring Harness Routing
357
Main Harness (Front 1/2)
357
Main Harness (Front 2/2)
358
Main Harness (Rear)
359
Wiring Harness Splice Location
360
Main Harness (Rear Part)
360
Deutsch Connectors
362
Deutsch Connector Application
362
Deutsch Connector Disassembly and Reassembly
362
Packard Connectors
363
Packard Connector (Multifunction Gauge)
363
Packard Connector Application
363
3-Pin Packard Connector
363
Molex Connector Application
365
Molex Connector Removal
365
Molex Connector Installation
365
Molex Connector Probing
366
Molex Connector Inspection
366
Molex Connector Terminal Removal
366
Furukawa Connector Application
367
Terminal Removal
367
Battery and Starter Cable Terminals
368
Cable Crimping
368
Ignition System
370
Ignition System Troubleshooting
370
Engine will Not Start (Engine Turns Over)
370
Engine Hard to Start
370
Ignition Switch Quick Test
371
Ignition Switch Access
371
Testing the Emergency Engine Stop Switch at ECM
371
Testing the Emergency Engine Stop Switch at Multifunction Switch Connectors
372
Ignition Coil Access
372
Installing the Ignition Coil
372
Testing the Ignition Coil Input Voltage
372
Testing the Ignition Coil Ground Circuit Continuity
373
Testing the Ignition Coil Resistance
373
Troubleshooting Fouled Spark Plug
374
Spark Plug Analysis
374
Charging System General
375
Charging System Troubleshooting
375
Magneto
375
Voltage Regulator
375
Battery Load Test
376
Charging System Load Test
376
Battery Regularly Discharged or Weak
376
Voltage Regulator (RD)
377
Voltage Regulator Access
377
Voltage Regulator Power Test
377
Voltage Regulator Ground Test
377
Battery Information
378
Battery Inspection
378
Battery Storage
378
Battery Cleaning
378
New Battery Activation
379
Battery Charging
379
Battery Installation
379
Starting System Operation
380
Starting System Troubleshooting
380
Engine will Not Turn
380
Engine Turns
380
Starting System Tests
381
Starter Solenoid
381
Starter Solenoid Control Circuit
381
Starter Solenoid Control Power Circuit
381
Starter Power Circuit Voltage Drop
382
Starter Solenoid Control Ground Circuit
383
Starter Solenoid Continuity
383
Solenoid Diode Test
384
Digitally Encoded Security System (D.E.S.S.) Description
386
Digitally Encoded Security System (D.E.S.S.) Troubleshooting
386
Key Programming
386
Lights, Gauge and Accessories
388
Multifunction Gauge Description
388
Multifunction Display Modes
389
Speed Mode
389
RPM Mode
389
Combined Mode
389
Navigating the LCD Gauge
390
Odometer (OD)
390
Clock
390
Trip Meter (TP)
390
Testing the Circuit
391
Inspecting the Electrical Connection
391
Diagnostic Guidelines (Gauge)
392
Diagnostic Guidelines (Lights)
392
Multifunction Gauge will Not Come on
392
No Fuel Quantity Indication
392
Multifunction Gaue
393
Hazard Lights Come on Without Being Selected
393
Position Lights will Not Come on
393
Horn will Not Function
393
Multifunction Gauge Wire Identification
394
Multifunction Gauge Circuit Protection
394
Setting the Clock with Gauge Selector Button
394
Setting the Multifunction Gauge with B.U.D.S.
394
Testing the Multifunction Gaugewith B.U.D.S.
395
Testing the Multifunction Gauge CAN Resistor
395
Removing the Multifunction Gauge
396
Cam Resistor Test
396
Test Result
396
Installing the Multifunction Gauge
397
Removing and Installing the 12 Volt Power Outlet
397
Headlight Wire Identification
397
Testing the Headlight
397
Replacing the Headlight Bulb
398
Adjusting the Headlamp Beam
398
Beam Aiming Adjustment
398
Brake Light Switch
399
Brake Light Circuit Protection
399
Taillight Wire Identification
399
Replacing the Taillight/Brake Light Bulb
399
Turn Signal/Hazard Circuit Protection
400
Flasher Module Access
400
Horn Wire Identification
400
Horn Circuit Protection
400
Winch Wire Identification
401
Winch Switch Circuit Protection
401
Removing the Winch
401
Winch Switch
401
Installing the Winch
403
Front Drive
404
Front Drive Shafts and Front Propeller Shaft
405
Front Differential
406
Drive System Description
407
Wheel Hub Removal
407
Wheel Hub Inspection
407
Wheel Hub Installation
407
Front Drive Shaft Removal
408
Front Drive Shaft Inspection
408
Front Drive Shaft Installation
408
Drive Shaft Boot Removal
408
Drive Shaft Boot Installation
409
Front Differential Removal
409
Front Differential Inspection
410
Backlash Specification
410
Front Differential Disassembly
411
Differential Housing
411
Backlash Adjustment Guideline
411
Visco-Lok Carrier/Ring Gear
412
Front Differential Assembly
413
Recommended Shim Thickness
413
Front Differential Installation
414
Front Propeller Shaft Removal
415
Front Propeller Shaft Inspection
416
Front Propeller Shaft Installation
416
Rear Drive
417
Drive Shaft Removal
422
Drive Shaft Inspection
422
Drive Shaft Installation
422
Propeller Shaft Removal
423
Propeller Shaft Inspection
424
Propeller Shaft Installation
424
Propeller Shaft U-Joint Removal
425
Propeller Shaft U-Joint Installation
425
Rear Final Drive Removal
426
Rear Final Drive Inspection
426
Rear Final Drive Disassembly
428
Rear Final Drive Assembly
429
Rear Final Drive Installation
431
Tire Pressure
432
Tire Inspection
432
Tire Replacement
432
Wheel Removal
432
Steering Alignment
436
Removing the Handlebar Grip
437
Installing the Handlebar Grip
437
Removing the Handlebar
438
Installing the Handlebar
438
Steering Connector Access
438
Removing the Multifunction Switch
438
Removing the Throttle Lever
439
Installing the Throttle Lever
439
Removing the Brake Lever (from Vehicle)
439
Steering Column Bearing
440
Removing the Brake Lever (at Handlebar)
440
Removing the Steering Column (with a DPS)
441
Inspecting the Steering Column
441
Installing the Steering Column
441
Removing the Tie-Rod
442
Inspecting the Tie-Rod
442
Installing the Tie-Rod
442
Removing the Knuckle
443
Installing the Knuckle
443
Inspecting the Wheel Bearing
443
Removing the Wheel Bearing
443
Pitman Arm (with a DPS)
444
Installing the Wheel Bearing
444
Dynamic Power Steering (DPS)
445
DPS Assist Mode
445
Derating Explanation
446
DPS Unit
446
DPS Unit Protection
446
Steering Torque Sensor
447
Torque Offset Reset
447
DPS Unit Fuse Test
454
DPS Unit Input Voltage Test
454
DPS Unit Ground Circuit Test
455
DPS Unit Communication Link
456
DPS System Load Test
456
DPS Unit Current Test
457
DPS Unit Removal
458
DPS Unit Installation
461
DPS Unit Replacement
465
Pitman Arm Removal
465
Pitman Arm Installation
467
Front Suspension
470
Upper Suspension Arms and Components
471
Lower Suspension Arms and Components
472
Shock Absorber Removal
473
Shock Absorber Inspection
473
Shock Absorber Installation
473
Lower Suspension Arm Removal
473
Lower Suspension Arm Installation
474
Upper Suspension Arm Removal
474
Upper Suspension Arm Installation
475
Suspension Arm Bushings Removal
475
Suspension Arm Bushings Installation
476
Ball Joint Removal
476
Ball Joint Installation
477
Rear Suspension
478
Trailing Arms and Sway Bar
479
Shock Absorbers
480
Shock Absorber Bushing Replacement
481
Spring Removal
482
Spring Inspection
482
Spring Installation
482
Sway Bar Removal
482
Sway Bar Inspection
483
Sway Bar Installation
483
Trailing Arm Removal
483
Trailing Arm Disassembly
484
Trailing Arm Pivot Bearing Removal
484
Trailing Arm Inspection
485
Trailing Arm Assembly and Installation
485
Front Circuit
487
Rear Circuit
488
Calipers and Brake Levers
491
Disc Brake Configurations
492
Brake System Pressure Validation
492
Brake Lever Verification
492
Brake Light Switches
493
Brake Pedal Verification
493
Brake Light Switch Location
493
Brake Light Switch Resistance Test
494
Brake Light Switch Replacement
494
Brake Pedal Removal
494
Brake Pedal Installation
495
Master Cylinder Removal
495
Master Cylinder Inspection
495
Master Cylinder Installation
495
Caliper Removal
496
Caliper Installation
496
Brake Pads Replacement
496
Brake Disc Inspection
498
Brake Disc Replacement
498
Body (Except X MR)
499
Body Parts Nomenclature
500
Front Body Module
500
Rear Body Module
500
Body Parts (Rear)
501
Body Parts (Front)
502
Body Parts (Central)
503
Rear Bumper
504
Front Bumper
505
Skid Plates
506
Plastic Rivet
507
Removing a Decal
507
Installing a Decal
507
Removing the Front Body Module
507
Installing the Front Body Module
509
Removing the Rear Body Module
509
Installing the Rear Body Module
510
Removing the Console
510
Installing the Console
510
Removing the Inner Fender Panel
510
Installing the Inner Fender Panel
511
Removing the Side Panel
511
Installing the Side Panel
511
Removing the Footrest Panel
511
Installing the Footrest Panel
512
Frame
513
Frame Inspection
515
Frame Welding
515
Frame Insert Replacement
515
Frame Replacement
515
Wiring Diagram Information
529
Wiring Diagram Location
529
Wiring Diagram Codes
529
Wiring Diagram Index
529
Wire Colors and Sizes
530
Splices in Wiring Harness
530
Splices Repair Procedure
530
Wire Broken from Splice
531
Specific Harness
534

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