2017 Skidoo G4 PDF

SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to ser- NOTE: Indicates supplementary information re-
vicing and repair the 2017 Ski-Doo® snowmobile quired to fully complete an instruction.
from the REV™ G4 platform. Although the mere reading of such information
This edition was primarily published to be used by does not eliminate the hazard, your understand-
mechanical technicians who are already familiar ing of the information provided will promote its
with all service procedures relating to BRP prod- correct use.
ucts. Mechanical technicians should attend train- Always observe common shop safety practice.
ing courses given by BRPTI.
Unless otherwise noted, the engine must be
Please note that the instructions in this manual stopped and the tether cord must be removed
will apply only if proper hand tools and special ser- prior to perform any services.
vice tools are used.
Torque wrench tightening specifications must be
The contents of this manual depicts parts and/or strictly adhered to. Use the torque values and ser-
procedures applicable to a particular product at vice products as in the exploded views or in the
the time of writing. Service and warranty bulletins procedures when noted.
may be published to update the content of this
manual. Dealer modifications that were carried Locking devices when removed must be replaced
out after manufacturing of the product, whether (e.g.: locking tabs, elastic stop nuts, self-locking
or not authorized by BRP, are not included. fasteners, cotter pins, etc.).
In addition, the sole purpose of the illustrations Hoses, cables and locking ties removed during a
throughout the manual, is to assist identification procedure must be reinstalled as per factory stan-
of the general configuration of the parts. They are dards.
not to be interpreted as technical drawings or ex- When ordering parts always refer to the specific
act replicas of the parts. model PARTS CATALOGS.
The use of BRP parts is most strongly recom- We strongly recommend that any services be car-
mended when considering replacement of any ried out and/or verified by a highly skilled profes-
component. Dealer and/or distributor assistance sional mechanic.
should be sought in case of doubt. It is understood that this manual may be trans-
The engines and the corresponding components lated into another language. In the event of any
identified in this document should not be utilized discrepancy, the English version shall prevail.
on product(s) other than those mentioned in this BRP disclaims liability for all damages and/or in-
document. juries resulting from the improper use of the con-
It is understood that certain modifications may tents of this publication.
render use of the vehicle illegal under existing
federal, provincial and state regulations.
This manual emphasizes particular information
which, is denoted by the following wording and
symbols:
WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.
CAUTION Indicates a hazardous situation

which, if not avoided, could result in minor or
moderate injury.
NOTICE Indicates an instruction which, if not
followed, could result in severe damage to ve-
hicle components or other property.
mmr2017-005 I
INTRODUCTION
INTRODUCTION
The information and component/system descrip- ENGINE IDENTIFICATION
tions contained in this manual are correct at time NUMBER (EIN)
of writing. BRP however, maintains a policy of
continuous improvement of its products without
imposing upon itself any obligation to install them
on products previously manufactured.
Due to late changes, there may be some differ-
ences between the manufactured product and the
description and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
VEHICLE INFORMATION
1
VEHICLE IDENTIFICATION
NUMBER (VIN)
mmr2017-005-002_a
850 E-TEC
1. Engine serial number
SNOWMOBILE LIFTING
To lift the snowmobile securely, it is important to
place the hooks of the lifting tool into the rein-
forcement holes of the footrests.
mmo2013-004-037_a
TYPICAL
1. Vehicle identification number
1
Identification Number Description
2BPS LSAB 9 A 1 000001
Serial number
Model number
Model year: A = 2010
B = 2011
C = 2012
etc.
mmr2017-005-001_a
1. Reinforced holes in footrest
NOTICE Do not use footrest opening or steer-

ing column to lift the snowmobile. Frame or
steering system could be seriously damaged.
II mmr2017-005
INTRODUCTION
ENGINE EMISSIONS procedures in this manual may lead a vehicle to

INFORMATION be out of compliance with applicable emission
regulations.
MANUFACTURER'S When servicing any vehicle; adjustments must be
kept within published factory specifications. Re-
RESPONSIBILITY placement or repair of any emission related com-
Manufacturers of engines must determine the ponent must be executed in a manner that main-
exhaust emission levels for each engine horse- tains emission levels within the applicable certifi-
power family and certify these engines with cation standards. Nobody is allowed to modify the
the United States of America Environmental engine in any manner that would alter the horse-
Protection Agency (EPA). An emissions control power or allow emission levels to exceed their
information label, showing emission levels and predetermined factory specifications. Exceptions
engine specifications, must be placed on each include manufacturer’s prescribed changes.
vehicle at the time of manufacture. The owner/operator is required to have engine
maintenance performed to maintain emission lev-
DEALER RESPONSIBILITY els within the prescribed certification standards.
The owner/operator is allowed and should not
When servicing any vehicle that carry an emis- allow anyone else to modify the engine in any
sions control information label, adjustments must manner that would alter the horsepower or allow
be kept within published factory specifications. emissions levels to exceed their predetermined
Replacement or repair of any emission related factory specifications.
component must be executed in a manner that
maintains emission levels within the prescribed MANUAL INFORMATION
certification standards.
Dealers are not to modify the engine in any man- MANUAL PROCEDURES
ner that would alter the horsepower or allow emis-
sion levels to exceed their predetermined factory Many of the procedures in this manual are inter-
specifications. related. Before undertaking any task, you should
read and thoroughly understand the entire section
Exceptions include manufacturer's prescribed
or subsection in which the procedure is contained.
changes.
WARNING
OWNER RESPONSIBILITY Unless otherwise specified, the engine
The owner/operator is required to have engine should be turned OFF and cold for all main-
maintenance performed to maintain emission tenance and repair procedures.
levels within prescribed certification standards.
The owner/operator is not to, and should not al- A number of procedures throughout the book re-
low anyone else to modify the engine in any man- quire the use of special tools. Before starting any
ner that would alter the horsepower or allow emis- procedure, be sure that you have on hand all re-
sions levels to exceed their predetermined factory quired tools, or their approved equivalents.
specifications. The use of RIGHT and LEFT indications in the text
are always referenced to the driving position (sit-
EMISSION REGULATIONS ting on the vehicle).
The vehicle you are servicing may have been
certified to applicable emission regulations in
your country or state. Not as an exhaustive list;
this may include standards for engine exhaust
emissions, crankcase emissions, permeation
emissions and evaporative emissions. Servic-
ing procedures in this manual must be strictly
followed in order to keep the vehicle within the
factory specifications. Failure to follow servicing
mmr2017-005 III
INTRODUCTION
1 2
mmr2017-005-003_a
1. Left
2. Right
This manual uses technical terms which may be

different from the ones of the PARTS CATALOGS.
When ordering parts always refer to the specific
model PARTS CATALOGS.
NOTICE Most fasteners are metric, and most
components are built with parts dimensioned
using the metric system. Consult the appropri-
ate PARTS CATALOG to obtain and use the cor-
rect parts and fasteners. Mismatched or incor-
rect fasteners could cause damage to the vehi-
cle.
MANUAL LAYOUT
This manual is divided into many major sections as
can be seen in the main table of contents at the
beginning of the manual.
Each section is divided into various subsections,
and again, each subsection has one or more divi-
sions.
Illustrations and photos show the typical construc-
tion of various assemblies and, in all cases, may
not reproduce the full detail or exact shape of the
parts used in a particular model vehicle. However,
they represent parts which have the same or a
similar function.
IV mmr2017-005
INTRODUCTION
TYPICAL PAGE
Section 06 ENGINE Page heading

Subsection 01 (MAGNETO) indicates section
and subsection.
Subsection title MAGNETO

Indicates applicable Models
models.
Loctite 243 Drop represents a

service product
Exploded view assists Model
to be applied.
you in identifying parts
and their related Dotted box contains
positions. parts applicable to a
specific model.
Bold face number

1 is used to identify
a part referred to
the text.
NEW indicates that the
part must be replaced NEW
with a new one.
5 Nm
(44 lbfin)
Illustration number
for publishing process. XXX0000
Document number for 55 Page number

publishing process.
mmr2008-001
NOTICE Pay attention to torque specifications.

Some of these are in lbf in instead of lbf ft.
Use appropriate torque wrench.
Typical_iso_2008_en
mmr2017-005 V
INTRODUCTION
TYPICAL PAGE
Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEM)
Tittle in bold
indicates category
of information to be GENERAL
carried out. NOTE: The following procedures can be done
without removing the engine.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Reference to a Clean threads before applying a threadlocker. Re-
specific section fer to the SELF-LOCKING FASTENERS and LOC-
or subsection. TITE APPLICATION sections at the beginning of
this manual for complete procedure. TYPICAL
WARNING indicates a general
Torque wrench tightening specifications
view which may
must be strictly adhered to. not represent exact
Locking devices (e.g.: locking tabs, elastic 1 details.
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones. TYPICAL
1. Starting pulley
PROCEDURES NOTE: To remove starting pulley bolts, hold mag- Call-outs pertaining
Indicates component neto flywheel with a socket as shown. to above illustration.
procedures apply to. MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
Indicates specific a clean cloth. Illustration always
procedure to be Magneto Flywheel Removal follows text to which
carried out. Remove muffler, refer to the EXHAUST SYSTEM it applies.
section.
Remove acoustic panel.
Remove rewind starter. mmr2007-016-002
Remove starting pulley no. 2. TYPICAL Italic bold face type-

Models
setting indicates a
Remove the connecting flange retaining the
procedure applicable
rewind starter to the engine housing. to a specific
model(s).
mmr2008-001 57
Bold face number following part

name refers to exploded view
at beginning of subsection.
typical_txt_2008_en
VI mmr2017-005
INTRODUCTION
TIGHTENING TORQUE
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When
a torque is not specified, refer to the following table.
WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices when removed (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter
pins, etc.) must be replaced.
In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following proce-
dure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
3. Tighten fastener to the recommended torque value.
NOTICE Be sure to use the recommended tightening torque for the specified fastener used.
NOTE: When possible, always apply torque on the nut.
NOTE: Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are
used to secure a part (eg. a cylinder head). Some parts must be torqued according to a specific sequence
and torque pattern as detailed in the installation procedure.
4.8 8.8 9.8 10.9 12.9

Property
class and
head 4.8 8.8 9.8 10.9 12.9
markings
4.8 8.8 9.8 10.9 12.9 12.9
5 8 10 12
Property
class and
12
10
nut
5
markings
A00A8BS
FASTENER FASTENER GRADE/TORQUE

SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5 – 2 N•m 2.5 – 3 N•m 3.5 N•m - 4 N•m 4 N•m - 5 N•m
M4
(13 – 18 lbf•in) (22 – 27 lbf•in) (31 lbf•in - 35 lbf•in) (35 lbf•in - 44 lbf•in)
3 N•m - 3.5 N•m 4.5 N•m - 5.5 N•m 7 N•m - 8.5 N•m 8 N•m - 10 N•m
M5
(27 lbf•in - 31 lbf•in) (40 lbf•in - 49 lbf•in) (62 lbf•in - 75 lbf•in) (71 lbf•in - 89 lbf•in)
6.5 N•m - 8.5 N•m 8 N•m - 12 N•m 10.5 – 15 N•m
M6 16 N•m (142 lbf•in)
(58 lbf•in - 75 lbf•in) (71 lbf•in - 106 lbf•in) (93 – 133 lbf•in)
M8 15 N•m (133 lbf•in) 25 N•m (18 lbf•ft) 32 N•m (24 lbf•ft) 40 N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 73 N•m (54 lbf•ft)
mmr2017-005 VII
INTRODUCTION
FASTENER INFORMATION Threadlocker Application for

Uncovered Holes (Bolts and Nuts)
NOTICE Most components in the vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners 1
could cause damage to the vehicle or possible
personal injury.
SELF-LOCKING FASTENERS
PROCEDURE
2
A00A3LA
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.

2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041)
A00A6LA on threads and allow to dry.
TYPICAL — SELF-LOCKING FASTENER 3. Choose proper strength Loctite threadlocker.
The following describes common procedures 4. Fit bolt in the hole.
used when working with self-locking fasteners. 5. Apply a few drops of threadlocker at proposed
Use a metal brush or a tap to properly clean a tightened nut engagement area.
threaded hole, then use a solvent. Allow the sol- 6. Position nut and tighten as required.
vent time to act, approximately 30 minutes, then
wipe off. Solvent utilization is to ensure proper Threadlocker Application for Blind
adhesion of the product used for locking the fas- Holes
tener.
LOCTITE® APPLICATION 1
PROCEDURE
The following describes common procedures 2
used when working with Loctite products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this shop manual.
lmr2007-040-004_a
1. On fastener threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.

on threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
VIII mmr2017-005
INTRODUCTION
4. Apply several drops along the threaded hole Threadlocker Application for
and at the bottom of the hole. Pre-Assembled Parts
5. Apply several drops on bolt threads.
6. Tighten as required.
Threadlocker Application for Stud

Installation in Blind Holes 1
1 3
2
A00A3OA
1. Apply here
lmr2007-040-005_a 2. Do not apply
1. On stud threads
2. On threads and in the hole 1. Clean bolts and nuts with solvent.
3. On retaining nut threads
2. Assemble components.
1. Clean threads (stud and hole) with solvent. 3. Tighten nuts.
2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041) 4. Apply a few drops of proper strength Loctite on
on threads and allow to dry. bolt/nut contact surfaces.
3. Put 2 or 3 drops of proper strength Loctite 5. Avoid touching metal with tip of flask.
threadlocker on female threads and in hole.
NOTE: For preventive maintenance on exist-
NOTE: To avoid a hydro lock situation, do not ap- ing equipment, retighten nuts and apply proper
ply too much Loctite. strength Loctite on bolt/nut contact surfaces.
4. Apply several drops of proper strength Loctite
on stud threads. Threadlocker Application for an
5. Install stud. Adjustment Screw
6. Install cover, part, etc.
7. Apply a few drops of proper strength Loctite on 2
1
uncovered stud threads.
8. Install and tighten retaining nut(s) as required.
A00A3PA
1. Apply here
2. Plunger
1. Adjust screw to proper setting.

2. Apply a few drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
mmr2017-005 IX
INTRODUCTION
NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application

a soldering iron (232°C (450°F)).
Application for Stripped Thread Repair 1 2
5
1
6
8
2
1
A00A3QA 4 7
1. Release agent
2. Stripped threads 1 3
3. Form-A-Thread
lmr2007-040-006_a
4. Tapes
5. Cleaned bolt 1. Proper strength Loctite
6. Plate 2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
7. New threads (P/N 293 800 038) on both sides of gasket
8. Threadlocker 3. Loctite Primer N only
Standard Thread Repair 1. Remove old gasket and other contaminants us-
Follow instructions on Loctite FORM-A-THREAD ing LOCTITE CHISEL (GASKET REMOVER) (P/N 413
81668 package. 708 500). Use a mechanical means only if nec-
essary.
If a plate is used to align bolt:
NOTE: Avoid grinding.
1. Apply release agent on mating surfaces.
2. Clean both mating surfaces with solvent.
2. Put waxed paper or similar film on the surfaces.
3. Spray Loctite Primer N on both mating surfaces
3. Twist bolt when inserting it to improve thread and on both sides of gasket and allow to dry 1
conformation. or 2 minutes.
NOTE: NOT intended for engine stud repairs. 4. Apply LOCTITE 518 (P/N 293 800 038) on both
Repair of Small Holes/Fine Threads sides of gasket, using a clean applicator.
Option 1: Enlarge damaged hole, then follow 5. Place gasket on mating surfaces and assemble
STANDARD THREAD REPAIR procedure. parts immediately.
Option 2: Apply FORM-A-THREAD on the screw NOTE: If the cover is bolted to blind holes, apply
and insert in damaged hole. proper strength Loctite in the hole and on threads.
Permanent Stud Installation (Light Duty) Tighten fastener.
1. Use a stud of the desired thread length. If holes are sunken, apply proper strength Loctite
on bolt threads.
2. DO NOT apply release agent on stud.
6. Tighten as usual.
3. Follow Standard Thread Repair procedure.
4. Allow 30 minutes for Loctite FORM-A-THREAD Threadlocker Application for Mounting
to cure. on a Shaft
5. Complete part assembly. Mounting with a Press
X mmr2017-005
INTRODUCTION
3. Apply a strip of proper strength Loctite on lead-

ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
1 strength and gap are required.
4. Install according to standard procedure.
2
5. Wipe off excess product.
3 6. Allow 30 minutes for product to cure.
A00A3UA NOTE: Normally used on worn-out housings to
prevent leaking or sliding.
1. Bearing
2. Proper strength Loctite It is generally not necessary to remove gasket
3. Shaft
compound applied on outer gasket diameter.
1. Clean shaft external contact surface.
2. Clean internal contact surface of part to be in-
stalled on shaft.
3. Apply a strip of proper strength Loctite on cir-
cumference of shaft contact surface at inser-
tion or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
4. DO NOT use antiseize Loctite or any similar
product.
5. No curing period is required.
Mounting in Tandem
1. Apply retaining compound on internal contact
surface (bore) of parts to be installed.
2. Continue parts assembly as per previous illus-
tration.
Threadlocker Application for Case-In

Components (Metallic Gaskets)
A00A3VA 1
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with LOCTITE 7649
(PRIMER) (P/N 293 800 041).
mmr2017-005 XI
Subsection XX (PERIODIC MAINTENANCE SCHEDULE (REV G4))
PERIODIC MAINTENANCE SCHEDULE

(REV G4)
All M ode ls
Procedures are detailed in PERIODIC MAINTENANCE PROCEDURES subsection.
PRE RIDE INSPECTION
Body including seat, footrests, lights, air filter, controls
Check condition and remove snow or ice
and instruments
Skis and steering actions Check for free movement and proper operation
Fuel and injection oil Check for proper level and no leaks
Coolant Check for proper level and no leaks
Brake fluid Check for proper level and no leaks
Check for proper latching and no heavy or
Storage compartment
breakable objects
Throttle lever Check for proper action
Track Check condition and remove snow or ice
Slider shoes Check for proper operation
Brake lever Check for proper operation
Parking brake, brake Check for proper operation
Emergency engine stop switch and engine cut-off Check for proper action. Tether cord must be
switch (tether cord cap) attached to operator clothing eyelet
Lights Check for proper operation
Ski and runners Check for proper condition (and operation if adjustable)
Drive belt Check condition for cracks, fraying or abnormal wear
M ou ntain Serie s O nly

DURING THE FIRST 1500KM (1000MI)
Adjust and align track after first 75KM (50MI)
Inspect track tension every 500KM (300MI), adjust if necessary
M ou ntain Serie s O nly

EVERY 1500KM (1000MI)
Adjust drive chain
Adjust and align track (if necessary)
mmr2017-007 1
Subsection XX (PERIODIC MAINTENANCE SCHEDULE (REV G4))
All M ode ls
EVERY YEAR AT PRESEASON OR 3 000 KM (2,000MI) (WHICHEVER COMES FIRST)
Perform PRE-RIDE INSPECTION
Check fault codes
Charge battery (on applicable models)
Adjust drive chain
Inspect track tension, adjust and align (if necessary)
Inspect brake hose, pads and disk
Check coolant density
Inspect drive belt
Inspect and clean drive pulley
Inspect and clean driven pulley
Lubricate rear suspension (lubricate whenever the vehicle is used in wet conditions (rain, puddles)
Inspect exhaust system and check for leaks
Tighten exhaust manifold screws or nuts to specified torque
Inspect fuel lines and connections
Inspect front suspension
Inspect rear suspension (including stopper straps and slider shoes)
Inspect tie-rod ends and ski alignment
Adjust headlight beam aiming
EVERY 2 YEAR OR 6 000KM (4,000 MI) (WHICHEVER COMES FIRST)

Replace brake fluid
Inspect throttle cable
Clean and lubricate rewind starter (on applicable models)
Change chaincase oil
Inspect engine rubber mounts
EVERY 3 YEARS OR 10 000KM (6,000 MI) (WHICHEVER COMES FIRST)

Replace spark plugs
Inspect oil injection pump strainer and clean if needed
Clean 3D rave valves
EVERY 5 YEARS
Replace engine coolant
Replace in-line fuel filter
2 mmr2017-007
Subsection XX (PERIODIC MAINTENANCE PROCEDURES)
PERIODIC MAINTENANCE
PROCEDURES
SERVICE TOOLS
Description Part Number Page
OETIKER PLIER............................................................................. 295 000 070 ............................................. 5
TENSIOMETER.............................................................................. 414 348 200 ............................................. 9
SERVICE PRODUCTS
BRAKE FLUID GTLMA DOT4........................................................ 293 600 131 ........................................... 11
LONG LIFE ANTIFREEZE .............................................................. 219 702 685 ............................................. 3
MOLYKOTE PG 54 ........................................................................ 420 899 763 ............................................. 2
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ......................................... 6, 8
SUSPENSION GREASE ................................................................. 293 550 033 ........................................... 13
XPS SYNTHETIC CHAINCASE OIL ............................................... 413 803 300 ............................................. 8
XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 13
mmr2017-008 1
GENERAL – Tuned pipe

– Donut gaskets
This subsection provides general maintenance in-
structions. Where detailed instructions for disas- – Shields
sembly or reassembly is required, refer to the ap- – Manifold.
plicable subsection.
LUBRICATION SYSTEM
PROCEDURES Inspecting and Cleaning the Oil
Injection Pump Strainer
ENGINE
Refer to OIL INJECTION PUMP in LUBRICATION
Cleaning and Lubricating the Rewind SYSTEM subsection.
Starter
Refer to REWIND STARTER ASSEMBLY in
Lubricating the Engine
REWIND STARTER subsection. Engine Storage Mode (Summerization
Function)
NOTICE It is of the utmost importance that
the rewind starter spring be lubricated period- Refer to applicable GAUGE subsection as proce-
ically using MOLYKOTE PG 54 (P/N 420 899 763). dure varies depending on the gauge.
The use of standard multipurpose grease could
result in rewind starter malfunction under very COOLING SYSTEM
cold temperatures and component life will be
shortened. WARNING
Never open coolant tank cap when engine is
Cleaning the 3D RAVE Valve hot.
NOTICE It is very important to perform 3D
Verifying the Engine Coolant Level
RAVE VALVE SYNCHRONIZATION whenever
link bar is removed. Refer to RAVE subsection. Check coolant level at room temperature with the
cap removed. Liquid should be at cold level line
Clean carbon deposits as required. (engine cold) of coolant tank.
Thoroughly clean all RAVE VALVES components NOTE: When checking level at low temperature it
and cylinder slots. may be slightly lower then the mark.
Use a clean rag when cleaning the valve.
NOTE: Do not use any solvents or cleaners for
cleaning the cylinder slots. Fluids can cause cor-
rosion of the cylinder bore which may result in se-
vere engine damage.
Inspecting the Rubber Mount

Check rubber mounts for cracks or other dam-
ages.
Adjusting the Engine Stopper

Refer to REMOVING AND INSTALLING THE EN-
GINE subsection. mmo2007-009-010_a
TYPICAL
EXHAUST SYSTEM 1. Coolant tank
2. COLD LEVEL line
Inspecting the Exhaust System
Verifying the Engine Coolant Strength
Check the following components for leaks,
cracks, or other damages: Remove pressure cap.
– Springs and retainers Use an antifreeze tester to test coolant strength.
– Exhaust system mounts
– Muffler
2 mmr2017-008
MINIMUM RECOMMENDED
COOLANT STRENGTH
-30°C (-22°F)
Replacing the Engine Coolant

Recommended Engine Coolant
RECOMMENDED
ACCEPTABLE
SERVICE PRODUCT
A blend of 50% distilled
LONG LIFE
water with 50% antifreeze
ANTIFREEZE
(especially formulated for
(P/N 219 702 685)
aluminum engines
mmr2017-018-025_a
To prevent antifreeze deterioration, always use REMOVE CLAMP (DISCARD ORIGINAL INSTALLED 1–EAR
the same brand. Never mix different brands un- CLAMP)
less cooling system is completely flushed and When coolant level is low enough, lift the rear of
refilled. vehicle to drain the heat exchangers.
NOTICE To prevent rust formation or freez-
ing condition, always replenish the system
with the BRP premixed coolant or with 50%
antifreeze and 50% distilled water. Do not use
tap water, straight antifreeze or straight water
in the system. Tap water contains minerals
and impurities which build up in the system.
During cold weather, straight water causes
the system to freeze while straight antifreeze
thickens (like slush ice) and does not have
the same efficiency. Always use ethylene gly-
col antifreeze containing corrosion inhibitors mmr2015-106-001
specifically recommended for aluminum en- TYPICAL VIEW

gines.
Install and tighten coolant hose clamp on water
Draining the Cooling System pump.
WARNING
Never drain or refill the cooling system when
engine is hot.
Remove RH side panel and hood. Refer to BODY

subsection.
Remove muffler and tuned pipe. Refer to EX-
HAUST SYSTEM subsection.
Place a large drain pan under the vehicle bottom
pan.
Remove clamp. Discard original installed gear
clamp.
Unplug coolant hose from water pump to drain
coolant. mmr2017-018-025_a
TIGHTENING TORQUE
3 N•m ± 0.4 N•m
Coolant hose clamp
(27 lbf•in ± 4 lbf•in)
mmr2017-008 3
Refilling and Bleeding the Cooling System

1. Apply parking brake.
2. Lift front of vehicle as shown and support it
safely.
mmr2015-106-003
8. Lift rear of vehicle and support it safely.
mmr2015-106-002
TYPICAL VIEW
A. 25 cm ± 5 cm (10 in ± 2 in)
3. With engine cold, slowly fill coolant tank up to

COLD LEVEL line allowing time for the air in the
cooling system to seep out.
mmr2015-106-001
TYPICAL VIEW
WARNING
Before revving engine, ensure that the track
is free of particles which could be thrown out
while track is rotating. Keep hands, tools,
feet and clothing clear of track. Always lift
the snowmobile on a wide-base stand with a
rear deflector panel. Ensure no one is stand-
ing in close proximity to the snowmobile,
especially at the rear of the track. Centrifugal
force could cause debris, damaged or loose
studs, pieces of torn track, or an entire track
mmo2007-009-010_a
to be violently thrown backwards out of the
TYPICAL
1. Coolant tank frame with tremendous force, possibly re-
2. COLD LEVEL line sulting in the loss of a leg or other serious
injury.
4. Start engine.
5. Refill coolant tank up to COLD LEVEL line while 9. Remove parking brake.
engine is idling until rear heat exchangers are
warm to the touch (about 4 to 5 minutes). 10. Activate throttle lever 3 - 4 times to bring en-
gine speed to 7000 RPM.
NOTE: Always monitor coolant level while filling
coolant tank to avoid emptying and thus allowing 11. Apply the brake.
air to enter the system. 12. Lower vehicle back to ground.
6. Install pressure cap. 13. Stop engine.
7. Lower vehicle back to the ground.
4 mmr2017-008
Replacing the In-Line Fuel Filter
mmr2015-106-003
14. Add coolant up to 15 mm (1/2 in) above the

COLD LEVEL line.
mmr2017-027-008
Removing the In-line Fuel Filter
WARNING
Work in a well ventilated area. Wipe up all
spilled fuel.
1. Release fuel pressure in the system. Refer to

FUEL TANK AND FUEL PUMP subsection.
2. Remove the upper body module. Refer to
mmo2007-009-010_a
BODY subsection.
TYPICAL
1. Coolant tank 3. Disconnect magneto connector.
2. Coolant 15 mm (1/2 in) above COLD LEVEL line
15. When engine has completely cooled down,

WARNING
recheck coolant level in coolant tank and refill The magneto connector must be discon-
up to line if needed. nected to prevent any spark in the engine
compartment and to remove power from
16. Visual check for any leakages.
the fuel pump. Otherwise, if the engine is
17. Perform VERIFYING THE ENGINE COOLANT cranked, fuel vapors may ignite in presence
STRENGTH. See procedure in this subsection. of a spark creating a fire hazard.
18. Adjust mixture as necessary.
19. Reinstall removed parts. 4. Place a rag between fuel filter and oil injection
tank.
FUEL SYSTEM 5. Cut both Oetiker clamps securing the fuel filter.
6. Remove fuel filter from vehicle.
Inspecting the Fuel Lines and
Connections Dispose fuel filter as per your local environmental
regulations.
Visually inspect fuel lines and connections for
cracks or leaks. Installing the In-Line Fuel Filter
The installation is the reverse of the removal pro-
cedure however, pay attention to the following.
Insert new Oetiker clamps on both hoses.
Install the new filter. Make sure printed arrow
pointed towards the ECM.
Using OETIKER PLIER (P/N 295 000 070), close
Oetiker clamps to secure the fuel filter.
mmr2017-008 5
WARNING
Ensure hose clamp is tight and that hose can-
not turn on the fitting.
When installation is complete, carry out a fuel sys-

tem leak test, refer to FUEL SYSTEM PRESSUR- 1 2
IZATION in FUEL TANK AND FUEL PUMP subsec-
tion.
WARNING
After working on the fuel system, carry out
a fuel system pressurization test to check A00E0BA
for leaks. Failure to carry out a fuel system

TYPICAL
leak test could result in severe injury or a life 1. Approved socket
threatening situation should a leak occur. 2. Improper socket
Removing the Spark Plugs

Reinstall all removed parts.
Inspecting and Cleaning the Throttle

Body
Clean throttle plates and throttle body bores.
THROTTLE BODY CLEANING
PULLEY FLANGE
Service product CLEANER (P/N 413
711 809)
Inspecting the Throttle Cable

Visually inspect cable sheath for kinks, wear or mmr2017-031-004
other damage.
Visually inspect cable at throttle body/carburetor 1. Disconnect the stator connector. Refer to STA-
and at throttle lever for fraying or other damage. TOR CONNECTOR ACCESS in the MAGNETO
AND STARTER subsection.
Make sure the throttle cable operates smoothly.
2. Remove the upper body module. For proce-
dure, refer to BODY subsection.
SPARK PLUGS
3. Remove cover, refer to TOP END subsection.
Replacing the Spark Plug 4. Clean the spark plug and cylinder head with
NOTE: Use only an approved spark plug socket pressurized air.
for removal and installation. Extra care should be
taken to avoid side stresses which could result in WARNING
a broken spark plug. Whenever using compressed air, always
wear protective eye wear.
5. Remove lock securing spark plug wire to spark

plug.
6 mmr2017-008
2. Using a wire gauge, confirm electrode gap is

as specified. Refer to TECHNICAL SPECIFICA-
TIONS.
NOTE: If spark plug gap is incorrect, use another
spark plug.
3. Hand screw spark plug into cylinder head until
it bottoms out.
4. Apply specific torque using a torque wrench
and approved spark plug socket.
NOTE: Spark plug tightening torque is particularly
mmr2017-031-002
important on this engine as it contributes to the
proper positioning of the negative electrode.
6. Remove spark plug cables by gently rotating
the cap and pulling it off the plug. TIGHTENING TORQUE
18 N•m ± 0.7 N•m
Spark plug
Installing the Spark Plugs (Non-OEM)

NOTE: When using a non-OEM spark plug , it
must be correctly indexed or engine may experi-
ence rough idling and higher emissions.
1. Using a marker, mark the open end of the nega-
tive electrode on the plug shell (above threads).
2. Ensure the contact surfaces of the cylinder
head and spark plug are free of grime.
3. Install and torque the spark plug, refer to previ-
mmr2017-031-003
ous table for specific torque.
7. Unscrew the spark plug sufficiently to break the 4. Visually check to ensure the open end of the
applied torque using the appropriate tools. negative electrode is facing the injector nozzle
within 90° each side of nozzle.
NOTE: The following illustration uses the point of
attachment of the negative electrode to depict the
angle. The injector is illustrated above the spark
plug.
mmr2017-031-001
8. Remove spark plugs by hand.

Installing the Spark Plugs (OEM)
1. Prior to installation, ensure the contact surfaces
of the cylinder head and spark plug are free of
grime.
mmr2017-008 7
Use the PULLEY FLANGE CLEANER (P/N 413 711

809) and a clean rag to clean pulley sheaves as
necessary.
CHAINCASE
Recommended Chaincase Oil
RECOMMENDED SERVICE PRODUCT
XPS SYNTHETIC CHAINCASE OIL (P/N 413 803 300)
NOTICE Use only the recommended type oil

when servicing. Do not mix synthetic oil with
other types of oil.
Verifying the Chaincase Oil Level

1. Place vehicle on a level surface.
2. Remove the check plug beside the speed sen-
sor on the chaincase cover. Oil level must be
mdd2009-001-551_a
equal with the lower edge.
SPARK PLUG INDEXING
1. Acceptable installation
2. Unacceptable installation
If the plug indexing angle is not within specifica-

tion, repeat procedure with another spark plug un-
til correct indexing is achieved.
LIGHTS
Adjusting the Headlights Beam Aiming
Refer to LIGHTS subsection.
DRIVE SYSTEM
mmr2017-043-027
Inspecting the Drive Belt
Refer to DRIVE BELT subsection. 3. Remove metal particles from magnetic check
plug.
Inspecting and Cleaning the Drive NOTE: It is normal to find metallic particles stuck
Pulley to magnetic check plug. If bigger pieces of metal
Refer to DRIVE PULLEY subsection. are found, remove the chaincase cover and in-
spect the chaincase parts.
Drive Pulley Retaining Screw 4. To add oil, remove the filler cap on top of chain-
Tightening case cover.
Refer to appropriate DRIVE PULLEY subsection.
Replacing the Drive Pulley Wear Parts

Replace drive pulley wear parts as per PERIODIC
MAINTENANCE SCHEDULE. Refer to DRIVE
PULLEY subsection.
Inspection and Cleaning the Driven
Pulley
Inspect pulley sheave for dirt, marks or scratches.
Test sliding sheave operation.
8 mmr2017-008
6. Pour approximately 350 ml (12 U.S. oz) of rec-

ommended oil in chaincase through the filler
hole until oil comes out by the magnetic check
plug hole.
7. Clean the magnetic check plug. Refer to
CHAINCASE OIL LEVEL VERIFICATION, see
procedure in this subsection.
Adjusting the Drive Chain

1. Tighten tensioner adjustment screw BY HAND.
NOTE: Turn adjustment screw until resistance is
mmr2017-041-001
strong enough that it can not be turned by hand.
5. Pour recommended oil in chaincase by the filler
hole until oil comes out by the magnetic check
plug hole.
6. Reinstall magnetic check plug and torque to
specification.
TIGHTENING TORQUE
6 N•m ± 1 N•m
Magnetic check plug
Replacing the Chaincase Oil

mmr2017-043-005
2. Place a container under vehicle in line with
chaincase to catch chaincase oil.
TRACK
3. Remove the drain plug on the bottom of the
chaincase. Adjusting and aligning the Track
Track tension and alignment are interrelated. Do
not adjust one without checking the other. Track
tension procedure must be carried out prior to
track alignment.
Verifying the Track Tension
1. Lift rear of vehicle and support it off the ground.
2. Allow rear suspension to fully extend.
3. Use a tensiometer.
REQUIRED TOOL
TENSIOMETER
mmr2017-043-024_a (P/N 414 348 200)
4. Reinstall the drain plug. 4. Set deflection to 3.2 cm (1.26 in) using bottom
TIGHTENING TORQUE O-ring.
6 N•m ± 1 N•m
Drain plug
5. Remove the magnetic check plug
mmr2017-008 9
mmr2009-133-003_b mmr2009-133-003_a
DEFLECTION SETTING LOAD READING

1. Bottom O-ring 1. Upper O-ring
5. Place upper O-ring to 0 kgf (0 lbf). Load reading must be as per the following table.
6. Position the tensiometer on track, halfway be- TRACK ADJUSTMENT SPECIFICATION
tween runner ends.
Track deflection setting 3.2 cm (1.26 in)
7. Push the tensiometer downwards until bottom
O-ring (deflection) is aligned with the bottom of 6.0 kgf to 8.5 kgf
Track load reading
slider shoe. (13 lbf to 19 lbf)
9. If load reading is not in accordance with the

specification, adjust track tension. Refer to AD-
JUSTING THE TRACK TENSION.
NOTICE Too much tension will result in
power loss and excessive stresses on suspen-
sion components.
Adjusting the Track Tension
2. Loosen rear axle
mmr2009-133-001_a
2.1 Loosen nut on 2 wheel idler system
TYPICAL 2.2 Loosen screw on 3 or 4 wheel idler system
3. Tighten or loosen both adjustment screws to
increase or decrease track tension.
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1. Deflection O-ring aligned with slider shoe
8. Read load recorded by the upper O-ring on the

mmr2015-142-008_a
tensiometer.
Step 1: Loosen axle nut
Step 2: Tighten or loosen adjustment screws
4. Verify track tension, refer to VERIFYING THE

TRACK TENSION.
5. Ensure track is properly aligned, refer to ALIGN-
ING THE TRACK.
10 mmr2017-008
Aligning the Track 7. If satisfactory track alignment is achieved

tighten idler wheels axle nut to specification:
WARNING
TIGHTENING TORQUE
Before checking track alignment, ensure that
the track is free of all particles which could Rear idler wheel
48 N•m ± 6 N•m
be thrown out while track is rotating. Keep retaining screws (3 and
(35 lbf•ft ± 4 lbf•ft)
4 idler wheels system)
hands, tools, feet and clothing clear of track.
Ensure no one is standing in close proximity Rear idler wheel
24.5 N•m ± 3.5 N•m
to the vehicle. Never rotate at high speed. retaining nut and screw
(2 idler wheels system)
2. Start engine and accelerate slightly so that track BRAKE
barely turns. This must be done in a short pe-
riod of time (10 seconds). Recommended Brake Fluid
3. Check that the track is well centered; equal dis- Always use brake fluid meeting the DOT 4 speci-
tance on both sides between edges of track fication.
guides and slider shoes. RECOMMENDED SERVICE PRODUCT
BRAKE FLUID GTLMA DOT4 (P/N 293 600 131)
1 meeting DOT 4 specification
2
Verifying the Brake Fluid Level
With the vehicle on a level surface, position steer-
ing in the straight-ahead position to ensure reser-
voir is level.
Brake fluid must always be above the MIN. line
when brake lever is squeezed.
3
A01F05A
1. Guides
2. Slider shoes
3. Equal distance
4. To correct track alignment:

4.1 Stop engine.
4.2 Loosen rear wheel nut.
4.3 Tighten adjustment screw on side where
the slider shoe is the farthest from the
track insert guides.
mmr2008-043-101_a
TYPICAL
1 2 1 1. MINIMUM line
Add fluid as required. Do not overfill.

NOTE: A low level may indicate leaks or worn
brake pads.
Replacing the Brake Fluid

3 Draining the Brake Fluid
A01F0BA
1. Guides
2. Slider shoes 2. Remove reservoir cover with its diaphragm.
3. Tighten on this side
5. Restart engine.
6. Rotate track slowly and recheck alignment.
mmr2017-008 11
3. Continue to push brake fluid until master cylin-

der reservoir is half full.
4. Close bleeder.
5. Fill up reservoir and install diaphragm and cover.
6. Squeeze brake lever.
6.1 If brake lever is firm, the brake system
does not require bleeding. Torque bleeder
as specified.
TIGHTENING TORQUE
mmr2015-137-019_a
Brake caliper 8.5 N•m ± 1.5 N•m
1. Reservoir cover bleeder (75 lbf•in ± 13 lbf•in)
2. Diaphragm
3. Connect a clear hose to caliper bleeder. 6.2 If brake lever is spongy, bleed brake sys-
tem as per following procedure.
4. Place the other end of hose in a container.
5. Loosen bleeder and pump brake lever until no Bleeding the Brake System
more fluid flows out of bleeder. 1. Install a clear hose on bleeder.
2. Place the other end in a container partially filled
with clean brake fluid.
3. Remove reservoir cover and diaphragm.
4. Pump up circuit pressure with brake lever until
lever resistance is felt.
5. Squeeze brake lever and open bleeder. When
lever touches the handlebar, do not release
lever and close bleeder.
6. Release brake lever slowly.
7. Repeat the procedure until no more air bubbles
mmr2008-043-103_a appear in hose.
TYPICAL
1. Bleeder NOTE: Check fluid level often to prevent air from
2. Clear hose to catch used brake fluid being pumped into the circuit.
Filling the Brake Fluid 8. Install cover and diaphragm on reservoir.
To fill brake circuit when it is empty do the follow- 9. Squeeze brake lever.
ing: 9.1 If brake lever is firm, bleeding procedure is
1. Ensure reservoir cover is removed. completed. Torque bleeder as specified.
2. Using a large syringe and a suitable tube, push 9.2 If brake lever is still spongy, repeat step 2
brake fluid slowly into the caliper. to step 6.
10. Torque bleeder as specified.
TIGHTENING TORQUE
8.5 N•m ± 1.5 N•m
Brake caliper bleeder
11. Refill reservoir.

12. Install diaphragm and cover on reservoir.
mmr2008-043-104
TYPICAL
12 mmr2017-008
Inspecting the Brake Hose, Pads and – Shock absorbers

Disc – Ball joints.
Break-In Inspection Rear Suspension, Stopper Strap and
Visually inspect the brake hose for leaks or any Slider Shoes
damage.
Inspecting the Rear Suspension Mechanism
Visually inspect pads and disc for abnormal wear and Stopper Strap
or any damage.
1. Inspect rear suspension components for wear,
Scheduled Maintenance and Preseason deterioration or damage, replace defective
Visually inspect the brake hose for leaks or any parts if necessary.
damage. 2. Inspect stopper strap(s) for wear or cracks.
Refer to BRAKE subsection and carry out: 3. Check bolt and nut securing strap(s) for tight-
– INSPECTING THE BRAKE PAD ness. If loose, inspect strap holes for deforma-
– INSPECTING THE BRAKE DISC. tion. Replace strap if necessary.
Inspecting the Slider Shoes
Lubricating the Brake Lever Pivot
Slider shoes are worn out and must be replaced
1. Remove brake lever pivot. when remaining material exceeding the 2 molding
2. Lubricate brake lever pivot using recommended lines is as specified.
product.
MINIMUM SLIDER SHOE THICKNESS
SERVICE PRODUCT
1 mm (.04 in)
XPS SYNTHETIC GREASE material remaining exceeding the
Brake lever pivot
(P/N 293 550 010) 2 molding lines
mmr2009-130-001_a
1. Lubricate this surface
3. Install brake lever pivot. mmr2012-005-003_a
4. Torque pivot nut of brake lever as specified. 1. Slider shoe

2. Molding lines
TIGHTENING TORQUE A. Minimum thickness: 1 mm (.04 in)
6 N•m ± 1 N•m NOTICE Slider shoes must always be re-

Brake lever pivot nut
(53 lbf•in ± 9 lbf•in) placed in pairs.
SUSPENSION Lubricating the Rear Suspension

Lubricate the following suspension pivots at
Inspecting the Front Suspension grease fittings using SUSPENSION GREASE
Visually inspect front suspension for tightness of (P/N 293 550 033).
components:
– Arms
– Stabilizer bar
mmr2017-008 13
mmr2015-142-041_a
TYPICAL - tMOTION REAR SUSPENSION
mmr2017-008-001
TYPICAL - rMOTION REAR SUSPENSION
STEERING
Inspecting the Ski and Runner
Lift the front of vehicle and check ski runners for
wear or damage (missing or broken carbide). Re-
place if necessary.
Inspect ski for excessive wear or other damage.
Replace if necessary.
Refer to STEERING SYSTEM subsection for ad-
justable ski mechanism inspection.
Inspecting the Steering Mechanism

Visually inspect steering mechanism for tightness
of components (steering arms, tie rods, ski bolts,
ski legs, etc.).
14 mmr2017-008
Subsection XX (STORAGE PROCEDURE)
STORAGE PROCEDURE
During summer, or when a snowmobile is not in
use for more than three months, proper storage
is a necessity.
Procedures are detailed in PERIODIC MAINTE-
NANCE PROCEDURES subsection.
STORAGE
Clean the vehicle
Add fuel stabilizer to fuel following the product
manufacturer recommendations.
Run the engine after adding the product to the fuel
Lubricate engine
Lubricate brake lever pivot
Inspect and lubricate rear suspension
Charge battery monthly to keep it fully charge
during storage (on applicable models)
Block muffler outlet with rags
Lift rear of vehicle until track is clear of the ground.
Do not release track tension
CAUTION Use appropriate lifting device

or have assistance to share lifting stress. If
a lifting device is not used, use proper lifting
techniques, notably using your legs force. Do
not attempt to lift the rear of vehicle if it is
above your limits.
NOTICE The snowmobile has to be stored
in a cool and dry place and covered with an
opaque but ventilated tarpaulin. This will pre-
vent sun rays and grime from affecting plastic
components and vehicle finish.
mmr2017-009 1
Subsection XX (PRESEASON PREPARATION)
PRESEASON PREPARATION
Proper vehicle preparation is necessary when a vehicle has not been used for more than three months.
Using the MAINTENANCE SCHEDULE, perform the items titled EVERY YEAR AT PRESEASON.
mmr2017-010 1
Subsection XX (ENGINE REMOVAL AND INSTALLATION)
ENGINE REMOVAL AND INSTALLATION

SERVICE TOOLS
ENGINE LIFTING HOOK................................................................ 529 035 829 ............................................. 9
ENGINE LIFTING TOOL ................................................................ 529 036 402 ............................................. 9
UPPER GEAR RETAINING TOOL .................................................. 529 036 110 ............................................. 7
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
Loctite 243
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)
10 ± 2 N•m
(89 ± 18 lbf•in)
10 ± 2 N•m
(89 ± 18 lbf•in)
mmr2017-011-028_a
mmr2017-011 1
31.5 ± 3.5 N•m

(23 ± 3 lbf•ft)
31.5 ± 3.5 N•m

(23 ± 3 lbf•ft)
mmr2017-011-200_a
2 mmr2017-011
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
See FRAME for the

installation procedure
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
NEW
See FRAME for the

installation procedure
NEW = Component must be replaced when removed.

mmr2017-011-201_a
mmr2017-011 3
GENERAL
During assembly/installation, use the torque
values and service products as shown in the ex-
ploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pin, etc.) must mmr2017-011-002_a
be replaced with new ones.

4. Remove the following parts. If required, refer
to BODY subsection.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
PROCEDURES
ENGINE
Removing the Engine
1. Place vehicle at workstation that will have ac-
cess to an engine-lifting hoist.
2. Remove fuel pressure. Refer to ELECTRIC
FUEL PUMP in FUEL TANK AND FUEL PUMP
subsection.
3. Disconnect the battery. mmr2017-011-003_a
LH SIDE PANEL AND LH BOTTOM PAN
mmr2017-011-001_a
mmr2017-015-100_a
RH SIDE PANEL
4 mmr2017-011
mmr2017-015-101_a
UPPER BODY MODULE

mmr2017-011-005_a
5. Remove the drive belt guard and acoustic
panel. 7. Remove the muffler and the tuned pipe. If re-
quired, refer to EXHAUST SYSTEM subsection.
mmr2017-014-013_a
mmr2017-011-006_a
DRIVE BELT GUARD
8. Place a drain pan under the front of the vehicle.

9. Drain the coolant by detaching the front cooling
hose from the engine then lift the rear of the
vehicle
NOTE: At the installation, replace the ear clamp
by an hose clamp.
mmr2017-014-014_a
ACOUSTIC PANEL
6. Disconnect the BLACK wire from the starter so-

lenoid. mmr2017-011-008_a
mmr2017-011 5
mmr2017-011-009_a mmr2017-011-011_a
12. Detach the coolant tank from the top of the

chaincase and unplug the vent hose from the
tank.
20 cm
mmr2017-011-007_a
10. If equipped, remove the rewind starter handle

and its housing.
mmr2017-011-012_a
13. Disconnect the ECM connector A and the

magneto connector.
14. Cut the locking tie retaining the engine har-
ness to the capacitor support.
mmr2017-011-010_a
11. Unplug the inlet and outlet cooling hoses from

the tunnel.
6 mmr2017-011
529036110
mmr2017-011-013_a
15. Unscrew fuel hoses from fuel rails. mmr2008-042-104_a
TYPICAL
1. Upper gear retaining tool
18. Remove the engine support screw.
mmr2017-011-014_a
16. Apply parking brake and remove the upper

gear screw and the conical spring washer.
mmr2017-011-026_a
19. Unclip the fuel hose from the primary air si-
lencer.
mmr2017-011-036_a
17. Install the UPPER GEAR RETAINING TOOL

(P/N 529 036 110) on countershaft end.
mmr2017-011-015_a
mmr2017-011 7
20. Remove engine cover.

20.1 Remove the 3 screws.
20.2 Pull on both halves of cover to remove.
mmr2017-011-017_a
23. From underneath of the oil tank, detach both

injection oil hoses from their support.
mmr2017-011-206
21. Detach the RAVE cable from the RAVE valve.

Refer to RAVE subsection for proper proce-
dure.
mmr2017-011-018_a
24. Detach the throttle cable from the throttle

housing.
mmr2017-011-016_a
22. Unscrew the oil tank support.
mmr2017-011-019_a
25. Remove the knock sensor from cylinder head

cover.
8 mmr2017-011
529035829
mmr2017-011-020_a mmr2017-011-022_a
26. Install the engine lifting tool instead of knock 28. Remove the driven pulley. Refer to appropri-
sensor. ate DRIVEN PULLEY AND COUNTERSHAFT
subsection.
REQUIRED TOOL
NOTE: If necessary, tap the upper gear retaining
ENGINE LIFTING TOOL tool with a plastic hammer.
(P/N 529 036 402)
529036402
mmr2017-011-023_a
mmr2017-011-021_a
29. Unscrew countershaft from the upper gear re-

27. Install the engine lifting hook. taining tool. Do not remove tool.
REQUIRED TOOL NOTE: While countershaft is removed from vehi-
ENGINE LIFTING HOOK
cle, the upper gear retaining tool maintains the
(P/N 529 035 829) drive chain and the upper gear in position inside
chaincase.
30. On LH side, remove the steering brace.
mmr2017-011 9
Installing the Engine

To install engine, reverse the removal procedure.
However, pay attention to the following.
– Install NEW self-locking fasteners (screw or
nut) where required, refer to exploded views
at the beginning of this subsection.
– When installing countershaft bearing support,
refer to FRAME subsection for proper proce-
dure.
– Install and tighten engine support bolts. Refer
to ENGINE SUPPORT INSTALLATION in this
subsection.
– If a new engine is installed or the engine was
mmr2017-011-024_a
repaired, restart the break-in procedure using
BUDS2.
31. Remove the primary air silencer. Refer to AIR
INTAKE SYSTEM subsection. ENGINE SUPPORT
Inspecting the Engine Support
Check if engine supports are cracked, bent or
damaged. Replace if necessary.
Replacing the PTO Side Engine

Support
Remove the LH bottom pan. Refer to BODY sub-
section.
Remove driven pulley. Refer to appropriate
DRIVEN PULLEY AND COUNTERSHAFT subsec-
tion.
Remove the injection oil tank support.
mmr2017-011-202_a
32. Remove engine support screws.
mmr2017-011-204_a
Place a piece of wood or any other appropriate tool

under the engine to support it during engine sup-
mmr2017-011-203_a
port removal.
Remove screws securing engine support to rub-
33. Lift engine and slide it out of vehicle. ber mount adapters.
10 mmr2017-011
To install the engine support, reverse the removal

procedure.
Position the concave washer as shown.
mmr2017-011-205_a
Remove engine support screws.
mmr2017-011-033_a
SOME PARTS REMOVED FOR CLARITY
Tighten screws as per the specifications indicated

in the exploded views.
ENGINE RUBBER MOUNTS

Inspecting the Engine Rubber Mount
Check rubber mounts. Replace them if brittle,
cracked or damaged.
Replacing the PTO Side Engine Rubber

Mount
mmr2017-011-203_a
Remove the PTO side engine support. See proce-
Remove engine support. dure in this subsection.
To install the engine support, reverse the removal Using a press, extract the engine rubber mount
procedure. from the engine support.
Replacing the MAG Side Engine

Support
HAUST SYSTEM subsection. 1
port removal.
Remove screw securing engine support to rubber
mount adapter.
Remove screw retaining engine support to en-
gine.
mmr2017-011-034_a
Remove engine support. 1. Press on this ring
mmr2017-011 11
Install the new engine rubber mount by pressing

on the external metallic ring.
mmr2017-011-035_a
1. Press on this metallic ring
Replacing the MAG Side Engine

Rubber Mount
port removal.
Remove screw securing engine support to rubber
mount adapter.
Remove screw retaining rubber mount adapter to
frame.
Remove rubber mount adapter.
To install the rubber mount adapter, reverse the
removal procedure.
12 mmr2017-011
Subsection XX (ENGINE LEAK TEST)
ENGINE LEAK TEST

SERVICE TOOLS
INTAKE PLUGS.............................................................................. 529 036 421 ............................................. 3
MANIFOLD PLUG 63 MM (2-1/2") ................................................ 529 035 961 ............................................. 3
SMALL HOSE PINCHER ............................................................... 295 000 076 ............................................. 3
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ............................................. 4
mmr2017-012 1
PROCEDURES
NOTE: This flow chart must be used as a visual reference during the engine leak test procedure.
PRESSURIZE ENGINE
NO
IS ENGINE LEAKING?
YES
CHECK ALL JOINTED SURFACES,
SCREW/STUD THREADS. MOUNTING
FLANGES ETC.
YES REPLACE GASKET OR O-RING,

ANY LEAK FOUND? RE-SEAL LEAKING AREA
NO
CHECK SMALL OIL LINES OF

INJECTION PUMP
AIR BUBBLES FOUND YES

O R OIL MOVING REPLACE CHECK VALVE(S)
TOWARD PUMP?
NO
REMOVE BLEED SCREW ON CYLINDER HEAD
YES REPLACE O-RING OF CYLINDER HEAD

ARE ANY AIR BUBBLES IN COOLANT?
AND/OR CYLINDER BASE GASKET
NO
BLOCK HOSE OF PUMP SHAFT GEAR

LUBRICATION SYSTEM
NO
IS ENGINE STILL LEAKING?
YES
CHECK CRANKSHAFT OUTER
SEAL OF PTO AND
MAG SIDES
YES
ARE SEALS LEAKING? REPLACE DEFECTIVE SEAL(S)
NO
PRESSURIZE PUMP SHAFT GEAR

RESERVOIR IN CRANKCASE
YES
PRESSURIZE PUMP SHAFT GEAR IS RESERVOIR LEAKING?
RESERVOIR IN CRANKCASE
NO
UNSEAL PTO CYLINDER AND MAG

CYLINDER SEPARATELY
YES REPLACE DEFECTIVE SEAL(S)

IS RESERVOIR LEAKING?
NO
CHECK LEAKAGE AT LEAK

YES INDICATOR HOLE BELOW COOLANT
IS RESERVOIR LEAKING? PUMP HOUSING
YES REPLACE OIL SEAL OF PUMP

NO ANY LEAK FOUND? SHAFT, BEHIND CERAMIC SEAL
NO
CHECK MATING SURFACE OF

COVER FOR LEAKS
YES
IS GASKET LEAKING? REPLACE DEFECTIVE GASKET
NO
CHECK SMALL AND LARGE OIL LINES
OF INJECTION PUMP
AIR BUBBLES FOUND OR OIL MOVING YES

OUTWARD PUMP? REPLACE PUMP
NO
CAREFULLY INSPECT ENGINE CASTINGS,

PARTICULARLY THE THREAD HOLE AREAS
YES
ANY LEAK FOUND? REPLACE DEFECTIVE PARTS
NO
ENGINE IS PERFECTLY SEALED

INTERNALLY
mmr2013-009-001_ben
2 mmr2017-012
ENGINE LEAK TEST

Prior to take apart an engine, it is important to
proceed with a leak test to diagnose engine prob-
lems. Whenever the engine is disassembled, a
leak test should be performed after reassembly.
1. Remove engine. Do not remove the exhaust
manifold. Refer to ENGINE REMOVAL AND IN-
STALLATION subsection.
2. Remove throttle body, refer to E-TEC DIRECT
FUEL INJECTION subsection.
3. Install appropriate plug over exhaust manifold
and secure with a clamp.
mmr2017-012-002_a
REQUIRED TOOL
6. Block oil hoses connected to the oil pump:
MANIFOLD PLUG 63 MM (2-1/2")
(P/N 529 035 961)
6.1 Partially remove corrugated tube from oil
hoses.
6.2 Install hose pincher right after check valve.
REQUIRED TOOL
SMALL HOSE PINCHER

(P/N 295 000 076)
mmr2017-012-001_a
4. Insert an intake plug in each intake adapters.

REQUIRED TOOL
mmr2017-012-009_a
INTAKE PLUGS (P/N 529 BLOCK OIL HOSES HERE

036 421)
5. Tighten with existing clamps.
mmr2017-012 3
8. If pressure drops before 3 minutes, spray a

soapy solution on tester kit (manifold and in-
take plugs, vacuum/pressure pump and its
hose).
8.1 If tester kit (manifold and intake plugs,
hoses and pump) is leaking, bubbles will
indicate where leak comes from.
8.2 If tester kit is not leaking, check engine,
see ENGINE COMPONENTS TO BE VER-
IFIED.
Engine Components to be Verified
mmr2017-012-010_a If air is escaping from engine check all jointed sur-
BLOCK OIL HOSES HERE faces and screw or stud threads of engine:
NOTICE Pay attention not to squeeze hose – Spark plug base, insulator
nipples. – Cylinder head
– RAVE valve oil seals and housing
7. Pressurize engine. – Cylinder block
REQUIRED TOOL – Crankcase halves (joint)
– Crankshaft outer seals (PTO and MAG)
VACUUM/PRESSURE PUMP – Fuel injector gaskets
(P/N 529 021 800)
– Base plate gasket and base plate.
Troubleshooting Tips
Air bubbles in cooling system indicate a defective
cylinder head O-ring or cylinder base gasket.
Check leak indicator hole for oil or coolant.
mmr2017-012-004_a
ENGINE LEAK TEST

TIME (WITHOUT
PRESSURE
PRESSURE DROP)
mmr2017-012-005_a
30 kPa (4.35 PSI) 3 minutes
Leaking coolant indicates:
NOTICE Do not exceed the specified pres- – A defective ceramic seal (on water pump side)
sure.
– Defective O-ring on bearing carrier, see COOL-
ING SYSTEM subsection.
Leaking oil indicates:
– A defective oil seal (behind ceramic seal)
– Defective O-ring on bearing carrier, see COOL-
ING SYSTEM subsection.
4 mmr2017-012
PUMP SHAFT OIL GEAR

RESERVOIR LEAK TEST
Install air pump on reservoir fitting and pressurize
engine.
PUMP SHAFT OIL GEAR RESERVOIR LEAK TEST
TIME (WITHOUT
PRESSURE
PRESSURE DROP)
NOTICE Do not exceed the specified pres-

sure.
mmr2017-012-008_a
CRANKCASE INSIDE VIEW

1. Leakage through water pump oil seal (reservoir side)
2. Leakage on plug screw side (gasket)
mmr2017-012-006_a
If pressure drops check for:

– Leaking plug screw gasket
– Defective O-ring on bearing carrier (see COOL-
ING SYSTEM subsection)
– Defective oil seal on water pump side
– Defective crankshaft inner seal.
mmr2017-012-007_a
CRANKCASE INSIDE VIEW

1. Leakage through inner seal on MAG side
2. Leakage through inner seal on PTO side
mmr2017-012 5
Subsection XX (AIR INTAKE SYSTEM)
AIR INTAKE SYSTEM

1.7 ± 0.2 N•m
(15 ± 2 lbf•in)
1.7 ± 0.2 N•m

(15 ± 2 lbf•in)
1.7 ± 0.2 N•m

(15 ± 2 lbf•in)
1.7 ± 0.2 N•m

(15 ± 2 lbf•in) 1 ± 0.2 N•m
(9 ± 2 lbf•in)
0.7 ± 0.1 N•m

(6 ± 1 lbf•in)
mmr2017-014-100_a
mmr2017-014 1
GENERAL
WARNING
Locking devices must be replaced with a
new ones when removed (e.g.: locking tabs,
elastic stop nuts, cotter pins, etc.).

PROCEDURES mmr2017-014-002_a
On some models, remove the air deflector.

AIR FILTER (MESH)
mmr2017-014-003_a
mmr2017-014-001_a
Remove the mesh filter housing from the upper
The same procedure applies for RH and LH side. body module.
Only one side is described in this procedure.
Removing the Air Filter

Remove screws from mesh filter housing.
mmr2017-014-004_a
Cleaning the Air Filter

Clean with fresh water and mild soap.
2 mmr2017-014
Replace air filter if required.

NOTE: If the filter is very dirty, clean the interior
of secondary air intake silencer at the same time.
Installing the Air Filter

cedure.
PRIMARY AIR INTAKE SILENCER

Removing the Primary Air Intake
Silencer
1. Remove the following parts. If required, refer
to BODY subsection.
mmr2017-014-013_a
REMOVE DRIVE BELT GUARD
mmr2017-011-003_a
LH SIDE PANEL AND LH BOTTOM PAN
mmr2017-014-014_a
REMOVE ACOUSTIC PANEL
3. Remove the driven pulley. Refer to appropriate

DRIVEN PULLEY AND COUNTERSHAFT sub-
section.
mmr2017-015-101_a
UPPER BODY MODULE
2. Remove the drive belt guard and acoustic pan-

els.
mmr2017-014-005_a
4. On LH side, remove the steering brace.

mmr2017-014 3
mmr2017-014-006_a mmr2017-011-015_a
5. Remove the drive belt guard support. 7. Remove the primary air silencer.
7.1 Loosen clamps securing primary air si-
lencer to intake adapters.
7.2 Carefully pull out the primary air intake si-
lencer with the steering brace.
NOTICE Make sure not touching the sec-
ondary injectors or their harnesses when
removing the primary air intake silencer .
mmr2017-014-012_a
6. Unclip the fuel hose from the primary air si- mmr2017-011-202_a
lencer.
Installing the Primary Air Intake
Silencer
cedure. However, pay attention to the following.
Make sure primary air intake is properly insert in
the intake adapters before applying the tightening
torque.
4 mmr2017-014
SECONDARY AIR INTAKE

SILENCER
mmr2017-014-009_a
Remove fasteners retaining secondary air intake

silencer to upper body module.
mmr2017-014-008_a
Removing the Secondary Air Intake

Silencer
Referring to the BODY subsection, remove the
upper body module.
Remove the following screws.
mmr2017-014-010_a
Installing the Secondary Air Intake

Silencer
cedure.
mmr2017-014-011_a
Turn the upper body module upside down and re-

move the soundproofing panel.
mmr2017-014 5
Subsection XX (EXHAUST SYSTEM)
EXHAUST SYSTEM
SERVICE TOOLS
SPRING INSTALLER/REMOVER ................................................... 529 035 983 ......................................... 5, 7
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 9
mmr2017-015 1
NEW
See
NEW tightening
procedure
Loctite 243

mmr2017-015-001_a
2 mmr2017-015
Models With One EGTS
7 ± 1 N•m
(62 ± 9 lbf•in)
NEW
45 ± 2 N•m
(33 ± 1 lbf•ft)
See E-TEC DIRECT
FUEL INJECTION
for testing
mmr2017-015-250_a
mmr2017-015 3
Models With Two EGTS
See E-TEC DIRECT

FUEL INJECTION
for testing
45 ± 2 N•m
(33 ± 1 lbf•ft)
7 ± 1 N•m
(62 ± 9 lbf•in)
NEW
45 ± 2 N•m
(33 ± 1 lbf•ft)
See E-TEC DIRECT
FUEL INJECTION
for testing
mmr2017-015-251_a
4 mmr2017-015
GENERAL
WARNING
To avoid potential burns, never touch ex-
haust system components immediately after
the engine has been running because these
components are very hot. Let engine and ex-
haust system cool down before performing
any servicing.
During assembly/installation, use the torque value

and service products as in the exploded view.
mmr2017-015-101_a
WARNING 2. Remove heat shields from the muffler pipe.

Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins,
etc.) must be replaced with new ones.
PROCEDURES
MUFFLER
Removing the Muffler
1. Refer to BODY subsection and remove the fol-
lowing parts.
mmr2017-015-201_a
3. Remove exhaust springs retaining the tuned

pipe to the muffler.
REQUIRED TOOL
SPRING INSTALLER/REMOVER
(P/N 529 035 983)
mmr2017-015-100_a
mmr2017-015-202_a
mmr2017-015 5
Models With One EGTS

4. Disconnect the power harness from the ther-
mocouple module (THCM)
mmr2017-015-205_a
All Models
7. Behind the muffler, remove the retaining screw
and its spring.
mmr2017-015-203_a
5. Detach the THCM module from the vehicle side

member.
mmr2017-015-206_a
8. Remove the muffler.

mmr2017-015-204_a
Models With Two EGTS

6. Disconnect the exhaust gas temperature sen-
sor (EGTSm) from the THCM module harness.
mmr2017-015-107_a
9. Remove exhaust gasket.
6 mmr2017-015
2. Remove exhaust springs retaining the tuned

pipe to the exhaust manifold.
REQUIRED TOOL
SPRING INSTALLER/REMOVER
(P/N 529 035 983)
mmr2017-015-207_a
Inspecting the Muffler

Check the muffler for cracks or other damages.
Check grommet condition.
Inspect exhaust gasket condition. Replace as re-
quired.
mmr2017-015-208_a
Installing the Muffler Models With 2 EGTS

For installation, reverse the removal procedure. 3. Disconnect the THCM harness from the THCM
However, pay attention to the following: module.
Muffler Retaining Screw
mmr2017-015-209_a
mmr2017-015-700
4. Detach the THCM module from the vehicle side
member.
TIGHTENING TORQUE
7 N•m ± 1 N•m
Muffler retaining screw
TUNED PIPE
Removing the Tuned Pipe
1. Remove the muffler.
mmr2017-015 7
mmr2017-015-204_a mmr2017-015-116_a
All Models Inspecting the Tuned Pipe

5. Remove tuned pipe. Check exhaust pipe for:
5.1 Move tuned pipe forwards until the hook – Damages
gets out of the anti vibration rubber mount. – Cracks.
5.2 Remove the tuned pipe by tilting it (engine Inspect exhaust gasket condition. Replace as re-
side). quired.
Installing the Tuned Pipe

For installation, reverse the removal procedure.
EXHAUST MANIFOLD
Removing the Exhaust Manifold
1. Remove tuned pipe. Refer to REMOVING THE
2 TUNED PIPE in this subsection.
1
2. Remove:
– Exhaust manifold screws (discard them)
– Washers.
REQUIRED TOOL
mmr2017-015-115_a Allen spherical socket
6. Remove exhaust gasket. NOTICE Heat screws for 30 seconds before

loosening to prevent screw breakage.
3. Remove:
– Exhaust manifold
– Gaskets (discard them).
Inspecting the Exhaust Manifold

Check if manifold is cracked or damaged. Replace
if necessary.
Installing the Exhaust Manifold

1. Install manifold with new gaskets.
8 mmr2017-015
2. Install new exhaust manifold screws with LOC-

TITE 243 (BLUE) (P/N 293 800 060) as per the fol-
lowing tightening sequence and procedure.
3. Tighten exhaust manifold screws to specifica-
tion using the following pattern.
NOTICE Do not use an impact wrench to
tighten exhaust manifold screws.
NOTE: Perform step A on all manifold screws be-
fore proceeding with step B.
mmr2017-015-002_a
TIGHTENING SEQUENCE
TIGHTENING PROCEDURE
Service LOCTITE 243 (BLUE)
product (P/N 293 800 060)
Exhaust
7 N•m ± 0.5 N•m
manifold Step A
screws
34 N•m ± 4 N•m
Step B
4. Install tuned pipe as the reverse of removal.
mmr2017-015 9
Subsection XX (REWIND STARTER)
REWIND STARTER
SERVICE TOOLS
SMALL HOSE PINCHER ............................................................... 295 000 076 ......................................... 3, 9
SERVICE PRODUCTS
MOLYKOTE PG 54 ........................................................................ 420 899 763 ............................................. 6
mmr2017-016 1
8 ± 0,5 N•m
(71 ± 4 lbf•in)
Molycote PG54
Molycote PG54
Molycote PG54
9 ± 0,6 N•m
(80 ± 5 lbf•in)
mmr2017-016-001_a
2 mmr2017-016
INSPECTION
Due to dust accumulation, rewind starter must
be periodically cleaned, inspected and lubricated.
Refer to MAINTENANCE section.
NOTICE It is of the utmost importance that
the rewind starter spring is lubricated peri-
odically using specific lubricant. Otherwise,
295000076
rewind starter component life will be short-
ened and/or rewind starter will not operate
properly under very cold temperatures.
Check if starter rope is fraying, replace if neces-
sary.
When pulling starter handle, starter mechanism mmr2017-016-203_a
must engage within 10 cm (3.94 in) of rope pull

Using a small screwdriver, extract rope knot from
length. If not, disassemble rewind starter, clean
stater handle.
and check for damaged plastic parts. Replace as
required, lubricate, reassemble and recheck. Cut rope close to knot.
When releasing starter handle, it must return to its
stopper and stay against it. If not, check for proper
spring preload or damage. Readjust or replace as
required.
When pulling starter handle 10 times in a row,
it must return freely. If not, check for damaged
parts or lack of lubrication. Replace parts or lubri-
cate accordingly.
PROCEDURES
REWIND STARTER HANDLE
Removing the Rewind Starter Handle
Pull out starter handle/rope for 50 cm (20 in) ap- mmr2017-016-204_a
proximately and lock rope near rewind starter.

REQUIRED TOOL
Installing the Rewind Starter Handle
Before installing starter handle on the rope, it is
SMALL HOSE PINCHER necessary to fuse the rope end with a lit match.
(P/N 295 000 076) Pass rope through starter handle and tie a knot on
the rope end.
Fuse the knot with a lit match then insert rope end
down and pull the starter handle over the knot.
mmr2017-016 3
mmr2017-016-003_a
mmr2017-016-205_a A. 30 mm to 35 mm (1.2 in to 1.4 in)

1. Knot
2. Fused rope end
REWIND STARTER ROPE
Insert rope end into rope sheave.
Rewind Starter Rope Replacement
Remove rewind starter, refer to REWIND
STARTER in this subsection.
Completely pull out rope. Hold rewind starter in a
vise.
mmr2017-016-002
Slide rope and untie the knot. mmr2017-016-004_a
Remove rope from rope sheave.

NOTE: A new rope must have a overall length of
REWIND STARTER
200 cm (78.74 in). Removing the Rewind Starter
Insert rope end in rope sheave orifice and lock it Remove starter handle.
by making a knot, leaving behind a free portion of
Remove:
30 mm to 35 mm (1.2 in to 1.4 in) in length.
– Retaining screws
Fuse rope end with a lit match
– Rewind starter.
4 mmr2017-016
Engine Inside the Vehicle Disassembling the Rewind Starter

Remove the hose pincher previously installed on
rope at rewind starter handle removal. Let rope
sheave get free to release spring preload.
Remove the following parts:
mmr2017-016-201_a
2
1
mmr2017-016-006_a
1. Taptite screw
2. Flange bushing
3. Lock lever
4. Thrust washer
5. Compression spring
6. Step collar
mmr2017-016-202_a
7. Pawl lock
Step 1: Slide the bottom of the rewind starter out of frame 8. Pawl
Step 2: Remove rewind starter from engine
Remove rope sheave from starter housing. Hold
Engine Out of the Vehicle spring in starter housing using a screwdriver.
mmr2017-016-007_a
WARNING
mmr2017-016-005_a
Since the spring is tightly wound inside the
1. Retaining screws guide it may fly out when rewind is handled.
2. Rewind starter Always handle with care.
mmr2017-016 5
For removing the spring, it is of best practice to

take the starter housing with the spring showing
to the floor and than let the starter housing fall
plane to the ground.
Discard spring.
Check sleeve for wear or any other damage. Re-
place rope sheave if necessary.
Assembling the Rewind Starter

NOTICE For rewind starter parts lubrication
use following specified service product. The
use of standard multipurpose grease could
result in rewind starter malfunction under very
cold temperatures and component life will be mmr2017-016-009_a
1. Outer spring end

shortened. 2. Paper carrier (discard it)
REWIND STARTER PARTS LUBRICATION Apply the lubricant at these locations:

MOLYKOTE PG 54
Service product
(P/N 420 899 763)
Apply the lubricant at these locations:
mmr2017-016-010_a
1. Spring
2. 1 cm (1/2 in) wide on bottom of housing
3. Housing post
Wind rope on rope sheave

mmr2017-016-008_a
1. Spring contact area Place rope sheave in starter housing making sure
2. Spring guide inside housing the sheave hub notch engages in the rewind
spring hook.
Position spring outer end in spring guide notch
with the opening of the spring clip pointing coun-
terclockwise. Then push the spring evenly in the
guide. Discard paper carrier.
WARNING
Since the spring is tightly wound inside the
guide it may fly out when rewind is handled.
Always handle with care.
6 mmr2017-016
mmr2017-016-011_a
REWIND SPRING HOOK
mmr2017-016-013_a
1. Knot
2. Lubricate contact surface of the pawl
Lubricate pawl at the contact surface and emboss.
mmr2017-016-012_a mmr2017-016-014_a
SHEAVE HUB NOTCH 1. Contact surface

2. Emboss
Rotate the rope sheave counterclockwise by
about 1/2 turn until rope end is accessible through Install pawl on rope sheave.
rope exit hole.
Pull rope out of starter housing.
Rotate the rope sheave counterclockwise 1 full
turn.
Temporarily make a knot to hold it.
Lubricate rope sheave at the contact surface of
the pawl.
mmr2017-016-015_a
mmr2017-016 7
Lubricate pawl lock at the contact surfaces and

emboss.
mmr2017-016-018_a
1. Contact surface
mmr2017-016-024_a
1. Contact surfaces Preassemble as shown:

2. Emboss
Install pawl lock on pawl.

NOTE: Pawl lock nose must engage between the
pawl lock stoppers.
mmr2017-016-019_a
1. Taptite screw
2. Flange bushing
3. Lock lever
4. Thrust washer
5. Compression spring
Install preassembled unit on rewind starter.
mmr2017-016-017_a
1. Pawl lock
2. Pawl lock nose
3. Pawl
4. Pawl lock stoppers
Lubricate step collar and install it on pawl lock.
mmr2017-016-020_a
8 mmr2017-016
Tighten Taptite screw to specification.

TIGHTENING TORQUE
8 N•m ± 0.5 N•m
Taptite screw
After completion, check if the pawl lock engages

and the rope is pulled back completely after relea-
sing the rope.
Installing the Rewind Starter

1. Loosen the temporary knot.
2. Check correct rope length:
2.1 Pull out rope until recess for knot in the
rope sheave is within the specified range.
2.2 Measure rope length. mmr2007-016-001_a
MINIMUM ROPE LENGTH 4. Reinstall rewind starter assembly on engine.

275 mm (10.8 in) TIGHTENING TORQUE
Rewind starter retaining 9 N•m ± 0.6 N•m
screws (80 lbf•in ± 5 lbf•in)
5. Thread starter rope through console.

6. Install handle, refer to INSTALLING THE
STARTER HANDLEin this subsection.
mmr2017-016-023_a
1. Knot
2. Bottom side of rewind starter
3. Range of ± 30°
If rope is too short replace rope, refer to REWIND

STARTER ROPE REPLACEMENT in this subsec-
tion.
3. Lock rope near rewind starter housing.
REQUIRED TOOL
SMALL HOSE PINCHER

(P/N 295 000 076)
mmr2017-016 9
Subsection XX (LUBRICATION SYSTEM)
LUBRICATION SYSTEM
SERVICE TOOLS
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................................... 12
IMPULSE FITTING PUNCH (BIG) .................................................. 529 036 412 ........................................... 16
IMPULSE FITTING PUNCH (SMALL) ............................................ 529 036 413 ........................................... 16
LEAK TEST KIT .............................................................................. 529 033 100 ............................................. 7
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ................................. 7, 14, 16
SERVICE PRODUCTS
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ........................................... 15
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ........................................... 15
XPS INJECTION OIL...................................................................... 293 600 117 ............................................. 7
XPS SYNTHETIC 2-STROKE OIL ................................................... 293 600 132 ............................................. 7
mmr2017-017 1
CHECK VALVES AND OIL HOSES
NEW
Loctite 648
NEW
NEW
NEW
NEW
NEW
Loctite 648
NEW
NEW
Loctite 648
NEW
NEW
Loctite 648
mmr2017-017-500_a
2 mmr2017-017
OIL INJECTION TANK AND OIL INJECTION PUMP
1.25 ± 0.25 N•m

(11 ± 1 lbf•in)
2.4 ± 0.2 N•m

(21 ± 2 lbf•in)
5 ± 1 N•m
(44 ± 9 lbf•in)
NEW
1.25 ± 0.25 N•m

(11 ± 1 lbf•in)

mmr2017-017-650_a
mmr2017-017 3
GENERAL
ploded view.
complete procedure.
WARNING
tabs, elastic stop nuts, self-locking fasteners,
etc.) must be replaced with new ones.
WARNING
Wipe off any oil spills. Oil is highly
flammable.
NOTICE Do not use a hose pincher on out-

let hose. This would damage the spring inside
hose.
4 mmr2017-017
ENGINE LUBRICATION SYSTEM DESCRIPTION
6 4
15
11 12
14 13
10 9 7 8 3
5 2
1
mmr2017-017-510_a
1. Oil supply from oil tank 9. To engine PTO side

2. Oil pump 10. Check valve PTO side main bearing
3. To 3D RAVE valve MAG side 11. From MAG side outer main bearing to PTO inner main bearing
4. Check valve RAVE MAG side 12. Check valve
5. To 3D RAVE valve PTO side 13. From PTO side outer main bearing to MAG inner main bearing
6. Check valve RAVE PTO side 14. Check valve
7. To engine MAG side 15. Oil supply from oil tank
8. Check valve MAG side main bearing
mmr2017-017 5
The engine oil supplied by the oil pump is going

through check valves to the outer main bearings.
Through oil collecting grooves in the outer crank
webs, the main quantity of oil is going through the
crank webs and by centrifugal force, the oil is di-
rectly transferred to the crank pins to lubricate the
big end bearings. After this oil exits the big end
bearings it lubricates the small ends, cylinder lin-
ers and pistons. A portion of the oil supplied to the
outer main bearings is supplied to the opposite in-
ner main bearings controlled by check valves. This
oil supply happens by use of pressure difference
between cylinder MAG and PTO. mmr2017-017-009_a
1. To engine PTO side

RAVE valves are lubricated by the electronic oil in- 2. To 3D RAVE valve PTO side
jection pump. 3. To engine MAG side
4. To 3D RAVE valve MAG side
SYSTEM DESCRIPTION NOTE: engine and 3D RAVE valve MAG side are
interchangeable.
An electronic oil injection pump with a mechanical
positive displacement type is used. An electronic The 4 plungers in the pump work synchronized.
pump is more accurate and injection rate can be They pump all at the same time.
changed according to engine requirements. This
results in a greatly reduced oil consumption.
The electronic oil injection pump is directly at-
tached under the oil injection tank.
mmr2011-014-001
TYPICAL
The ECM controls the pump to inject a variable

mmr2017-017-001 a
amount of oil through the entire engine operating
1. Oil injection tank range and conditions.
2. Electronic oil injection pump
Oil Injection Pump Operation
The E-TEC pump features a total of 4 outlets:
– 2 large outlets to the crankcase to lubricate en- For the first 6 hours of engine break-in period, oil
gine internal parts. delivery is increased.
– 2 small outlets to the 3D RAVE valves to lubri- Oil/fuel ratio can go up to approximately 70:1 after
cate valves to prevent carbon deposits. the break-in period.
At idle, pump works at approximately less than
1 pulse per minute. A very low quantity of oil is in-
jected to reduce engine smoke and to reduce en-
gine emissions.
As engine speed increases, oil flow increases but
not proportionally. It varies according to the spe-
cific engine requirements.
6 mmr2017-017
At 8000 RPM, pump works at approximately 180 The storage mode can be activated either by using
pulses per minute. BUDS2 or the multifunction gauge on the vehicle.
When operating vehicle in high altitude area, Refer to STORAGE PROCEDURE subsection.
oil flow is reduced proportionally as altitude in-
creases. RECOMMENDED INJECTION OIL
Oil Warm-Up Mode RECOMMENDED INJECTION OIL
When injection oil is very cold and engine is above XPS SYNTHETIC
XPS INJECTION OIL
idle speed, the oil warm-up mode is active. (P/N 293 600 117)
2-STROKE OIL (P/N 293
600 132)
To warm-up the oil, the oil injection pump is kept
ON after the oil delivery stroke, as long as possi-
ble, to then turn OFF for the return stroke. The NOTICE These engines have been devel-
extra time the pump is ON generates more heat oped and validated using the XPS™ 2-stroke
that is dissipated through the oil. oils. BRP strongly recommends the use of
the applicable XPS 2-stroke oils at all times.
NOTE: The premium gauge displays WARM UP Damages caused by oil which is not suitable
whenever the oil warm-up or engine warm-up for the engine will not be covered by the BRP
modes are active. limited warranty.
To determine if injection oil is cold, the ECM uses
a feedback switch, located in oil injection pump, INSPECTION
that closes at the end of the oil delivery stroke and
opens when the oil injection pump coil is de-en-
ergized. Thus, the ECM can calculate the time it
OIL SYSTEM LEAK TEST
takes to deliver the oil which is related to the oil 1. Install the test cap on oil tank.
viscosity.
REQUIRED TOOL
The ECM uses a complex algorithm to vary the
warm-up time and the rev limiter according to oil LEAK TEST KIT
pump requirements based on engine speed and (P/N 529 033 100)
TPS position. Therefore, the rev limiter is set dy-
namically as per the driver inputs.
NOTE: If a fault code related to the feedback
switch is active (P1233, P1234), the oil injection
warm-up mode uses data from the ATS but it
uses the following parameter values. Engine lu-
brication does not change, only the warm-up time
may be longer than usual.
OIL WARM-UP MODE STRATEGY WHEN
FEEDBACK SWITCH IS FAULTY
ENGINE
AIR WARM-UP
SPEED mmr2017-017-710
TEMPERATURE TIME
LIMITATION TYPICAL
1. Test cap on tank
Within
Warm-up starts Within 2. Connect the pressure pump to test cap.
approximately
below -20°C approximately 8
4000 - 6000
(-4°F) and 11 minutes REQUIRED TOOL
RPM
VACUUM/PRESSURE PUMP
Automated Engine Oil Fogging (P/N 529 021 800)
An automated engine oil fogging has been im-
plemented to automatically inject the required
3. Pressurize oil system as follows.
oil to protect the engine during vehicle storage.
Engine speed will be increased to approximately
1600 RPM and excess oil will be injected for
approximately 30 seconds then, the engine will
automatically be stopped.
mmr2017-017 7
TIME TO HOLD
PRESSURE
PRESSURE
If pressure drops, locate leak(s) and repair or re-

place leaking component(s).
If pressure does not drop, this validate the oil in-
jection tank and the oil pump for leakage.
TROUBLESHOOTING
SYMPTOM CAUSE ACTION
Check oil injection
Damaged or
pump wires and
disconnected oil
connectors on oil
injection pump. mmr2009-014-034_a
injection pump.
Circuit wires, Check Oil injection pump bleeding is done with
connectors or WHITE/RED wire BUDS2Refer to BLEEDING OIL INJECTION
ECM output pins. on oil injection PUMP in this subsection.
pump connector
for 55 volts. Oil Injection Pump Hoses Connection
Check system
circuit to ECMA
connector
Repair or replace
defective part(s).
Repair or replace
Damaged, kinked
hose and test oil
or obstructed inlet
injection pump (oil
hose.
outflow).
Engine
seizure Damaged oil
Replace oil
(PTO or injection pump
injection pump.
MAG side) inner piston.
Repair or replace mmr2017-017-009_a
Mechanical 1. To engine PTO side
engine defective
engine problem. 2. To 3D RAVE valve PTO side
part(s). 3. To engine MAG side
4. To 3D RAVE valve MAG side
PROCEDURES NOTE: engine and 3D RAVE valve MAG side are

interchangeable.
OIL INJECTION PUMP
Oil Injection Pump Identification
Every pump is bench tested. Its electrical and
flow characteristics are registered throughout
all its operating range and are associated to a
compensation number.
When a pump is replaced, the compensation
number must be entered in BUDS2. so that the
ECM properly controls the pump according to its
optimized characteristics.
The compensation number is located on a label on
the pump as shown.
8 mmr2017-017
mmr2017-017-013
mmr2017-017-003_a
1. Oil inlet hose (PTO side) 2. Remove and discard Oetiker clamp securing oil
2. Oil inlet hose (MAG side)
injection pump to oil tank.
mmr2017-017-004_a mmr2017-017-214_a
1. MAG 3D RAVE valve 1. Oetiker clamp

2. PTO 3D RAVE valve
3. Move oil injection pump downward to remove
Testing Oil Injection Pump with BUDS2 it from oil tank.
1. Connect BUDS2. Refer to COMMUNICATION
TOOLS AND B.U.D.S. subsection.
2. Navigate to the functions page.
3. Start engine.
4. Activate oil pump
5. Listen if oil injection pump is activated.
NOTE: Touching the oil injection pump may help
to feel if pump is activated.
6. If test fails, check wires and connector.
Removing the Oil Injection Pump

mmr2017-017-016
1. Remove the pump bracket.
Inspecting the Oil Injection Pump
1. Check the strainer on the top of oil injection
pump. Replace oil injection pump if the strainer
is clogged.
mmr2017-017 9
mmr2009-014-020_a
BACK OF OIL INJECTION PUMP

1. Oil injection pump code (0 to 9)
5. Correct oil injection pump code in BUDS2 if re-

quired.
mmr2011-014-001_a Write any changes.
1. Oil injection pump strainer 6. Navigate to the Functions page.
NOTE: Do not replace oil injection pump need- 7. Activate the oil pump.
lessly. If strainer is slightly dented, oil injection 8. Start engine.
pump is still functional.
9. Check for air into hoses. If so, the bleeding pro-
Installing the Oil Injection Pump cedure must be repeated as often as needed
until all air is pumped through entire system.
OIL INJECTION TANK
Install NEW Oetiker clamp to secure oil injection
pump. Removing the Oil Injection Tank
Ensure Oetiker clamp makes contact with oil tank 1. Remove upper body module. Refer to BODY
ribs. subsection.
2. Remove side panel
3. Empty oil injection tank completely by siphon-
ing injection oil.
4. Remove belt guard
mmr2017-017-214_a
1. Oil tank rib
Refer to INSTALLING THE OIL TANK to properly

reinstall oil tank.
mmr2017-017-005
Bleeding Oil Injection Pump
1. Connect BUDS2. Refer to COMMUNICATION 5. Remove bottom pan
TOOLS AND B.U.D.S. subsection.
2. Navigate to the settings page.
3. Select configuration tab then the ECM tab.
4. Compare oil pump codes in B.U.D.S. and on oil
injection pump sticker.
10 mmr2017-017
mmr2017-017-010 mmr2017-017-008
6. Unbolt Rave Valve actuator and set aside. 9. Remove bracket
mmr2017-017-006 mmr2017-017-012
7. Remove acoustic panel. 10. Remove screws
mmr2017-017-007 mmr2017-017-211_a
8. Remove Ignition coil. 11. Remove Oil Tank support screw.
mmr2017-017 11
2. Apply injection oil on oil injection pump hoses.

3. Properly route and connect oil hoses into oil in-
jection pump. Refer to OIL INJECTION PUMP
HOSES CONNECTION in this subsection.
NOTICE Oil injection pump fittings are very
fragile, care must be taken when installing
hoses on oil injection pump.
Position oil injection tank on vehicle.
Tighten oil injection tank screws to specification.
Refer to exploded view.
mmr2017-017-218
Reinstall all remaining components as the reverse
12. Disconnect crankcase vent hose on oil injec- of removal procedure.
tion tank side. Fill up oil injection tank using recommended oil.
13. Disconnect oil level sensor connector. See RECOMMENDED INJECTION OIL in this
14. Place a rag under oil injection pump to catch subsection.
oil spillage. Bleed oil injection system. Refer to BLEEDING
15. Carefully disconnect hoses from oil injection OIL INJECTION PUMP in this subsection.
pump using a small screwdriver.
OIL LEVEL SENSOR
Testing the Oil Level Sensor
1. Measure resistance by probing sensor connec-
tor.
REQUIRED TOOL
FLUKE 115 MULTIMETER (P/N 529 035 868)
SENSOR TEST
RESISTANCE
CONDITION
LOW float Closed circuit
Empty position (close to 0 )
oil tank HIGH float Open circuit
mmr2011-014-010_a
SOME PARTS REMOVED FOR CLARITY PURPOSE position infinite (OL)

1. Oil hoses (4x)
NOTICE Oil injection pump fittings are very

fragile, care must be taken when removing
hoses from oil injection pump.
16. Disconnect oil injection pump electrical con-
nectors.
17. Slide out oil tank.
18. Remove oil injection pump from oil injection
tank. Refer to OIL INJECTION PUMP RE-
MOVAL in this subsection.
Installing the Oil Injection Tank mmr2017-017-002 a
Before tightening oil injection tank on vehicle, pro- 1. Probe sensor connector here
ceed as follows.
1. Install oil injection pump on oil injection tank.
Refer to OIL INJECTION PUMP INSTALLA-
TION.
12 mmr2017-017
Check Valves and Fittings (RAVE)
mmr2017-017-003 a
MEASURING RESISTANCE WITH FLOAT HELD IN HIGH

POSITION
1. Oil tank cap removed
2. Float
mmr2017-017-016_a
3. Use a locking tie to lift float
RAVE CHECK VALVES
1. Oil hose to MAG 3D RAVE valve
If test fails, replace oil tank. 2. Oil hose to PTO 3D RAVE valve
3. RAVE check valves
If test succeeds check float condition in oil tank.
Remove cover, refer to TOP END subsection.
Removing the Oil Level Sensor
Oil level sensor is part of the oil tank and is not
removable.
CHECK VALVES AND FITTINGS

Check Valves and Fittings Access
Check Valves and Fittings (Engine)
Lift engine to access the check valves and fittings
at the bottom of the crankcase. Refer to ENGINE
REMOVAL AND INSTALLATION subsection.
mmr2017-020-003_b
TYPICAL - RAVE FITTINGS
Fitting (Water Pump Drive)

Remove starter, refer to MAGNETO AND
STARTER subsection.
mmr2017-017-005_a
1. Check valves
2. Fittings
mmr2017-017 13
Check Valves and Fittings (Engine)
mmr2017-018-025_b
Inspecting the Check Valves mmr2017-017-011_a
1. Check valves
Pressurize check valves at inlet side. 2. Fittings
REQUIRED TOOL 1. Clean area around check valve or fitting to re-
move oil or dirt.
(P/N 529 021 800) 2. Heat check valve or fitting then pull it out of
crankcase.
PUMP SET TO Check Valves (RAVE)
SET TO PRESSURE
SETTING VACUUM 1. Remove clamps and oil hoses from check
Slowly activate valve.
Activate pump
TO DO pump and listen to
several times
check valve
You should hear it
Air must NOT
release pressure
RESULT flow through
at approximately
check valve
20.7 kPa (3 PSI)
Success: Success:
Perform next test Check valve is good
ACTION Failed:
Failed:
Replace check
Replace check valve
valve
Removing the Check Valves and mmr2017-017-016_b

Fittings
NOTICE Do not remove check valve need-
lessly. It is likely to be damaged.
14 mmr2017-017
Fittings (RAVE) CHECK VALVE AND FITTING SEALANT

LOCTITE 648 (GREEN)
Service product
(P/N 413 711 400)
mmr2017-017-008_a
TYPICAL - RAVE FITTINGS
1. Remove RAVE valve housing. Refer to RAVE

subsection.
2. Clean area around fittings to remove oil or dirt.
3. Heat fitting then pull it out of RAVE valve hous- mmr2017-017-006_a
ing. APPLY SEALANT ON INDICATED AREA ONLY
Fitting (Water Pump Drive) 3. Punch in the check valves and fittings care-
fully with a plastic hammer by using a suitable
punch.
For correct orientation of the check valves and fit-
ting refer to the next illustrations.
mmr2017-017-013_a
1. Clean area around fitting to remove oil or dirt.

2. Heat fitting then pull it out of crankcase.
mmr2017-017-007_a
Installing the Check Valves and Fittings CAST MARKS FOR CHECK VALVES AND FITTING ORIENTATION
cedure. However pay attention to the following.
1. Ensure check valve bodies and fittings are clean
from dirt or oil and dry.
CHECK VALVE CLEANING
PULLEY FLANGE
711 809) mmr2017-017-008_b
A. 55°
2. Apply sealant on the outer diameter of the B. 90
check valve (machined section) or fitting. Ap-
ply sealant ONLY in the specified area.
mmr2017-017 15
mmr2017-017-013_b
mmr2017-017-012_a
A. 30° FITTING (ENGINE) - IMPULSE FITTING PUNCH (SMALL)
1. Cast mark for fitting orientation (P/N 529 036 413)
For bent fitting use following service tool for in-

stallation:
REQUIRED TOOL
IMPULSE FITTING PUNCH
(BIG) (P/N 529 036 412)
(SMALL) (P/N 529 036 413)
mmr2017-017-010_a
4. Clean area around check valve from surplus

sealant with a rag.
5. Connect pressure pump and check if check
valves and fittings are not blocked with glue
after installation.
REQUIRED TOOL
mmr2017-017-014_a VACUUM/PRESSURE PUMP

FITTING (WATER PUMP DRIVE) - IMPULSE FITTING PUNCH (P/N 529 021 800)
(BIG) (P/N 529 036 412)
16 mmr2017-017
Subsection XX (COOLING SYSTEM)
COOLING SYSTEM
SERVICE TOOLS
CERAMIC SEAL INSTALLER......................................................... 529 036 014 ........................................... 10
HANDLE ........................................................................................ 420 877 650 ............................................. 9
IMPULSE FITTING PUNCH (BIG) .................................................. 529 036 412 ............................................. 6
LARGE HOSE PINCHER................................................................ 529 032 500 ......................................... 4–5
OIL SEAL PUSHER........................................................................ 529 035 757 ............................................. 9
PROTECTOR SLEEVE ................................................................... 529 036 406 ........................................... 10
TEST CAP ...................................................................................... 529 035 991 ............................................. 4
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ......................................... 4–5
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 7
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ............................................. 5
PETAMO GREASE GHY 133N ...................................................... 420 899 271 ........................................... 10
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ................................... 5, 7, 11
mmr2017-018 1
NEW
NEW
11 ± 0,8 N•m
(97 ± 7 lbf•in)
3 ± 0,4 N•m
(27 ± 4 lbf•in)
NEW
5 ± 0,3 N•m 15 ± 1 N•m
(44 ± 3 lbf•in) (133 ± 9 lbf•in)
Transmission
oil
NEW
See
E-TEC DIRECT Petamo grease GHY 133 NEW
FUEL INJECTION
Transmission
oil
Loctite 648 Loctite 243
50ml (1.7 U.S. oz)

Loctite 243 Injection oil
5 ± 0,3 N•m
(44 ± 3 lbf•in)
NEW
NEW
30 ± 2 N•m
(22 ± 1 lbf•ft)
6 ± 0,4 N•m
(53 ± 4 lbf•in)
mmr2017-018-001_a
2 mmr2017-018
NEW
From
throttle From
body cylinder
head
From
cylinder
head
5.5 ± 0.5 N•m

(49 ± 4 lbf•in)
NEW
Towards vehicle
heat exchanger
From vehicle
heat exchanger
5.5 ± 0.5 N•m

(49 ± 4 lbf•in)
NEW NEW
Towards
water
pump
3 ± 0.4 N•m
NEW = Component must be replaced when removed. (27 ± 4 lbf•in)
mmr2017-018-225_a
mmr2017-018 3
GENERAL
NOTE: It is a good practice to check for fault
codes using BUDS2 software as a first trou-
bleshooting step
During assembly/installation, use torque values
and service products as shown in the exploded
views.
complete procedure.
mmr2017-018-200
WARNING TYPICAL
must be strictly adhered to. If pressure drops, check all hoses and engine for
Locking devices must be replaced with new coolant leaks. Spray a soap/water solution and
ones when removed (e.g.: locking tabs, elas- look for air bubbles.
tic stop nuts, self-locking fasteners, cotter If no external leak is found and pressure drops,
pins, etc.). carry out the ENGINE COOLING CIRCUIT LEAK
TEST to find a potential engine internal leak.
INSPECTION
ENGINE COOLING CIRCUIT LEAK
COOLING SYSTEM LEAK TEST TEST
NOTE: This test confirms if there is a leak in the NOTE: An engine leak test should be performed
cooling system, including the engine. prior to installing engine in vehicle each time the
engine is disassembled.
WARNING Install a suitable hose on the water pump cover
To prevent potential burns, do not remove and block it.
the coolant tank cap if the engine is hot.
REQUIRED TOOL
Remove the RH side panel. LARGE HOSE PINCHER
(P/N 529 032 500)
Remove coolant tank cap.
Pressurize system through coolant tank.
REQUIRED TOOL
TEST CAP (P/N 529 035 991)
(P/N 529 021 800)
TEST PRESSURE
100 kPa (15 PSI)
mmr2017-018-030_a
Install a suitable hose on the cylinder head and

block it.
4 mmr2017-018
REQUIRED TOOL
LARGE HOSE PINCHER
(P/N 529 032 500)
Install a suitable hose on the bleeder nipple and

block it
REQUIRED TOOL
SMALL HOSE PINCHER

(P/N 295 000 076)
mmr2017-018-026_a
Install the pressure pump on the bent fitting for TYPICAL - PARTS REMOVED FOR CLARITY
throttle body heating.
Clean area around fitting to remove oil or dirt.
REQUIRED TOOL
Heat fitting then pull it out of cylinder head.
VACUUM/PRESSURE PUMP Ensure fitting is clean from dirt or oil and dry.
(P/N 529 021 800) FITTING CLEANING
PULLEY FLANGE
711 809)
Apply sealant on the outer diameter of fitting.

CHECK VALVE AND FITTING SEALANT
LOCTITE 648 (GREEN)
Service product
(P/N 413 711 400)
Punch in the fitting carefully with a plastic ham-

mer.
For correct orientation of the fitting refer to the
next illustration.
mmr2017-018-029_a
1. Bent fitting for throttle body heating

2. Bleeder nipple
3. Cylinder head hose
Pressurize the engine.

TEST PRESSURE
100 kPa (15 PSI)
If pressure drops, spray a soap/water solution

onto engine jointed surfaces and look for air bub-
bles.
A. 90°
FITTING (THROTTLE BODY
HEATING)
Fitting Replacement
Remove throttle body from intake manifolds and
put it aside.
mmr2017-018 5
REQUIRED TOOL
(BIG) (P/N 529 036 412)
mmr2017-018-003_a
1. Screws
2. Water pump cover
3. Gasket
mmr2017-018-028_a
Remove impeller by turning it counterclockwise.
FITTING - IMPULSE FITTING PUNCH (BIG) (P/N 529 036 412) NOTICE Be careful not to damage impeller
fins.
WATER PUMP
Water Pump Location
The water pump is located on the front of the en-
gine, below the intake manifold.
Removing the Water Pump

Drain cooling system, refer to PERIODIC MAIN-
TENANCE PROCEDURES subsection.
Remove starter, refer to MAGNETO AND
STARTER subsection.
Remove oil lines.
mmr2017-018-004_a
mmr2017-018-002_a
Remove the following parts.

mmr2017-018-005_a
1. Impeller
2. Washer, 1 mm (.039 in) thick
Clean gasket surfaces of water pump cover and

crankcase.
6 mmr2017-018
Installing the Water Pump BEARING CARRIER AND PUMP

The installation is the reverse of removal proce- SHAFT
dure. However, pay attention to the following de-
tails. Removing the Bearing Carrier and
Pump Shaft
Clean water pump shaft thread using a part
cleaner and compressed air. Remove plug screw and discard sealing ring.
WATER PUMP SHAFT THREAD CLEANING
PULLEY FLANGE
711 809)
Ensure to install the 1 mm (.039 in) thick washer.

Apply thread locker on water pump shaft thread.
WATER PUMP SHAFT THREAD
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Tighten impeller to specification.

mmr2017-018-006_a
TIGHTENING TORQUE
1. Plug screw
15 N•m ± 1 N•m 2. Sealing ring
Impeller
Remove WATER PUMP. See procedure in this
Install a NEW water pump cover gasket. subsection.
Tighten screws of water pump cover to specifica- Remove bearing carrier retaining screws.
tion in a crisscross sequence.
TIGHTENING TORQUE
11 N•m ± 0.8 N•m
Water pump cover screws
Install and tighten coolant hose clamp on water

pump.
mmr2017-018-007_a
Push pump shaft out with a suitable drift punch

and a hammer.
mmr2017-018-025_a
TIGHTENING TORQUE
3 N•m ± 0.4 N•m
Coolant hose clamp
mmr2017-018 7
Properly support bearing carrier.

Push pump shaft out using a press.
mmr2017-018-008_a
PUSH OUT SHAFT HERE
Extract bearing carrier and pump shaft. mmr2017-018-010_a
1. M8 nut
2. Shaft
NOTICE Pay attention not to damage the

bearing carrier during disassembly. Marks
or other damages will lead to coolant or oil
leakage.
Pry inner part of ceramic seal out.
mmr2017-018-009_a
For water pump shaft ball bearing replacement re-

fer to BOTTOM END subsection.
A35C4AA
Remove O-rings and discard them.

Remove bearing using a blind hole bearing puller.
mmr2017-018-011_a
Disassembling the Bearing Carrier and

Pump Shaft
NOTE: The pump shaft cannot be disassembled
without damaging the ceramic seal and oil seal.
Protect the threads of shaft with a suitable M8
nut.
8 mmr2017-018
mmr2017-018-012_a
A35C4DA
1. O-rings
2. Ball bearing
1. Outer part of ceramic seal
Remove oil seal using as appropriate punch.
Remove sealant from bearing carrier with sand pa-
per no. 180.
mmr2017-018-013_a
FOR CLARITY OUTER PART OF CERAMIC SEAL REMOVED

mmr2017-018-016_a
Carefully press the outer part of ceramic seal out. 1. Remove sealant
NOTE: Use a mandrel with a diameter of approx- Reassembling the Bearing Carrier and
imately 16 mm (.63 in). Pump Shaft
Reverse disassembly procedure and pay attention
to the following.
NOTE: Never put oil in the press fit area of the oil
seal and ceramic seal.
Push the NEW oil seal in bearing carrier with the
sealing lip facing to the ball bearing.
REQUIRED TOOL
HANDLE (P/N 420 877 650)
OIL SEAL PUSHER

(P/N 529 035 757)
mmr2017-018-014_a
mmr2017-018 9
mmr2017-018-017_a mmr2017-018-019_a
1. Oil seal 1. Ceramic seal installer

2. Oil seal pusher 2. Ceramic seal
3. Bearing carrier
NOTICE Never use a hammer for the ce-
Lubricate sealing lip of the oil seal. ramic seal installation. Only use a press to
SEALING LIP OF OIL SEAL avoid damaging the ceramic component.
Service product
PETAMO GREASE GHY Install protector sleeve on pump shaft.
133N (P/N 420 899 271)
NOTE: Apply some grease inside the protector
sleeve to prevent the protector sleeve fall off the
Press bearing into bearing carrier.
pump shaft during installation.
REQUIRED TOOL
PROTECTOR SLEEVE (P/N 529

036 406)
Apply injection oil on pump shaft.

Press pump shaft into the bearing carrier with the
appropriate force.
NOTICE Inadequate force will damage the oil
seal and bearing.
mmr2017-018-018_a
NOTE: During installation support the ceramic

Push the NEW ceramic seal in bearing carrier. seal as shown on the following illustration.
REQUIRED TOOL REQUIRED TOOL
CERAMIC SEAL INSTALLER CERAMIC SEAL INSTALLER
(P/N 529 036 014) (P/N 529 036 014)
10 mmr2017-018
Install pump shaft and bearing carrier in crankcase

while turning shaft to mesh gears.
Tighten bearing carrier retaining screws to speci-
fication.
TIGHTENING TORQUE
5 N•m ± 0.3 N•m
Bearing carrier screws
Install NEW sealing ring and tighten plug screw to

specification.
mmr2017-018-020_a TIGHTENING TORQUE
1. Pump shaft
2. Apply injection oil 30 N•m ± 2 N•m
3. Potector sleeve Plug screw
4. Bearing carrier
5. Ceramic seal installer
Remove oil seal guide from pump shaft. THERMOSTAT

Clean water pump shaft thread using a part Thermostat Location
cleaner and compressed air.
The thermostat is located on the RH side of the
WATER PUMP SHAFT THREAD CLEANING engine (PTO side), behind the muffler
PULLEY FLANGE
711 809)
Installing the Bearing Carrier and

Pump Shaft
The installation is the reverse of removal proce-
dure, however pay attention to the following.
Pour injection oil in the pan under crankshaft
worm gear.
CRANKSHAFT WORM GEAR LUBRICATION
Service product Injection oil
Quantity 50 ml (1.7 U.S. oz)
mmr2017-018-220
Install NEW O-rings on bearing carrier and apply

injection oil. Removing the Thermostat
To remove thermostat:
– Block all four thermostat hoses with hose
pinchers or
– Drain cooling system.
mmr2017-018-021_a
mmr2017-018 11
mmr2017-018-023_a
mmr2017-018-220 Testing the Thermostat

Remove spring clip from thermostat housing. To check thermostat, put in water and heat water.
THERMOSTAT TEMPERATURE
Starts to open 37°C (99°F)
Fully open 55°C (131°F)
Inspecting the Thermostat

Check for proper alignment of the thermostat
plunger.
mmr2017-018-022_a
Cut Oetiker clamps (3x) then unplug hoses.

Remove thermostat housing from molded hose
assembly.
mmr2017-018-032_a
A. 90°
Installing the Thermostat

Install NEW O-rings and apply coolant.
Take care that the nose of the thermostat housing
is properly positioned in the recess of the molded
hose assembly.
mmr2017-018-221_a
Remove O-rings and discard them.
12 mmr2017-018
COOLANT TANK
Removing the Coolant Tank
1. Remove the RH side panel.
2. Siphon the coolant tank.
3. Unplug the upper vent hose.
mmr2017-018-024_a
After installation ensure proper distance of ther-

mostat housing to the cylinder block and exhaust
manifold.
mmr2017-018-210_a
4. Block the three lower coolant hoses with pinch-

ers.
5. Cut Oetiker clamps and remove coolant hoses
from coolant tank.
295000076
mmr2017-018-031_a
A. 5 mm ± 2 mm (.2 in ± .08 in)
Properly refill cooling system. Refer to COOLING

SYSTEM REFILL AND BLEEDING in PERIODIC
MAINTENANCE PROCEDURES subsection.
COOLANT TANK CAP

Using a pressure cap tester, check the relief pres-
sure of coolant tank cap.
If the test failed, install a new 110 kPa (16 PSI)
mmr2017-018-208_a
cap.
NOTICE Do not install a tank cap exceeding 6. Disconnect the oil level sensor connector.
the recommended pressure.
COOLANT TEMPERATURE
SENSOR (CTS)
To test and replace the CTS, refer to E-TEC DI-
RECT FUEL INJECTION subsection.
mmr2017-018 13
mmr2017-018-209_a
7. Detach the coolant tank from the top of the

chaincase.
mmr2017-018-207_a
Inspecting the Coolant Tank

Check if the tank is cracked or melted. Replace if
necessary.
Installing the Coolant Tank

14 mmr2017-018
Subsection XX (MAGNETO AND STARTER)
MAGNETO AND STARTER

SERVICE TOOLS
ACG ADAPTER .............................................................................. 529 036 410 ........................................... 10
CLUTCH HOLDER......................................................................... 529 036 369 ......................................... 3, 6
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ....................................... 9–10
HANDLE ........................................................................................ 420 877 650 ........................................... 15
MAGNETO HOLDER ..................................................................... 529 036 404 ..................................... 3–4, 6
MAGNETO PULLER ...................................................................... 529 036 403 ......................................... 4, 6
STARTER DRIVE NEEDLE INSTALLER ......................................... 529 035 934 ........................................... 15
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................... 293 550 004 ........................................... 13
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ................................... 5, 7, 11
LOCTITE 5910 ............................................................................... 293 800 081 ............................................. 9
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ............................................. 5
TRIPLE-GUARD GREASE .............................................................. 296 000 329 ..................................... 13, 15
mmr2017-019 1
11 ± 0,8 N•m
(97 ± 7 lbf•in)
Triple Guard Grease
Triple Guard Grease
Loctite
243 Loctite
243
Loctite 5910
8 ± 0,5 N•m
(70 ± 4 lbf•in)
10 ± 0,7 N•m
(89 ± 6 lbf•in)
125 ± 9 N•m
(92 ± 7 lbf•ft)
6 ± 0,4 N•m
(53 ± 4 lbf•in)

mmr2017-019-001_a
2 mmr2017-019
GENERAL 529 036 369

NOTE: The following procedures can be carried
out without removing the engine.
CAUTION Ensure tether cord is removed

from D.E.S.S. post and engine shut-off switch
is in the OFF position.
ploded view.
fer to the SELF-LOCKING FASTENERS and LOC-
TITE APPLICATION subsections at the beginning
mmr2017-019-206_a
of this manual for complete procedure.
Engine Out of the Vehicle
WARNING
2. Install the magneto holder.
must be strictly adhered to. REQUIRED TOOL
Locking devices must be replaced with new
ones when removed (e.g.: locking tabs, elas-
tic stop nuts, self-locking fasteners, etc.). MAGNETO HOLDER (P/N 529
036 404)
PROCEDURES
MAGNETO FLYWHEEL
Magneto Flywheel Access
Remove the rewind starter, refer to REWIND
STARTER subsection.
Removing the Magneto Flywheel

Engine In the Vehicle mmr2017-019-002_b
1. Block the drive pulley to avoid engine turning 1. Magneto holder

during the removal of the magneto retaining
screw.
REQUIRED TOOL
CLUTCH HOLDER
(P/N 529 036 369)
mmr2017-019 3
Engine In or Out of the Vehicle REQUIRED TOOL

3. Remove magneto flywheel retaining screw.
NOTICE The hexagon head of the retaining
CRANKSHAFT PROTECTOR
screw is very flat. To avoid slipping off thor-
(P/N 529 036 434)
oughly hold socket against the screw head
when loosening the retaining screw.
REQUIRED TOOL
MAGNETO PULLER (P/N 529

MAGNETO HOLDER (P/N 529 036 403)
036 404)
32 mm socket
MAGNETO HOLDER (P/N 529
036 404)
24mm socket
Install service tools on engine.
mmr2017-019-002_a
1. Magneto holder (engine out of vehicle)

2. Magneto flywheel retaining screw
Engine In the Vehicle

4. Remove the crankshaft position sensor (CPS).
Refer to procedure in this subsection.
mmr2017-019-024_a
Engine Out of the Vehicle
1. Crankshaft protector
5. Unscrew crank position sensor (CPS). Refer to 2. Magneto puller
3. Magneto holder (engine out of vehicle)
6. Slightly pull crank position sensor and cut sili- Tighten puller bolt, while holding the magneto
cone sealer between crank position sensor and flywheel in place until magneto flywheel releases
crankcase. from crankshaft.
7. Move CPS aside.
Engine In or Out of the Vehicle
8. Remove magneto flywheel.
4 mmr2017-019
mmr2017-019-025_a
mmr2017-019-003_a
1. Keyway
1. Puller bolt
2. Ventilation holes
2. Magneto holder (engine out of vehicle) 3. INOX sheet metal ring (magnets underneath)
4. INOX sheet metal ring flush with flywheel (no gap)
Inspecting the Magneto Flywheel 5.
6.
Bead of silicone
Starter gear
Clean magneto flywheel using only a clean cloth.
Inspect magneto flywheel for abnormal coloration Installing the Magneto Flywheel
(brown or blue) that would indicate overheating 1. Clean:
condition. – Crankshaft taper
If overheating condition is suspected, carry out – Thread in crankshaft
the following: – Magneto flywheel taper
– Check flywheel magnetic field using a piece of – Magneto flywheel retaining screw threads.
metal. If magnetic field is not felt or weak, re-
place flywheel. TAPER AND THREADS CLEANING
– Inspect flywheel for cracks, pay particular atten- PULLEY FLANGE
tion to the inside circumference (magnets), and Service product CLEANER (P/N 413
the tapered center portion. 711 809)
– Check if magneto flywheel ventilation holes are
clean. 2. Apply thread locker on magneto flywheel taper.
– Check if magneto housing ventilation holes are MAGNETO FLYWHEEL TAPER
clean. LOCTITE 243 (BLUE)
– Check stator for signs of overheating. Service product
(P/N 293 800 060)
– Test stator, see procedures in this subsection.
Check INOX sheet metal ring on inside of mag- 3. Install woodruff key on crankshaft.
neto flywheel for proper position and fixation. 4. Turn crankshaft to position woodruff key in top
Check if bead of silicone is not damaged. position.
Check starter gear teeth for wear or any other 5. Mark keyway position on magneto flywheel.
damage.
Check keyway of the magneto flywheel for wear
or damages.
mmr2017-019 5
mmr2017-019-026_a mmr2017-019-027_a
MARK KEYWAY POSITION

8. Block the drive pulley or the magneto flywheel
6. Install magneto flywheel. using the appropriate tool.
REQUIRED TOOL
CAUTION For installation use magneto
puller to avoid injuries due to the high mag-
netic pull of the magneto flywheel. CLUTCH HOLDER
(P/N 529 036 369)
REQUIRED TOOL
MAGNETO HOLDER
MAGNETO PULLER (P/N 529 (P/N 529 036 404)
036 403)
Hold magneto flywheel with mark in top position. 529 036 369
mmr2017-019-206_a
IN VEHICLE
mmr2017-019-004_a
1. Woodruff key in top position

2. Magneto flywheel
3. Mark on magneto flywheel
4. Magneto puller
7. Check if woodruff key is in proper position.
6 mmr2017-019

1. Remove magneto housing screws.
mmr2017-019-002_b
OUTSIDE VEHICLE
1. Magneto holder
2. Magneto flywheel screw
9. Install magneto flywheel retaining screw and

tighten to specification.
mmr2017-019-005_a
NOTICE The hexagon head of the retaining
screw is very flat. To avoid slipping off thor- 2. Slightly pull magneto housing and cut silicone
oughly hold socket against the screw head sealer from between CPS and magneto hous-
when tightening the retaining screw. ing.
TIGHTENING TORQUE NOTE: Do not lose starter drive spring during re-
moval of magneto housing.
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Magneto flywheel 125 N•m ± 9 N•m
retaining screw (92 lbf•ft ± 7 lbf•ft)
mmr2017-019-006_a
PULL MAGNETO COVER

1. Magneto cover
2. CPS
3. Spring
mmr2017-019-002_a
1. Magneto holder 3. Remove magneto housing.

2. Magneto flywheel retaining screw
Installing the Magneto Housing
MAGNETO HOUSING The installation is the reverse of the removal pro-
Inspecting the Magneto Housing cedure, however pay attention to the following.
Inspect housing for cracks or other apparent dam- Remove the old silicon at CPS.
age. Replace if necessary. Tighten magneto housing screws to specification.
Removing the Magneto Housing

NOTE: The engine removal is required to remove
the magneto housing.
mmr2017-019 7
TIGHTENING TORQUE
Magneto housing 6 N•m ± 0.4 N•m
On a new magneto cover install adhesive pad.
mmr2017-019-201_a
Testing the CPS

Refer to E-TEC DIRECT INJECTION subsection.
mmr2017-019-013
Removing the CPS

CRANKSHAFT POSITION
SENSOR (CPS) CAUTION Ensure tether cord is removed
CPS Connector Access is in the OFF position.
1. Remove the muffler. Refer to EXHAUST SYS- 1. Remove magneto housing, refer to MAGNETO
TEM subsection. HOUSING in this subsection.
2. Cut locking ties securing the wiring harness to 2. Remove CPS retaining screws.
engine harness support.
mmr2017-019-007_a
3. Disconnect CPS connector, refer to CPS CON-

mmr2017-019-200_a
NECTOR ACCESS in this subsection.
4. Remove CPS.
3. Move wirings aside and disconnect the CPS
connector. 5. Remove the old silicon at CPS sensor location
Installing the CPS

NOTICE Do not apply silicone dielectric
grease or any other product on Deutsch wa-
terproof housings as housing seal may be
damaged.
8 mmr2017-019
The installation is the reverse of the removal pro- STATOR

cedure, however pay attention to the following.
Stator Connector Access
Insert CPS cable into stator cable grommet.
1. Remove the RH side panel.
2. Disconnect stator connector (3-pin connector).
mmr2017-019-008_a
Tighten CPS retaining screws to specification.

TIGHTENING TORQUE
mmr2017-019-202_a
8 N•m ± 0.5 N•m
CPS retaining screws
Testing the Stator Continuity
NOTE: It is important to remove the old silicon at 1. Disconnect stator connector.
CPS location. 2. Set multimeter to .
Fill out the gap between CPS and magneto hous- REQUIRED TOOL
ing with silicon.
CPS HARNESS FLUKE 115 MULTIMETER
(P/N 529 035 868)
LOCTITE 5910
Service product
(P/N 293 800 081)
3. Measure resistance of each stator coil as fol-
lows.
STATOR CONTINUITY TEST
RESISTANCE @
TEST PROBES
20°C (68°F)
Pin 1 Pin 2
Pin 1 Pin 3 0.63 ± 0.03
Pin 2 Pin 3
mmr2017-019-009_a
1. Fill up with silicon.

2. Magneto housing
3. CPS
mmr2017-019 9
If results are out of specification, the stator and/or

the wiring need to be repaired/replaced.
Testing the Stator Voltage Output

1. Disconnect stator connector.
2. Set multimeter to Vac and manually set a scale
capable of reading at least 20 Vac.
REQUIRED TOOL
FLUKE 115 MULTIMETER

(P/N 529 035 868)
mmr2017-019-010_a
STATOR CONNECTOR PIN-OUT ACG ADAPTER (P/N 529

036 410)
NOTE: The stator resistance values mentioned in
the table are manufacturers specifications under 3. Manually crank engine and read voltage from
ideal conditions. If stator coil resistance is less each winding as follows.
than 1 , consider stator to be in good working
condition. 4. Repeat the test 3 times for each winding.
If resistance is out of specification, replace stator. STATOR OUTPUT VOLTAGE TEST
TEST PROBES VOLTAGE
Testing the Stator Insulation
Pin 1 Pin 2
1. Disconnect stator connector. Approximately
Pin 1 Pin 3
2. Set multimeter to . 15 - 20 Vac
Pin 2 Pin 3
REQUIRED TOOL

(P/N 529 035 868)
3. Measure resistance as follows.

STATOR INSULATION TEST
RESISTANCE @
TEST PROBES
20°C (68°F)
Pin 1
OL
Pin 2 Engine ground
(open circuit)
Pin 3
mmr2017-019-010_a
STATOR CONNECTOR PIN-OUT
5. If voltage is lower than specification, remove

and inspect magneto flywheel and stator. Refer
to MAGNETO FLYWHEEL in this subsection.
6. Replace magneto flywheel and/or stator if appli-
cable.
Removing the Stator

1. Refer to procedures in this subsection and re-
move:
– Magneto flywheel
– Magneto housing
mmr2017-019-010_a
STATOR CONNECTOR PIN-OUT – CPS.
10 mmr2017-019
2. Remove stator retaining screws.

3. Remove grommet from crankcase.
mmr2017-019-012_a
2. Install stator into crankcase.

NOTE: During installation, ensure stator harness
is located on the left side.
3. Tighten stator retaining screws to specification.
mmr2017-019-011_a
1. Stator retaining screws TIGHTENING TORQUE

2. Grommet
LOCTITE 243 (BLUE)
4. Disconnect stator connector. Refer to STATOR Service product
(P/N 293 800 060)
CONNECTOR ACCESS in this subsection.
10 N•m ± 0.7 N•m
NOTE: To ease harness routing at installation, tie Stator retaining screws
a string on the connector and let the string follow
through as you pull on the harnesses. 4. Position grommet into crankcase recess.
5. Remove stator.
Cleaning the Stator

NOTICE Clean stator using only a clean cloth.
Inspecting the Stator

Refer to MAGNETO FLYWHEEL INSPECTION in
this subsection.
Installing the Stator

NOTICE Do not apply silicone dielectric
grease or any other product on Deutsch wa- mmr2017-019-014_a
terproof housings as housing seal may be

damaged. 5. Tie the string on the connector used during re-
moval of the stator connector, then pull on him
1. Install adhesive pad on crankcase. to route the harness up to his original locations.
6. Reinstall all other removed parts.
STARTER
Starter Location
The starter is located at the front of the engine,
below the exhaust manifold.
mmr2017-019 11
Testing the Starter Operation

Use booster cables and a booster battery to sup-
ply current directly to the starter.
1. Connect the RED jumper cable from the
booster battery to the starter screw.
2. Momentarily connect the BLACK jumper cable
to an ear of the exhaust manifold.
mmr2017-019-204_a
4. Clean starter and surrounding area.

5. Remove starter mounting screws.
mmr2017-019-203_a
If the starter turns, test other starting system

components. Refer to STARTING SYSTEM sub-
section.
Removing the Starter

1. Disconnect the BLACK (-) battery cable from
the battery.
WARNING
mmr2017-019-205_a
Always disconnect BLACK (-) battery cable
first and reconnect last.
2. Remove the tuned pipe, refer to EXHAUST

SYSTEM subsection.
3. Disconnect the RED (+) power cable from
starter.
mmr2017-019-015_a
1. Starter mounting screws

2. Starter
6. Pull starter out of crankcase.
Installing the Starter

Reverse the removal procedure. However, pay
particular attention to the following.
12 mmr2017-019
Make sure the starter and engine mating surfaces

are free of debris. Serious problems may arise if
the starter is not properly aligned.
mmr2017-019-205_a
mmr2017-019-016_a Connect the RED (+) cable to the starter and

1. Clean starter mating surfaces tighten screw to specification.
Lubricate starter O-ring. TIGHTENING TORQUE
STARTER O-RING DIELECTRIC GREASE

Service product
(P/N 293 550 004)
TRIPLE-GUARD
Service product GREASE (P/N 296 RED (+) power cable 2.7 N•m ± 0.7 N•m
000 329) screw (24 lbf•in ± 6 lbf•in)
Connect the BLACK (-) battery cable last.
WARNING
Always connect the RED (+) starter cable first,
then the BLACK (-) battery cable last. When-
ever connecting the RED (+) cable to the
starter motor, always make sure the BLACK
(-) battery cable is disconnected to prevent
electric shock.
Test starter operation.
mmr2017-019-017_a STARTER DRIVE

LUBRICATE STARTER O-RING
Removing the Starter Drive
Install starter and tighten mounting screws to Refer to procedures in this subsection to remove:
specification
TIGHTENING TORQUE – Magneto housing.
11 N•m ± 0.8 N•m NOTE: Do not lose starter drive spring during re-
Starter mounting screws
(97 lbf•in ± 7 lbf•in) moval of magneto housing.
mmr2017-019 13
mmr2017-019-006_b
mmr2017-019-019_a
1. Starter drive pinion

Pull out starter drive. 2. Starting position (spring released)
3. Gear is engaged drive pulley fixed half (spring loaded)
NOTE: Do not lose washer of starter drive gear
during removal. Check needle bearing excessive play and smooth
operation. If damaged see STARTER DRIVE
NEEDLE BEARING REPLACEMENT in this sub-
section.
mmr2017-019-018_a
1. Starter drive
2. Washer
Inspecting the Starter Drive mmr2017-019-020_a
1. Starter drive needle bearing

Check if starter drive pinion is free of movement.
Check magneto housing:
Ensure proper operation of the starter drive sprag
clutch. – for cracks at the starter drive bore location
– if starter drive bore is worn or otherwise dam-
NOTE: Centrifugal weights avoid disengaging of
aged.
the pinion while starting the engine.
Replace magneto housing if necessary.
Starter Drive Needle Bearing

Replacement
Remove needle bearing using a blind hole bearing
puller.
14 mmr2017-019
STARTER DRIVE LUBRICATION

TRIPLE-GUARD
Service product GREASE (P/N 296
000 329)
mmr2017-019-021_a
1. Needle bearing
2. Blind hole bearing puller
Install needle bearing.

REQUIRED TOOL
STARTER DRIVE NEEDLE
INSTALLER (P/N 529 035 934)
mmr2017-019-023_a
HANDLE (P/N 420 877 650)
LUBRICATE
1. Starter drive bore
2. Spring
mmr2017-019-022_a
1. Needle bearing
mmr2017-019-020_a
2. Starter drive needle bearing installer
3. Handle LUBRICATE NEEDLE BEARING IN CRANKCASE
Installing the Starter Drive Install starter drive with washer.

Clean out all residues of grease from:
– Needle bearing in the crankcase
– Starter drive journals
– Starter drive bore in magneto housing
– Spring.
Lubricate:
– Needle bearing in crankcase
– Starter drive bore in magneto housing
– Spring. mmr2017-019-018_a
1. Starter drive
2. Washer
mmr2017-019 15
Subsection XX (RAVE)
RAVE
SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ....................................... 7, 16
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................. 6–7, 15–17
PROTECTOR SLEEVE ................................................................... 529 036 406 ........................................... 12
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ................................... 8–9, 18
MOLYKOTE G-N ............................................................................ 420 297 433 ........................................... 12
mmr2017-020 1
RAVE VALVE
See
3D RAVE VALVE
SYNCHRONIZATION
Loctite 243
20 ± 2 N•m
(15 ± 1 lbf•ft)
4 ± 0,3 N•m
(35 ± 3 lbf•in)
NEW
Loctite 243
5 ± 0,6 N•m
(44 ± 5 lbf•in) 8 ± 0,5 N•m
(70 ± 4 lbf•in)
8 ± 0,5 N•m Super lube NEW
20 ± 2 N•m (70 ± 4 lbf•in) grease
(15 ± 1 lbf•ft)
5 ± 0,6 N•m See
(44 ± 5 lbf•in) NEW tightening
sequence
10 ± 0,7 N•m
Molycote G-N (89 ± 6 lbf•in)
8 ± 0,5 N•m
(70 ± 4 lbf•in)
Molycote G-N
Injection
oil
8 ± 0,5 N•m
(70 ± 4 lbf•in)

mmr2017-020-001_a
2 mmr2017-020
GENERAL
and service products as shown in the exploded
view.
fer to SELF-LOCKING FASTENERS PROCEDURE
and LOCTITE APPLICATION PROCEDURE at the
beginning of this manual for complete procedure.
WARNING
Locking devices when removed (e.g.: locking mmr2017-020-002_a
tabs, elastic stop nuts, self-locking fasteners, COVER REMOVED FOR CLARITY
cotter pins, etc.) must be replaced with new 1. Servomotor
2. Rave cable
ones. 3. 3D RAVE valve
A hall-effect position sensor (RPS: RAVE position

NOTICE Hoses, cables and locking ties re- sensor) is used to provide RAVE valve position
moved during a procedure must be reinstalled feedback to the ECM.
SYSTEM DESCRIPTION
3D RAVE Basic Operation
3-step RAVE valves are used. Their positions vary
according to engine operating condition.
The RAVE valve steps are:
– Fully closed
– Partially opened
– Fully opened.
RAVE valves are moved to the desired position by
a servomotor via a Rave cable that is controlled by
the ECM through mappings. mmr2017-020-003_a
Different mappings are used by the ECM to con- PARTS REMOVED FOR CLARITY
trol the 3D RAVE valves. The mappings are based The RAVE position sensor (RPS) provides the
on current engine RPM and the following inputs: ECM the actual position of the RAVE valves. Ei-
intake temperature, TPS, knock sensor, engine ther closed, mid-position or opened. This informs
coolant temperature and APS. the ECM that the RAVE valves are really at the
NOTE: 3D RAVE valves may go through all 3 po- expected position so that the proper amount of
sitions or skip the partially opened position and go fuel is injected as well as other required operating
directly to either the fully opened or closed posi- parameters are applied.
tions depending on present engine load and how RAVE valves are lubricated by the electronic oil in-
quickly the throttle is depressed. jection pump.
RAVE valves are moved and monitored with a link
bar.
mmr2017-020 3
RAVE VALVE POSITION MEASURED FROM

COUNTER BEARING OF THE RAVE CABLE
TO THE LINK BAR
1. Measure from counter bearing to
Fully closed link bar.
2. Set calliper to 0 mm (0 in).
A: Approximately 6 mm (1/4 in)
Mid position from 0 mm (0 in) (fully closed
position)
A: Approximately17.5 mm
Fully opened (11/16 in) from 0 mm (0 in) (fully
closed position)
mmr2017-020-004_a
PARTS REMOVED FOR CLARITY

1. Linked RAVE valves
2. Link bar
1
3. Oil lines to RAVE valves

RAVE VALVE SYNCHRONIZATION and RAVE 2
VALVE POSITION SENSOR SETTING whenever

link bar is removed. 3
3D RAVE Position According to Engine 100 %

75 %
Operation 25 % 4000 RPM
7800 RPM
50 %
0% 0 RPM
RAVE POSITION
1. Fully opened
2. Mid
3. Fully closed
TROUBLESHOOTING
DIAGNOSTIC TIPS
As a first troubleshooting step, perform the fol-
lowing procedures to ensure RAVE system is
mmr2017-020-006_a properly adjusted.
A. Measure from counter bearing to link bar 1. 3D RAVE VALVE SYNCHRONIZATION
NOTICE For correct measurement the Rave 2. 3D RAVE VALVES POSITION SENSOR SET-
cable must be removed.
TING
3. 3D RAVE VALVES POSITION VALIDATION.
Move both RAVE valves simultaneously to fully
opened / mid / fully closed position by hand. TROUBLESHOOTING
GUIDELINES
RAVE Valves Position Sensor Fault
Code
The ECM may generate a position sensor fault
code if the RAVE valve is not reaching the desired
position.
If a position sensor fault code is generated by the
ECM, check for the following:
4 mmr2017-020
Defective Position Sensor

– Test position sensor operation, perform 3D
RAVE VALVES POSITION VALIDATION, see
– Check position sensor wiring, perform IN-
SPECTING THE 3D RAVE VALVES POSITION
SENSOR, see procedures in this subsection.
– Check movement of the RAVE manually.
Excessive Carbon Build-up in RAVE Valves
– Use the recommended oil quality, refer to LU-
BRICATION SYSTEM subsection.
– Check oil lines (installed incorrectly, air bubbles) mmr2017-020-010_a
– Check for proper oil injection pump code in
BUDS2, refer to LUBRICATION SYSTEM sub- 6.2 Select "Rave Closed Position Setting" in
section. the list.
NOTE: Insufficient oil delivery to RAVE valves 6.3 Confirm that Rave Actual Position (V) is
may result in a carbon build-up. within specification.
7. Perform setting at fully opened position:
PROCEDURES 7.1 Pull both RAVE valves simultaneously to
fully opened position by hand.
3D RAVE VALVES POSITION
NOTICE For a correct setting hold both
SENSOR RAVE stems simultaneously in its proper
3D RAVE Valves Position Sensor position. Never push or pull in the center
Setting of the link bar.
1. Ensure RAVE valves are properly synchronized
as per 3D RAVE VALVE SYNCHRONIZATION
procedure.
RAVE VALVE SYNCHRONIZATION and RAVE
link bar is removed.
2. Remove upper body module. Refer to BODY.
3. Remove Rave cable from link bar. Refer to RE-
MOVING THE RAVE CABLE in this subsection.
4. Connect vehicle to BUDS2, Refer to COMMU-
NICATION TOOLS AND B.U.D.S. subsection. mmr2017-020-010_b
5. Go to:
– Settings / Initializations / RAVE Setting 7.2 Select "Rave Fully Position Setting" in the
list.
6. Perform setting at fully closed position:
7.3 Confirm that Rave Actual Position (V) is
6.1 Push both RAVE valves simultaneously to within specification.
fully closed position by hand.
8. Perform setting at middle position:
NOTICE For a correct setting hold both 8.1 Move both RAVE valves simultaneously to
RAVE stems simultaneously in its proper mid position by hand.
position. Never push or pull in the center
of the link bar. NOTICE For a correct setting hold both
RAVE stems simultaneously in its proper
position. Never push or pull in the center
of the link bar.
mmr2017-020 5
3D RAVE VALVES POSITION SENSOR

INPUT VOLTAGE
Position Sensor
Connector Measurement
(harness side) Battery ground
Pin 3 5 ± 0.25 Vdc
mmr2017-020-010_b
8.2 Select "Rave Middle Position Setting" in

the list.
8.3 Confirm that Rave Actual Position (V) is
within specification.
9. Validate that position sensor is properly set.
Refer to 3D RAVE VALVES POSITION VALIDA-
TION in this subsection. mmr2017-020-038_a
10. Start engine. If voltage is exceeding the range check ECM

At first engine start after RAVE position sensor power supply (fuses F1 and F3) and wiring har-
setting is completed RAVE valves travel to fully ness.
opened position and than moving slowly to fully
Testing the Continuity of 3D Rave Valves
closed position Position Sensor Ground Circuit
NOTICE Do not push throttle lever during this 1. Disconnect position sensor connector.
initialization procedure, otherwise the ECM will 2. Set multimeter to and probe terminals as per
discontinue the initialization and starts initial- following table.
ization from the beginning.
REQUIRED TOOL
Inspecting the 3D Rave Valves Position
Sensor FLUKE 115 MULTIMETER
NOTE: As a first troubleshooting step, always (P/N 529 035 868)
check for applicable fault codes using BUDS2
software.
3D RAVE VALVES POSITION SENSOR
Testing the 3D Rave Valves Position Sensor RESISTANCE
Voltage Input
Position Sensor
1. Disconnect position sensor connector. RESISTANCE @
Connector
2. Install D.E.S.S. key and press start/RER button Battery ground 20°C (68°F)
(harness side)
to wake up ECM.
Pin 1 Close to 0
3. Set multimeter to Vdc and probe terminals as
per following table.
REQUIRED TOOL

(P/N 529 035 868)
6 mmr2017-020
mmr2017-020-038_b mmr2017-020-038_c
If resistance is out of specifications check ECM If resistance is not within specification, repair or
grounding and wiring harness. replace the wiring harness.
Testing the Continuity of 3D Rave Valves Removing the 3D Rave Valves Position
Position Sensor Circuit
Sensor
1. Disconnect:
– ECM connector
– Position sensor connector.
3. Remove Rave cable from link bar. Refer to RE-
2. Connect ECM connector to ECM adapter tool.
MOVING THE RAVE CABLE in this subsection.
REQUIRED TOOL 4. Disconnect position sensor connector.
ECM ADAPTER TOOL

(P/N 529 036 166)
3. Set multimeter to and probe terminals as per

following table.
REQUIRED TOOL

(P/N 529 035 868)
3D RAVE VALVES POSITION SENSOR mmr2017-020-011_a
RESISTANCE
5. Unscrew:
Position Sensor
RESISTANCE @ – RAVE valves position sensor retaining
Connector ECM-A
20°C (68°F) screws
(harness side)
– Link bar retaining nuts.
Pin 1 E2
Pin 2 E3 Close to 0
Pin 3 F3
mmr2017-020 7
TIGHTENING TORQUE
Position sensor retaining 8 N•m ± 0.5 N•m
5. Install connector.
3D RAVE VALVES
3D RAVE Valve Synchronization
Synchronization Adjustment Procedure
1. Remove link bar retaining nuts and clean
threads.
mmr2017-020-012_a
1. RAVE valves position sensor retaining screws 2. Install PTO link bar retaining nut and tighten by
2. Link bar collar nuts hand.
6. Remove link bar with RAVE valves position sen- LINK BAR RETAINING NUTS
sor.
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
mmr2017-020-013_a
1. Link bar
2. RAVE valves position sensor mmr2017-020-035_a
NOTICE It is very important to perform 3D 3. Check if the link bar rests flat on the retaining
RAVE VALVES SYNCHRONIZATION whenever nut.
Tip on link bar at MAG side an listen if link bar rests
Installing the 3D Rave Valves Position on retaining nut.
Sensor
1. Position RAVE valves position sensor with link
bar on RAVE valve housing.
2. Install position sensor retaining screws but do
not tighten yet.
3. Perform 3D RAVE VALVE SYNCHRONIZATION
procedure in this subsection to complete link
bar installation.
RAVE VALVES SYNCHRONIZATION and RAVE
mmr2017-020-035_b
4. Install position sensor retaining screws.
1. Tip here
8 mmr2017-020
4. If the link bar does not rest flat: 1.2 If out of specification, redo the SYNCHRO-
4.1 Unscrew PTO nut then slightly move link NIZATION ADJUSTMENT PROCEDURE.
bar.
3D RAVE Valves Position Validation
4.2 Tighten PTO nut by hand and recheck po-
sition. 1. Ensure RAVE valves are properly synchronized
as per 3D RAVE VALVE SYNCHRONIZATION.
4.3 Repeat above sequence until the link bar
rests flat. 2. Ensure position sensor is properly set as per 3D
RAVE VALVES POSITION SENSOR SETTING.
5. Install MAG link bar retaining nut and tighten by
hand. 3. Remove upper body module. Refer to BODY.
4. Connect vehicle to BUDS2, Refer to COMMU-
LINK BAR RETAINING NUTS NICATION TOOLS AND B.U.D.S. subsection.
LOCTITE 243 (BLUE) 5. Go to:
Service product
(P/N 293 800 060)
– Measurement/Custom/RAVE Actual Position
6. Push the center of link bar downwards in order (%)
to seat both RAVE valves on their fully closed – Select the appropriate RAVE position in the
position. list.
7. Firmly hold link bar downwards. RAVE ACTUAL POSITION SPECIFICATION
8. Tighten both retaining nuts. Closed Below 2%
Middle 37 ± 2 %
Fully opened Above 97%
TYPICAL
If RAVE valves actual position are out of specifica-

tion, check the following:
– RAVE valve position sensor setting
– RAVE valve synchronization
– RAVE valves cleanliness.
Removing the 3D RAVE Valves

mmr2017-020-012_c
Step 1: Push link bar

Step 2: Tighten retaining nuts 3. Remove Rave cable from link bar, refer to RE-
TIGHTENING TORQUE MOVING THE RAVE CABLE in this subsection.
4. Disconnect Rave valve position sensor connec-
4 N•m ± 0.3 N•m
Link bar retaining nuts
(35 lbf•in ± 3 lbf•in) tor and put harness away.
5. Unscrew:
9. Adjust position sensor using BUDS2 Refer to – RAVE valves position sensor retaining
3D RAVE VALVES POSITION SENSOR SET- screws
TING. – Link bar retaining nuts.
10. Push link bar down to fully closed position.
11. Install Rave cable, refer to INSTALLING THE
RAVE CABLE in this subsection.
Synchronization Validation Procedure
1. Push and pull link bar to force RAVE valves to
pass through their 3 positions.
1.1 Ensure that only one step is felt at mid po-
sition.
mmr2017-020 9
mmr2017-020-012_a mmr2017-020-014_a
1. RAVE valves position sensor retaining screws 1. Collar nuts

2. Link bar retaining nuts 2. Harness support screw
3. Lubrication hoses
6. Remove link bar with RAVE valves position sen-
sor. 8. Remove:
– RAVE valve housing
– Gasket (discard it).
NOTE: Be careful not to loose springs underneath
housing.
NOTICE If signs of oil are found outside the
housing, replace seals.
mmr2017-020-013_a
1. Link bar
2. RAVE valves position sensor
7. Remove:
– Collar nuts
– Screw from harness support
– Disconnect lubrication hoses and discard
mmr2017-020-036_a
Oetiker clamps.
1. Retaining screws
2. RAVE valve housing
3. Gasket (discard it)
9. Take note of seals orientation and carefully pry

them out using a screwdriver.
10 mmr2017-020
No special solvents or cleaners are allowed when

cleaning the valve.
RAVE Valves Frequently Gummed
If the valves are getting gummed more frequently
than usual, do the following:
– Check if the recommended injection oil is used.
– Check lubrication hoses for restriction.
– Check lubrication hoses for presence of air.
Bleed system if needed.
– Check lubrication hose check valves as ex-
mmr2017-020-015_a
plained in this subsection.
10. Pull RAVE valve assembly out. Inspecting the 3D RAVE Valve
Check valves for:
– wear at sliding points
– straightness
– breakage.
mmr2017-020-016_a
11. If necessary separate RAVE valve assembly.
mmr2017-020-018
SIGNS OF WEAR
Check spring condition and straightness.

NOTE: Make sure hoses are not leaking, kinked
or damaged.
Installing the 3D RAVE Valve

1. Use an appropriate pusher to reinstall seals.
Lubricate outer oil seal diameter.
OIL SEAL INSTALLATION
mmr2017-020-017_a Service product Injection oil
1. Springs
2. Main valve upper part
3. Main valve lower part
4. Side valves
Cleaning the 3D RAVE Valve

Thoroughly clean all RAVE VALVES components
and cylinder slots.
mmr2017-020 11
mmr2017-020-019_a
1. Oil seal
2. Pusher
2. Lubricate sealing lips of oil seals. mmr2017-020-016_a
SEALING LIPS LUBRICATION

6. Install NEW gasket.
Service product Super lube grease 7. Install springs on stud ends of valves.
3. Preassemble the main and side valves.
mmr2017-020-021_a
1. Gasket
mmr2017-020-005_a
2. Springs
1. Main valve upper part
2. Main valve lower part 8. Lubricate valve shaft.
3. Side valves
VALVE SHAFT
4. Lubricate:
– RAVE chamber in cylinder block, main and MOLYKOTE G-N
Service product
side valves (P/N 420 297 433)
– Sliding surfaces of RAVE valves. 9. Place protector sleeves on RAVE valve threads.
RAVE SLIDING SURFACES LUBRICATION
REQUIRED TOOL
5. Insert RAVE valves in cylinder. PROTECTOR SLEEVE (P/N 529

036 406)
12 mmr2017-020
mmr2017-020-025_a
mmr2017-020-022_a
13. Tighten RAVE valve housing screws and check
10. Install RAVE valve housing and carefully align valve stem for free movement again. If some
springs in recess of RAVE valve housing. friction is felt, slightly loosen screws and read-
just housing then retighten screws.
TIGHTENING TORQUE
RAVE valve housing 10 N•m ± 0.7 N•m
screw (89 lbf•in ± 6 lbf•in)
mmr2017-020-024_a
RECESS FOR RAVE SPRINGS
mmr2017-020-026_a
TIGHTENING SEQUENCE
14. Repeat the process until a free movement is

obtained.
15. Install lubrication hoses using NEW Oetiker
clamps.
16. Tighten collar nuts to specification.
TIGHTENING TORQUE
4 N•m ± 0.3 N•m
Collar nuts
mmr2017-020-023_a (35 lbf•in ± 3 lbf•in)
11. Remove protector sleeves.

12. Install and hand tighten screws.
Push and pull main valve stems to make sure they
move freely.
mmr2017-020 13
CHECK VALVES
mmr2017-020-027_a
17. Position RAVE valves position sensor with link

bar on RAVE valve housing.
18. Refer to INSTALLING THE 3D RAVE VALVES mmr2017-017-016_b
POSITION SENSOR in this subsection and in-
stall: For testing and replacement refer to the LUBRI-
– Position sensor retaining screws CATION SYSTEM subsection.
– Link bar retaining nuts.
RAVE CABLE
RAVE VALVES SYNCHRONIZATION whenever Removing the Rave Cable
link bar is removed. NOTE: To avoid twisting the Rave cable, start
with removal at the link bar.
1. Push RAVE valves to closed position.
2. Loosen Rave cable lock nut. Hold counter nut.
3. Remove retaining plate screw.
mmr2017-020-028_a
1. RAVE valves position sensor

2. Link bar
3. Position sensor retaining screws
4. Link bar retaining nuts
19. Connect the RAVE valves position sensor.

mmr2017-020-029_a
20. Install Rave cable. Refer to INSTALLING THE 1. Rave cable lock nut
RAVE CABLE in this subsection 2. Retaining plate screw
21. Bleed oil lines. Refer to OIL INJECTION 4. Remove Rave cable.
PUMP in the LUBRICATION SYSTEM subsec-
tion. 5. Remove Rave cable lock nut at servomotor
bracket. Hold counter nut.
6. Remove snap ring from servomotor lever.
14 mmr2017-020
TIGHTENING TORQUE
20 N•m ± 2 N•m
Rave cable lock nut
4. Install Rave cable on the link bar.

5. Install retaining plate screw but do not tighten
yet.
6. Install Rave cable lock nut.
TIGHTENING TORQUE
20 N•m ± 2 N•m
Rave cable lock nut
mmr2017-020-030_a
1. Rave cable lock nut 7. Tighten retaining plate screw.

2. Counter nut
3. Snap ring TIGHTENING TORQUE
7. Remove Rave cable. 5 N•m ± 0.6 N•m

Retaining plate screw
Inspecting the Rave Cable
Check Rave cable and retaining plate for wear or SERVOMOTOR
any other damage.
The servomotor consists of a brush DC motor
(actuator) and a non-contacting angle sensor inte-
grated in one housing.
Testing the Servomotor

As a first troubleshooting step, always connect
vehicle to the applicable BUDS2. software ver-
sion to check for applicable fault codes. Refer to
COMMUNICATION TOOLS AND B.U.D.S. sub-
section.
Testing the Sensor Input Voltage
1. Disconnect the servomotor connector.
2. Install D.E.S.S. key and press start/RER button
to wake up ECM.
mmr2017-020-031
3. Set multimeter to Vdc and check voltage as per
Check if cable moves freely. following table.
If not, lubricate both ends of the Rave cable sleeve SENSOR INPUT VOLTAGE
and check if the Rave cable is sliding without any
resistance. Replace if necessary. Servomotor
connector
RAVE CABLE SLEEVE LUBRICATION MEASUREMENT
(wiring harness Battery ground
side)
Service product O-ring chain lubricant
Pin 1 5 ± 0.25 Vdc
Installing the Rave Cable
REQUIRED TOOL
1. Install Rave cable on the servomotor lever.
2. Install snap ring. FLUKE 115 MULTIMETER
3. Install Rave cable lock nut at the Servomotor (P/N 529 035 868)
bracket.
mmr2017-020 15
mmr2017-020-032_a mmr2017-020-032_b
If voltage is exceeding the range check ECM If resistance is incorrect check ECM grounding
power supply (Fuses F1 and F3) and servomotor and servomotor wiring.
wiring.
Testing the Servomotor Wiring
Testing the Sensor Ground 1. Disconnect ECM connector.
1. Disconnect the servomotor connector. 2. Connect ECM connector to ECM adapter tool.
REQUIRED TOOL
following table.
REQUIRED TOOL
ECM ADAPTER TOOL
(P/N 529 036 166)
(P/N 529 035 868)
SENSOR GROUND following table.
Servomotor REQUIRED TOOL
connector
MEASUREMENT
(wiring harness Battery ground
side) FLUKE 115 MULTIMETER
(P/N 529 035 868)
Pin 2 Close to 0
16 mmr2017-020
SERVOMOTOR Remove the upper body module to work on the

CONNECTOR servomotor.
ECM
(WIRING RESISTANCE
ADAPTER
HARNESS Removing the Servomotor
SIDE) Remove Rave cable. Refer to REMOVING THE
E4 1 RAVE CABLE in this subsection.
F4 2 Remove servomotor from the oil tank.
D4 3
H4 4 Close to 0
G4 4
J4 5
K4 5
Testing the Servomotor Resistance

following table.
REQUIRED TOOL
mmr2017-020-200_a
(P/N 529 035 868) Remove:
– Bracket retaining screws
– Bracket.
mmr2017-020-033_a
mmr2017-020-034_a
1. Retaining screws
SERVOMOTOR RESISTANCE 2. Servomotor
3. Servomotor bracket
SERVOMOTOR SERVOMOTOR
CONNECTOR CONNECTOR RESISTANCE Inspecting the Servomotor
(SERVOMOTOR (SERVOMOTOR @ 20°C (68°F)
SIDE) SIDE) Check ease of movement of the servomotor lever.
4 5 Close to 0 Check mechanical end stop of servomotor lever.
If necessary replace servomotor.
Servomotor Location
Installing the Servomotor
The servomotor is located on the top of the oil
tank, on the LH side of the vehicle. The installation is the reverse of the removal pro-
mmr2017-020 17
TIGHTENING TORQUE
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
11 N•m ± 0.8 N•m
Bracket retaining screws
Servomotor retaining 4 N•m ± 1 N•m
18 mmr2017-020
Subsection XX (TOP END)
TOP END
SERVICE TOOLS
PISTON CIRCLIP INSTALLER 21MM............................................ 529 036 138 ........................................... 16
PISTON PROJECTION .................................................................. 529 036 215 ........................................... 12
TDC DIAL INDICATOR .................................................................. 295 000 143 ........................................... 12
SERVICE PRODUCTS
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ....................................... 7, 10
mmr2017-021 1
See E-TEC DIRECT

FUEL INJECTION
See RAVE
See tightening
sequence
10 ± 0,7 N•m
(89 ± 6 lbf•in)
NEW
8 ± 0,5 N•m 8 ± 0,5 N•m

(70 ± 4 lbf•in) (70 ± 4 lbf•in)
NEW
1,5 ± 0,3 N•m

(13 ± 3 lbf•in)
6 ± 0,4 N•m
(53 ± 4 lbf•in)
8 ± 0,5 N•m
(70 ± 4 lbf•in)
6 ± 0,4 N•m
(53 ± 4 lbf•in)

mmr2017-021-001_a
2 mmr2017-021
See tightening 24 ± 2 N•m See E-TEC DIRECT

sequence (18 ± 1 lbf•ft) FUEL INJECTION
28 ± 1 N•m 16 ± 1 N•m
(21 ± 1 lbf•ft) (142 ± 9 lbf•in)
8 ± 0,5 N•m
(70 ± 4 lbf•in) Loctite 243
5 ± 0,3 N•m
(44 ± 3 lbf•in)
See PERIODIC MAINTENANCE

PRODCEDURES
NEW
See tightening See tightening

sequence sequence
50 ± 1,5 N•m 50 ± 1,5 N•m
(37 ± 1 lbf•ft) (37 ± 1 lbf•ft)
NEW
Injection oil
Injection oil
NEW
NEW See replacment procedure
NEW
Injection oil

mmr2017-021-002_a
mmr2017-021 3
GENERAL WARNING
Before completely disassembling the engine, Prior to measuring engine compression, en-
check airtightness. Refer to ENGINE LEAK TEST sure vehicle is properly lifted with the track
subsection. off the ground.
During assembly or installation:
– Use torque values and service products as 3. Safely warm up engine.
shown in the exploded view. 4. Remove a spark plug.
– Clean threads before applying a threadlocker. 5. Install an appropriate ENGINE COMPRESSION
Refer to the INTRODUCTION subsection. TOOL on engine.
WARNING Place emergency engine stop switch to OFF posi-
tion.
must be strictly adhered to. Crank engine several times:
Locking devices when removed (e.g.: locking – Pull rewind starter several times (if applicable) -
tabs, elastic stop nuts, self-locking fasteners, or
cotter pins, etc.) must be replaced with new – Press START/STOP button to crank engine.
ones. Check if engine compression is according to spec-
ification.
NOTICE Hoses, cables and locking ties re- SERVICE LIMIT
as per factory standards. ENGINE
COMPRESSION 7.5 bar (110 PSI)
SPECIFICATION
WARNING
Always disconnect the magneto connector
prior to: PROCEDURES
– Disconnecting any fuel hose.
– Removing a fuel injector. REED VALVES
– Removing a spark plug cable or spark plug. Removing the Reed Valve
Otherwise, if the engine is cranked, fuel va-
pors may ignite in presence of a spark creat- 1. Remove throttle body, refer to E-TEC DIRECT
ing a fire hazard. FUEL INJECTION subsection.
2. Remove the following parts.
ENGINE BREAK-IN
NOTICE After a repair involving major parts
replacement, a break-in period must be ob-
served. Follow OPERATOR'S GUIDE recom-
mendation relating to break-in.
To reactivate the break-in period, use the BUDS2
software.
Go to:
– Setting/Initialization/Restart Break-In
INSPECTION
mmr2017-021-003_a
ENGINE COMPRESSION TEST 1. Retaining screws (12x)

2. Clamps
3. Intake adapters with reed valves
1. Remove body parts as required to access to the
spark plugs. 3. Remove reed valves from intake adapter.
2. Lift rear of vehicle to clear track from the
ground. Support it with a wide base stand.
4 mmr2017-021
mmr2017-021-004_a mmr2017-021-005_a
1. Reed valves
2. Intake adapter Ensure to position intake adapter as shown.
Install clamps as shown in the illustration.
Inspecting the Reed Valve
Check reed valve for proper tightness.
Check blades for breakouts at their end tips. In
case of breakouts replace it.
There must not be any play between blade and
valve body when exerting a finger pressure on
blade at blade stopper location.
In case of a play, turn blade upside down and
recheck.
TIGHTENING TORQUE
1.5 N•m ± 0.3 N•m
Reed valve blade screws
mmr2017-021-006_a
If there is still a play, replace blade and/or reed 1. Intake adapter
valve assembly. 2. Clamps
Installing the Reed Valve Tighten intake adapter retaining screws to specifi-
cation.
cedure. However, pay attention to the following. TIGHTENING TORQUE
Blades have a curved shape. Install with their Intake adapter retaining 6 N•m ± 0.4 N•m
curve facing reed block. screws (53 lbf•in ± 4 lbf•in)
TIGHTENING TORQUE
1.5 N•m ± 0.3 N•m COVER
Reed valve blade screws
Removing the Cover
Ensure to position reed valves so that they rest flat Carefully lift cover until rubber caps come off from
in intake opening. distance screw.
mmr2017-021 5
mmr2017-021-028_a mmr2017-021-010_a
Inspecting the Cover 4. Pull RAVE valves to fully open position and lift
RAVE position sensor.
Check if heat protection mat inside cover is dam-
aged. Replace cover if necessary. 5. Remove knock sensor retaining screw and
move knock sensor aside.
Check rubber caps if they are brittle or otherwise
damaged. Replace as required. 6. Disconnect:
– Fuel injector connectors
Installing the Cover – Coolant temperature sensor connector.
Position rubber caps onto the distance screw. 7. Remove retaining screws and move harness
Push the cover until rubber caps snapping on the support towards RAVE valves.
distance screw.
mmr2017-021-032_a
1. Fuel injector connectors

2. Coolant temperature sensor connector
3. Knock sensor retaining screw
4. Harness support retaining screws
mmr2017-021-029_a
1. Rubber caps 8. Disconnect coolant hose at cylinder head.

2. Distance screws
9. Disconnect hose from bleeding nipple.
10. Disconnect throttle body heater inlet hose at
CYLINDER HEAD cylinder head.
Removing the Cylinder Head
1. Remove cover, refer to procedure in this sub-
section.
2. Drain coolant, refer to PERIODIC MAINTE-
3. Remove RAVE position sensor screws
6 mmr2017-021
2. If cylinder head is out of specification, replace

it.
mmr2017-021-021_a
1. Coolant hose
2. Bleeder nipple
mmr2009-010-001_c
3. Throttle body heater inlet hose
TYPICAL
11. Remove fuel injectors, refer to E-TEC DIRECT 1. Straight edge
2. Feeler gauge
12. If necessary remove following parts from SERVICE LIMIT
cylinder head: 0.05 mm (.002 in) per
– Spark plugs CYLINDER HEAD 50 mm (2 in) of surface
– Knock sensor WARPAGE 0.5 mm (.02 in) for total
– Distance screws length of cylinder head
– Bleeder hose nipple.
13. Remove the following parts: . Cleaning the Cylinder Head
Scrape off any carbon deposits from cylinder
head.
CYLINDER HEAD CLEANING
LOCTITE CHISEL
Service product (GASKET REMOVER)
(P/N 413 708 500)
Installing the Cylinder Head

Install NEW rubber ring and round O-rings on
cylinder block.
mmr2017-021-022_a Tighten cylinder head screws to specification as
1. Cylinder head screws (12x) per the following sequence.
2. Cylinder head
3. Cylinder rubber ring TIGHTENING TORQUE
4. O-rings
28 N•m ± 1 N•m
Cylinder head screws
Inspecting the Cylinder Head (21 lbf•ft ± 1 lbf•ft)
Check cylinder head for cracks or other damages.
Replace if necessary.
Cylinder Head Warpage
1. Check gasket mating surface of the cylinder
head with a straight edge and a feeler gauge.
Make sure part is within the given specifica-
tion.
mmr2017-021 7
mmr2017-021-025_a
mmr2017-021-023_a MAGNETO SIDE

TIGHTENING SEQUENCE
CYLINDER BLOCK
Removing the Cylinder Block
1. Remove CYLINDER HEAD, see procedure in
this subsection.
2. Disconnect throttle bodies from intake adapters
and set aside.
3. Loosen bowden cable lock nut and remove re-
taining plate screw and put cable aside.
mmr2017-021-027_a
EXHAUST SIDE
6. Remove ground cable.
mmr2017-020-029_a
1. Bowden cable lock nut

2. Retaining plate screw
4. Disconnect RAVE valves oil lines.

5. Remove screws from harness support and put mmr2017-021-007_a
wiring harness with support aside.

7. If necessary remove:
– RAVE assembly.
8 mmr2017-021
mmr2017-021-038_a
CYLINDER TAPER MEASUREMENTS

mmr2017-021-026_a
1. Retaining screws FROM TOP OF

2. RAVE assembly POSITION MEASUREMENT
3. Gasket
CYLINDER BLOCK
1 A 30 mm (1.18 in)
8. Remove:
– Cylinder block screws 2 B 140 mm (5.51 in)
– Cylinder block. REQUIRED TOOL
Cylinder bore gauge
mmr2017-021-008_a
1. Cylinder block screws

2. Cylinder block
Inspecting the Cylinder Block

Remove RAVE valves, refer to RAVE subsection.
Remove reed valves, refer to REMOVING THE
REED VALVES in this subsection.
Check cylinder bores for cracks and scoring on the
top and bottom of cylinders. Replace if necessary.
Cylinder Taper
1. Measure cylinder diameter at the following po- mmr2017-021-037_a
sitions:
2. Compare cylinder diameters.
– Above exhaust port
– Below intake port. 3. If the difference exceeds the specified dimen-
sion, replace the cylinder block.
CYLINDER BORE TAPER
SERVICE LIMIT 0.10 mm (.0039 in)
mmr2017-021 9
Cylinder out of Round

1. Check if the cylinder out of round is more than
the specified dimension.
Measure above exhaust port:
– in piston pin axis
– perpendicular to piston pin axis.
mmr2017-021-038_b
CYLINDER OUT OF ROUND MEASUREMENT

mmr2017-021-037_a
FROM TOP
POSITION MEASUREMENT OF CYLINDER 2. If the measurement exceeds the specifications,
BLOCK
replace the cylinder block.
1 A 30 mm (1.18 in)
CYLINDER BORE OUT OF ROUND
Cleaning the Cylinder Block

Scrape off any carbon deposits from exhaust
ports.
Carefully clean cylinder block screws, specifically
under screw head.
CYLINDER BLOCK AND SCREWS CLEANING
LOCTITE CHISEL
(P/N 413 708 500)
Installing the Cylinder Block

Ensure top surface of crankcase is clean.
mmr2017-021-039_a Check if dowel pins are in crankcase holes.
A. Measure in piston pin axis
B. Measure perpendicular to piston pin axis
REQUIRED TOOL
Cylinder bore gauge
10 mmr2017-021
Measure piston projection as described in PIS-

TON PROJECTION MEASUREMENT in this
subsection.
NOTICE Always install a cylinder block base
gasket of the proper thickness. Failure to do so
may cause detonation and severe engine dam-
age.
Install RAVE assembly with NEW gasket.
Tighten RAVE valve housing screws to specifica-
tion following the illustrated sequence.
RAVE valve housing 10 N•m ± 0.7 N•m
Install a NEW cylinder block base gasket of the
same thickness as the old one. Refer to PISTON
PROJECTION MEASUREMENT in this subsec-
tion.
NOTE: If thickness of the factory-installed gas-
ket is unknown, install a 7-holes gasket (0.7 mm
(.028 in)) as a base line.
Lubricate cylinder bores.
CYLINDER BORE LUBRICATION
Service product Injection oil mmr2017-020-026_a
TIGHTENING SEQUENCE
Carefully slide cylinder block down while squeez-
ing piston rings to allow cylinder insertion. Push and pull RAVE link bar to be sure that RAVE
Proceed one piston at a time, the help of an assis- valves move freely.
tant may be required.
Tighten cylinder block screws to specification as
per the following sequence.
TIGHTENING SEQUENCE
50 N•m ± 1.5 N•m
Cylinder block screws
mmr2017-020-010_c
PUSH AND PULL RAVE LINK BAR
Install bowden cable on the link bar, refer to BOW-

DEN CABLE in the RAVE subsection.
mmr2017-021-008_b
TIGHTENING SEQUENCE
mmr2017-021 11
PISTON PROJECTION 4. Clean top surface of cylinder block.

MEASUREMENT 5. Ensure piston dome is clean and free of any car-
bon deposits.
NOTE: The piston projection measurement is
used to determine the correct cylinder base 6. Ensure cylinder block screws are properly tight-
gasket thickness when engine components are ened.
replaced.
Piston Projection Measurement
Cylinder Block Base Gasket 1. Place piston projection tool on a flat steel sur-
The cylinder block base gasket is available in dif- face.
ferent thicknesses to adjust precisely the piston REQUIRED TOOL
projection.
PISTON PROJECTION
CYLINDER BLOCK BASE GASKET
(P/N 529 036 215)
THICKNESS HOLES QUANTITY
0.9 9 TDC DIAL INDICATOR
(P/N 295 000 143)
0.8 8
0.7 7 2. Rotate dial indicator face to position the 0 in line
0.6 6 with needle.
0.5 5
mmr2017-021-011_a
mmr2011-010-002_a
TYPICAL - GASKET THICKNESS IDENTIFICATION HOLES
SETTING THE ZERO
NOTICE Always install a cylinder block base
gasket of the proper thickness. Failure to do so 3. Install tool on PTO cylinder.
may cause detonation and severe engine dam- 4. Center tool with cylinder to ensure that dial in-
age. dicator reads piston dome.
Engine Preparation
1. Bring PTO piston to TDC.
REQUIRED TOOL
TDC DIAL INDICATOR

(P/N 295 000 143)
2. Remove cylinder head from engine. Refer to

CYLINDER HEAD in this subsection.
3. Remove O-rings from cylinder block.
12 mmr2017-021
NOTICE Take care to use the proper specifi-

cation according to the type of engine and the
model of vehicle.
PISTONS
Removing the Piston
1. Remove CYLINDER BLOCK, see procedure in
this subsection.
2. Place a clean cloth over crankcase.
3. Using a pointed tool inserted in piston notch,
remove circlips from piston.
mmr2011-010-003
TYPICAL - TOOL PROPERLY CENTERED
5. Ensure that PTO piston is set to TDC.

6. Read dial indicator then note measurement.
mmr2017-021-012
4. Push piston pin out of piston.

5. Remove piston.
6. Remove bearing.
7. Discard circlips.
Inspecting the Piston

mmr2011-010-004
TYPICAL
Inspect piston for scoring, cracking or other dam-
age.
NOTE: Convert dial indicator measurement to mil-
Cylinder/Piston Clearance
limeter.
1. Measure piston diameter at “A” perpendicu-
PISTON PROJECTION MEASUREMENT larly (90°) to piston pin.
1.75 mm to 1.82 mm (.069 in to .072 in) REQUIRED TOOL
7. If piston projection measurement is out of Micrometer
specification, change cylinder block base gas-
ket thickness. Refer to CYLINDER BLOCK in
this subsection.
CYLINDER BLOCK BASE GASKET
SELECTION GUIDELINE
MEASURED PISTON
GASKET TO INSTALL
PROJECTION
Below specification Thinner
Above specification Thicker
mmr2017-021 13
2 1
mmr2017-021-033_a F00B09A
1. Measuring diameter perpendicularly (90°) to piston pin axis

A. 15 mm (.591 in) 1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
2. Adjust and lock a micrometer to the piston di-
ameter.
F00B08A
F00B0AA
1. Micrometer set to the piston diameter

1. Indicator set to 0 (zero)
3. Adjust a cylinder bore gauge to the locked mi- NOTE: Make sure the cylinder bore gauge indica-
crometer and set the indicator to 0. tor is set exactly at the same position as with the
REQUIRED TOOL micrometer, otherwise the reading will be false.
Cylinder bore gauge 4. Position the dial bore gauge above the exhaust
port.
NOTICE Always remove cylinder-block from
crankcase before measuring.
mmr2017-021-038_b
14 mmr2017-021
CYLINDER OUT OF ROUND MEASUREMENT RING END GAP MEASUREMENT

FROM TOP FROM TOP OF
POSITION MEASUREMENT
POSITION MEASUREMENT OF CYLINDER CYLINDER BLOCK
BLOCK
1 A 89 mm (3.5 in)
1 A 30 mm (1.18 in)
NOTE: In order to correctly position the ring in the
cylinder, use piston as a pusher.
2. Check ring end gap. Replace ring if gap ex-
ceeds specified tolerance.
REQUIRED TOOL
Feeler gauge
RING END GAP

0.400 mm to 0.600 mm
NEW
(.0157 in to .0236 in)
mmr2017-021-034_a
1. Measuring perpendicularly (90°) to piston pin axis

A. 30 mm (1.18 in)
5. Read the measurement on the cylinder bore

gauge. The result is the exact piston/cylinder
wall clearance.
CYLINDER/PISTON CLEARANCE
0.136 mm to 0.160 mm
NEW
(.0054 in to .0063 in)
6. If clearance exceeds specified tolerance, re- mmr2017-021-036
place cylinder and piston.

Cleaning the Piston
Ring End Gap 1. Scrape off any carbon deposits from piston
1. Position ring halfway between transfer ports dome.
and intake port. NOTE: The arrow on the piston dome must be
visible after cleaning.
mmr2017-021-038_c
mmr2017-021 15
6. Use the following procedure to properly install

circlip.
6.1 Insert circlip into support so that, when in-
stalled in piston groove, the gap will be be-
low the tab.
mmr2017-021-013_a
EXHAUST DIRECTION INDICATION
2. Clean the piston ring groove with a groove

cleaner tool or with a piece of broken ring.
Installing the Piston

1. Lubricate needle bearing. mmr2017-021-014
NEEDLE BEARING LUBRICATION 6.2 With round end of pusher, position circlip
perpendicularly to the support axis.
2. Insert bearing into connecting rod.

3. Place pistons over connecting rods with the ar-
row on the piston dome facing towards exhaust
port.
mmr2017-021-015_a
6.3 With the other end of the pusher, push cir-

clip into the support groove.
mmr2017-021-013_a
EXHAUST DIRECTION INDICATION
4. Install piston pin in piston.

5. Install NEW circlips.
REQUIRED TOOL
PISTON CIRCLIP INSTALLER
21MM (P/N 529 036 138)
NOTICE Always install NEW mono-hook cir-

clips. If circlip installation fails at the first at-
tempt, always retry with a new one. mmr2017-021-016_a
16 mmr2017-021
mmr2017-021-017_a mmr2017-021-019_a
GROOVE GAP BELOW THE TAB
NOTICE Circlips must not move freely

after installation; if so, replace them.
7. Install all other removed parts as the reverse of
removal procedure.
mmr2017-021-018_a
CIRCLIP READY TO BE INSTALLED ON PISTON
mmr2017-021-020_a
6.4 Using a plastic hammer, tap pusher to put

the new circlip in place.
NOTE: Make sure to install new circlips with
the gap below the tab exactly as shown on
the following photo.
mmr2017-021 17
Subsection XX (BOTTOM END)
BOTTOM END
SERVICE TOOLS
BEARING HEATER ........................................................................ 529 035 969 ........................................... 11
CRANKSHAFT BEARING PULLER ................................................ 529 036 004 ........................................... 10
CRANKSHAFT PROTECTOR ......................................................... 529 036 405 ........................................... 10
DEGREE WHEEL........................................................................... 529 035 607 ........................................... 9
DISTANCE GAUGE ........................................................................ 529 036 415 ........................................... 13
HALF-RING .................................................................................... 529 036 414 ........................................... 10
PULLER RING ............................................................................... 420 977 490 ........................................... 10
TEMPERATURE INDICATOR STICK .............................................. 529 035 970 ........................................... 11
WATER PUMP BEARING PUNCH................................................. 529 036 417 ........................................... 6
SERVICE TOOLS – OTHER SUPPLIER

SNAP-ON MANUAL IMPACT DRIVER .......................................... PIT120 ........................................... 3
SERVICE PRODUCTS
LOCTITE 5910 ............................................................................... 293 800 081 ........................................... 6
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ........................................... 5
PETAMO GREASE GHY 133N ...................................................... 420 899 271 ........................................... 12
XPS LUBE...................................................................................... 293 600 016 ........................................... 10
mmr2017-022 1
11 ± 0,8 N•m
(97 ± 7 lbf•in)
See tightening
sequence
11 ± 0,8 N•m
(97 ± 7 lbf•in)
Petamo grease
GHY 133N
50 ml (1.7 U.s.oz)
Injection oil
Loctite 5910
Petamo grease
GHY 133N
29 ± 2 N•m 11 ± 0,8 N•m

(21 ± 1 lbf•ft) (97 ± 7 lbf•in)
See tightening
sequence
See tightening
sequence
11 ± 0,8 N•m
(97 ± 7 lbf•in)
NEW
29 ± 2 N•m
(21 ± 1 lbf•ft)
See tightening
sequence 11 ± 0,8 N•m
(97 ± 7 lbf•in)
See tightening
sequence

mmr2017-022-001_a
2 mmr2017-022
GENERAL PROCEDURES
Engine removal is required to repair bottom end.
CRANKCASE
All oil seals and gaskets must be discarded and
replaced with new ones when crankcase is split. Disassembling the Crankcase
Clean all metal components in a non-ferrous metal Remove engine from vehicle. Refer to ENGINE
cleaner. REMOVAL AND INSTALLATION subsection.
During assembly or installation: Refer to TOP END subsection to remove:
– Use torque values and service products as – Cylinder head
shown in the exploded view. – Cylinder block
– Clean threads before applying a threadlocker. – Pistons.
Refer to the INTRODUCTION subsection.
Refer to MAGNETO AND STARTER subsection to
WARNING remove:
Torque wrench tightening specifications – Stator
must be strictly adhered to. – Magneto housing
Locking devices when removed (e.g.: locking – Starter drive
tabs, elastic stop nuts, self-locking fasteners, – Starter.
cotter pins, etc.) must be replaced with new .
ones. Remove drive pulley. Refer to DRIVE PULLEY
subsection.
NOTICE Hoses, cables and locking ties re- Remove PTO oil seal cover.
moved during a procedure must be reinstalled NOTE: Tap screw heads to break the Loctite
as per factory standards. bond or use a SNAP-ON MANUAL IMPACT DRIVER
(P/N PIT120).
WARNING
Remove oil line from crankcase. Discard 1-ear
clamp.
prior to:
– Removing a fuel injector.
– Removing a spark plug cable or spark plug.
pors may ignite in presence of a spark creat-
ing a fire hazard.
ENGINE BREAK-IN
NOTICE After a repair involving major parts
replacement, a break-in period must be ob-
served. Follow OPERATOR'S GUIDE recom-
mendation relating to break-in. mmr2017-022-002_a
1. PTO oil seal cover

To reactivate the break-in period, use the BUDS2 2. Ol line
software. Remove engine front supports.
Go to: Remove M6 crankcase screws.
– Setting/Initialization/Restart Break-In
mmr2017-022 3
mmr2017-022-009_a
1. Base plate
2. Gasket (discard it)
Split crankcase.
mmr2017-022-018_d
NOTE: To prevent damage to crankcase mating
M6 CRANKCASE SCREWS - BOTTOM SIDE
surfaces, use prying lugs to “unstick” crankcase.
mmr2017-022-005_a
mmr2017-022-010
M6 CRANKCASE SCREW - WATER PUMP SIDE
PRYING LUGS
Remove M8 crankcase screws.
mmr2017-022-011
mmr2017-022-008_a PRYING LUGS

TYPICAL - BASE PLATE RETAINING SCREWS
Remove:
Remove base plate and discard gasket. – Starter drive needle bearing
NOTICE Whenever base plate is removed, – Crankshaft assembly
crankcase must be opened, cleaned, and re- – Shims.
sealed.
4 mmr2017-022
mmr2017-022-012_a
STARTER DRIVE NEEDLE BEARING
mmr2017-022-013_a
OIL BORES IN CRANKCASE LOWER PART
mmr2017-022-004_a
SHIMS
Cleaning the Crankcase and Base Plate

Clean all metal components in a non-ferrous metal
cleaner.
CRANKCASE CLEANING
LOCTITE CHISEL
(P/N 413 708 500)
mmr2017-022-014_a
NOTICE Never use a sharp object to remove OIL BORES IN BASE PLATE
sealant as score marks incurred are harmful to
crankcase sealing. Inspecting the Crankcase and Base
Plate
Blow out the oil orifices using compressed air and
Check crankcase and base plate for cracks or
make sure they are not clogged.
other damages. Replace if necessary.
Water Pump Bearing Replacement

Use a suitable punch to push ball bearing out of
crankcase.
mmr2017-022 5
mmr2017-022-048_a
Install NEW ball bearing.

REQUIRED TOOL
mmr2017-022-015_a
WATER PUMP BEARING
PUNCH (P/N 529 036 417) Ensure dowel pins are in their holes.
mmr2017-022-049_a
mmr2017-022-017_a
1. Ball bearing
2. Water pump bearing punch
Assemble crankcase lower half.
Assembling the Crankcase Install base plate with NEW gasket.
Install crankshaft in upper crankcase. See Install crankcase screws.
CRANKSHAFT for procedure. Tighten crankcase screws to specification as per
Install needle bushing in crankcase upper with the illustrated sequence.
writing showing to the outside.
TIGHTENING TORQUE
Apply sealant on lower crankcase as per following
procedure. 29 N•m ± 2 N•m
M8 Crankcase screws
CRANKCASE SEALANT
LOCTITE 5910 (P/N 293
Service product
800 081)
NOTE: The total assembly sequence, including

sealing compound application and crankcase
torquing, must be performed within 10 minutes.
6 mmr2017-022
mmr2017-022-019_a
TIGHTENING SEQUENCE- M6 CRANKCASE SCREWS - TOP

VIEW
Install PTO oil seal cover.

mmr2017-022-018_b
Tighten oil seal cover to specification.
TIGHTENING SEQUENCE - M8 CRANKCASE SCREWS
TIGHTENING TORQUE
TIGHTENING TORQUE
11 N•m ± 0.8 N•m
11 N•m ± 0.8 N•m Oil seal cover screws
M6 Crankcase screws (97 lbf•in ± 7 lbf•in)
NOTE: It is recommended to test engine cooling
system for leaks after engine assembly, before in-
stallation in vehicle. Refer to COOLING SYSTEM
subsection.
NOTE: It is recommended to always check the
functionality of the check valves before installa-
tion in vehicle. Refer to CHECK VALVES AND FIT-
TINGS in LUBRICATION SYSTEM subsection.
CRANKSHAFT
Removing the Crankshaft
To remove crankshaft, use crankcase disassembly
procedure.
Inspecting the Crankshaft

For crankshaft specifications refer to TECHNICAL
mmr2017-022-018_c SPECIFICATIONS subsection.
TIGHTENING SEQUENCE - BOTTOM VIEW
Crankshaft Deflection (Measuring in
Crankcase)
1. Using a dial indicator, check deflection with
crankshaft in crankcase.
mmr2017-022 7
CRANKSHAFT DEFLECTION MAG SIDE

2. If deflection exceeds the specified tolerance,

recheck deflection using V-shaped blocks to de-
termine the defective part(s). See MEASUR-
ING ON BENCH.
Crankshaft Deflection (Measuring on Bench)
1. Once engine is disassembled, check crankshaft
deflection on V-shaped blocks.
mmr2017-022-040_a
CRANKSHAFT PTO SIDE

A. 17 mm (.67 in)
CRANKSHAFT DEFLECTION PTO SIDE

mmr2017-022-042_a
TYPICAL — V-SHAPED BLOCKS POSITION WITH BEARINGS

A. 17 mm (.67 in)
B. 3 mm (.12 in)
NOTE: Crankshaft deflection cannot be correctly

measured between centers of a lathe.
2. If deflection exceeds the specified tolerance, it
can be worn bearings or a bent crankshaft.
mmr2017-022-041_a
3. Remove crankshaft bearings and check deflec-
CRANKSHAFT MAG SIDE tion again on V-shaped blocks to determine the
A. 3 mm (.12 in) defective part(s).
Measure deflection circumferential excluding the

woodruff key.
mmr2017-022-043_a
TYPICAL — V-SHAPED BLOCKS POSITION WITHOUT

BEARINGS
mmr2017-022-047_a
A. 17 mm (.67 in)
B. 3 mm (.12 in)
8 mmr2017-022
4. If the deflection exceeds the specified toler-

ance, replace crankshaft.
Connecting Rod Big End Axial Play
1. Measure distance between connecting rod and
crankshaft counterweight.
REQUIRED TOOL
Feeler gauge
A35C32A
5. Remove dial indicator and install it in spark plug

hole on PTO side.
6. Bring PTO piston to top dead center. Degree
mmr2017-022-044_a
wheel must rotate with crankshaft.
CONNECTING ROD BIG END AXIAL PLAY 7. Interval between cylinders must be 180° ± 0.5.
0.152 mm to 0.352 mm 8. Any other reading indicates a misaligned
New (twisted) crankshaft.
(.006 in to .0139 in)
2. If the distance exceeds specified tolerance, re- Removing the Crankshaft Bearing
place crankshaft. NOTE: 10 minutes is required to heat up a new
Crankshaft Alignment bearing for its installation, To save time, it is rec-
ommended to start the heating process prior to
1. Remove injectors. Refer to E-TEC DIRECT bearing removal operation. See procedure further.
To remove MAG side bearings from crankshaft, in-
2. Bring MAG piston at top dead center. Refer to stall proper half rings and puller ring on the outer
IGNITION SYSTEM subsection. bearing race.
3. Scribe a mark on crankcase (see illustration). The roller bearing on PTO side has a sliding seat
4. Install a degree wheel on crankshaft end so that and can be removed without a tool.
360° mark aligns with the mark on crankcase. NOTE: Position tools in the groove of the inner
Do not rotate crankshaft. bearing and pull out both bearings together.
REQUIRED TOOL
350 360 10 20
340 30
0 10 360 350 3
DEGREE WHEEL
33 20 40
0 30 33 40
32 40 0
32
50 0
50
0
31
60
31
60
0
0
70
30
300
70
80
290
290
80
110 100 90
280
280 270 26
90 100 11
270
260
120
(P/N 529 035 607)

0
0
250
130
250
120
0
24
14
24
13
0
0
2
30
30
15 2
1
0 22 40
16 0 0
210 0 22 15
200 190 180 17 0 0
160 21
170 00
180 190 2
mmr2017-022 9
REQUIRED TOOL REQUIRED TOOL
CRANKSHAFT BEARING
PULLER (P/N 529 036 004)
HALF-RING (P/N 529 036 414)
Secure the bearing puller in a vise at its rib.
PULLER RING (P/N 420

977 490)
CRANKSHAFT PROTECTOR
(P/N 529 036 405)
Ensure to position bearing pin between half ring

gap. mmr2017-022-046_a
TYPICAL - BEARING PULLER SECURED IN THE VISE
NOTICE Never use any air impact tool for

tightening the puller bolt. Lubricate the bolt
with XPS LUBE (P/N 293 600 016) to avoid dam-
aging the threads.
Screw in the puller bolt until the bearings come
out.
During bearing removal take care not to lose the
distane shim installed between inner and outer
bearing.
mmr2017-022-021_a
MAG SIDE
mmr2017-022-027_a
MAG SIDE
1. Inner bearing
2. Distance shim
3. Outer bearing
mmr2017-022-022_a
MAG SIDE
1. Half rings Installing the Crankshaft Bearing
2. Puller ring
3. Crankshaft protector Inspect crankshaft ends for damage.
Install bearing puller on the half rings. Clean crankshaft ends with sand paper no. 400 to
remove possible seal marks and debris.
10 mmr2017-022
A32CB8A
1. Bearings
mmr2017-022-024_a
Probe the side of the inner race of the bearing
Remove all residue. with a temperature indicator stick. Stick will liq-
uefy when the bearing reaches the proper temper-
CRANKSHAFT ENDS CLEANING ature.
PULLEY FLANGE REQUIRED TOOL
711 809) TEMPERATURE
INDICATOR STICK
Heating the Bearing (P/N 529 035 970)
Heat up the bearing(s) to ease installation.

REQUIRED TOOL
BEARING HEATER
(P/N 529 035 969)
NOTICE Bearing(s) should not be heated to

more than 80°C (176°F). Do not heat bearing(s)
with direct flame, or with a heat gun or soaked
in a heated oil bath. Inappropriate bearing(s)
heating may result in cage failure.
For even heat distribution, turn bearing several
times during heating process.
A32CB9A
NOTE: Two bearings can be heated at the same
time on one bearing heater.
WARNING
Do not touch heated bearing with bare hands.
Always wear heat resisting gloves before
handling the heated bearing(s).
NOTICE Never reinstall a bearing that has

been removed.
MAG Side Bearings
Install MAG bearings on crankshaft so that locat-
ing pins will be positioned as shown.
mmr2017-022 11
Lubricate oil seal sealing lip and slide it on crank-

shaft until it sits on outer bearing.
SEALING LIP LUBRICATION
PETAMO GREASE GHY
Service product
133N (P/N 420 899 271)
mmr2017-022-025_a
MAG SIDE
Slide the inner MAG bearing until it bottoms on

crankshaft shoulder.
NOTE: Heated bearing should slide easily onto
the crankshaft. If required, push with a steel tube
on the inner race of the bearing. mmr2017-022-028_a
Installing the Crankshaft

1. Slide cylinder roller bearing on crankshaft jour-
nal PTO side.
mmr2017-022-026_a
Put distance shim on inner MAG bearing.

Slide the outer bearing until it sits on distance
shim. mmr2017-022-029_a
2. Position locating pins in their recess as illus-

trated.
mmr2017-022-027_a
MAG SIDE
1. Inner bearing
2. Distance shim
3. Outer bearing mmr2017-022-030_a
12 mmr2017-022
3. Pay attention to properly locate MAG seal in its

groove.
mmr2017-022-033_a
1. Roller bearing
2. Distance gauge
3. Distance ring
6. Put the biggest shim and try to install it in the

groove right hand side of the distance ring
mmr2017-022-045_a
AVAILABLE SHIMS
4. Place distance gauge between distance ring
SHIM NUMBER SHIM THICKNESS
and crank web PTO.
50 0.50 mm (.02 in)
REQUIRED TOOL
75 0.75 mm (.03 in)
DISTANCE GAUGE
(P/N 529 036 415) 100 1.00 mm (.039 in)
125 1.25 mm (.049 in)
150 1.50 mm (.059 in)
200 2.00 mm (.079 in)
250 2.50 mm (.098 in)
mmr2017-022-032_a
1. Distance gauge
2. Distance ring
3. Crank web PTO
5. Tap the cylinder roller bearing with a plastic

hammer until the distance gauge is in contact mmr2017-022-034_a
with the distance ring and crank web. 1. Shim (right hand)
2. Distance ring
If the thickest shim does not fit, try to install the

next thinner shim.
If the thickest shim fits, try to install a second shim
until no gap is left.
NOTICE Maximum 2 shims must be installed
to achieve the proper adjustment.
mmr2017-022 13
7. Remove the distance gauge carefully.

8. Put the biggest shim and try to install it in the
groove left hand side of the distance ring
AVAILABLE SHIMS
SHIM NUMBER SHIM THICKNESS
50 0.50 mm (.02 in)
75 0.75 mm (.03 in)
100 1.00 mm (.039 in)
125 1.25 mm (.049 in)
mmr2017-022-038_a
150 1.50 mm (.059 in)
1. Shims
200 2.00 mm (.079 in) 2. Distance ring
250 2.50 mm (.098 in) 10. Pour injection oil in the oil bath under worm
gear as shown.
CRANKSHAFT WORM GEAR LUBRICATION
mmr2017-022-036_a
1. Shim (left hand)

2. Distance ring
3. Shim (right hand)
If the shim does not fit, try to install the next thin-
ner shim.
mmr2017-022-039_a
If the shim fits, try to install another shim until no
OIL BATH
gap is left.
9. Measure the width of the complete package
(shims + distance ring).
MINIMUM WIDTH OF THE PACKAGE
(SHIMS + DISTANCE RING)
3.80 mm (.15 in)
14 mmr2017-022
Subsection XX (ENGINE MANAGEMENT SYSTEM (EMS))
ENGINE MANAGEMENT SYSTEM (EMS)
mmr2017-023-001_a
mmr2017-023 1
GENERAL
ACRONYM DEFINITION
SH Left hand multi-function switch
COILS Ignition Coils
CPS Crankshaft Position Sensor
CTS Coolant Temperature Sensor
RFID DESS Digitally Encoded Security System
ECM Engine Control Module
EGTSm Exhaust Gas Temperature Sensor muffler
EGTStp Exhaust Gas Temperature Sensor tuned pipe
FP Fuel Pump
INJ DI MAG E-TEC Direct Injector (Mag Side)
INJ DI PTO E-TEC Direct Injector (PTO Side)
INJ TB MAG Throttle body Injector (Mag Side)
INJ TB PTO Throttle body Injector (PTO Side)
KS Knock Sensor
MAPTS Manifold (intake) Air Pressure / Temperature Sensor
OP Oil Pump
RER Rotax Electronic Reverse
ERF Rave Position Sensor
E-RAVE Rave Actuator
SD Starter Solenoid
TPS Throttle Position Sensor
THCM Thermocouple Module
SYSTEM DESCRIPTION The ECM features a monitoring system that self-

diagnoses its electronic components. For more
The Engine Control Module (ECM) ensures a high information, refer to DIAGNOSTIC FAULT CODES
power output with a clean combustion with prac- subsection.
tically no exhaust smoke.
Electrical power distribution is also controlled by
There are 8 main systems that are controlled by the ECM. Refer to POWER DISTRIBUTION sub-
the ECM: section.
1. E-TEC Direct fuel injection
2. Throttle body injection Engine Control Module (ECM)
3. Ignition system The ECM reads the inputs and makes computa-
4. Starting system tions by comparing them to pre-determined pa-
5. Rotax electronic reverse (RER) rameters, and sends the required control signals
6. Digitally encoded security system (D.E.S.S.) to the outputs to ensure proper engine manage-
ment.
7. Lubrication system
8. 3D RAVE
9. Fuel pump
10.Electrical accessories.
2 mmr2017-023
SYSTEM FEATURES
Throttle Protection
If the throttle is not completely closed during en-
gine startup, engine RPM will be limited to idle
speed by the ECM.
To revert to normal operation, release the throttle
completely and then depress it again.
Warm-Up Protection
The engine's RPM is limited until the desired en-
mmr2017-023-002 gine and injection oil temperatures are obtained.
ECM
WARM-UP ENGINE WARM-UP
PROTECTION TEMPERATURE
20°C to 30°C
850 E-TEC
(68°F to 86°F)
Engine Warm-Up
During the engine warm-up period, the RAVE
valves will be limited to the MID position which,
limits the engine to a maximum of 7500 ± 200
RPM.
Injection Oil Warm-Up
The injection oil warm-up period is based on oil
mmr2017-023-003
viscosity.
The ECM features a permanent memory that will This is accomplished by measuring the time it
store fault codes, customer information and other takes for the electric oil pump to complete a
engine information when the engine is stopped. stroke (oil pump switch signal) from the time
at which is was commanded. This provides an
ECM Cooling
indication of the oil viscosity, and therefore tem-
Since the ECM manages all the vehicle's power perature and flow capacity.
needs as it incorporates the voltage regulator/
This function will limit engine speed to 5500 -
rectifier and other power components, a lot of
7500 RPM depending on detected oil viscosity.
heat needs to be dissipated.
This function may remain active for up to 10 - 15
To ensure adequate heat dissipation, a constant
minutes.
fresh fuel flow from the fuel pump is used to cool
down the ECM. Automated Engine Oil Fogging (E-TEC)
An automated engine oil fogging has been imple-
mented to automatically inject the required oil to
protect the engine during vehicle storage. Refer
to STORAGE PROCEDURE subsection for details.
mmr2017-023-004
ECM COOLING (FUEL FLOW DIRECTION)
mmr2017-023 3
Subsection XX (COMMUNICATION PROTOCOLS)
COMMUNICATION PROTOCOLS
CAN HI WH/BG
CAN LO WH/BK
ECMB C1 C2 THCM 1 2 COM 1 2 MG 23 24
B A
mmr2017-024-001
COM (Diagnostic connector)

ECM (Engine control module)
MG (Multifunction gauge)
THCM (Thermocouple module)
WH/BG (White/beige)
WH/BK (White/black)
mmr2017-024 1
Subsection XX (COMMUNICATION PROTOCOLS)
GENERAL
CONTROLLER AREA NETWORK
(CAN)
The CAN protocol is an ISO standard for serial data
communication.
The ECM forms a network with other components
linked with the CAN bus.
The CAN bus (or CAN lines) consist of a pair of
wires (WHITE/BEIGE and WHITE/BLACK) that
connect every component to each other. The
electronic modules are in constant communica-
tion within the network.
There are resistors on the CAN lines in the ECM,
multifunction gauge and the thermocouple mod-
ule.
CAN network resistance can be measured from
the COM connector pins.
TROUBLESHOOTING
CAN COMMUNICATION
PROBLEMS
1. Measure CAN network resistance from the
COM connector pins.
2. Disconnect modules one by one and observe
change in network resistance to find network
communication fault.
NOTE: Disconnect THCM last.
CAN NETWORK RESISTANCE
CONDITION SPECIFICATION ± 10%
Good network
or 60
THCM fault
ECM
or 120
MG network fault
ECM
and above 1 M
MG network fault
ECM, MG, and THCM
O.L.
network fault
1M = 1,000,000
If the resistance does not vary when a module is

unplugged ensure wiring harness and pins are in
good condition before replacing a module.
NOTE: There is no resistor in the COM connector.
2 mmr2017-024
Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.)
COMMUNICATION TOOLS AND

B.U.D.S.
SERVICE TOOLS
12 V BATTERY SUPPLY CABLE .................................................... 529 035 997 ............................................. 2
DIAGNOSTIC CABLE .................................................................... 710 000 851 ............................................. 2
POWER INTERFACE ..................................................................... 515 177 223 ............................................. 2
GENERAL
Use BUDS2.
Refer to the B.U.D.S. directory on KNOWLEDGE
CENTER for all BUDS related information, includ-
ing:
– Current version download link
– User manual (programming keys, reading fault vdd2006-001-151_b
codes, writing data to modules etc.) MPI-2 CARD
– Installation instructions
– Navigation through menus
– BRP BUDS chart
Search keyword: "BUDS". USB
CAN
mmr2017-025-001
vmr2016-128-001_a
TROUBLESHOOTING MPI-3 CARD
Refer to the BRP BUDS chart to ensure you are Prerequisite for USB Communication:
using the approriate hardware and tools.
– PC Computer turned ON
– MPI connected to PC computer.
COMMUNICATION PROBLEMS
COMMUNICATION PROBLEM (USB)
MPI Connection Troubleshooting
STATUS WHAT TO DO
MPI Status Lights
– Check USB connection between MPI-2
The MPI includes 2 status lights to show the con- USB
and PC computer.
nection conditions: USB and CAN. Both lights Light is
OFF – Check USB operation on PC computer
must be GREEN for the MPI to function properly. (hardware or Windows drivers).
Otherwise, refer to the following charts.
USB – Connections are GOOD.

Light is Communication can take place on
GREEN USB side.
Prerequisite for CAN Communication:

1. MPI connected to diagnostic connector.
mmr2017-025 1
Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.)
2. The tether cord cap (D.E.S.S. key) is installed Power Interface Test
on the engine cut-off switch and pull the emer- When the POWER INTERFACE (P/N 515 177 223) is
gency stop switch. connected to the vehicle diagnostic connector and
3. B.U.D.S. started and logged. the emergency stop switch is pulled, the multi-
4. ECM is powered. function gauge and the headlight should turn on.
Otherwise, check the following and repair or re-
place Power interface if any test failed.
1. Set the emergency stop switch to run position.
2. Power interface fuses.
mmr2013-024-206_a
1. Fuse 1
2. Fuse 2
mmr2013-024-002_a
1. MPI Interface carn 3. External battery voltage should be displayed on

2. DIAGNOSTIC CABLE (P/N 710 000 851) Power interface (primary voltage if engine run-
3. POWER INTERFACE (P/N 515 177 223)
4. To vehicle diagnostic connector ning).
5. 12 V BATTERY SUPPLY CABLE (P/N 529 035 997) 3.1 Ensure battery charge is high enough to
6. To 12 V battery
keep the vehicle ON for the duration of the
NOTE: The battery supply cable is only necessary maintenance.
on models without a battery. NOTE: This is especially IMPORTANT if you
COMMUNICATION PROBLEM (CAN) are updating vehicle software. In case of
doubt, charge battery for at least 15 min-
STATUS WHAT TO DO utes; disconnect charger prior to updating
– B.U.D.S. does not communicate with software.
the vehicle.
– Check connections from computer to
vehicle.
CAN
Light is – Check if B.U.D.S. is started.
OFF – Check if vehicle is powered: is cluster
turned ON. If it is not ON, install the
tether cord cap (D.E.S.S. key) on the
engine cut-off switch and pull the
emergency stop switch.
This occurs when B.U.D.S. looses
communication with vehicle.
– Check connections from computer to
CAN vehicle.
Light is – Check if vehicle is powered: is cluster
RED turned ON? If not, install the tether
cord cap (D.E.S.S. key) on the engine
cut-off switch and pull the emergency
stop switch.
CAN – Connections are GOOD.
Light is B.U.D.S. communicates normally
GREEN with the vehicle.
2 mmr2017-025
Subsection XX (DIAGNOSTIC AND FAULT CODES)
DIAGNOSTIC AND FAULT CODES

GENERAL
MONITORING SYSTEM
The ECM features a monitoring system that self-
diagnose its electronic components.
When a predefined condition (engine overheat for
example) or a fault occurs, the ECM sends a signal
to the multifunction gauge and/or audible signals
to a beeper to inform you of this particular condi-
tion.
The ECM monitors the following functions and
components.
COMPONENT
ECM, TPS, CTS, CPS, KS, RAVE valve solenoids,
MAPTS, RPS, ignition coils, fuel injectors and THCM
(EGTSm and EGTStp)
12 volts under/over voltage
60 volts under/over voltage
D.E.S.S.
RER
Low oil level, electronic oil injection pump
Oil temperature (end of piston stroke feedback from
electronic oil injection pump )
Engine RPM
CAN
Fuel pump
Limp Home Mode

The ECM may automatically set default parame-
ters to ensure the adequate operation of the ve-
hicle if a component of the engine management
system is not operating properly.
NOTE: Sensor failures will not automatically re-
sult in limp home mode. The appropriate fault
code will turn on and in some cases the beeper
will sound.
The engine RPM may be limited if some critical
components fail. In this case, releasing the throt-
tle and letting the engine return to idle speed may
allow normal operation to come back. If it does
not, try removing and reinstalling the tether cord
cap (D.E.S.S. key) on the engine cut-off switch.
These performance-reduced modes allow the
rider to continue on to seek help, or return home,
which would otherwise not be possible.
mmr2017-026 1
ECM ACTION CAUSE

Fuel pump wiring short circuit to ground or open
circuit.
Engine is gradually stopped. Fuel pump current requirement is too high.
Engine idle overheat protection:
Continuous fast short beeps and a shutdown message
is displayed in multifunction gauge until shutdown. – Engine idled more than 5 seconds after engine
temperature increased above 95°C (203°F).
– Engine idled more than 5 minutes after engine
temperature increased above 37°C (99°F).
D.E.S.S. key is not recognized by the ECM.
Engine speed is limited to 2500 RPM. The antitheft system is active.
RAVE valves are kept at closed position.
Oil injection pump wiring shorted to ground or open
circuit.
Low voltage in the 55 Vdc system. Voltage dropped
by 5 V.
Engine speed is limited to 5500 RPM ECM overheat (85°C (185°F)).
(RAVE valves are kept closed).
Engine overheat (100°C (212°F) and above).
Exhaust gas temperature too high (800°C (1,472°F)
and above).
High engine detonation.
Max. RPM allowed to the engine in reverse.
Engine speed is limited to 7000 RPM.
RAVE valves are kept closed.
Max. RPM allowed varies when engine is cold,
Engine speed is limited (Variable limit)
according to oil viscosity
Engine speed is limited to 8600 RPM. Maximum engine RPM allowed.
Pilot Lamps and Beep Codes IMPORTANT: After a problem has been solved,
Warning lights in the multifunction gauge and/or be sure to clear the fault(s) in the ECM using the
a beeper provide signals as to a vehicle operation BUDS2 software. This will properly reset their
feedback, or to indicate a problem. states.
A pilot lamp can flash alone or in combination with How to Read Fault Codes Using
another lamp. BUDS2 Software
Beeper codes will be heard and messages (de- Refer to COMMUNICATION TOOLS AND
pending on gauge model) will be displayed to at- B.U.D.S. subsection.
tract your attention and inform you of the situa-
tion. For more information pertaining to the faults code
status and report, refer to B.U.D.S. online help.
DIAGNOSTIC FAULT CODES How to Read Fault Codes on the
(DTC) Multifunction Gauge
A fault code is an indication that a glitch or mal- Same gauges can display fault codes.. Refer to
function is detected by the monitoring system of the applicable GAUGE subsection.
the vehicle.
When there is a problem, the ECM can provide
How to Find Fault Code Descriptions
fault codes to ease troubleshooting. Connect BUDS2 to the vehicle. Refer to COM-
MUNICATION TOOLS AND BUDS subsection.
The faults registered in the ECM are stored in
memory. Navigate to the faults page in BUDS2.
2 mmr2017-026
Browse lists of active/occurred and inactive fault

codes.
mmr2017-026 3
Subsection XX (FUEL TANK AND FUEL PUMP)
FUEL TANK AND FUEL PUMP

SERVICE TOOLS
LEAK TEST KIT .............................................................................. 529 033 100 ............................................. 6
OETIKER PLIER ............................................................................. 295 000 070 ............................................. 9
PRESSURE GAUGE....................................................................... 529 036 395 ......................................... 7–8
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ......................................... 6–7
mmr2017-027 1
NEW 1 ± 0.2 N•m

(9 ± 2 lbf•in)
NEW
10 ± 2 N•m
(89 ± 18 lbf•in)
NEW
3.5 ± 0.5 N•m

(31 ± 4 lbf•in)
NEW
NEW
NEW
NEW
5 ± 0.5 N•m
(44 ± 4 lbf•in) NEW
3.5 ± 0.5 N•m

(31 ± 4 lbf•in)
3.5 ± 0.5 N•m
(31 ± 4 lbf•in)
NEW
NEW

tmr2017-027-305_a
2 mmr2017-027
GENERAL
NOTE: It is a good practice to check for fault 1
codes using the BRP diagnostic software BUDS2
as a first troubleshooting step. Refer to DIAG-
NOSTIC AND FAULT CODES.
WARNING
prior to:
– Removing a spark plug cable or spark plug. 2
pors may ignite in presence of a spark creat- tmr2017-027-306_a
ing a fire hazard. 1. Fuel pressure regulator

2. Fuel hose connector
When disconnecting a fuel line, cover the con-

nection with an absorbent shop rag and proceed SYSTEM DESCRIPTION
slowly to minimize spilling. Electric Fuel Pump
WARNING
Do not allow fuel to spill on hot engine parts
and/or on electrical connectors. Wipe off
any fuel spillage in the engine compartment.
Fuel is flammable and explosive under cer-
tain conditions.
WARNING
After working on the fuel system, always
carry out a fuel system pressurization test to
check for leaks.
WARNING mmr2017-027-002
Never remove the eyelet connectors from the An electric fuel pump is mounted in the front cen-
fuel pressure regulator and the fuel hose con- ter portion of the fuel tank.
nector. A bad connection may create a static A 12 Vdc high pressure fuel pump with an inte-
electricity discharge causing a fire hazard. grated jet pump is used.
NOTE: Although the fuel pump is connected
to the 55 Vdc system, the ECM modulates the
voltage (Pulse Width Modulation) between 9 and
16 Vdc depending on the engine RPM. The fuel
pump output will change as voltage changes.
As soon as the engine is cranking, the electric fuel
pump turns on in preparation for the engine start.
When the engine runs, the fuel pump is ON con-
tinuously to provide a constant fuel pressure to
the injectors.
To ensure a constant delivery of fuel to the engine
for all riding conditions when the fuel level is low,
a rear pickup and a fuel pump reservoir is used.
mmr2017-027 3
The fuel pump reservoir is actually the housing of

the fuel pump module in which the fuel pump is lo-
cated. A check valve at the bottom of the housing
allows the fuel in the tank to enter the fuel pump
reservoir.
mmr2017-027-005
1. Remote pickup
When riding the vehicle on a level surface, fuel en-

ters into the fuel pump reservoir through its check
valve and through the remote pickup simultane-
ously, as long as there is enough fuel in the tank
mmr2017-027-003
to cover the remote pickup.
When the fuel pump runs, it draws the fuel from When riding downhill with a low amount of fuel
the fuel pump reservoir and feeds it to the injec- in the tank, the fuel moves towards the front of
tion system. This causes fuel in the tank to enter fuel tank. The fuel enters the fuel pump reservoir
the fuel pump reservoir, by gravity, through its bot- through the check valve only as there is no fuel at
tom inlet check valve. the remote pickup.
At the same time, a portion of the fuel flow from When riding uphill with a low amount of fuel in the
the electric fuel pump flows through a jet pump tank, the fuel moves towards the rear of the fuel
that contains a venturi. tank. The check valve closes and traps the fuel in
the pump reservoir. The fuel pump continues to
draw fuel from the fuel pump reservoir, which is
now only fed by the jet pump using the remote
pickup. This prevents air from being drawn into
the fuel lines from the fuel tank.
The continuous fuel flow cools down the fuel
pump, the injectors and the ECM. To cool these
components, the fuel circulates as follows:
– Out of fuel pump
– Through the ECM
– To the direct injectors (around the voice coils)
– Through the pressure regulator
mmr2017-027-004
– Back to fuel tank.
TYPICAL - VIEW INSIDE FUEL PUMP RESERVOIR
1. Fuel pump reservoir
2. Bottom inlet
3. Check valve (open upwards)
As the fuel accelerates through the venturi, it

generates a low pressure area at a connection to
the remote pickup, which draws fuel into the fuel
pump reservoir from the remote pickup.
mmr2017-027-050
4 mmr2017-027
Fuel Pickup As fuel is consumed by the engine, a negative

Fuel enters the fuel pump reservoir from either a pressure would occur in the fuel tank. This could
check valve at the bottom of the fuel pump reser- eventually prevent the fuel pump from drawing
voir, or from a remote pickup in the rear portion of enough fuel. The negative pressure relieve
the fuel tank. function of the valve allows the higher outside
air pressure in.
If pressure builds up and exceeds
2.0 kPa to 4.8 kPa (.3 PSI to .7 PSI) in the
fuel tank, the check valve opens and lets the
excess pressure vent out of the tank.
Fuel Filters
Fuel Pump Pre-Filter
A fuel pump pre-filter is used at the electric fuel
pump inlet. It is a replaceable nylon mesh filter
located within the fuel pump module housing (fuel
pump reservoir).
mmr2017-027-006
1. Remote pickup
Fuel Pressure Regulator

An integrated fuel pressure regulator is mounted
on the fuel pump flange. It is basically a spring
loaded valve that opens and closes the path of fuel
returning to the tank, thus maintaining a constant
fuel pressure in the system. mmr2017-027-011
The fuel pump pre-filter protects the fuel pump

and prevents clogging of the fuel passages within
the fuel pump module.
In-Line Fuel Filter
mmr2017-027-007
FUEL PRESSURE
Approximately 303 kPa (44 PSI) at 2000 RPM
(will be lower at idle)
mmr2017-027-008
Fuel pressure should drop less than 35 kPa (5 PSI)

when engine stops running. An in-line filter on the supply side is located be-
tween the fuel pump and the ECM.
If a leak is present, pressure will continue to drop
within the first minute after engine stops running. It is a replaceable metallic canister type filter used
to deliver dirt-free fuel to the injectors.
Fuel Tank Vent
The fuel tank is vented through a combination
type check valve that allows ambient air pressure
to enter fuel tank at all times.
mmr2017-027 5
Fuel Level Indication
mmr2017-027-010
4. Install the appropriate test cap from the LEAK

mmr2017-027-009
TEST KIT (P/N 529 033 100) on fuel tank inlet.
A float type fuel level sensor varies its resistance
with fuel level thus providing a signal to the mul-
tifunction gauge for fuel level indication.
INSPECTION
TESTING FUEL SYSTEM FOR
LEAKS 529033100
Activate the fuel pump from the Functions page 5. Install VACUUM/PRESSURE PUMP (P/N 529 021
in BUDS2. 800) on pressure test fuel cap.
Check for fuel leaks.
WARNING
After working on the fuel system, carry out
a fuel system pressurization test to check for
leaks. Failure to carry out a fuel system pres-
surization test could result in severe injury or
a life threatening situation should a leak oc-
cur.
FUEL TANK LEAK TEST

1. Fill up fuel tank. 529021800
2. Open the left side panel to access the fuel vent

tube.
3. Install a SMALL HOSE PINCHER (P/N 295 000 076)
on the vent tube.
295000076
6 mmr2017-027
mbg2008-011-063_b
mmr2008-030-002_a
TYPICAL
1. Pressure test fuel cap TYPICAL - VACUUM/PRESSURE PUMP ON VENT TUBE
2. Vacuum/pressure pump
NOTE: If fuel vent check valve does not function
6. Set pump selector to pressure. as indicated in test, replace vent valve.
7. Pressurize fuel tank as follows. 8. Remove vacuum/pressure pump.
PRESSURE
TIME WITHOUT 9. Install vent tube on its fitting.
PRESSURE DROP
10. Install normal fuel tank cap.
21 kPa (3 PSI) 3 minutes
TESTING FUEL PRESSURE
If pressure drops, locate fuel leak(s) and repair or
replace leaking component(s). REQUIRED TOOLS
To ease locating leak(s), spray soapy water on
components; bubbles will indicate leak loca-
tion(s).
PRESSURE GAUGE
Fuel Tank Vent Valve Test (P/N 529 036 395)
1. While the fuel tank is still pressurized as in the
previous test, carry out the following:
2. Place a finger over the vent hose outlet.
3. When removing hose pincher, alternately touch Open right hand side panel.
and release vent hose outlet. You should feel Move rewind starter handle assembly (applicable
pressurized air flowing out indicating the pres- models).
sure relief valve function is working.
4. Release any remaining pressure in the fuel tank
by slowly unscrewing fuel tank cap.
5. Remove the pressure test fuel cap.
6. Remove the fuel tank vent tube from its fitting
on the lower left front body panel.
7. Install the VACUUM/PRESSURE PUMP (P/N 529
021 800) on the vent tube and apply air pressure
through the vent valve. Air must flow freely to-
wards the fuel tank neck.
mmr2017-027-050_a
mmr2017-027 7
The pressure test provides an indication of the FUEL PRESSURE TROUBLESHOOTING

available fuel pressure at the fuel pump outlet.
It validates the pressure regulator and the fuel RESULT POSSIBLE CAUSE
pump. Pressure above
Defective fuel regulator
1. Ensure there is enough gas in fuel tank. specifications
2. Install a rag under the ECM hose quick connect Clogged fuel filter
to catch fuel spillage. Poor electrical
3. Disconnect fuel pressure hose from ECM. connection
Pressure below
Defective fuel regulator
specifications
Defective fuel pump
Leak in the fuel system
circuit
7. Stop engine.
Fuel pressure should remain stable.
8. If fuel pressure drops, check the following for
leaks:
– Tools
– Hoses
mmr2017-027-001 – Fuel injectors
4. Install the PRESSURE GAUGE (P/N 529 036 395) – Fuel pressure regulator
between fuel pressure hose and ECM. – Fuel pump.
9. Bleed away any remaining fuel in the pressure
WARNING gauge and fuel hose adapter using the bleed
When carrying out pressure test, ensure fuel valve on the fuel hose adapter.
is not leaking from test equipment onto hot 10. Remove pressure gauge and fuel hose
exhaust system or electrical components. adapter.
Ensure fuel hose do not come into contact
11. Reinstall the fuel pressure hose on ECM and
with hot engine parts or hot exhaust system.
gently but firmly pull on hose to ensure quick
disconnect fitting is properly locked and se-
5. Start engine. cure on the ECM.
6. Run engine above 2000 RPM and observe the 12. Reinstall all remaining removed parts.
fuel pressure.
FUEL PRESSURE
303 kPa (44 PSI)
If pressure is lower than specified, momentarily

block the return hose while monitoring the pres-
sure gauge.
NOTICE Do not block the fuel return for more
than 2 seconds.
If pressure rises to reach or exceed specification
with the fuel return blocked, replace fuel regulator.
If pressure does not rise with the fuel return
blocked, refer to PRESSURE BELOW SPECIFI-
CATIONS in the following table.
8 mmr2017-027
PROCEDURES Replacing Oetiker Clamps
FUEL HOSE AND OETIKER

CLAMPS
Replacing Fuel Hoses
mmr2017-027-012
REQUIRED TOOL
OETIKER PLIER
(P/N 295 000 070)
mmr2017-027-013
TYPICAL PRE-FORMED FUEL HOSE
When replacing fuel hoses, be sure to use hoses WARNING

as available from BRP parts department. This will Whenever removing a hose in the fuel sys-
ensure continued proper and safe operation. tem, always use new Oetiker clamps at as-
sembly.
WARNING
Use of fuel lines other than those recom- FUEL TANK
mended by BRP may compromise fuel sys-
tem integrity. Removing the Fuel Tank
1. Remove seat.
WARNING
– Never use a hose pincher on high pressure
hoses.
– Never change the routing of a fuel hose.
– Always reinstall the corrugated protective
tubing on fuel hoses.
– Secure fuel hoses using the appropriate
locking tie or fastener to prevent contact
with sharp edges or hot, rotating and mov-
ing parts.
– After connecting a hose or a quick connect
fitting, pull on the hose near the fitting to
mmr2017-027-014
make sure it is securely locked.
– Always validate fuel system tightness by 2. Remove glove box.
performing a FUEL SYSTEM PRESSURIZA-
TION AND LEAK TEST.
mmr2017-027 9
mmr2017-027-015 mmr2017-027-018
3. Remove cluster and trim. 6. Remove battery cover and battery, if applicable.
mmr2017-027-016 mmr2017-027-019
4. Remove console. 7. Remove pyramidal structure.
mmr2017-027-020
8. Remove fuel tank retaining screws.
mmr2017-027-017
5. Remove tank cover.
10 mmr2017-027
mmr2017-027-021 mmr2017-027-024
9. Remove fuel tank vent. 12. Remove fuel tank.
Installing the Fuel Tank

Reverse removal procedure.
Pressurize and test fuel system for leaks.
FUEL PUMP
Relieving Fuel Pressure
1. Connect vehicle to BUDS2, refer to the COM-
MUNICATION TOOLS AND B.U.D.S. subsec-
tion.
2. From the Functions page, relieve fuel pres-
mmr2017-027-022
sure.
10. Remove fuel pump electrical connector.
Activating the Fuel Pump with
B.U.D.S.
NOTE: Activating the fuel pump as described in
this procedure can be used for purging air from
the fuel system whenever a fuel hose has been
disconnected and reconnected. The pump should
be activated for 15 seconds to ensure proper purg-
ing of the system.
1. Connect vehicle to BUDS2 software, refer to
COMMUNICATION TOOLS AND B.U.D.S. sub-
section.
2. From the Functions page, activate the fuel
mmr2017-027-023
pump.
3. Listen for fuel pump operation.
11. Remove fuel hoses from pump.
If you do not hear the pump come ON, select the
Faults tab in BUDS2 and check for fault codes.
If there is no fault code, connect a known good
fuel pump to the vehicle harness (in parallel) and
repeat the test.
NOTE: No voltage test can be done when the fuel
pump is disconnected.
If the second fuel pump functions when con-
nected to the vehicle harness, then replace the
fuel pump installed in the vehicle.
mmr2017-027 11
Removing the Fuel Pump WARNING

1. Remove the fuel tank. After working on the fuel system, carry out
2. Remove fuel pump assembly snap ring from a fuel system pressurization test to check
fuel tank. for leaks. Failure to carry out a fuel system
leak test could result in severe injury or a life
threatening situation should a leak occur.
FUEL PUMP INLET FILTER

Replacing the Fuel Pump Inlet Filter
1. Remove fuel pump assembly from fuel tank.
Refer to procedure in this subsection.
2. Free the wires of the fuel level sensor of the
fuel pump reservoir.
NOTICE Do not pull / push on wires or metal
mmr2017-027-026
terminals that connect the grounding wires to
the plastic parts. Keep hands and tools away
3. Remove and discard fuel pump gasket. from this area.
mmr2017-027-300_a
mmr2017-027-027
4. Visually inspect for broken or damaged ground 3. Unlock fuel pump reservoir by carefully insert-
wires, if any issue are found, the module should ing a small screwdriver between the tab and the
be replaced. fuel pump reservoir.
NOTICE Do not push directly on tabs or twist
Installing the Fuel Pump the screwdriver.
For installation, reverse the removal procedure
however, pay attention to the following.
Make sure the remote pick-up is inserted all the
way to the rear of fuel tank and does not interfere
with the fuel level sensor float.
Install a NEW gasket on the fuel pump prior to
installing the pump in the tank.
Ensure the fuel pump snap ring is fully engaged
with the gap on top. Refer to image in removal
procedure.
NOTE: The gasket must be installed on the fuel
tank side so it is located between the pump and
the fuel tank.
Install fuel tank.
12 mmr2017-027
mmr2017-027-302_a
6. Discard inlet fuel pump filter and steel ring.

7. Install new fuel pump inlet filter.
7.1 Insert inlet filter onto fuel pump by press-
ing it downward.
7.2 Push the filter on until the fitting bottoms
out on the pump inlet face, there should
be no gap.
tmr2017-027-307_a
4. Completely remove fuel pump reservoir by

pulling it carefully.
mmr2017-027-600_a
1. No gap here
7.3 Ensure that the filter hole is properly posi-

tioned into the pin.
mmr2017-027-031
NOTICE To avoid damaging wires, Pull the

reservoir carefully and do not let reservoir 1
hang by wires.
5. Remove inlet fuel pump filter by pulling on it. If
the filter is hard to remove, pry the filter gently
using a small screwdriver.
NOTICE Be careful to avoid scratching the
outside diameter of the pump inlet fitting
where the filter fits.
mmr2017-027-303_a
1. Pin
mmr2017-027 13
8. Install fuel pump reservoir carefully and ensure 9. Ensure that fuel tank reservoir tabs are properly
that all parts are properly positioned. locked.
10. Route the fuel level sensor wires properly.
mmr2017-027-300_a
mmr2017-027-700_a 11. Reinstall fuel pump in fuel tank. Refer to pro-

ELECTRICAL CONNECTOR MUST BE IN THIS POSITION cedure in this subsection.
NOTE: Make sure the pump motor is positioned
between the molded ribs in the reservoir.
FUEL LEVEL SENSOR
NOTE: Verify the gauge functions related to the
fuel level sensor before testing the sensor. Refer
to GAUGE subsection.
Measuring Fuel Level Sensor

Resistance with BUDS2
1. Connect vehicle to BUDS2.
2. Select the Measurements page.
3. Monitor the fuel level sensor resistance under
Fuel Level and compare to the table below.
FUEL LEVEL SENSOR RESISTANCE TABLE
Full level
9 ± 2
resistance value
Empty level
mmr2017-027-702_a 95 ±5
resistance value
1. Fuel pump motor
2. Reservoir
3. Ribs If resistance is within specifications, the fuel level
sensor, and wiring are ok.
If resistance is not within specifications, measure
resistance at the fuel pump connector (FP). Refer
to TESTING FUEL LEVEL SENSOR RESISTANCE
Testing Fuel Level Sensor Resistance

1. Remove fuel pump from fuel tank, refer to
FUEL PUMP in this subsection.
2. Ensure the fuel level sensor is properly con-
nected in the fuel pump module.
3. Measure the resistance at the fuel pump con-
mmr2017-027-304_a nector (FP).
14 mmr2017-027
FUEL LEVEL SENSOR BENCH TEST

FLOAT
PROBE RESISTANCE
POSITION
FP- B to Empty 95 ±5
FP-D Full 9 ±2
mmr2017-027-038
3. Slide the potentiometer out of the fuel pump

reservoir.
mmr2017-027-037
TYPICAL FUEL PUMP FLOAT

1. Full position
2. Empty position
4. When fuel level sensor travels from full to

empty or vice-versa, there should be a con-
stant linearity to the resistance readings. Any
spike or drop of resistance indicates a "flat
spot" in the fuel level sensor circuitry.
mmr2017-027-039
If fuel level sensor fails bench test, replace the
fuel level sensor. 4. Remove fuel level sensor.
5. Replace the fuel level sensor with a new one
Replacing the Fuel Level Sensor and reverse steps.
1. Remove the fuel pump.
mmr2017-027-040
2. Disconnect fuel level sensor connector.
mmr2017-027 15
Subsection XX (E-TEC DIRECT FUEL INJECTION)
E-TEC DIRECT FUEL INJECTION

SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ................... 20, 30–33, 36–37
EXTRACTOR ADAPTOR................................................................ 529 036 136 ........................................... 14
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................... 12, 20, 32–34, 36
OETIKER PLIER ............................................................................. 295 000 070 ............................................. 6
SMALL HOSE PINCHER ............................................................... 295 000 076 ........................................... 27

SNAP-ON HAMMER ..................................................................... CJ125-6 ........................................... 14
SNAP-ON SCREW ......................................................................... CJ93-1 ........................................... 14
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................... 293 550 004 ..................................... 18, 34
GENERAL WARNING
When testing electrical systems, the emergency Perform a fuel pressure test each time a
stop switch must always be in the RUN position component from the fuel system is removed.
unless otherwise mentioned, or test is performed Prior to starting the engine when a fuel hose
while cranking engine. was disconnected or a fuel injector removed:
– Ensure all fuel lines are properly con-
WARNING nected.
Always disconnect the magneto connector – Inspect engine compartment to detect any
prior to: fuel leakage or an abnormally strong fuel
– Disconnecting any fuel hose. odor which may be an indication of a fuel
leak that is not readily visible.
– Removing a spark plug cable or spark plug.
Otherwise, fuel vapors may ignite in pres- SYSTEM DESCRIPTION
ence of a spark creating a fire hazard. The ECM reads the input signals from different
sensors which indicate engine operating condi-
WARNING tions at micro-second intervals.
The fuel system is under high pressure. Pro- The ECM calculates the proper air/fuel ratio and
ceed with care when working on the fuel sys- activates the output to fuel injectors.
tem. Wear safety glasses and work in a well Signals from sensors are used by the ECM to de-
ventilated area. termine the injection parameters (fuel maps re-
quired for optimum air-fuel ratio).
Release fuel system pressure prior to removing
fuel system components. Refer to FUEL TANK The crankshaft position sensor (CPS), the throt-
REMOVAL in FUEL TANK AND FUEL PUMP sub- tle position sensor (TPS) are the primary sensors
section. used to control the injection. Other sensors (like
temperature sensors, etc.) are used as secondary
input.
mmr2017-028 1
Air Induction
1. Idle ports
Since there is a constant airflow through the idle

1. Primary air intake silencer
2. Secondary air intake silencer ports of the throttle plates, the idle speed is con-
3. MAPTS trolled by the ECM by varying the amount of fuel
injected in the combustion chamber and by con-
Air flows through a mesh filter in the secondary
trolling the injection timing.
air intake silencer mounted on top of engine. The
mesh filter prevents snow from being drawn into The TPS (Throttle Position Sensor) is fitted on the
the engine. throttle body. The TPS sends throttle angle posi-
tion to the ECM.
Air pressure and temperature is measured in the
secondary air intake silencer by the Manifold Ab- Engine coolant flows through the throttle body to
solute Air and Temperature Sensor (MAPTS). prevent potential freezing of throttle plates due to
the temperature drop naturally created by the ven-
Air then flows through the primary air intake si-
turi.
lencer.
Air is then drawn in through a dual throttle body
mounted on the engine intake side.
Throttle Body
mmr2017-028-103
The air then continues through the reed valves

into the cylinder base then into the crankcase.
Fuel Injectors
mmr2017-028-001_b Each cylinder is supplied with fuel by a fuel injec-
1. Throttle body tor on the top of the cylinder (high pressure direct
2. TPS (Throttle Position Sensor)
3. Throttle body injectors ETEC injectors) and a fuel injector on the throttle
body (throttle body injectors).
A dual throttle body assembly is directly mounted
on the intake flange of each cylinder (52 mm
(2.05 in)).
The air flow is controlled by two throttle plates.
Each throttle plate has a 6.8 mm (.268 in) idle port
in it.
2 mmr2017-028
High Pressure Direct E-TEC Injectors
mmr2009-019-021_a
mmr2017-028-104 FUEL INJECTOR CLOSED
DIRECT INJECTORS 1. Voice coil
The fuel injectors are powered from the 55 Vdc When a positive current is supplied to the coil
system. by the ECM, the fuel injector plunger moves to-
One fuel injector per cylinder is used. wards the spring loaded injector needle. As the
injector plunger moves, this builds up a pressure
The E-TEC fuel injector is mounted directly on top in the fuel injector chamber. When the pressure
of the cylinder head. reaches approximately 1724 kPa (250 PSI), the in-
jector needle spring is overcome and the needle
opens. Fuel injection then takes place while the
pressure peaks at 3103 kPa (450 PSI).
mmr2017-028-106
The fuel injector achieves a direct injection right

into the combustion chamber. This keeps the pis-
ton cooler with less fuel.
mmr2009-019-022_a
A voice coil type is used to open and close the fuel FUEL INJECTOR OPENED
injector nozzle. This allows for quick operation of 1. Voice coil
the fuel injector; opening stage as well as the clos-
Swirl channels are used in the fuel injector to bet-
ing stage. This results in the ability to operate the
ter atomize the fuel charge.
engine at a higher RPM and lowers unburned fuel
to the exhaust port. The quantity of injected fuel is controlled by vary-
ing the injector plunger stroke.
To bring the injector plunger backward to its rest
position, the current is reversed and the return
springs close the injector needle and plunger.
Near the end of the return stroke, a brief positive
current is applied to “brake” the injector plunger.
This results in a quieter operation of the fuel
injectors.
mmr2017-028 3
The fuel injectors provide a stratified fuel charge The fuel injectors are supplied with fuel by the fuel
to the combustion chamber up to clutch engage- rail. The fuel rail ensures all times that enough
ment speed. Beyond this RPM, the fuel charge fuel at the right pressure can be delivered to the
becomes homogeneous. fuel injectors. The fuel rail is fed by the fuel pump
The stratified fuel charge provides a cleaner com- module.
bustion, better idling and less smoke.
Fuel is used to maintain proper fuel injector oper- ADJUSTMENT
ating temperature.
The flow starts from the fuel pump, through the
IDLE SPEED
ECM, then around the voice coil inside the fuel Idle speed is controlled by the ECM and is not ad-
injector housings to cool down the fuel injector justable with an idle screw.
components. If idle speed is not as per specification (refer
Fuel enters the inlet port located at the bottom to TECHNICAL SPECIFICATIONS), perform the
of the fuel injector housing and exits through the CLOSED THROTTLE RESET (TPS).
outlet port on top of the fuel injector.
RESETTING CLOSED THROTTLE
VALUE (TPS)
General Information
This operation performs a reset of the TPS (throt-
tle position sensor) values in the ECM when the
throttle is closed. This reset is very important as
the setting of the TPS will determine the basic pa-
rameters for all fuel mapping and several ECM cal-
culations for idle speed control of the engine.
NOTICE An improperly set TPS may lead to
poor engine performance.
mmr2017-028-125
Throttle Body Injectors Verifying TPS Closed Throttle Value

The fuel injectors are mounted directly on top of 1. Connect vehicle to BUDS2. Refer to COMMU-
the throttle body. NICATION TOOLS AND B.U.D.S. subsection.
2. In BUDS2, navigate to the Measurements
page.
3. Ensure throttle cable is properly adjusted, refer
to ADJUSTING THROTTLE CABLE in this sub-
section.
4. Look for the throttle opening value .
NOTE: The Throttle Opening indication must be
within the following specification.
THROTTLE OPENING
TEMPERATURE
SPECIFICATION
(0 % ± 0.2) Above 5°C (41°F)
mmr2017-028-001_a If the throttle opening is within the % specifica-

tion, DO NOT reset the closed throttle value un-
Fuel injectors are used to inject fuel into the trans- less the following parts were replaced:
fer port of the cylinder. One injector is used per – Engine control module (ECM)
cylinder.
– Throttle body
– Throttle position sensor (TPS).
4 mmr2017-028
If TPS is not within specification, reset the closed Crankshaft Position Sensor (CPS)
throttle value. Confirm that ECM receives the CPS signal. Re-
fer to CRANKSHAFT POSITION SENSOR (CPS) in
Resetting the Closed Throttle Value this subsection.
NOTICE Proper throttle cable adjustment
must be verified before proceeding. Electrical System
It is important to check that the electrical system
1. In BUDS2, navigate to the Settings page. is functioning properly:
2. Confirm the Actual TPS Voltage is within spec- – 55V system voltage
ification. – Capacitor (refer to CHARGING SYSTEM)
ACTUAL TPS VOLTAGE SPECIFICATION – Ground connections
0.3 to 0.7 Volts – Wiring and connectors.
Ensure that all electronic components are original
NOTE: If the Actual TPS Voltage is out of specifi- BRP recommended components.
cation, the TPS cannot be reset. The cause must Any modification to the wiring harness may lead
be found. See TROUBLESHOOTING ACTUAL to fault codes or bad operation.
TPS VOLTAGE OUT OF RANGE.
Always refer to the wiring diagram when diagnos-
3. Press on the Reset button. ing an electrical problem.
4. Confirm Throttle Opening value indicates 0.0%.
NOTE: A throttle opening of 0.0% after reset in- WARNING
dicates the operation is successful. The EMS operates on high voltage (55 Vdc),
be careful to avoid electrical shocks.
Troubleshooting Actual TPS Voltage
Out of Range WARNING
If the Actual TPS Voltage is out of specification, All electrical actuators (example: fuel injec-
check the following. tors, fuel pump, ignition coils and electronic
– Fault codes related to TPS oil injection pump) are powered as soon as
– Throttle cable adjustment engine is cranked when the emergency en-
– TPS properly installed gine stop switch is at the RUN position.
– TPS connector and terminal condition.
Electrical Connections
TROUBLESHOOTING Pay particular attention to ensure that pins are not
out of their connectors or out of shape.
DIAGNOSTIC TIPS Make sure that connections are very tight, make
good contact, are corrosion-free, and show no
Engine problems are not necessarily related to the signs of moisture. Particularly check ECM ground
injection system. connections.
It is important to ensure the mechanical integrity NOTE: Do not apply dielectric grease or other lu-
of the engine is present. bricant in the ECM connectors.
Spark Plugs Check if wiring harness shows any signs of scor-
ing.
Improper spark plug indexing may lead to engine
misfiring. Check if BRP spark plugs are installed or Resistance Measurement
if spark plugs are properly indexed. Refer to RE- When measuring the resistance with an ohmme-
PLACING SPARK PLUGS in the PERIODIC MAIN- ter, all values are given for a temperature of 20°C
TENANCE PROCEDURES subsection. (68°F). The value of a resistor varies with the
temperature. The value for common resistor or
3D RAVE Valves windings (such as solenoid) increases as the tem-
Improper position of RAVE valves may lead to en- perature increases. However, our temperature
gine misfiring. Check RAVE valves. Refer to RAVE sensors are NTC types (Negative Temperature
subsection. Coefficient) except for the EGTS, which means
mmr2017-028 5
that the value decreases as the temperature

increases. Use the provided tables for sensor
resistive values at given temperature.
The resistive value of a temperature sensor may
test good at a certain temperature but may be de-
fective at other temperatures.
A good test is to put the sensor in a container filled
with ice and water and measure resistance. Then,
heat the water and read the resistance at different
temperatures.
PROCEDURES mmr2017-028-108
3. Pull throttle cable out of the throttle lever hous-

FUEL HOSES AND OETIKER ing.
CLAMPS
Removing and Installing Oetiker
Clamps
REQUIRED TOOL
OETIKER PLIER
(P/N 295 000 070)
Always use a shop rag when disconnecting a fuel

hose.
CAUTION Fuel system is under high pres- mmr2017-028-109
sure.
WARNING
– Never use a hose pincher on high pressure
hoses.
– Never change the routing of a fuel hose.
– Always reinstall the corrugated protective
tubing on fuel hoses.
– Secure fuel hoses using the appropriate
locking tie or fastener to prevent contact
with sharp edges or hot, rotating and mov-
ing parts.
– After connecting a hose or a quick connect mmr2017-028-110
fitting, pull on the hose near the fitting to

make sure it is securely locked. 4. Unhook cable end barrel from throttle lever and
Use of improper fuel lines could compromise remove cable.
fuel system integrity.
THROTTLE CABLE
Removing the Throttle Cable
1. Depress and hold throttle lever.
2. Pull out circlip using long nose pliers. Keep cir-
clip for re-use.
6 mmr2017-028
WARNING
Ensure proper routing of throttle cable as per
following illustrations.
mmr2017-028-111
NOTE: Take note of cable routing before removal.

5. At throttle body, fully unscrew cable lock nut.
mmr2017-028-130
CROSS-COUNTRY WITH ADJUSTABLE RISER
mmr2017-028-112
THROTTLE CABLE LOCK NUT
6. Unhook throttle cable end.

mmr2017-028-131
CROSS COUNTRY WITH FIXED RISER
mmr2017-028-114
7. Remove throttle cable. mmr2017-028-132
MOUNTAIN WITH FIXED RISER

Installing the Throttle Cable
Reverse removal procedure however, pay atten- Ensure that cable ends are properly secured in
tion to the following. their levers.
Route cable as noted prior to removal. Proceed with throttle cable adjustment.
mmr2017-028 7
Adjusting the Throttle Cable 7. Lock throttle cable adjuster lock nut.
1. Connect BUDS2. Refer to COMMUNICATION 8. Remove the 4 mm (.157 in) spacer.
TOOLS AND BUDS subsection. 9. Fully depress the throttle lever and ensure the
2. Navigate to the measurements page and mon- opening value is more than 95 % in BUDS2.
itor TPS opening % in BUDS2. 10. Ensure there is free play in the cable with the
3. Position handlebar straight and level. throttle lever at rest.
NOTICE Do not tamper with any throttle
body adjustment screws. Otherwise, throttle
body must be replaced.
NOTE: To ensure cable free play, lightly press on
throttle cable as in following illustration.
mmr2013-027-002
TYPICAL - HANDLEBAR IN STRAIGHT AHEAD POSITION
4. Insert a 4 mm (.157 in) spacer between throttle

lever and throttle lever housing.
mmr2012-033-002_a
THROTTLE CABLE FREE PLAY

1. Cable slightly loose here
11. Activate and release throttle lever 2 - 3 times

to settle throttle plate.
12. Confirm throttle plate stopper is STILL in con-
tact with master zero position screw.
mmr2017-028-134_a
5. Unlock throttle cable adjuster lock nut.

6. Adjust throttle cable until the TPS value (%) is
between 3 and 5% in BUDS2.
mmr2017-028-002_a
THROTTLE BODY MASTER ZERO POSITION

1. Master zero position screw
2. Throttle plate stopper
3. Contact here
mmr2017-028-133
1. Throttle cable adjuster lock nut 13. Readjust throttle cable if necessary.
2. Throttle cable adjuster
8 mmr2017-028
14. Inspect the throttle cable operating range with NOTICE When a fuel injector is replaced, the
BUDS2 matching calibrated file must be loaded in the
15. Reset the Closed Throttle Value, refer to pro- ECM using BUDS2 so that the ECM properly
cedure in this subsection. controls the fuel injector.
Inspecting the Throttle Cable Operating Fuel Injectors Access

Range BUDS2 1. Remove upper body module.
1. In BUDS2, navigate to the Measurements 2. Remove engine cover.
page.
2. Fully depress throttle lever and hold. Visually Inspecting Fuel Injectors
2.1 Confirm throttle opening is within specifi- 1. Visually inspect the fuel injector area.
cation.
THROTTLE OPENING SPECIFICATION
(WIDE OPEN THROTTLE)
More than 95%
3. If throttle opening is out of specification, read-

just as follows.
THROTTLE OPENING OUT OF SPECIFICATION
Above specification Loosen throttle cable
Below specification Tighten throttle cable
E-TEC DIRECT INJECTORS mmr2017-028-004_a
FUEL INJECTORS
If a fuel leak is noticed in the hoses area, inspect

hoses and connections.
If a fuel leak is noticed in fuel injector base area, it
indicates a leak of the lower O-ring of fuel injector.
If a dark carbon sooted area is noticed in fuel injec-
tor base area, it indicates a leak between the fuel
injector nozzle and the cylinder head. The fuel in-
jector retaining screws may not be tight enough.
Fuel Injector Troubleshooting Tips

Usually, a faulty fuel injector will lead to poor en-
gine idling and a low RPM (around 800 RPM and
below). It may also lead to engine misfiring.
Ensure the correct fuel injector is installed on the
mmr2017-028-003_a
proper cylinder. Refer to FUEL INJECTOR POSI-
1. Fuel injector housing TION VALIDATION.
2. Top O-ring
3. Bottom O-ring While engine is running, try disconnecting a fuel
4. Crush ring injector connector:
5. Gasket
Every fuel injector is bench tested. Its electrical

and flow characteristics are registered throughout
all its operating range in a calibration file.
mmr2017-028 9
WARNING CAUTION If both fuel injectors are not

Be careful while working close to rotating lifted carefully from the engine together, the
parts. strain on the injector fuel fittings may cause
them to crack and leak fuel when pressurized,
resulting in a fire hazard.
– If engine RPM does not change, the fuel injec-
tor could be faulty.
– If engine RPM decreases, the other fuel injector
could be faulty.
If one injector is thought to be faulty, proceed with
the injector tests.
Testing for Fuel Injector Leaks

Test Preparation
1. First make sure fuel pressure is within specifi-
cations. Refer to FUEL TANK AND FUEL PUMP
subsection.
NOTE: Keep the pressure gauge installed for the
leak test. mmr2017-028-005_a
2. Disconnect magneto connector. Refer to NOTE: Do not install the gaskets against fuel in-
WIRING HARNESS AND CONNECTORS sub- jectors.
section.
NOTE: Use a new crush ring. If a new crush ring
WARNING is not installed, it will be difficult to determine if
The magneto connector must be discon- the E-TEC direct injector is leaking.
nected to prevent any spark in the engine 7. Secure the injectors on a cylinder head (either
compartment should the engine be cranked. remove it from engine or order a spare one as
Fuel vapors may ignite in presence of a spark a tool).
creating a fire hazard.
NOTICE Test injectors when removed from
the engine, while attached to the cylinder
3. Using BUDS2, release fuel pressure. Refer to
head.
FUEL TANK AND FUEL PUMP subsection
NOTICE If the fuel pressure is not released, WARNING
the pressure will push the fuel injector out of its Fuel injector must be secured during the leak
housing when removing the fuel injector from test to avoid the fuel injector to be projected.
the engine. This could damage the fuel injector
and lead to an important fuel spill. 8. Place an appropriate container under the fuel
injectors.
4. Remove upper body module. Refer to BODY
subsection. 9. Ensure spark plug caps are installed on spark
plugs.
NOTE: Fuel injector leak test can only be done on
both injectors simultaneously. 10. Ensure there is enough fuel in fuel tank.
5. Unscrew both E-TEC direct fuel injectors. Re- 11. Connect vehicle to BUDS2. Refer to COM-
fer to REMOVING THE FUEL INJECTOR in this MUNICATION TOOLS AND B.U.D.S. subsec-
subsection. tion.
6. Carefully lift both fuel injectors. Be careful not Leak Test
to pry hoses against their plastic fittings. 1. UsingBUDS2, activate the fuel pump.
NOTE: Fuel pump will operate until deactivated in
BUDS2.
2. Check for fuel leakage from the fuel injector
nozzle.
10 mmr2017-028
3. Monitor fuel pressure at fuel pressure gauge.

If pressure drops below 275 kPa (40 PSI) during
the test, re-activate fuel pump as necessary.
FUEL INJECTOR LEAKAGE
TEST DURATION SPECIFICATION
2 drops per minute
2 minutes
maximum
4. If test is not within specification, replace the

faulty fuel injector.
5. Properly reinstall fuel injectors. Refer to IN-
STALLING FUEL INJECTORS in this subsec- mmr2017-028-006_a
tion. FUEL INJECTOR CONNECTOR
6. Reinstall remaining removed components.
If measurement is out of specification, replace
7. Connect magneto connector. fuel injector.
WARNING Testing the Fuel Injector Input Voltage
Wipe up any spilled fuel. 1. Connect vehicle to BUDS2. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. subsection.
Testing the Fuel Injector 2. Read the voltage on the 55 V System Circuit
1. Connect vehicle to BUDS2. Refer to COMMU- meter in BUDS2.
55 V SYSTEM CIRCUIT VALUE
2. Activate each fuel injector.
30 Vdc minimun
With each activation a sound coming from the tar-
geted injector should be heard. 3. Measure voltage at E-TEC direct fuel injector
If the fuel injector does not work, possible causes connector with a multimeter.
are:
PROBE SPECIFICATION
– Injector
– Harness 30 Vdc
INJ_DI_MAG-1 Chassis Ground
minimun
– ECM.
30 Vdc
If the fuel injector does not work, connect it to the INJ_DI_PTO-1 Chassis Ground
minimun
opposite fuel injector connector, then test again.
If the suspected fuel injector works normally with If voltage test is as per specification, carry out
the opposite fuel injector connector, carry out the TESTING THE FUEL INJECTOR CONTROL CIR-
TESTING THE FUEL INJECTOR INPUT VOLTAGE CUIT SIGNAL.
in this subsection. If voltage test is not as per specification, check
If the fuel injector still does not work, carry out the wire continuity between ECM and fuel injector
TESTING THE FUEL INJECTOR RESISTANCE. connector.
Measuring E-TEC Direct Fuel Injector Testing the Fuel Injector Control Circuit
Resistance Signal
1. Disconnect the fuel injector connector. 1. Connect vehicle to BUDS2. Refer to COMMU-
2. Measure fuel injector resistance directly on its NICATION TOOLS AND B.U.D.S. subsection.
terminals. 2. Backprobe injector connector, do not discon-
nect injector connector.
E-TEC DIRECT FUEL MEASUREMENT
INJECTORS @ 22°C (72°F) 3. Set multimeter to Vdc (Hz).
Pin 1 Pin 2 Below 2.7
mmr2017-028 11
REQUIRED TOOL

(P/N 529 035 868)
4. Repeatedly press the RANGE button until the

display shows Manual Range 6.
mmr2017-028-007_a
FUEL INJECTOR WIRING HARNESS CONNECTOR
If there is no reading, check continuity of wiring

between ECM and fuel injector connector.
If you hear the injector click, control circuit is good.
If reading is good, the control circuit is functional.
Removing the Fuel Injector

IMPORTANT: NEW O-rings, retaining screws, and
crush ring must be installed if fuel injector is re-
moved (fuel injector disassembly required). Oth-
erwise, leakage or damage to fuel injector/cylinder
head might occur.
mmr2009-023-027_d 1. Release the fuel pressure in the system. Refer
DC VOLTS AND MANUAL RANGE 6 SELECTED to FUEL TANK AND FUEL PUMP subsection.
5. Press the Hz button so that the display shows 2. Disconnect magneto connector (3-pin connec-
Hz. tor). Refer to Stator Connector Access in MAG-
NETO AND STARTER subsection.
6. Activate fuel injector and read the frequency on
the multimeter.
NOTE: The multimeter counts the pulses per sec-
ond (Hertz) of current the ECM sends to the fuel
injector.
FUEL INJECTOR CONNECTOR MEASUREMENT
Approximately
Pin 1 Pin 2
2 Hz
mmr2017-019-202_a
3. Remove upper body module.

12 mmr2017-028
WARNING
The magneto connector must be discon-
nected to prevent any spark in the engine
compartment should the engine be cranked.
Fuel vapors may ignite in presence of a spark
creating a fire hazard.
5. Clean fuel injector area.

NOTICE If fuel pressure is not released, the
pressure will push the fuel injector out of its
housing when removing the fuel injector. This mmr2017-028-115
could damage the fuel injector and lead to an
important fuel spill. 9. Disconnect fuel hoses from fuel injector.
WARNING
Fuel vapors in the engine compartment could
be lit by a spark. This might create a fire.
6. Disconnect fuel injector connectors.

NOTE: Locking ties must not be removed.
mmr2017-028-116
WARNING
More fuel than usual will flow out of the fuel
injectors. Work in a well ventilated area and
wipe up spilled fuel.
10. Remove and discard:

– Fuel injector screws
mmr2017-028-008_a
– Spring washers
1. Locking ties
2. Fuel injector connectors – Washers.
7. Install a rag under the hose ends to catch fuel
spillage.
8. Remove fuel hose retainer screw and retainer.
mmr2017-028-009_a
1. Fuel injector screw

2. Spring washer
3. Washer
mmr2017-028 13
11. Gently pull up on the fuel injectors to remove Disassembling the Fuel Injector
them.
REQUIRED TOOL
SNAP-ON SCREW (P/N CJ93-1)
SNAP-ON HAMMER (P/N CJ125-6)
EXTRACTOR ADAPTOR
(P/N 529 036 136)
1. Install the extractor adapter on the Snap-on

screw.
mmr2017-028-005_a
NOTICE Use caution when handling fuel

injector. Never hold injector by its electrical mmr2009-023-032
1. Snap-on screw
wires. Prevent dirt and debris from entering 2. Snap-on hammer
fuel inlet and outlet ports of fuel injectors or 3. Extractor adapter (P/N 529 036 136)
fuel hoses. Cover the fuel injector nozzle port
in cylinder head to prevent contamination of 2. Thread the extractor adapter into the fuel injec-
combustion chamber. tor.
3. Securely hold the fuel injector housing upside
12. Separate fuel injectors and connecting tubes. down to avoid dropping it.
Remove and discard O-rings. 4. Work slide hammer to pull the fuel injector out.
mmr2017-028-021_b
1. Fuel injectors
2. Connecting tubes mmr2009-023-033_a
3. O-rings
14 mmr2017-028
mmr2009-023-036
mmr2009-023-034
8. Clean connecting tube bores in injector hous-
5. Remove the extractor adaptor from the fuel in- ing.
jector.
6. Remove O-rings, crush ring and filter from the
fuel injector.
mmr2017-028-022_a
Assembling the Fuel Injector

The assembly procedure is the reverse of disas-
sembly. However, pay attention to the following:
mmr2009-023-035_b
Lubricate O-rings.
1. Crush ring O-RINGS LUBRICATION
2. ORANGE O-ring
3. Filter
4. BLUE O-ring Service product Injection oil
7. Inspect and clean fuel injector filter. Install a NEW crush ring.
Install a NEW orange O-ring on top.
NOTICE Always use the O-rings specifically
designed for these fuel injectors.
Install filter. Ensure filter is retained firmly on fuel
injector. Otherwise, remove it, invert it half a turn,
then reinstall. If it still not retained securely, install
a new one.
Install a NEW blue O-ring at bottom.
mmr2017-028 15
mmr2017-028-011_a
CORRECT INSTALLATION
mmr2009-023-035_c
Reinstall locking tie.
OIL INJECTION ON O-RINGS
1. ORANGE
2. BLUE
Reinstall fuel injector in its housing.

NOTE: Be sure to fully insert fuel injector in the
housing with the wire outlets towards the fuel
ports.
NOTICE Never press or tap the fuel injector
tip.
mmr2017-028-135
Installing the Fuel Injector

The following items and their mating surfaces
must be cleaned and inspected prior to assembly:
– Fuel Injector
– Cylinder head: fuel injector housing and fuel in-
jector tip contact surfaces
– Fuel injector screw threads and cylinder head
threads (must be dry).
mmr2017-028-010_a
NOTICE All fuel injector components must
WRONG INSTALLATION
be clean to ensure correct torque tightening
specifications and to avoid leakage. Carefully
follow the installation instructions.
NOTE: When installing a used fuel injector, rein-
stall the fuel injector in the same location. If it was
not marked at removal, verify the correct fuel in-
jector-cylinder match using BUDS2 Refer to FUEL
INJECTOR POSITION VALIDATION.
1. Position the NEW gaskets on cylinder head.
NOTICE Smooth surface of gasket must face
toward injector housing.
16 mmr2017-028
mmr2017-028-012_a mmr2017-028-009_b
1. Smooth surface of gasket 1. Washer

2. Tab facing towards intake side 2. Spring washer
3. Fuel injector screw
2. Install NEW O-rings on connecting tubes.
5. Tighten fuel injector retaining screws alter-
3. Lubricate O-rings and pre-assemble fuel injec- nately in the following procedure:
tors and connecting tubes.
TIGHTENING PROCEDURE
O-RINGS LUBRICATION
7 N•m ± 0.5 N•m
Service product Injection oil Step A
Fuel injector
20 N•m ± 0.6 N•m
retaining Step B
screws
35 N•m ± 1 N•m
Step C
6. Install both fuel injector connectors between

the fuel injectors.
mmr2017-028-021_a
LUBRICATE O-RINGS
4. Place the fuel injectors on the cylinder head,

then thread in NEW screws with NEW wash-
ers.
mmr2017-028-008_b
7. Check condition of fuel hose O-rings and plastic

flange on hose fittings.
8. Apply injection oil on O-rings.
9. Insert fuel hoses in fuel injector housing.
mmr2017-028 17
NOTICE Never fasten the electrical connec-

tor to the fuel injector. The connector must be
"free floating".
15. If installing a NEW fuel injector, use BUDS2 to
configure it in the ECM. Refer to SETTING A
FUEL INJECTOR TO A CYLINDER.
NOTE: The engine will be able to run with an im-
properly matched fuel injector. However, the en-
gine may misfire, run rough at idle, have poor fuel
economy or run lean.
mmr2017-028-116
WARNING
NOTE: Both hose fittings must be fully seated in Perform a fuel pressure test and make sure
the fuel injector housing. there is no leak.
10. Insert the hose retainer so that it engages the
groove in the fuel injector fittings. Fuel Injector Position Validation
When troubleshooting or reinstalling a fuel injec-
tor, the correct matching of the fuel injector and
cylinder must be confirmed using BUDS2 An in-
correct match between the fuel injector and cylin-
der may lead to engine misfiring, improper idling
or poor fuel economy.
NOTE: To configure a new fuel injector at instal-
lation, refer to SETTING A FUEL INJECTOR TO A
CYLINDER.
1. Look for the fuel injector identification tag.
2. Note the fuel injector serial number (SN) on the
tag of the fuel injector you want to validate.
mmr2017-028-115
NOTE: Ensure open end of retainer that locks in

the fuel hoses faces inboard. The hole in the hose
retainer used to secure the injector wiring must be
on top for the PTO injector, and on the bottom for
the MAG injector.
11. Install a NEW screw to secure hose retainer.
NOTICE The screw features a scotch grip
threadlocker coating that is destroyed when
loosening screw. Always replace screw with a
new one each time it is loosened.
TIGHTENING TORQUE
fuel hose retainer screw 5 N•m (44 lbf•in)
12. Secure fuel injector wiring using a NEW lock-

ing tie. mmr2009-019-023_b
13. Grease fuel injector connector. SN: Serial number

CS: Checksum number
FUEL INJECTOR CONNECTOR LUBRICATION
3. In BUDS2, navigate to the Settings page.
DIELECTRIC GREASE 4. In the Injector Coefficient box, look for the fuel
Service product
(P/N 293 550 004)
injector serial numbers (S/N) that are registered
14. Reconnect fuel injector connector. in the ECM.
18 mmr2017-028
5. Compare the MAG or PTO Injector S/N that is 6. Select and open the fuel injector serial number
configured in the ECM with the fuel injector SN file that matches the fuel injector installed on
installed on the engine. the engine.
NOTICE The actual fuel injector number (SN) 7. Enter the checksum number noted earlier and
must match the number in BUDS2 (Injector select Write.
S/N). NOTE: The file will be loaded in BUDS2
If numbers do not match, configure the fuel injec- 8. Click the OK button when the confirmation box
tor in BUDS2 Refer to SETTING A FUEL INJEC- appears.
TOR TO A CYLINDER. 9. Click on the Write Data button to save the
changes to the ECM.
Setting a Fuel Injector to a Cylinder IMPORTANT: To ensure the proper file has been
1. Note the serial number (SN) and the checksum saved in the ECM, do the following:
number (CS) on the fuel injector tag. 10. Click on the Scan button again in BUDS2
11. Look in the Injector Coefficient area in the
ECM Setting page.
12. Ensure the S/N in BUDS2 matches the SN of
the fuel injector installed on the engine and the
PTO/MAG numbers are not inverted.
13. If there is a mismatch, reload the proper con-
figuration file. Write data and read it again to
recheck.
FUEL RAIL AND THROTTLE

BODY INJECTORS
Testing the Fuel Injector Operation
Using BUDS2 (Dynamic)
NOTE: As a first troubleshooting step, always
check for applicable fault codes using BUDS2
mmr2009-019-023_b
SN: Serial number

1. Connect vehicle to BUDS2. Refer to COMMU-
CS: Checksum number NICATION TOOLS AND B.U.D.S. subsection.
2. Download the E-TEC injector coefficient file 2. Start engine.
from the COMCENTER tab in BOSSWEB.. 3. Using the BUDS2, shut down fuel injection to
each engine cylinder one at a time by clicking
DOWNLOAD INJECTOR COEFFICIENT FILE
on the button under the applicable cylinder.
Log in to BOSSWeb If the engine RPM drops momentarily when click-
Under the COMCENTER tab , click on E-TEC ing on a cylinder, the injector on this cylinder is
injector coefficient link functioning normally.
If the engine RPM does not drop momentarily
3. Start BUDS2 and click on the Scan button. when clicking on a cylinder, this cylinder is not
4. Navigate to the Settings page and Injector Co- functioning properly. Check the following:
efficient tabs. – Fuel injector operation. Refer to TESTING THE
5. In the Injector Coefficient box, click on the New FUEL INJECTOR BALANCE USING BUDS2
button of the fuel injector you want to replace – Spark plug and ignition coil. Refer to IGNITION
(MAG or PTO). SYSTEM subsection.
NOTE: Every time the New button is clicked, – Engine condition.
BUDS2 will automatically open the Injector Coef-
ficients folder.
mmr2017-028 19
Testing the Fuel Injector Balance Using This will validate the injector mechanical and elec-
BUDS2 trical operation.
NOTICE After fuel injector activation us- If the injector does not function, carry out the
ing BUDS2, always crank engine in drowned TESTING THE FUEL INJECTOR RESISTANCE.
mode to ventilate engine and prevent a po-
tential backfire due to fuel accumulation in
Testing the Fuel Injector Resistance
engine. Disconnect connector “A” from the ECM. Refer
to WIRING HARNESS AND CONNECTORS
1. Set emergency stop switch to RUN.
Check resistance value between terminals as fol-
2. Install a fuel pressure gauge as described in lows.
REQUIRED TOOL
4. In BUDS2, activate fuel pump. (P/N 529 035 868)
5. Fuel pressure must be within specification. Re-
fer to FUEL TANK AND FUEL PUMP subsec-
tion. Re-activate fuel pump as necessary.
ECM ADAPTER TOOL
6. In BUDS2, energize fuel injector no. 1. (P/N 529 036 166)
7. Record the fuel pressure drop for injector no. 1.
8. In BUDS2, ctivate fuel pump.
FUEL INJECTOR RESISTANCE TEST AT ECMA
9. Repeat the procedure for fuel injector no. 2 and CONNECTOR
record the pressure drop.
RESISTANCE
10. The maximum fuel pressure drop between in- INJECTOR ECM CONNECTOR “A”
@ 20°C (68°F)
jectors should not exceed the following spec-
MAG ECMA-A3 ECMa_A4
ification: 11.4 - 12.6
PTO ECMA-A2 ECMA-A1
MAXIMUM FUEL PRESSURE DROP ALLOWED
BETWEEN FUEL INJECTORS
If resistance value is as specified, the injector and
10 kPa (1.5 PSI) its circuits are good. Refer to TESTING FOR FUEL
INJECTOR INPUT VOLTAGE in this subsection.
If pressure drop of any fuel injector is greater than If resistance value is NOT as specified, remove
the specification, replace that injector then repeat injector connector and check resistance value be-
the test. tween injector pins.
11. Using the valve on the fuel pressure gauge,
release the pressure in the system (if so FUEL INJECTOR RESISTANCE TEST AT INJECTOR
CONNECTOR
equipped).
12. Remove fuel pressure gauge and reinstall re- RESISTANCE
INJECTOR INJECTOR PIN
moved parts. @ 20°C (68°F)
MAG
Testing for Fuel Injector Leaks 1 2 11.4 - 12.6
PTO
Carry out the TESTING THE FUEL PUMP PRES-
SURE as detailed in the FUEL TANK AND FUEL
PUMP subsection.
Testing the Fuel Injector Activation
Using BUDS2
Connect vehicle to BUDS2. Refer to COMMUNI-
CATION TOOLS AND B.U.D.S. subsection.
On the Functions page of BUDS2, energize the
fuel injector to be tested.
You should hear or feel the injector functioning.
20 mmr2017-028
INJECTOR
CONNECTOR
CYLINDER MEASUREMENT
INJECTOR
PIN
MAG Pin 2 Battery
Battery voltage
PTO Pin 2 ground
mmr2017-028-013_a
If readings are out of specifications, replace injec-

tor.
If readings are good, carry out TESTING THE FUEL
INJECTOR CIRCUIT RESISTANCE.
Testing the Fuel Injector Input Voltage
Disconnect the fuel injector connector.
mmr2017-028-014_a
NOTE: If the connector is hard to unlock, gently
use a screwdriver to release connector. If supply voltage is good:
1. Check if ground circuit is faulty, repair/replace
wiring and connectors. Refer to TESTING THE
FUEL INJECTOR CIRCUIT RESISTANCE.
2. If the ground circuit is good, the injector prob-
lem may be mechanical. Replace injector.
3. If injector is good the problem may be in the
power distribution system in the ECM (does
not provide a ground signal) refer to PRO-
GRAMMING A NEW ECM.
If the injector input voltage is good, the injector
problem may be mechanical.
Fuel Rail with Fuel Injectors Access

Remove upper body module. Refer to BODY sub-
section.
vmr2006-014-001_a
TYPICAL
Remove engine cover.
Remove primary air intake silencer.
NOTE: It is not necessary to activate the injector
since it is continuously powered when the emer-
gency stop switch is set to RUN and BUDS2 is
connected.
Use a multimeter and set it to Vdc. Read voltage.
mmr2017-028 21
Removing the Fuel Rail with Fuel

Injectors
mmr2017-028-015_a
1. Locking ties
2. Injector connectors
mmr2017-028-118
Release fuel pressure from fuel system, refer to Remove fuel rail retaining screws .
Place an absorbent shop rag around the fuel sup-
ply hose fitting at the fuel rail to catch any fuel
leakage.
Disconnect fuel hose from fuel rail.
mmr2017-028-016_a
Gently wiggle fuel rail side to side as you pull the

fuel rail out with fuel injectors.
mmr2017-028-119
Remove the injector retaining clip.
Pull the fuel injector out of the fuel rail and discard
Cut locking ties securing engine harness to fuel the O-rings.
rail.
Disconnect fuel injector connectors.
22 mmr2017-028
NOTICE Pay attention to not damage the

O-rings.
mmr2017-028-017_a
1. Fuel rail
2. Retaining clip
3. Fuel injector
4. O-rings mmr2017-028-029_a
Installing the Fuel Rail and Fuel Tighten fuel rail retaining screws.
Injectors TIGHTENING TORQUE
For the installation, reverse the removal proce- 8 N•m ± 0.5 N•m
dure. Pay attention to the following details. Fuel rail retaining screws
NOTICE If installing the removed injector(s),
Connect fuel pressure hose to fuel rail.
always install NEW O-rings.
Pressurize the fuel system and check for fuel
Lubricate NEW O-rings to ease insertion in rail. leaks. Refer to FUEL TANK AND FUEL PUMP
subsection.
FUEL INJECTOR O-RINGS
Service product Injection oil WARNING
Failure to pressurize the fuel system and
Install fuel injector with your hand. Do not use any checking for fuel leaks may result in severe
tool. injury or a life threatening situation should a
Carefully insert fuel injectors in fuel rail and install leak occur.
injector retaining clips..
Reinstall all remaining removed parts.
ECM
(ENGINE CONTROL MODULE)
mmr2017-028-017_b
1. O-rings
2. Fuel injector
3. Retaining clip
mmr2017-023-002
Gently push the fuel rail together with injectors in
ECM
the throttle body.
mmr2017-028 23
NOTE: Prior to replacing an ECM, carry out all

testing procedures.
Troubleshooting ECM Power Supply

Verifying System Voltage
Set emergency stop switch to RUN.
Connect vehicle to BUDS2. Refer to COMMUNI-
CATION TOOLS AND B.U.D.S. subsection.
In BUDS2, navigate to the Measurements screen
View high voltage system circuit voltage.
mmr2017-028-121
Start or crank engine while viewing System Volt-
age. 5. Install a rag under the ECM fuel hose quick con-
TEST CONDITION VOLTAGE nect to catch fuel spillage.
6. Place a container under the hose connector to
Manual crank speed 30 Vdc min.
recover fuel.
Engine running 55 Vdc 7. Slowly disconnect fuel both hoses from ECM
and drain fuel.
If voltage is as per specification, ECM is properly
powered.
If voltage is out of specification, refer to CHARG-
ING SYSTEM.
Removing the ECM
Save a BUDS2 File.
1. Set emergency engine stop switch to STOP.
subsection.
mmr2017-028-126
3. Move rewind starter handle assembly (applica-
ble models). 8. Disconnect magneto, ECMA, and ECMB con-
nectors. Refer to WIRING HARNESS AND
CONNECTORS.
9. Remove connectors from ECM housing.
mmr2017-027-050_a
4. Detach coolant tank from its support.

mmr2017-028-122
10. Remove ECM retaining screw and nut.
24 mmr2017-028
Set engine stop switch to RUN.

Install tether cord cap on engine cut-off switch.
Transfer or enter data in new ECM. Refer to PRO-
GRAMMING A NEW ECM in this subsection.
Programming a New ECM
There are 2 possible methods to manually collect
the required information. The 1st being the easi-
est.
– Use BUDS2 software and obtain the data from
a saved file on your PC computer.
mmr2017-028-123
– Collect the information from the vehicle and
11. Move coolant hose. obtain the fuel injector coefficient files from
Knowledge Center.
1. Remove the faulty ECM, refer to REMOVING
ECM in this subsection.
2. Install and connect the new ECM, refer to IN-
STALLING ECM in this subsection.
3. Connect vehicle to BUDS2 version and log
on. Refer to COMMUNICATION TOOLS AND
BUDS2 subsection.
4. Click on the Scan button.
5. Navigate to the Summary page and Healthtab.
6. Initiate the new ECM and perform any required
mmr2017-028-128 updates
12. Carefully slide ECM forwards to unhook clip 6.1 Enter vehicle model number
behind ECM. 6.2 Follow instructions in BUDS2.
NOTE: If you were not able to save a BUDS2 file,
refer to COLLECT THE INFORMATION FROM
THE VEHICLE to get the required information.
7. Refer to the saved BUDS2 file and write the
following information to the Settings page
7.1 Keys
7.2 Oil pump offset
7.3 Ignition timing offset. Refer to IGNITION
SYSTEM
7.4 Injector coefficient. Refer to SETTING A
FUEL INJECTOR TO A CYLINDER
mmr2017-028-127
7.5 RAVE setting
13. into the new ECM.
14. Remove. Cut locking ties as applicable. 8. Check the Settings page and Options tab to en-
sure options and any accessories are entered.
Installing ECM 9. Perform the CLOSED THROTTLE RESET (TPS)
Reverse removal procedure however, pay atten- procedure in this subsection.
tion to the following.
Collect the Information from the Vehicle
WARNING 1. Record model number.
Wipe up all spilled fuel.
mmr2017-028 25
1 Record the serial number (SN) and the checksum

(CS) on the fuel injector tag.
2
xx/xxxx 3
xxxxxxxxxxxxxxxxx
4 xxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxx
9
xxxx xxxx xxxxxxxx xxxxxxxx
5 6 7 8
514005671
VEHICLE DESCRIPTION DECAL

1. Manufacturer name
2. Manufacturing date
3. Vehicle identification number (VIN)
4. Model and package name
5. Model number SN: Serial number
6. Model year CS: Checksum number
7. Engine type
8. Vehicle weight (European models)
9. Vehicle engine power (European models) Use the BOSSWeb Com Center tab to download
the matching injector coefficient file.
NOTE: If prompted to enter engine serial number, Save the calibration file to your PC computer in the
it can be found on the cylinder block. folder:
THROTTLE BODY
mmr2017-019-015_b
CYLINDER BLOCK, EXHAUST SIDE
2. Record oil injection pump code.
mmr2017-028-018_a
1. Throttle body
2. TPS (Throttle position sensor)
mmr2009-023-093_a
BACK OF OIL INJECTION PUMP

1. Oil pump code (0 to 9)
3. Record MAG/PTO injector S/N and Checksum

numbers.
26 mmr2017-028
Throttle Body Screw Identification Removing the Throttle Body

WARNING
Always remove tether cord cap (D.E.S.S. key)
before removing the throttle body.
1. Remove fuel rail with fuel injectors and put

it aside, refer to FUEL RAIL AND THROTTLE
BODY INJECTORS in this subsection.
2. Block coolant hoses of throttle body heating.
REQUIRED TOOL
SMALL HOSE PINCHER

mmr2017-028-019_a
(P/N 295 000 076)
1. Master zero position screw (capped)
2. Synchronizing screw (capped)
3. Remove coolant hoses from throttle body.
NOTICE Do not tamper with any capped
screw. Otherwise, throttle body may have to
be replaced.
Inspecting the Throttle

– Ensure throttle plates move freely and
smoothly when depressing throttle lever.
– Ensure throttle body master zero position
screw is NOT loose. If so, replace throttle
body.
– Ensure that the master zero position screw
stops the throttle plate.
– Ensure TPS is NOT loose.
– Check for corroded or damaged wiring or con-
nectors. mmr2017-028-023_a
Throttle Body Access 4. Loosen clamps retaining throttle body.
WARNING

subsection.
3. Remove primary intake silencer. Refer to AIR
INTAKE SILENCER subsection.
mmr2017-028-024_a
5. Disconnect TPS connector.
mmr2017-028 27
THROTTLE BODY CLEANING

PULLEY FLANGE
711 809)
2. Install cooling hoses on throttle body.

3. Remove hose pinchers.
4. Connect TPS connector.
NOTICE Ensure TPS connector tab is prop-
erly locked.
5. Install throttle body on intake adapters.
mmr2017-028-025_b
6. Position throttle body clamps and tighten to
6. Disconnect throttle cable. specification.
7. At throttle body, fully unscrew cable lock nut.
mmr2017-028-112 mmr2017-028-026_a
THROTTLE CABLE LOCK NUT A. 25°
8. Unhook throttle cable end. TIGHTENING TORQUE

1.5 N•m ± 0.2 N•m
Throttle body clamps
7. Install throttle cable loosely.

8. Carry out the ADJUSTING THROTTLE CABLE
procedure as detailed in this subsection.
9. Install fuel rail with fuel injectors and put it
aside, refer to FUEL RAIL AND THROTTLE
BODY INJECTORS in this subsection.
10. If a new throttle body or TPS is installed, carry
out the CLOSED THROTTLE RESET (TPS) as
mmr2017-028-114
detailed in this subsection.
11. Refill and bleed cooling system, refer to PE-
9. Remove throttle cable. RIODIC MAINTENANCE PROCEDURES sub-
10. Remove throttle body from vehicle. section.
12. Install adapter plate (primary air intake si-
Installing the Throttle Body lencer) on throttle body.
1. If installing the removed throttle body, clean
throttle plates and bores before installation.
28 mmr2017-028
TIGHTENING TORQUE
0.7 N•m ± 0.1 N•m
Adapter plate clamps
13. Install primary air intake silencer, refer to AIR

INTAKE SYSTEM subsection.
14. Install all remaining removed parts.
NOTICE Make sure the TPS wire does not
touch the frame. Install locking tie as found
from factory.
Throttle Body Synchronization

mmr2017-028-018_b
No synchronization is required as it has already THROTTLE POSITION SENSOR (TPS)
been done at the factory.
NOTICE Do not alter synchronization screw TPS Connector Access
setting. Otherwise throttle body must be re- 1. Remove upper body module. Refer to BODY
placed. subsection.
WARNING
2. Disconnect TPS connector.
mmr2017-028-019_b
TPS (THROTTLE POSITION

SENSOR)
Description
mmr2017-028-025_b
The throttle position sensor (TPS) is a potentiome-
ter that sends a signal to the ECM which is propor- Testing the TPS Wear using BUDS2
tional to the throttle shaft angle.
1. Ensure TPS connector is properly connected.
2. While engine is not running, activate throttle
and pay attention for smooth operation without
physical stops of the cable.
3. Use BUDS2 software.
4. Select the Measurements and ECM tabs. Mon-
itor the TPS voltage.and percentage
5. Slowly and regularly depress the throttle.
The values must change gradually and regularly
as the throttle is activated. If the values “stick”,
bounce, suddenly drops off or if any discrepancy
mmr2017-028 29
between the throttle movement and the needle THROTTLE WIDE OPEN
movement is noticed, it indicates a worn TPS that ECMA
IDLE THROTTLE
CONNECTOR
needs to be replaced. POSITION POSITION
PIN RESISTANCE
Reset TPS (Closed Throttle)
Refer to RESETTING THE CLOSED THROTTLE D3 C2 1140±300 5140±1900
VALUE in the ADJUSTMENT topic of this subsec- D3 D2 5140±1900 540±300
tion.
C2 D2 5000±2000 5000±2000
Testing the TPS Input Voltage
NOTE: The resistive value should change
1. Remove parts required to access TPS connec- smoothly and proportionally to the throttle move-
tor, refer to TPS CONNECTOR ACCESS in this ment. Otherwise, replace TPS.
subsection.
If resistive values are correct, try a new ECM. Re-
2. Connect BUDS2 to power 12 Vdc and 5 Vdc fer to ENGINE CONTROL MODULE (ECM) else-
system. where in this subsection.
3. Disconnect TPS connector. If resistive values are incorrect:
4. Read voltage at TPS harness connector as fol- – Repair/replace wiring/connectors.
lows. – Replace TPS.
TPS HARNESS CONNECTOR VOLTAGE
Replacing the TPS
Pin 3 Pin 2 5.0 Vdc
1. Remove the throttle body, refer to REMOVING
If voltage is good, carry out TESTING THE TPS THE THROTTLE BODY in this subsection.
SIGNAL WIRE. 2. Disconnect TPS connector.
3. Remove TPS retaining screw.
Testing the TPS Circuit Continuity
Disconnect connector A from ECM, refer to CON-
NECTOR INFORMATION subsection.
Check the wiring continuity as follows.
REQUIRED TOOL
ECM ADAPTER TOOL

(P/N 529 036 166)
TPS HARNESS ECMA

RESISTANCE
CONNECTOR CONNECTOR
Pin 1 D3
Close to 0 mmr2017-028-025_a
Pin 2 C2
(continuity) 1. TPS connector
2. Screw
Pin 3 D2
4. Remove TPS.
If tests are good, replace the TPS.
5. Install new TPS and secure wire with a locking
If tests are not good, continue to check the resis- tie.
tance of the remainder of the TPS circuit.
NOTICE Make sure the TPS wire does not
Testing the TPS Resistance touch the frame. Install locking tie as found
1. Reconnect the TPS. from factory.
2. Disconnect ECMA connector . 6. Tighten TPS retaining screw to specification.
30 mmr2017-028
TIGHTENING TORQUE CPS CONNECTOR VOLTAGE

4 N•m ± 0.5 N•m Pin 1 Pin 2 1 - 2 Vac min.
TPS retaining screw
7. Open and quickly release throttle plates 6 times

(throttle plates must snap shut).
mmr2017-028-027_a
If voltage is out of specification, inspect

wiring/connectors. Replace CPS if wiring is good.
mmr2017-028-019_b
PUSH TO OPEN THROTTLE PLATES Testing the CPS Resistance

8. Reinstall remaining removed parts. 1. Disconnect connector ECMA from ECM.
9. Reset TPS, refer to CLOSED THROTTLE RE- 2. Measure the resistance of the sensor through
SET (TPS) in this subsection. its wiring.
REQUIRED TOOL
CRANKSHAFT POSITION
SENSOR (CPS) ECM ADAPTER TOOL
(P/N 529 036 166)
Testing the CPS with BUDS2
NICATION TOOLS AND B.U.D.S. subsection. RESISTANCE
ECMA CONNECTOR
2. In BUDS2, navigate to the Measurements @ 20°C (68°F)
screen K1 K2 190 - 290
3. Monitor the Engine Speed (RPM) indicator
while cranking engine. If measurement is out of specification, check
wiring continuity between ECM and CPS.
The value should move proportionally to the crank-
ing RPM. If no value movement is observed, test 3. Also check for a shorted connection to ground
the CPS OUTPUT VOLTAGE. as per table.
NOTE: A loose CPS or CPS connector can send RESISTANCE
ECMA CONNECTOR
an intermittent signal that can prevent the engine @ 20°C (68°F)
from starting. Engine
K1
ground
Testing the CPS Output Voltage Open circuit (OL)
Engine
1. Disconnect CPS connector (2-pin connector). K2
ground
Refer to WIRING HARNESS AND CONNEC-
TORS for connector location. If the previous tests were good, replace CPS.
2. Probe terminals coming from CPS while crank-
ing engine. CPS Replacement
Refer to MAGNETO AND STARTER subsection.
mmr2017-028 31
3D RAVE VALVES POSITION 4. Perform the same test with a new MAPTS and
SENSOR compare both readings.
Refer to RAVE subsection. MAPTS Input Voltage Test

1. Connect BUDS2. Refer to COMMUNICATION
MANIFOLD ABSOLUTE TOOLS AND BUDS.
PRESSURE AND TEMPERATURE 2. Remove electrical connector from MAPTS.
SENSOR (MAPTS) 3. Install tether cord cap on engine shut-off
switch.
NOTE: This sensor is a multifunction device. It
measures ambient absolute pressure and intake 4. Using a FLUKE 115 MULTIMETER (P/N 529 035
air temperature for air flow calculations. 868) set to Vdc, measure for MAPTS input volt-
age as per following table.
MAPTS Location MAPTS CONNECTOR MEASUREMENT
The MAPTS is on the secondary air intake silencer. PIN VOLTAGE
MAPTS Pressure Function 1 3 5 Vdc
The sensor measures the ambient atmospheric air
If voltage test is good, replace the MAPTS.
pressure. The ambient air pressure is at that mo-
ment stored in the ECM. If voltage test is not good, carry out the MAPTS
CIRCUIT CONTINUITY TEST (PRESSURE FUNC-
The sensor must be correctly installed on the sec-
TION).
ondary air intake silencer. Otherwise, the MAPTS
could generate a fault code for an unexpected MAPTS Circuit Continuity Test (Pressure
sensor range at idle when it reads an erroneous Function)
pressure. If this is the case, remove sensor and 1. Remove parts required to access ECM connec-
check for oil or dirt on its end and if problem per- tors, refer to ECM CONNECTOR ACCESS in
sists, check throttle plate condition/position and this subsection.
the wiring harness. Perform the following tests.
2. Disconnect the ECM-B connector from the
MAPTS Quick Test (Pressure Function) ECM and connect it to the ECM adapter tool.
1. Connect vehicle to BUDS2 Refer to COMMU-
NICATION TOOLS AND B.U.D.S. subsection. ECM ADAPTER TOOL
2. Navigate to the Measurements page in BUDS2 (P/N 529 036 166)
to view the manifold pressure value.
3. Look for and take note of the MAPTS pressure 3. Using the FLUKE 115 MULTIMETER (P/N 529 035
reading while the engine is stopped. 868) set to and check continuity of the follow-
NOTE: The indicated intake air pressure in ing circuits.
BUDS2 must be within 3.4 kPa (.5 PSI) of lo-
cal atmospheric pressure when the engine is
stopped.
MAPTS PRESSURE FUNCTION QUICK TEST
RESULT Service action
Circuit
Continuity MAPTS
Repair or
NO Test of Input
replace
READING MAPTS Voltage
wiring
Pressure Test
Function 529035868
VALUE IS
OUT OF Replace MAPTS
RANGE
32 mmr2017-028
MAPTS CIRCUIT CONTINUITY TEST MAPTS TEMPERATURE SENSOR TABLE

(PRESSURE FUNCTION)
RESISTANCE
TEMPERATURE
MAPTS RESISTANCE (ohms)
ECM-B
CONNECTOR VALUE
°C °F MAPTS
Pin E4 Pin 3
40528 TO
- 40 - 40
Pin F3 Pin 4 Close to 0 56935
Pin F4 Pin 1 - 10 - 14 8103 to 10919
20 68 2193 to 2863
If resistance is not within specification, repair or
replace the wiring harness between ECM connec- 80 176 294 to 368
tor and the MAPTS. Refer to WIRING DIAGRAM. 120 248 98 to 122
If value is not correct, try a new ECM.
If resistance is not within specification, replace
MAPTS Temperature Function the MAPTS.
The MAPTS also monitors the temperature of the If resistance tests good, reconnect the MAPTS
air in the intake manifold. and proceed with the following steps.
MAPTS Quick Test (Temperature Function) 3. Disconnect the ECM-B connector.
1. Connect vehicle to BUDS2 Refer to COMMU- 4. Install ECM-B connector on the ECM adapter
NICATION TOOLS AND B.U.D.S. subsection. tool.
2. Navigate to the measurements page. REQUIRED TOOL
3. Look for the Intake Air temperature reading
while the engine is stopped. ECM ADAPTER TOOL
(P/N 529 036 166)
NOTE: If the complete vehicle is at room temper-
ature, BUDS2 should display the ambient air tem-
perature at the intake manifold. 5. Using a multimeter, recheck resistance value as
4. Perform the same test with a new MAPTS and per following table.
compare both readings. ECM
MEASUREMENT
If the engine's MAPTS temperature reading is sig- ADAPTER
nificantly different than the new MAPTS, replace PIN
it. Refer to MAPTS TEMPERATURE
B2 F4 SENSOR TABLE
NOTE: Both sensors must feel same ambient air
temperature.
MAPTS TEMPERATURE SENSOR TEST RESULTS
If there is no reading, carry out a TESTING MAPTS
RESISTANCE (TEMPERATURE FUNCTION). RESULT Service action
Circuit
MAPTS Resistance Test (Temperature Continuity MAPTS
Function) NO Test of Input
Repair or
replace
1. Disconnect the MAPTS connector. READING MAPTS Voltage
wiring
Temperature Test
2. Using the FLUKE 115 MULTIMETER (P/N 529 035
Function
868) set to , test MAPTS resistance at the sen-
sor as per following tables. INCORRECT
Check condition of connector
RESISTANCE
MAPTS MEASUREMENT pins, replace MAPTS
VALUE
PIN Refer to MAPTS CORRECT
1 2 TEMPERATURE SENSOR TABLE RESISTANCE Try a new ECM
VALUE
mmr2017-028 33
MAPTS Circuit Continuity Test (Temperature 3. Measure resistance between sensor terminals.
Function)
CTS MEASUREMENT
MAPTS CIRCUIT CONTINUITY TEST
(TEMPERATURE FUNCTION) Refer to CTS SENSOR
Pin 1 Pin 2
TEMPERATURE TABLE
ECM MAPTS RESISTANCE
ADAPTER CONNECTOR VALUE Pin 1 Engine
Open circuit (OL)
or 2 ground
Pin F4 Pin 1
Pin B2 Pin 2 Close to 0
Pin E4 Pin 3
Repair or replace wiring as required.
Replacing MAPTS
1. Disconnect MAPTS connector and remove the
MAPTS from the intake manifold.
2. Install new MAPTS as per following table.
MAPTS INSTALLATION
TORQUE
Retaining screw 4.5 N•m ± 0.5 N•m mmr2017-028-028_a
(40 lbf•in ± 4 lbf•in) CTS RESISTANCE CHECK
Service PRODUCT
CTS SENSOR TEMPERATURE TABLE
Connector DIELECTRIC GREASE
(P/N 293 550 004) TEMPERATURE RESISTANCE
25°C (77°F) 2138 - 2570
COOLANT TEMPERATURE 38°C (100°F) 1284 - 1514
SENSOR (CTS) 104°C (219°F) 156 - 174
Testing the CTS with BUDS2 121°C (250°F) 103 - 115
NICATION TOOLS AND B.U.D.S. subsection. If resistance is out of specifications, replace CTS.
2. In BUDS2, navigate to the Measurements If resistance tests good, carry out the following
screen steps.
3. Monitor the Engine temperature indicator. It 4. Reconnect the CTS.
should show the coolant temperature. Oth- 5. Disconnect the ECMA connector from ECM.
erwise, perform TESTING THE CTS RESIS- 6. Measure CTS circuit resistance as follows.
TANCE.
ECMA CONNECTOR MEASUREMENT
Testing the CTS Resistance Refer to CTS SENSOR
1. Disconnect CTS sensor connector. Refer to B1 C1 TEMPERATURE TABLE
(E-TEC)
WIRING HARNESS AND CONNECTORS for
connector location.
If resistance value is correct, sensor and
2. Set multimeter to . wiring/connectors are good.
REQUIRED TOOL If resistance value is incorrect, repair/replace
wiring/connectors between ECM and CTS.
FLUKE 115 MULTIMETER Replacing the CTS
(P/N 529 035 868)
1. Disconnect CTS connector.
2. Cut locking ties and remove CTS.
34 mmr2017-028
mmr2017-028-129
MODELS WITH SENSOR ON MUFFLER

mmr2017-028-028_b 1. THCM Module
1. Locking ties
2. CTS
THCM Test with BUDS2
3. Install new CTS. 1. Connect vehicle to BUDS2. Refer to COMMU-
TIGHTENING TORQUE
2. In BUDS2, navigate to the Measurements
16 N•m ± 1 N•m
CTS
screen
3. In BUDS2, monitor the Exhaust (Muffler) and
4. Reinstall removed parts. Tuned Pipe temperature indicators (as applica-
5. Refill engine coolant. If an important quantity of ble).
coolant spilled from the engine, bleed cooling If sensor temperature continuously read(s),
system. Refer to PERIODIC MAINTENANCE 1 500°C (2,732°F) then the sensor is defective
PROCEDURES subsection. (open circuit). Replace THCM.
If sensor temperature is(are) read, THCM oper-
THCM ates normally.
(THERMOCOUPLE MODULE) If BUDS2 cannot communicate with the THCM,
On models with an exhaust gas temperature sen- check the power, ground, and CAN wires. Refer
sor on the tuned pipe and the muffler, the THCM to WIRING DIAGRAM.
monitors the sensor on the tuned pipe.
EXHAUST GAS TEMPERATURE
SENSOR (EGTSM AND EGTSTP)
mmr2017-028-124
MODELS WITH SENSOR ON TUNED PIPE AND MUFFLER

1. THCM Module
mmr2017-028-124
On models with an exhaust gas temperature sen- MODELS WITH SENSOR ON TUNED PIPE AND MUFFLER
sor on the muffler only, the THCM monitors the 1. THCM Module
sensor on the muffler.
mmr2017-028 35
EGTS Test with BUDS2 The Knock Sensor Signal value should move be-
Connect vehicle to BUDS2. Refer to COMMUNI- tween 0 and 100. The movement pattern is of
CATION TOOLS AND B.U.D.S. subsection. no importance as long as it moves indicating the
knock sensor senses the engine vibrations.
In BUDS2, navigate to the Measurements screen
If the value changes as described, the knock sen-
Monitor the Exhaust temperature indicators. They sor should be good.
should show the exhaust temperature.
If the value sticks either at 0 or 100, there is a
Use an infrared thermometer and measure the problem.
sensor's temperature.
NOTE: Ensure ignition coil cables are not close to
The measured temperature should be close to the knock sensor harness. If so, this might generate
temperature displayed in BUDS2. a false fault code.
If temperature is not the same, replace EGTS. Perform TESTING THE KS RESISTANCE.
NOTE: If engine runs with the EGTS connected
but not installed in the muffler, the reading will be Testing the KS Resistance
710°C (1,310°F) steady. Disconnect ECMA connector and install it on the
ECM adapter tool. Refer to WIRING HARNESS
EGTS Replacement AND CONNECTORS subsection.
Refer to EXHAUST SYSTEM subsection.
REQUIRED TOOL
KNOCK SENSOR (KS)

ECM ADAPTER TOOL
Knock Sensor Location (P/N 529 036 166)
The knock sensor is located on top of the cylinder
head, between the fuel injectors.
Measure the knock sensor circuit resistance as
per following table.
REQUIRED TOOL

(P/N 529 035 868)
RESISTANCE
ECMA CONNECTOR
@ 20°C (68°F)
ECMA-H1 ECMA-G1 3.92 - 5.88 M
If resistance measured at ECMA connector is not

close to specification, measure resistance at KS
mmr2017-028-008_c
connector.
Testing the KS with BUDS2 If resistance measured at KS connector is not as
1. Lift rear of vehicle off the ground and support it specified, replace knock sensor.
with a wide-base mechanical stand. If resistance test at KS connector is good perform
2. Connect BUDS2 and navigate to the measure- TESTING THE KS CIRCUIT CONTINUITY.
ments page. NOTE: Although the knock sensor resistance is
3. Use the latest applicable BUDS2 version. as specified, it may still be at fault as it may not
be producing a signal within its design specifica-
4. Monitor the knock sensor value . tion.
5. Start the engine.
6. Bring engine speed above 5200 RPM and vary
Testing the KS Circuit Continuity
engine RPM above 5200 RPM. 1. Ensure sensor and cylinder head contact sur-
faces are clean and mounting bolt is properly
NOTE: Use the custom screen and graph the
torqued.
knock sensor signal.
36 mmr2017-028
2. Disconnect knock sensor connector. Refer to

REPLACING THE KS.
3. Disconnect ECMA connector from ECM.
4. Check wire continuity of circuit as per following
table.
REQUIRED TOOL
ECM ADAPTER TOOL

(P/N 529 036 166)
ECMA KS
MEASUREMENT
CONNECTOR CONNECTOR
ECMA-H1 Pin 1 Close to 0
ECMA-G1 Pin 2 (continuity)
If test is not good, repair/replace wiring/

connectors between ECM and knock sensor.
If test is good, try a new knock sensor.
Replacing the KS
subsection
3. Disconnect knock sensor connector. Refer to
WIRING HARNESS AND CONNECTORS sub-
section for connector location.
4. Unscrew and remove knock sensor from cylin-
der head.
5. Clean contact surfaces on cylinder head, then
install the new knock sensor.
6. Tighten knock sensor screw.
TIGHTENING TORQUE
24 N•m ± 1 N•m
Knock sensor screw
NOTICE Improper torque may prevent sen-

sor from functioning properly possibly leading
to severe internal engine component damage.
7. Reconnect connector.
8. Reinstall remaining parts.
mmr2017-028 37
Subsection XX (POWER DISTRIBUTION)
POWER DISTRIBUTION
POWER DISTRIBUTION
55 Vdc
Ignition coils
Voltage rectifier/
Fuel pump
Magneto (Vac)
regulator
Oil injection pump
Fuel injectors
Capacitor
VSS
MAPTS
ERF
1 TPS
5V 5 Vdc
DC - DC converter E-RAVE
E-RAVE Actuator
Microprocessor THCM
Lights
2 12V 12 Vdc
DC - DC converter Multifunction gauge
25A Starter solenoid

RFID (D.E.S.S.)
Throttle Body Injectors
3
Charging Com Connector Pin 6
system Accessories
relay 7.5A
1 DC - DC converter
turns on when capacitor
is powered
12 Vdc secondary Start/RER
2 DC - DC converter switch
turns on at 800 RPM
5A
Multifunction
3 Models with battery: relay gauge (clock)
turns on when start switch is
pressed Com Connector Pin 5
3 Models without battery: relay Battery
turns on at 1000RPM (if equipped)
ECM 30A
en_mmr2017-029-199_a
mmr2017-029 1
GROUNDS
Engine
Chassis
Battery
mmr2017-029-099
2 mmr2017-029
GENERAL
OVERVIEW
Power distribution is shown in red on the wiring
diagram. Refer to KNOWLEDGE CENTER.
The magneto stator is wired with a 3 phase star
configuration winding.
At high RPM if the magneto power is greater than
the loads, the ECM will shunt the stator windings
to regulate its power as necessary.
The voltage regulator/rectifier is part of the ECM. mmr2017-029-006
The ECM receives the energy produced by the

magneto, rectifies the alternating current (AC) to Ignition Coil
direct current (DC) and regulates the voltage. For more information, refer to IGNITION SYSTEM
subsection.
SYSTEM VOLTAGE (55 VDC)
Since the available power is low when cranking,
the ECM first supplies 55 Vdc to the illustrated
components that need voltage for the starting and
the basic operation of the engine.
NOTE: When starting, voltage may be closer to
40Vdc until RPM increases.
ECM
For more information, refer to ENGINE MANAGE-
MENT SYSTEM subsection.
mmr2017-029-004
Fuel Pump
For more information, refer to FUEL TANK AND
FUEL PUMP subsection.
mmr2017-029-002
Fuel Injector
For more information, refer to E-TEC DIRECT
mmr2017-029-003
Capacitor
For more information, refer to CHARGING SYS-
TEM subsection.
mmr2017-029 3
GROUNDS
Engine
mmr2017-029-001
SYSTEM VOLTAGE (12 VDC)

A DC-DC converter, in the ECM, steps down the mmr2017-029-007
55 DC voltage to 12 Vdc when the engine reaches
800 RPM. TIGHTENING TORQUE
Since the available power is not at its maximum at 10 N•m ± 2 N•m
M6 screw on chassis
the early stage of engine starting, the ECM sup- (89 lbf•in ± 18 lbf•in)
plies 12 Vdc to the following components when
engine reaches 800 RPM. Chassis
– THCM (thermocouple module)
– E-RAVE actuator
– Communication connector
– Lighting system
– Multifunction gauge
– Heaters
– Heated visor
– Auxiliary lights
– 12 V power outlet
– Other accessories.
Approximately 25 A are available at idle (1200
RPM). Refer to CHARGING SYSTEM for more
mmr2017-029-008
information.
Below 2000 RPM, the total available current is lim- TIGHTENING TORQUE
ited to reduce the load on the system voltage. 5 N•m ± 0.5 N•m
M5 screw on chassis
Above 2000 RPM, the 12 Vdc system has a maxi- (44 lbf•in ± 4 lbf•in)
mum of 30 A available.
If electrical system load is increased, or the RPM
is decreased, the 12 Vdc system output is re-
duced in order to maintain 55 Vdc for engine
operation.
4 mmr2017-029
Battery
mmr2017-029-005
TIGHTENING TORQUE
10 N•m ± 2 N•m
M6 shoulder nut
mmr2017-029 5
Subsection XX (WIRING HARNESS AND CONNECTORS)
WIRING HARNESS AND CONNECTORS

SERVICE TOOLS
CRIMPING TOOL (HEAVY GAUGE WIRE) .................................... 529 035 730 ........................................... 13
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 9
ECM TERMINAL REMOVER 2.25................................................. 529 036 175 ............................................. 9
ECM TERMINAL REMOVER 3.36................................................. 529 036 174 ............................................. 9

DELPHI TERMINAL EXTRACTOR ................................................. 12094429 ..................................... 11–12
FCI TERMINAL EXTRACTOR TOOL ............................................. 54241678 ..................................... 10–11
MOLEX 150 TERMINAL EXTRACTOR TOOL ............................... 63813 - 1500 ..................................... 10–11
mmr2017-030 1
REV G4 CROSS-COUNTRY (WITH BATTERY) CHASSIS HARNESS
HL2
MG
HL1
ACC1 MAPTS
RFID
THCM
SD
SH1
STR 6P
SD+
STR 4P
BAT+ COM
ECMB
VSS
FB
FP
TL
mmr2017-030-099
2 mmr2017-030
REV G4 MOUNTAIN (WITHOUT BATTERY) CHASSIS HARNESS
HL2
MG
MAPTS HL1
THCM
ACC1
STR 6P
EGTS
RFID GRIP STR 4P
RER
DIMMER
FP
TL
SD
COM
ECMB
VSS
FB
mmr2017-030-199
mmr2017-030 3
850 E-TEC ENGINE HARNESS
INJ_DI_MAG
INJ_TB_MAG
INJ_DI_PTO
INJ
INJ_TB_PTO COILS E-RAVE
ERF OLS
OP
PC1
PC2
CTS
KS
TPS
CPS
ECMA
MAG
mmr2017-030-299
4 mmr2017-030
GENERAL ACRONYM DESCRIPTION
ACRONYMS MG Multifunction Gauge

OLS Oil Level Sensor
ACRONYM DESCRIPTION
OP Oil Pump
ACC Accessory
OLS Oil Level Sensor
BAT+ Battery +
OPS Oil Pressure Switch
CAN Controller Area Network
Radio Frequency
Camshaft Position RFID
CAPS Identification
Sensor
SD Starter Solenoid
COM Communication
SH1 Switch Housing 1
Crankshaft Position
CPS THCM Thermocouple Module
Sensor
Coolant Temperature TL Tail Light
CTS
Sensor TPS Throttle Position Sensor
CYL Cylinder VSS Vehicle Speed Sensor
Digitally Encoded DIMMER Dimmer switch
DESS
Security System
GRIP Heater switch
ECM connector A
ECMA FLS Fuel level sensor
(Engine)
ECM connector B
ECMB
(Chassis) PROCEDURES
Engine Gas Temperature
EGTS
Sensor
WARNING
When disassembling any connector for re-
E-RAVE E-Rave pair or replacement on the vehicle, always
E-Rave Feedback disconnect the battery to ensure all electrical
ERF
(position sensor) power is removed and prevent any possi-
Electronic Throttle bility of a short circuit. Refer to CHARGING
ETC SYSTEM subsection.
Control
FB Fusebox
FP Fuel Pump
GND Ground Engine
HL HeadLamp
COILS Ignition Coil Pack
INJ_DI_MAG Direct Injector Magneto
INJ_DI_PTO Direct Injector PTO
Throttle Body Injector
INJ_TB_MAG
Magneto
Throttle Body Injector
INJ_TB_PTO
PTO
KS Knock Sensor
MAG Magneto
Manifold Air Pressure &
MAPTS
Temperature Sensor
mmr2017-030 5
DIAGNOSTIC CONNECTOR
(DEUTSCH)
Connector Disassembly and
Reassembly
3 1
3
2
V01G0PA 1
4
F00H1CA
TYPICAL - MALE CONNECTOR
TYPICAL - DEUTSCH CONNECTOR 1. Male lock
1. Male connector
2. Female connector NOTE: Before pin extraction, push wire forward
3. Secondary lock
4. Sealing cap to relieve pressure on retaining tab.
2. Insert a 4.8 mm (.189 in) wide screwdriver
NOTICE Do not apply dielectric grease on ter-
blade inside the front of the terminal cavity.
minal inside connector.
3. Pry the retaining tab away from the terminal
To remove terminals from connector, proceed as while gently pulling the wire and terminal out
follows: of the back of the connector.
1. Using long nose pliers, pull out the plastic lock
from between the terminals. 1
V01G0QA 1
TYPICAL - FEMALE CONNECTOR
1. Retaining tabs
To install:
V01G0OA 1
1. For insertion of a terminal, ensure the plastic
TYPICAL - FEMALE CONNECTOR lock is removed.
1. Female lock
2. Insert terminal through the back of the connec-
tor in the appropriate position, and push it in as
far as it will go. You should feel or hear the ter-
minal lock engage.
6 mmr2017-030
3. Pull back on the terminal wire to ensure the re- Connector Removal
tention fingers are holding the terminal. 1. To access the ECM, refer to ELECTRONIC
4. After all required terminals have been inserted, FUEL INJECTION (EFI) subsection.
the lock must be installed. 2. Press and hold the locking tab on the connec-
tor to be disconnected.
1 1
F04H6LA
TYPICAL - CONNECTOR PIN-OUT

1. Terminal position identification numbers smr2009-045-011_a
LOCKING TAB TO PRESS AND HOLD

ECM CONNECTOR (MOLEX) 3. As you hold the locking tab, rotate the connec-
There are 2 connectors on the ECM. tor locking cam until it stops.
The engine wiring harness connector is con-
nected to ECM connector "A". The vehicle wiring
harness connector is connected to ECM connec-
tor "B".
Each ECM connector has 48 pins however, con-
nectors "A" and "B" are not interchangeable due to
their specific keyways.
NOTE: If you need to remove the connector,
be sure to not disconnect fuel quick-connector at
ECM. If you need to remove the ECM or fuel quick
connector, insure the ECM electrical connectors
are securely in place and avoid fuel intrusion into
connector/seal.
smr2009-045-012_a
CONNECTOR LOCKING CAM ROTATION TO RELEASE
4. Pull connector off ECM.
mmr2017-029-100
ECM CONNECTORS
mmr2017-030 7
smr2009-045-013_a
smr2009-045-011_b
1. Locked here
Connector Installation
1. Fully open connector locking cam. 4. Ensure the locking tab is fully out.
smr2009-045-013_b
smr2009-045-011_a
CONNECTOR LOCKING CAM IN RELEASE POSITION
LOCKING TAB FULLY OUT
2. Insert connector on ECM.
3. As you push the connector onto the ECM, ro- Connector Inspection
tate the connector locking cam until it snaps Before replacing an ECM, always check electrical
locked. connections.
1. Ensure connector locking mechanism is func-
tioning properly.
2. Ensure all wire terminals (pins) are properly
locked in the connector.
3. Ensure they are very tight, make good contact
with the pins in the ECM.
4. Ensure the pins in the harness connector
and the ECM connector are clean, shiny and
corrosion-free.
NOTE: A “defective ECM module” could possi-
bly be repaired simply by disconnecting and recon-
necting it.
NOTICE Do not apply any lubricant product
to the pins of the ECM connector.
8 mmr2017-030
Connector Probing
The most recommended and safest method to
probe the MOLEX (ECM) connector terminals is
to use the ECM ADAPTER TOOL (P/N 529 036 166).
This tool will prevent deforming or enlarging of
the terminals, which would lead to bad ECM ter-
minal contact creating intermittent or permanent
problems.
529036175
1. Remove rear protector from connector.

2. Pull out the connector lock.
529036166
1. Disconnect the ECM connector to be probed,

and reconnect it on the ECM adapter.
2. Probe wire terminals of the circuit to be tested
directly in the adapter holes.
smr2009-045-025_a
3. Insert tool to unlock terminal.
vmr2008-139-016_a
TYPICAL
1. ECM connector
2. ECM adapter
NOTICE Never probe directly on the ECM

harness connector. This could change the
shape or enlarge the terminals and create in- smr2009-045-026_a
termittent or permanent contact problems. 1. Unlock here
Connector Terminal Removal (Harness 4. Gently pull on the wire to extract the terminal
Connector) out the back of the connector.
To remove a signal terminal from the ECM har-
ness connector, use the ECM TERMINAL RE-
MOVER 2.25 (P/N 529 036 175).
To remove a power terminal, use the ECM TERMI-
NAL REMOVER 3.36 (P/N 529 036 174).
mmr2017-030 9
smr2009-045-027_a
smr2014-030-012_b
NOTICE Before installing wire terminals in
1. Socket locator
the connector, ensure all terminals are prop- 2. Pry holes
erly crimped on wires. After installation of 3. Holes for inserting terminal extractor tool
wire terminals in the connectors, ensure they 2. Carefully pull out the socket locator out to the
are properly locked by gently pulling on them detent position (approximately 5 mm).
as if to extract them.
NOTE: Do not remove the socket locator from the
connector housing.
MOLEX CONNECTORS (EXCEPT
ECM) 3. Insert the extractor tool in the small hole adja-
cent to the socket.
Connector Probing NOTE: Push the extractor tool in only as far as re-
1. Disconnect the steering connector in the vehi- quired to release the lock from the socket. The
cle and connect it to the Diagnostic Harness tool should slide along the socket and be inserted
(P/N 284560054). between the socket and the lock.
2. Probe the applicable circuit using the test con- REQUIRED TOOL
nector on the diagnostic harness.
FCI TERMINAL EXTRACTOR TOOL
NOTICE Attempting to probe the connector (P/N 54241678) or,
without using the diagnostic connector may MOLEX 150 TERMINAL EXTRACTOR TOOL
damage the connector pins, or even cause a (P/N 63813 - 1500)
short circuit if testing an energized circuit.
Socket Extraction (Female Connector)

1. Insert a small flat screwdriver in the pry holes
of the socket locator, on the socket side of the
smr2010-052-002
connector. FCI TERMINAL EXTRACTOR TOOL (P/N 54241678)
smr2014-045-001
MOLEX 150 TERMINAL EXTRACTOR TOOL 6(P/N 3813 - 1500)
4. Gently pull on the wire to extract the socket out

the back of the connector.
10 mmr2017-030
Pin Extraction (Male Connector) Pin Insertion

1. Using a pair of thin long nose pliers, pull the 1. Ensure the terminal (pin) is properly crimped
pin locator out to the detent position (approxi- onto the wire.
mately 5 mm). This will allow unlocking of the 2. Ensure the pin locator (the white plastic insert
pins. in the connector) is out in the detent position.
NOTICE Do not attempt to remove the pin lo- 3. Insert the pin in through the back of the connec-
cator or damage will occur. Be careful not to tor.
bend the pins when using the pliers. NOTE: When inserting the pin, insert the
stepped portion facing the notch in the con-
nector pin hole.
smr2014-045-002_a
1. Pin locator
2. Insert long nose pliers here
3. Holes for inserting terminal extractor tool
smr2014-045-004_a
2. Insert the extractor tool in the small hole adja- TYPICAL - PIN INSERTION
1. Notch
cent to the pin. 2. Stepped portion towards notch
NOTE: Push the extractor tool in only as far as
4. Push the pin in until the pin lock engages the
required to release the lock from the pin. The
pin.
tool should slide along the pin and be inserted
between the pin and the lock. 5. Gently pull on the pin to ensure it is properly
locked.
REQUIRED TOOL
6. Repeat previous steps for each pin to be in-
FCI TERMINAL EXTRACTOR TOOL serted.
(P/N 54241678) or,
7. Push the pin locator into the connector to the
MOLEX 150 TERMINAL EXTRACTOR TOOL locked position.
(P/N 63813 - 1500)
DELPHI/PACKARD CONNECTORS
Connector Terminal Removal
To remove a terminal (pin) from the connector, use
smr2010-052-002 a special tool such as the DELPHI TERMINAL EX-
FCI TERMINAL EXTRACTOR TOOL (P/N 54241678) TRACTOR (P/N 12094429).
smr2014-045-001 smr2010-052-001
MOLEX 150 TERMINAL EXTRACTOR TOOL 6(P/N 3813 - 1500) DELPHI TERMINAL EXTRACTOR (P/N 12094429)
3. Gently pull on the wire to extract the pin out the NOTE: Grinding the tool end to a taper is required.
back of the connector. 1. Carefully insert the tool in the space provided to
release the pin lock.
mmr2017-030 11
2. Push the pin out the front of the connector by 2. Carefully insert the DELPHI TERMINAL EXTRAC-
pushing on the wire. TOR (P/N 12094429) in the space provided to re-
lease the pin lock.
smr2010-052-001
DELPHI TERMINAL EXTRACTOR (P/N 12094429)
smr2009-045-014_a
1. Unlock terminal here
smr2009-045-024_a
1. Unlock here
3. Gently pull on the wire to extract the pin out the

back of the connector.
smr2009-045-015_a
NOTICE Before installing terminals in the

connectors, ensure all terminals are properly
crimped on the wires. After installation of the
wire terminals in the connectors, ensure they
are properly locked by gently pushing on them
DELPHI CONNECTORS
Terminal Removal
1. To remove a terminal from connector, first re-
move the locking cap.
smr2009-045-028_a
NOTICE Before installing terminals in the

connectors, ensure all terminals are properly
crimped on the wires. After installation of the
wire terminals in the connectors, ensure they
are properly locked by gently pushing on them
BATTERY CABLES
smr2009-045-023_a Battery Cable Crimping
1. Pry out locking cap Carefully strip the wire approximately to 10 mm
(3/8 in) in length, using a wire stripping tool or
sharp blade/knife.
12 mmr2017-030
A
A32E2QA
A. 10 mm (3/8 in)
NOTE: Make sure not to cut wire strands while

stripping the wire. 2
Install the appropriate terminal on the wire ac- A32E2SA
cording to the requirement. Refer to appropriate POSITIONING THE CRIMPING PLIERS

PARTS CATALOG. Step 1: Press
Step 2: Rotate
After positioning the crimping pliers, crimp the ter-

minal already installed on wire.
A32E2RA
INSTALLATION OF TERMINAL
Follow the instructions provided with the CRIMP-

ING TOOL (HEAVY GAUGE WIRE) (P/N 529 035 730)
to select the proper position of the tool.
A32E2TA
529035730
CRIMPING OF WIRE
NOTE: Different wires require different crimping
pliers settings, so make sure to follow the instruc-
tion supplied with the tool.
A32E2UA
PROPERLY CRIMPED WIRE
To verify, if the wire is properly crimped, apply

some pulling force on wire and the terminal at the
same time from both directions.
mmr2017-030 13
NOTICE Never weld the wire to the terminal.

Welding can change the property of the wire
and it can become brittle and break.
Install the protective heat shrink rubber tube on
the terminal. Heat the heat shrink rubber tube us-
ing the heat gun so that it grasps the wire and the
terminal.
NOTICE Make sure that the protective heat
shrink rubber tube has been properly installed
and no part of wire is exposed.
14 mmr2017-030
Subsection XX (IGNITION SYSTEM)
IGNITION SYSTEM
SERVICE TOOLS
DIAL INDICATOR ADAPTER ......................................................... 529 036 132 ............................................. 4
DIAL INDICATOR ADAPTER ......................................................... 529 036 418 ............................................. 4
IGNITION TIMING TOOL............................................................... 529 036 419 ............................................. 4
TDC DIAL INDICATOR .................................................................. 295 000 143 ............................................. 4
TDC DIAL INDICATOR .................................................................. 414 104 700 ............................................. 4
GENERAL Ignition System Basic Operation

Each ignition coil uses an active circuitry to ener-
WARNING
gize the primary winding when it receive a pulse
Always electrically disconnect both fuel injec- from the ECM. The pulse has an amplitude of ap-
tors prior to testing for ignition spark. Other- proximately 10 volts. At the end of the dwell time,
wise, fuel vapors may ignite in presence of a the power is released from the primary winding
spark creating a fire hazard. which induces a current that produces a high volt-
age in the secondary winding. This high voltage is
SYSTEM DESCRIPTION then fed to the spark plug.
This ignition system is an inductive type specifi- A resistive core spark plug cable is used to prevent
cally designed for the E-TEC engine with a rapid the RFI (Radio Frequency Interference). There is
rise time to prevent spark plug fouling. It provides no resistor in the spark plug cap.
a quick spark with a long duration.
Spark Plugs
The ignition system is fully managed by the ECM
The OEM spark plug used is specially indexed for
which controls the ignition system parameters
optimum engine operation and efficiency.
such as spark timing, dwell time, and firing order.
The threads on the spark plug and in the cylin-
The system uses two separate ignition coils which
der head are indexed so that when the plug is in-
induce high voltage in their secondary winding to
stalled, the open end of the negative electrode will
produce a spark at each spark plug independently.
be facing the injection spray, within ± 90°. This
ensures the negative electrode does not deviate
the injection spray and ensures proper ignition.
mmr2017-029-004
The ignition coils receive power from the 55 Vdc

system. Their operating voltage varies from 20 to mmr2009-019-027_a
55 Vdc. CORRECTLY INDEXED
1. Injector nozzle
2. Ground electrode
NOTE: Using an incorrectly indexed spark plug

will result in poor idle and increased emissions.
mmr2017-031 1
Imperial Dial Gauge
mmr2009-019-026_a
INCORRECTLY INDEXED
1. Injector nozzle
2. Ground electrode
If using a non OEM spark plug, a specific installa-

tion procedure must be followed. Refer to PERI-
ODIC MAINTENANCE PROCEDURE subsection.
Ignition Timing mmr2012-035-002_a
IMPERIAL GAUGE EXAMPLE

The crankshaft position sensor (CPS), the air 1. 001 inch means it is graduated each 1/1000 inch
pressure sensor (MAPTS) and the throttle posi-
TYPICAL IMPERIAL DIAL GAUGE
tion sensor (TPS) are the primary sensors used to
control the ignition timing. MEASURE MEASURE
The ECM is programmed with data (ignition map- GRADUATION PER NEEDLE EXAMPLE:
TURN .128 INCH
pings). Using feedback provided by the sensors,
the ECM controls the ignition timing for optimum 1/1000 inch
1 complete turn
engine operation under all operating conditions. 1 turn = .100 +
(.001) per
inch 28 graduation
Ignition timing can be adjusted using BUDS2 graduation line
lines
Knock Detection NOTE: The small dial indicates the number of
The knock sensor detects specific vibration that turns the long needle traveled around the main
would be typically generated by engine detona- dial.
tion.
If detonation occurs, the ECMs retards the igni-
tion and increases the fuel injected temporarily (it
goes into a specific operating mode) until detona-
tion stops.
ADJUSTMENT
UNDERSTANDING THE TDC
GAUGE
Dial gauges can be either in imperial or metric
units. It is crucial to identify gauge units and
graduation.
2 mmr2017-031
NOTE: The small dial indicates the number of

turns the long needle traveled around the main
dial.
mmr2012-035-004_a
.128 INCH AS AN EXAMPLE

Step 1: 1 complete turn
Step 2: 28 lines
Metric Dial Gauge

mmr2012-035-005_a
3.25 mm AS AN EXAMPLE
Step 1: Complete turns (3 X)
Step 2: 25 lines
IGNITION TIMING
Normally, ignition timing adjustments should not
be required. It has been set at the factory and
should remain correctly adjusted as every compo-
nent is fixed and non adjustable.
The only time the ignition timing may require ad-
justment is when replacing the:
– Crankshaft
– CPS
– ECM.
Adjustment procedure summary:
– Ignition Timing Tool Installation
mmr2012-035-003_a
– TDC Gauge Installation
METRIC GAUGE EXAMPLE
1. 0.01mm means its graduated each 1/100 millimeter – Locating Piston TDC
– Scribing the Timing Mark
METRIC DIAL GAUGE EXAMPLE – Checking Ignition Timing
MEASURE MEASURE – Adjusting Timing.
GRADUATION PER NEEDLE EXAMPLE:
TURN 3.25 mm If the ignition timing is incorrect, first check for
proper crankshaft alignment. This might be an in-
3 complete dication of a twisted crankshaft. Refer to ENGINE
1/100
turns MEASUREMENT subsection.
millimeter (.01) 1 turn = 1
+
per graduation millimeter
25 graduation
line
lines
mmr2017-031 3
Installing the Ignition Timing Tool REQUIRED TOOL

REQUIRED TOOL DIAL INDICATOR
ADAPTER (P/N 529
IGNITION TIMING TOOL 036 418)
(P/N 529 036 419)
2. Use the rounded tip from the DIAL INDICATOR
Ignition timing tool ADAPTER (P/N 529 036 132).
retaining screw M8 X 1.25
(diameter X thread pitch)
WARNING
Ensure tether cord is removed from engine
cut-off switch and emergency engine stop
switch is in the STOP position.
1. Install the ignition timing tool on the engine.
mmr2011-201-001_a
1. Roller tip removed

2. Rounded tip to install
3. Install the rounded tip on the gauge.

Preparing the Long Reach Gauge
1. Replace the roller tip by the rounded tip as de-
scribed in the PREPARING THE SHORT REACH
GAUGE.
Installing Gauge (both gauges)
1. Remove the PTO injector, refer to E-TEC DI-
mmr2017-031-100 RECT FUEL INJECTION subsection.
2. Install the DIAL INDICATOR ADAPTER (P/N 529
Installing the TDC Gauge 036 418) over the PTO injector hole.
WARNING 3. Use two screws M10 x 1.5 x 35 to secure the
adaptor.
Ensure tether cord is removed from engine
cut-off switch and emergency engine stop 4. Carefully insert the TDC gauge through the dial
switch is in the STOP position. indicator adapter hole.
Two TDC gauges can be used:

TDC GAUGES
Preferred Gauge
TDC DIAL INDICATOR
(P/N 295 000 143)
(short reach)
TDC DIAL INDICATOR
(P/N 414 104 700)
(long reach)
Preparing the Short Reach Gauge (Preferred

Gauge)
1. Remove the roller tip from the gauge.
4 mmr2017-031
Scribing the Timing Mark

IMPORTANT: Make sure to understand the TDC
gauge functioning. Refer to UNDERSTANDING
THE TDC GAUGE in this subsection.
1. From the “0” (TDC), rotate the drive pulley
clockwise (backwards engine rotation) until the
dial needle rotates past the BTDC specification
(see table below).
mmr2009-024-001_a
TYPICAL
1. TDC gauge
2. Dial indicator adaptor
3. Screws
5. Screw the gauge into the adapter plate with the

dial face towards the PTO and tighten it suffi-
ciently to prevent movement.
Locating Piston TDC

NOTE: Normal engine rotation as seen from the mmr2009-024-001_c
PTO side is counterclockwise. TYPICAL

1. Pass the BTDC specification
1. With a firm hold on the drive pulley, slowly ro-
tate the drive pulley counterclockwise while ob- 2. Then carefully rotate engine forward until nee-
serving the TDC gauge needle. dle precisely points the measurement specified
NOTE: Note that the needle stops moving only as in the table.
the piston is changing direction at the top of its
stroke.
2. Rotate the dial face so the “0” is in line with the
needle when it stops moving.
3. Resume rotating the engine in the same direc-
tion (counterclockwise) until the gauge needle
has rotated approximately 1/4 turn past TDC.
4. Then slowly rotate the engine in a clockwise
direction until needle stops moving.
NOTE: The needle should stop on the “0”. If not,
reset the dial “0” to the needle.
5. Again, slowly rotate the drive pulley back and
forth across TDC and confirm the needle al- mmr2009-024-001_b
ways stops exactly at “0” before changing TYPICAL
direction. “0” now indicates exact TDC. 1. Bring dial needle to the BTDC specification
6. Lock the dial face with the dial lock screw. NOTE: Final setting must always be made in the
NOTE: If a difference in “0” setting the dial in normal engine rotation.
each direction of rotation is easily noticeable, the
engine components may suffer from excessive
wear. The engine may require further inspection
and maintenance.
mmr2017-031 5
IGNITION TIMING BTDC WARNING

DEGREE Place ski tips against a wall, raise rear of
BTDC
ENGINE
SPECIFICATION
SETTING vehicle on a stand, so that track does not
BTDC contact the ground. Do not allow anyone in
850 E-TEC 6 mm (.236 in) 28° front of or behind the vehicle while engine
is running. Keep clear of track and do not
3. With the TDC gauge indicating specified tim- wear loose clothing which can get caught in
ing, use a permanent marker to draw a line on moving parts.
the drive pulley fixed sheave directly in line with
pointer end. 1. Connect the timing light pick-up to the PTO
spark plug cable.
NOTE: Be careful to route timing light cable away
from drive belt and pulleys.
mmr2008-034-010_a
TYPICAL mmr2009-024-002_a
1. Timing mark in line with pointer end
TYPICAL — TIMING LIGHT CONNECTION
1. PTO spark plug cable
4. Repeat the procedure to ascertain the mark is 2. Timing light connection to PTO plug cable
exactly in line with the pointer. 3. Timing light wire routing
5. Remove the TDC gauge and dial indicator 2. Connect the vehicle to BUDS2, refer to COM-
adapter. MUNICATION TOOLS AND B.U.D.S. subsec-
6. Reinstall the fuel injector. Refer to E-TEC DI- tion.
RECT INJECTION subsection. 3. Start engine and let idle.
7. Reconnect magneto connector. 4. In BUDS2, navigate to the Settingspage.
8. Check ignition timing as per applicable proce- 5. Select the Ignition/Injection Timing field.
dure in this subsection. NOTE: Timing will be frozen on the PTO cylinder
only for RPM stability. RPM will be limited to
Checking Ignition Timing 4000 RPM.
The ignition timing can be checked with either the
6. Point the timing light on the timing mark and
engine hot or cold at the specified RPM.
increase engine to 3500 RPM for a brief instant.
ENGINE SPEED FOR IGNITION TIMING CHECK 7. The timing mark must be aligned with the
ENGINE RPM pointer end within the specified tolerance.
2500 to 4000 (1) TOLERANCE
(1) In this range, the spark advance does not change ± 0.5°
during the procedure.
If timing mark and pointer are aligned, no adjust-
To check the ignition timing proceed as follows: ment is required.
6 mmr2017-031
If they are not aligned, note if timing is retarded 7. Recheck timing to ensure ignition timing adjust-
or advanced, see following illustrations. Then, ad- ment was properly stored in the ECM.
just timing as described in ADJUSTING TIMING 8. Increase engine RPM past 4000 RPM to ascer-
further in this subsection. tain the Freeze Timing function is no longer ac-
tive.
NOTE: The Freeze Timing function automatically
disengages when the engine is stopped.
9. Remove all tools.
MAINTENANCE
For maintenance, including replacing spark plugs,
refer to PERIODIC MAINTENANCE PROCE-
DURES.
TROUBLESHOOTING
IGNITION SYSTEM TESTING
mmr2008-034-011 SEQUENCE
TYPICAL — TIMING RETARDED BY ABOUT 1°
NOTE: It is good practice to check for fault
codes using the B.U.D.S. software as a first trou-
bleshooting step. Refer to the DIAGNOSTIC AND
FAULT CODES subsection.
In the case of ignition problems, check the follow-
ing in the prescribed order until the problem can
be solved:
1. Spark plugs
2. Spark plug cables
3. Wiring harness/electrical connectors
4. Emergency engine stop switch
5. Ignition cut-off switch
6. Ignition coil(s)
7. CPS
mmr2008-034-012 8. ECM (Engine Control Module).
TYPICAL — TIMING ADVANCED BY ABOUT 2°
If engine idles roughly or shows signs of increased
Adjusting Timing emissions, the spark plugs may be incorrectly in-
dexed. Refer to PERIODIC MAINTENANCE PRO-
1. In the Ignition/Injection Timing area on the CEDURES subsection.
Settings page, select Advance or Retard to
change the ignition timing.
PROCEDURES
NOTE: Timing will be changed in 0.5° increments.
2. Adjust the timing using the appropriate button SPARK PLUGS
until the timing mark is in line with the pointer,
within 0.5°. For spark plug type, refer to TECHNICAL SPECI-
FICATIONS.
3. Unfreeze ignition timing.
For procedure to replace spark plugs, refer to PE-
4. Click Close button to store the ignition timing RIODIC MAINTENANCE PROCEDURES.
correction.
5. Shut down engine.
6. Restart engine and Scan in BUDS2.
mmr2017-031 7
SPARK PLUG CABLES EMERGENCY ENGINE STOP

SWITCH
NOTICE Do not interchange spark plug ca-
bles. The lower LH coil must be matched to Emergency Engine Stop Switch
the PTO spark plug. Operation
The emergency engine stop switch provides a
ground signal to the ECM when STOP is selected.
Refer to applicable WIRING DIAGRAM for details.
Testing Emergency Engine Stop

Switch
1. Disconnect STR 6P connector. For connector
location, refer to WIRING HARNESS AND CON-
NECTORS.
2. Measure resistance as per following table.
EMERGENCY
STR 6P ENGINE STOP
mmr2017-031-005 SPECIFICATION
CONNECTOR SWITCH
ARROW POINTS TO FRONT OF VEHICLE
1. PTO side POSITION
2. MAG side
RUN O.L.
Pin 3 to pin 6
Measuring Spark Plug Cable STOP Continuity
Resistance
If the spark plug cables are in good condition, carry NOTE: If emergency engine stop switch is un-
out the following resistance test. plugged, engine will start and run. If emergency
engine stop switch is jumped, engine will stop.
1. Remove each spark plug cable from its ignition
coil and spark plug.
IGNITION COILS
2. Insert a probe in each cable end and measure
the resistance. Testing for Spark
SPARK PLUG CABLE RESISTANCE NOTE: Ensure emergency stop switch is set to
RUN.
2160 – 6870
NOTE: Use ONLY an approved inductive spark
plug tester or a new spark plug to test for ignition
spark. In-line (series connected) spark testers
must not be used. Radio frequency interference
(RFI) generated by the arcing current may cause
erratic behavior in the ECM.
WARNING
Always electrically disconnect both fuel injec-
tors prior to testing for ignition spark. Other-
wise, fuel vapors may ignite in presence of a
spark, creating a fire hazard.
1. Install the inductive spark tester (or a new spark

mmr2009-024-008_a
plug) on the spark plug cable (Do not remove
SPARK PLUG CABLE RESISTANCE TEST spark plugs installed on engine).
2. Activate ignition coil with BUDS2
If resistance is not as specified, replace spark plug
cable. 3. If no spark is produced, test ignition coil.
8 mmr2017-031
4. If a spark is produced, install new spark plugs Removing Ignition Coil

in the engine and repeat the test to assure the
new spark plugs are in good condition and func-
tioning correctly.
Testing Ignition Coils

NOTE: Ensure emergency stop switch is set to
RUN.
1. Backprobe the ignition coil connector and mea-
sure voltage as per following table.
mmr2017-031-007
1. Remove the left hand side panel.

2. Note position of spark plug cables and remove
them from the spark plugs.
mmr2017-031-006
2. Use BUDS2 to activate ignition coil and mea-

sure the control signal.
IGNITION COIL
DESCRIPTION SPECIFICATION
CONNECTOR
Pin 1 Ground Battery ground
Vary when mmr2017-031-011
Pin 2 Control MAG activated
0.015V-0.222V1 3. Remove retaining screws.
40V engine off
Pin 3 55 Volts 55V engine
running
Pin 4 Ground Battery ground
Vary when
Pin 5 Control PTO activated
0.015V-0.222V1
40V engine off
Pin 6 55 Volts 55V engine
running
1 Control signal actually varies between 13 - 15
volts for 800 micro-seconds (DWELL time) but most
mmr2017-031-008
multimeters cannot read it, it happens so fast.
4. Unplug ignition coil connector.
3. If all inputs are as per specifications and there
is no spark, replace ignition coil.
4. If a pin does not test as per specification, trou-
bleshoot the affected wire continuity to ground
or ECM. Refer to WIRING DIAGRAM.
mmr2017-031 9
mmr2017-031-010
5. Remove ignition coil.
Installing Ignition Coil

Reverse the removal procedures but pay attention
to the following:
TIGHTENING TORQUE
Ignition coil retaining 2.4 N•m ± 0.2 N•m
10 mmr2017-031
Subsection XX (CHARGING SYSTEM)
CHARGING SYSTEM
SERVICE TOOLS
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 5, 7
POWER INTERFACE ..................................................................... 515 177 223 ............................................. 4

NAPA ULTRA PRO BATTERY LOAD TESTER ............................... 95260 ............................................. 3
GENERAL TROUBLESHOOTING
WARNING GUIDELINES
Unless otherwise specified, always discon- Low or No System Voltage
nect the magneto connector and ensure (Engine May Not Start)
spark plugs are installed on the engine be- The vehicle cannot start without having a
fore carrying out electrical system checks. minimum voltage to the 55 V power circuit.
Should the engine be made to rotate with If the engine does not start, see VOLTAGE
magneto connected, a spark may occur REGULATOR/RECTIFIER in this subsection and
resulting in electrical shock, a fire, or an ex- test the Vdc Output using BUDS2
plosion.
If voltage is not as specified, check the following
items in the recommended order until you find the
SYSTEM DESCRIPTION fault:
12V System Capacity – Stator (refer to MAGNETO subsection)
– Capacitor (see procedure in this subsection).
12V SYSTEM CAPACITY
NOTE: The 55 Vdc may be unstable or unobtain-
Over 2000 RPM 30 A able if the capacitor is faulty, not connected, or in-
1200 RPM (Idle) 25 A correctly connected.
If the above mentioned checks were good, iso-
Magneto late each of the following components by discon-
necting them individually, and repeating the volt-
A magneto provides the primary source of electri- age test after each one.
cal energy. It transforms a magnetic field into an
alternating current (AC). – Each injector
– Each ignition coil
The magneto stator is wired with a 3 phase star
configuration winding. – Fuel pump
– Oil injection pump.
AC current is rectified and regulated by a voltage
regulator/rectifier circuit within the ECM to pro- NOTE: When the 55 Vdc test good after a com-
vide 55 volts for engine component operation. It ponent is disconnected, replace that component
is then converted into 14.5 volts by a DC to DC and repeat the test.
converter for vehicle operation.
PROCEDURES
TROUBLESHOOTING Ensure battery is fully charged (if applicable).
NOTE: It is good practice to check for fault codes Refer to WIRING HARNESS AND CONNECTORS
using B.U.D.S. as a first troubleshooting step. Re- subsection for harness layout and connector loca-
fer to DIAGNOSTIC AND FAULT CODES. tions on vehicle.
mmr2017-032 1
Refer to appropriate WIRING DIAGRAM for addi- Use the following guidelines for charging. Always
tional information. verify battery state of charge before charging, and
The magneto is covered in MAGNETO AND 30 minutes after charging.
STARTER subsection. It is not recommended to overcharge sealed
VRLA batteries. Because of their characteristics,
WARNING too much charging will decrease the volume
Ensure vehicle cannot move when perform- of electrolyte. The longer the overcharge time,
ing charging system tests with the engine the greater the drop in electrolyte – and starting
running. power.
Refer to the following tables for charging routine.
BATTERY Note that charging times can vary depending
on type of charger. Follow the manufacturer's
Charging Battery instructions for details.
Initial Charging STATE OF CHARGE : 100%
Sealed VRLA batteries require an initial charge be-
CHARGE
fore being used in the vehicle. VOLTAGE ACTION
TIME
NOTE: Since batteries state of charge need to be
Check in 3 months or
checked 3 months after their manufacturing date 12.8 – 13.0
when vehicle is sold***
None required
or their last charge, it is highly recommended to
check the batteries of all newly arrived vehicles.
Consult the "Identification of reminder sticker" *** Identify battery as being checked on "date" or
section and battery chart on last page. needs to be rechecked at "date"
If you are using a constant current charger, refer
STATE OF CHARGE : 75% - 100%
to the standard (STD) charging method printed on
the battery. VOLTAGE ACTION
CHARGE
TIME *
For YTX20HL batteries (18.9 AH), the initial charge
must be 1.8 A for 5 - 10 hours. May need slight charge.
If no charge given, check
12.5 – 12.8 3 – 6 hours
in 3 months or when
vehicle is sold***
* Using a constant current charger at standard
amps specified on the battery
*** Identify battery as being checked on "date" or
mbs2014-002-200_a needs to be rechecked at "date"
YTX20HL CHARGING METHOD
If you are using an automatic type taper charger,
check to make sure that the charger current CHARGE
VOLTAGE ACTION
(amps) is equal to or greater than the standard TIME *
charging method listed on the battery. Need charge. Check
If the battery gets very hot to the touch, cease 12.0 – 12.5 in 3 months or when 5 – 11 hours
vehicle is sold***
charging and allow battery to cool down for 6 to
12 hours. Check voltage using a voltmeter. A fully * Using a constant current charger at standard
charged, battery should be 12.8 volts or higher af- amps specified on the battery
ter the battery has been off the charger 1-2 hours. *** Identify battery as being checked on "date" or
If less, it needs additional charge. needs to be rechecked at "date"
Routine Charging
NOTICE Overcharging can harm the battery
beyond recovery.
The single most important thing to maintaining a
VRLA battery is to not let it sit discharged: keep
it fully charged for peak performance.
2 mmr2017-032
STATE OF CHARGE : 25% - 50% TEST CONDITIONS

VOLTAGE ACTION CHARGE TIME * 3 times the amp-hour
Load
(AH) rating
Need charge.
Check in 3 months At least 13 hours Time 15 seconds
11.5 – 12.0
or when vehicle verify state of charge
is sold*** ‡ Required for accurate testing
* Using a constant current charger at standard SPECIFICATION

Battery Above 9.6 Vdc
needs to be rechecked at "date"
If battery voltage drops below specification during
test, replace battery and test charging system.
VOLTAGE ACTION CHARGE TIME * Removing Battery
11.5 or less Need charge. 1. Remove seat.
(see Check in 3 months
20 hours
2. Remove battery cover.
instructions or when vehicle
below) is sold***
* Using a constant current charger at standard
needs to be rechecked at "date"
Charging for Voltage of 11.5 V or Less

Batteries with voltage below 11.5 V may require
special equipment and procedures to recharge.
In charging an over discharged battery having a
terminal voltage of 11.5 V or lower, its internal re-
sistance may be too high to charge at a normal mmr2017-032-005
charge voltage.
3. Disconnect negative before positive terminal.
Therefore, it may be necessary to raise the volt-
age of the battery initially (20 V as a maximum),
and charge for approximately 5 minutes. If the
ammeter shows no change in current after 5 min-
utes, you need a new battery.
Current flowing into the battery at high voltage
can become excessive. Monitor amperage and
adjust voltage as necessary to keep current at
the battery’s standard amp rating. Charge for
approximately 20 hours.
Testing Battery
Battery Load Test
mmr2017-032-002
1. Connect a battery load tester such as the NAPA

ULTRA PRO BATTERY LOAD TESTER (P/N 95260). 4. Remove battery hold down bracket.
2. Ensure proper test conditions.
TEST CONDITIONS
Initial battery voltage‡ Above 12.5 Vdc
Engine OFF
mmr2017-032 3
55 Vdc Output
ECMB CONNECTOR
pins M1, M2, M4
mmr2017-032-003
5. Remove battery.
mmr2017-032-001
Testing Continuity
(Voltage Regulator/Rectifier)
Due to internal circuitry, there is no static test
available to check continuity.
Testing 55 Vdc Voltage

Output with B.U.D.S.
mmr2017-032-004
(Voltage Regulator/Rectifier)
1. Raise vehicle so that the track is off the ground
Installing Battery and can turn freely.
TIGHTENING TORQUE
WARNING
Battery terminals 10 N•m ± 2 N•m Ensure vehicle track is completely raised off
(positive and negative) (89 lbf•in ± 18 lbf•in)
ground. If the track should come into con-
Battery hold down 5 N•m ± 0.5 N•m tact with the ground when the engine is at
bracket (44 lbf•in ± 4 lbf•in) 5000 RPM, equipment damage and severe in-
Battery cover retaining 7 N•m ± 1 N•m jury may result.
2. Remove RH side panel, refer to BODY subsec-
tion.
VOLTAGE REGULATOR/
RECTIFIER Procedure When Engine Cannot be Started
1. Install the following tools to supply power to
Description the 12 Vdc circuits for this test. Refer to COM-
The voltage regulator/rectifier is integrated within MUNICATION TOOLS AND B.U.D.S. subsec-
the ECM. It receives alternating current (AC) from tion for proper connections.
the magneto which it rectifies and regulates to – POWER INTERFACE (P/N 515 177 223)
55 Vdc. – 12 V BATTERY SUPPLY CABLE (P/N 529 035 997)
On a single pull start with the engine between 250 – 12 volts battery.
and 500 RPM, the magneto, is capable of produc-
2. Select the Measurements page.
ing 30-40 Vdc.
3. Read the voltage on the 55V System Circuit
meter in B.U.D.S. as the engine is turning over.
4 mmr2017-032
55 VDC VOLTAGE OUTPUT TEST 12 Vdc Output Voltage Tests

(DC-DC Converter)
TEST ENGINE SPEED VOLTAGE
12 VDC OUTPUT VOLTAGE
Pull start (engine not
At least 30 Vdc
running) OUTPUT CONNECTOR - -PIN
If you cannot obtain the specified voltage, refer to Primary 12 Vdc COM - 6
TROUBLESHOOTING in this subsection and carry Secondary 12 Vdc COM - 5
out the required tests.
Also carry TESTING VOLTAGE REGULATOR/REC- Testing Primary 12 Vdc Circuit with B.U.D.S.
TIFIER GROUND CIRCUIT in this subsection. 1. Start engine.
Procedure with Engine Running 2. Turn off any accessories.
1. Connect vehicle to the applicable B.U.D.S. 3. Disconnect any external batteries.
software version, refer to COMMUNICATION 4. Select the Measurements page.
TOOLS AND B.U.D.S. subsection. 5. Read the voltage on the Primary 12 V Circuit
2. Start engine. meter in B.U.D.S.
3. Select the Measurements page. PRIMARY 12 VDC CIRCUIT TEST WITH B.U.D.S.
4. Read the voltage on the 55 V System Circuit
TEST ENGINE SPEED VOLTAGE
meter in B.U.D.S.
Any RPM from idle
55 VDC VOLTAGE OUTPUT TEST (ENGINE 14.5 ± 0.5 Vdc
and above
RUNNING)
TEST ENGINE SPEED VOLTAGE If voltage is above specification, replace ECM.
Any RPM from idle If voltage is below specification, check the PRI-
55 Vdc ± 2 MARY 12 VDC CIRCUIT
and above
Also test the ECM ground circuit (voltage regula-
If voltage is below or above specification, refer to tor/rectifier).
TROUBLESHOOTING in this subsection and carry
out the required tests. Install all removed parts and connectors.
Also test the ECM ground circuit. Secondary 12 Vdc Circuit Test
The secondary 12 Vdc system is not monitored in
Testing ECM Ground Circuit B.U.D.S.
To test it, carry out the following procedure.
1. Disconnect the ECMA connector.
1. Remove RH side panel to expose the fuse(s).
2. Test ground circuit continuity as follows. Refer to BODY.
ECM GROUND CIRCUIT 2. Set FLUKE 115 MULTIMETER (P/N 529 035 868) to
Vdc scale.
ECMA 3. Start the engine.
Black wire of
Connector Pins Continuity 4. Unplug battery (if applicable)
capacitor
L3, L4, M3, M4
5. Probe the COM connector as follows.
Black wire of
Chassis ground Continuity 12 VDC OUTPUT VOLTAGE
capacitor
OUTPUT CONNECTOR - -PIN
DC-DC CONVERTER Secondary 12 Vdc COM - 5
System voltage (12 Vdc) is explained in POWER
DISTRIBUTION AND GROUNDS subsection.
mmr2017-032 5
SECONDARY 12 VDC CIRCUIT TEST To properly discharge capacitor, leave it con-

nected for at least 5 minutes after engine has
TEST ENGINE SPEED VOLTAGE been stopped, or after engine was last cranked
Any RPM from idle before carrying out any maintenance procedure
14.5 ± 0.5 Vdc
and above on the capacitor or 55 volt electrical system.
If voltage cannot be measured, test continuity of Testing Capacitor Charge Hold

wire from COM-5 to ECMB pins L1, L2, and L3.
Procedure Setup
If the wire continuity is good and other voltages
from ECM tested good, ECM may not output sec- 1. Remove capacitor from vehicle. Refer to RE-
ondary 12 Vdc. MOVING CAPACITOR in this subsection
Test the VOLTAGE REGULATOR/RECTIFIER 2. Work on a non metallic workbench.
GROUND CIRCUIT. If the ground circuit tests 3. Connect the following items to the capacitor.
good, the ECM will need to be replaced. See following illustration.
NOTE: Before replacing ECM, all ECM grounds, – A switch
power output circuits, and input circuits from the – Resistor (300 /5 W)
magneto must be tested. – 12 V battery (fully charged).
Repair or replace as applicable. NOTICE Ensure the test switch is in the OFF
position when connecting the battery to the ca-
CAPACITOR pacitor to prevent sparking or electrical shock.
The fuel injectors, which require a stable 55 Vdc
for their operation, are particularly sensitive to WARNING
voltage variations. A capacitor is connected to Connect the battery POSITIVE post to the ca-
the 55 Vdc electrical system to stabilize the sys- pacitor POSITIVE terminal.
tem voltage.
The capacitor is located next to the ECM on the
RH side of the vehicle.
Quick Troubleshooting
A faulty capacitor will lead to the following symp-
toms:
– Unstable, low, or no system voltage (55 V).
– Engine will not start
– Engine hard to start
– Poor idling
– Engine misfiring.
NOTE: A defective capacitor is likely to give off a
burning like odor.
Discharging Capacitor mmr2009-023-072_k
SWITCH AT OFF
WARNING
The capacitor remains charged approxi- Test Procedure
mately 10 seconds after engine is stopped. 1. Turn switch to ON and read capacitor voltage.
A high energy could suddenly be discharged Wait until voltage reaches 12 V.
if capacitor terminals were shorted. Always
discharge capacitor before servicing.
6 mmr2017-032
mmr2009-023-072_l mmr2009-023-072_j
SWITCH AT ON SWITCH AT OFF
2. Turn test switch to OFF. 7. The difference between the readings should
3. Use the FLUKE 115 MULTIMETER (P/N 529 035 not exceed the specification.
868) set to Vdc. ALLOWED VOLTAGE DIFFERENCE
4. Read capacitor voltage. BETWEEN READINGS
0.5 Vdc
If readings are out of specification, replace capac-

itor.
Reinstall capacitor. Refer to INSTALLING CAPAC-
ITOR in this subsection.
Testing Capacitor Residual Voltage
Procedure Setup
Follow the same steps as described in Procedure
Setup of TESTING CAPACITOR CHARGE HOLD.
Test Procedure
1. Turn switch to ON and read capacitor voltage.
Wait until voltage reaches 12 V to ensure the
mmr2009-023-072_j capacitor is fully charged.
SWITCH AT OFF
5. Wait 5 minutes.
6. Read capacitor voltage again.
mmr2017-032 7
mmr2009-023-072_e mmr2009-023-072_g
SWITCH AT ON
2. Turn test switch to OFF.
NOTE: Carry out the following steps within one CAPACITOR RESIDUAL VOLTAGE
minute to ensure the capacitor does not begin to Must be above 2.6 Vdc
discharge before the test.
3. Remove battery from circuit and connect the If voltage is out of specification, replace capacitor.
resistor and switch across capacitor terminals.
Removing Capacitor
NOTICE Ensure test switch is in the OFF po- 1. Remove upper body module. Refer to BODY
sition during the circuit configuration change. subsection.
2. Disconnect magneto connector.
3. Remove muffler.
WARNING
Disconnect the magneto connector. Should
the engine be made to rotate with magneto
connected, a spark may occur resulting in
electrical shock, a fire or an explosion.
4. Ensure capacitor remains connected for at least

1 minute after engine shut down, or after en-
gine was last cranked. This ensures capacitor
is fully discharged.
5. Disconnect wire terminals from capacitor.
mmr2009-023-072_f
SWITCH AT OFF
4. Turn test switch to the ON position for 12 sec-

onds ± 1 second to slowly discharge capacitor.
5. Read capacitor voltage.
mmr2017-032-021
8 mmr2017-032
6. Remove capacitor from bracket.
mmr2017-032-022 mmr2009-076-003_a
1. Perforated shield
WARNING 2. Capacitor fluid leakage
Do not remove plastic protector from top of Installing Capacitor

capacitor unless the capacitor is to be re-
placed. The cover prevents the two capacitor 1. If capacitor was replaced, install a plastic pro-
contacts from being easily shorted together tector cap on new capacitor.
which may cause a spark, possibly resulting
in a fire.
7. Check inspection hole on top of capacitor.
mmr2017-032-009
NOTE: When reinstalling plastic protector, ensure

the + sign on top of capacitor is visible through the
hole in protector.
mmr2017-032-006
INSPECTION HOLE (SHIELD IS INTACT)
If the top shield is open (pierced), replace capaci-

tor.
NOTE: The following illustration shows a perfo-
rated shield with capacitor fluid leakage. This ca-
pacitor was connected in reverse polarity.
mmr2017-032-010
mmr2017-032 9
Otherwise, pull off protector, rotate it one half

turn, then reinstall it.
mmr2017-032-008
2. Route capacitor wires as per illustration and

connect wire terminals to capacitor. Connect
the WH/RD wire to the + terminal.
NOTICE Improper polarity could destroy the
capacitor while in operation.
mmr2017-032-020
NOTICE Be careful not to damage threads

when tightening capacitor screws.
3. Torque screws to 2 N•m (18 lbf•in).
4. Complete assembly of remaining parts in the
reverse order of removal.
10 mmr2017-032
Subsection XX (STARTING SYSTEM)
STARTING SYSTEM
SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 3–4
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................................. 3
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................... 293 550 004 ............................................. 5
GENERAL
STARTING SYSTEM BASICS
(WITHOUT BATTERY)
Conditions for Engine Starting
– Emergency engine stop switch set to RUN;
– D.E.S.S. key on the D.E.S.S. post.
Starting System Operation

mmr2017-033-001_a
Refer to REWIND STARTER subsection for start- 1. Start/RER button
ing system operation. 2. Emergency engine stop switch
3. ECM
4. Starter solenoid
STARTING SYSTEM BASICS 5.
6.
Starter
D.E.S.S. post
(WITH BATTERY) 7. D.E.S.S. key
Basic Starting System Operation (With Engine Cranking Conditions

Battery) The following conditions must be met to allow en-
gine cranking:
When the START button is pressed, 12 Vdc is ap-
plied to the ECM. The ECM activates the inter- 1. Emergency engine stop switch set to RUN.
nal ECM relay which provides 12 volts to one end 2. D.E.S.S. key on the D.E.S.S. post.
of the coil of the starter solenoid. If the engine 3. START button pressed and held.
cranking conditions are met, the ECM completes
the starter solenoid control circuit by providing a Starting System Logic
ground. If the START button is activated while the throttle
lever is depressed more than 60%, the engine will
crank but will not start (engine drowned mode).
If the START button is held after engine has
started, the ECM automatically stops the starter
if engine speed reaches at least 1400 RPM.
mmr2017-033 1
TROUBLESHOOTING (WITH 3. Poor/bad or corroded ground contacts (engine,

battery ground cable, starter etc.)
BATTERY)
- Check/clean/repair, refer to POWER DISTRIBU-
TION AND GROUNDS subsection.
DIAGNOSTIC TIPS
4. Starter solenoid
NOTE: It is a good practice to check for fault - Test solenoid, wiring and connections.
codes using B.U.D.S. as a first troubleshoot-
ing step. Refer to DIAGNOSTIC SYSTEM AND 5. Damaged starter or ground cables
FAULT CODES subsection. - Carry out SOLENOID DYNAMIC TEST.
Starting system failures are not necessarily re- 6. No ground provided by ECM to starter solenoid
lated to the starter but may be due to one the - Refer to CONTINUITY TEST OF START/RER
following: SWITCH CONTROL CIRCUIT in this subsection.
– Crankshaft position sensor (CPS)
7. Engine cannot be rotated (possibly seized)
– Starter solenoid fuse and start fuse
- Refer to ENGINE subsection.
– Battery, refer to CHARGING SYSTEM
– START/RER button ENGINE CRANKS SLOWLY
– Starter solenoid 1. Loose, corroded or dirty battery cable connec-
– Emergency engine cut-off switch tions
– ECM - Check/clean/tighten.
– Wiring/connections.
2. Discharged/weak battery
Check these components before removing the - Recharge and test. Refer to CHARGING SYSTEM
starter. subsection.
NOTE: This subsection assumes the problem is 3. Low voltage from starter solenoid
related to an electrical component of the starting
- Carry out a SOLENOID DYNAMIC TEST.
system. If the starting system tests good, ensure
engine is in good condition. Refer to applicable 4. Damaged starter or ground cables
subsection. - Carry out SOLENOID DYNAMIC TEST.
DIAGNOSTIC GUIDELINES STARTER TURNS, BUT STARTER DRIVE

DOES NOT MESH WITH RING GEAR
NOTHING HAPPENS WHEN START/RER
BUTTON PRESSED 1. Worn starter drive gear/starter gear/ring gear
- Replace worn parts. Refer to MAGNETO AND
1. Battery not connected STARTER subsection.
- Connect battery.
2. Defective drive
2. Burnt fuse - Replace starter drive. Refer to MAGNETO AND
- Check fuses STARTER subsection.
3. Defective internal ECM relay or related circuits STARTER KEEPS RUNNING

- Test power and ground circuits to starter sole-
noid. 1. Sticking solenoid contacts
- Replace solenoid.
4. Defective START/RER switch
- Test START/RER switch, wiring and connections. 2. Sticking or defective starter drive
- Lubricate or replace. Refer to MAGNETO AND
ENGINE DOES NOT CRANK STARTER.
1. Discharged battery
- Recharge and test. Refer to CHARGING SYSTEM
subsection.
2. Battery connections
- Check/clean/tighten.
2 mmr2017-033
PROCEDURES (WITH CONTINUITY TEST OF START/RER

BATTERY) SWITCH CIRCUIT
REQUIRED TOOLS SWITCH

SH RESISTANCE
POSITION
FLUKE 115 MULTIMETER Released Pins 1 and 2 Close to 0
(P/N 529 035 868)
Pressed and
Pins 2 and 8 Close to 0
held
ECM ADAPTER TOOL (P/N 529
036 166) If the switch does not test as specified, replace
the START/RER switch.
WARNING If the switch tests as specified, check for an open
circuit in harness.
Ensure vehicle cannot move when perform-
ing starting system tests.
STARTER SOLENOID
START/RER SWITCH Starter Solenoid Location
Pressing the start/RER switch sends a start sig-
nal (battery voltage) to the ECM. If the ENGINE
CRANKING CONDITIONS are met, the ECM will
ground the starter solenoid.
In B.U.D.S., select the Measurements page and
press the start/RER button to see if the ECM re-
ceives the start signal.
START/RER Switch Continuity Test
mmr2017-033-002
Testing Solenoid Input Voltage

1. Disconnect solenoid connector.
mmr2016-027-004_a
1. Disconnect the steering connector SH2. Refer

to WIRING HARNESS AND CONNECTORS
subsection.
2. Measure resistance through switch as per fol-
lowing table.
mmr2016-027-003
2. Set the multimeter to Vdc.

3. Install D.E.S.S. key on post.
4. Press the START/RER button to activate ECM.
5. Measure voltage.
mmr2017-033 3
SOLENOID INPUT VOLTAGE TEST SOLENOID DYNAMIC TEST (ENGINE CRANKING)

(SOLENOID COIL)
TEST PROBES SPECIFICATION
VOLTAGE
TEST PROBES Solenoid
READING Battery ground Battery voltage
battery post
Pin A Battery ground Battery voltage
If test succeeded, carry out a SOLENOID CON- 2 1

TROL CIRCUIT TEST.
If test failed, carry out a START/RER SWITCH CIR-
CUIT CONTINUITY TEST. M
Testing Solenoid Control Circuit
1. Set the multimeter to .
2. Disconnect connector "B" from ECM, refer to smr2009-034-010_a
WIRING HARNESS AND CONNECTORS sub- 1. Starter motor
section. 2. Starter solenoid
3. Install the ECM ADAPTER TOOL (P/N 529 036 166) 5. If test failed, check battery positive cable (from
on ECM harness connector. battery to solenoid).
4. Test continuity of wiring from solenoid to ECM 6. If test succeeded, continue with next step.
as per following table.
SOLENOID DYNAMIC TEST (ENGINE CRANKING)
SOLENOID CONTROL CIRCUIT TEST
TEST PROBES SPECIFICATION
SOLENOID ECM
RESISTANCE Solenoid
CONNECTOR CONNECTOR B Battery ground Battery voltage
starter post
Close to 0
Pin B ECMB-A1
(continuity)
2 1
If test failed, repair or replace wiring/connectors.
If test succeeded, carry out a SOLENOID COIL
RESISTANCE TEST. M
Testing Solenoid Coil Resistance
1. Set multimeter to .
2. Disconnect solenoid connector.
smr2009-034-010_b
3. Measure solenoid coil resistance as per follow- 1. Starter motor
ing table. 2. Starter solenoid
SOLENOID COIL RESISTANCE TEST 7. If test failed, test SOLENOID INPUT VOLTAGE.
SOLENOID CONNECTOR RESISTANCE 8. If test succeeded, continue with next step.
Pin A Pin B 4.5 to 5.5 SOLENOID DYNAMIC TEST (ENGINE CRANKING)
If test fails, replace solenoid. TEST PROBES SPECIFICATION

Solenoid Solenoid
Testing Solenoid (Dynamic) 0.2 Vdc max.
battery post starter post
1. Depress the throttle lever to place the ECM in
engine drowned mode. Hold throttle lever in
place using a rubber band.
2. Set multimeter to Vdc.
3. Crank engine.
4. As engine is cranking, measure the voltage as
per following tables.
4 mmr2017-033
2 1
smr2009-034-010_c
1. Starter motor
2. Starter solenoid
If test failed, replace solenoid.

mmr2016-027-003
If all solenoid dynamic tests are as specified, re-
place starter. 4. Press down on the tabs and release the sole-
9. Remove rubber band from throttle lever. noid.
10. Reinstall removed parts.
Removing Solenoid
1. Disconnect battery. Refer to CHARGING SYS-
TEM subsection.
WARNING
Always disconnect the BLACK (-) battery ca-
ble first and reconnect last.
2. Disconnect solenoid cables.
mmr2017-033-003
Installing Solenoid
Reverse the removal procedure and pay attention
to the following.
1. Secure solenoid on its support, ensure the tabs
lock.
NOTE: Apply DIELECTRIC GREASE (P/N 293 550
004) under and over each connections and make
sure each nut are well covered.
mmr2016-027-007
TIGHTENING TORQUE
3. Disconnect starter solenoid connector.
Solenoid cable retaining 4 N•m ± 0.5 N•m
nuts (35 lbf•in ± 4 lbf•in)
2. Close or slide protective caps.

3. Reconnect battery and test starter solenoid op-
eration.
STARTER
For starter information refer to MAGNETO AND
STARTER subsection.
mmr2017-033 5
Subsection XX (RF DIGITALLY ENCODED SECURITY SYSTEM (RF D.E.S.S.))
RF DIGITALLY ENCODED SECURITY

SYSTEM (RF D.E.S.S.)
SERVICE TOOLS
POWER INTERFACE ..................................................................... 515 177 223 ........................................... 2
GENERAL
SYSTEM DESCRIPTION
The following components are specially designed for this system: ECM, D.E.S.S. key (inside tether cord
cap) and engine cut-off switch.
This system allows the engine to reach pulley engagement speed only if a D.E.S.S. key is installed on
engine cut-off switch and the key is recognized as valid by the ECM.
The D.E.S.S. key contains a magnet and a RFID chip.
– The magnet closes the hall effect switch inside the engine cut-off switch.
– The RFID chip contains a unique digital code. It is the equivalent of the tooth-pattern cut on a conven-
tional ignition key.
Up to 8 D.E.S.S. keys may be programmed in the ECM memory using the B.U.D.S. The keys can also
be erased individually.
NOTE: If desired, a D.E.S.S. key can be used on another vehicle equipped with the D.E.S.S. system. It
only needs to be programmed for that vehicle.
D.E.S.S. Beeper Codes

When starting the engine with a D.E.S.S. key on the engine cut-off switch, the key is identified by the
ECM and D.E.S.S. signals will be issued according to the key recognition. See table.
D.E.S.S. SIGNAL
DISPLAYED DESCRIPTION COMMENT
BEEPER
MESSAGE
Compact
digital gauge:
"Good Key"
2 shorts beeps Valid key read Working D.E.S.S. key.
Other gauges:
DESS tell-tale
light will flash
– Reinstall key
Short beeps CHECK – RPM limited to 2500
Unable to read key
repeating slowly KEY – Check D.E.S.S. status in B.U.D.S.
– No voltage at RFID connector pin D
– Use the proper key for this vehicle or
Shorts beeps BAD Invalid key or key not
have the key programmed.
repeating rapidly KEY programmed
– Vehicle can not be driven.
mmr2017-034 1
Subsection XX (RF DIGITALLY ENCODED SECURITY SYSTEM (RF D.E.S.S.))
PROCEDURES
D.E.S.S. KEY
D.E.S.S. Key Programming
Use BUDS2.
Refer to the B.U.D.S. directory on KNOWLEDGE
CENTER for all BUDS related information, includ-
ing:
– Current version download link mmr2015-131-005_a
– User manual (programming keys, reading fault 1. D.E.S.S. post
codes, writing data to modules etc.)
– Installation instructions Key Not Present
– Navigation through menus Possible causes:
– BRP BUDS chart – No key installed
Search keyword: "BUDS". – No voltage at RFID-B connector
– No ground at RFID-A connector
Condition can be duplicated by unplugging the
RFID connector.
mmr2017-025-001
Invalid Key
Possible causes:
D.E.S.S. / ENGINE CUT-OFF – Key not programmed to ECM
OPERATION
Connect BUDS2, refer to COMMUNICATION
BEEPER
TOOLS AND BUDS. The beeper is integrated in the multifunction
Navigate to the keys page. gauge and cannot be replaced alone.
Read key. Consult the sections below to trou- If the beeper does not sound when starting the
bleshoot a key problem. engine, check the beeper operation. Refer to
GAUGE subsection.
Normal Operation (Good Key)
Refer to WIRING DIAGRAM.
SPECIFICATIONS with
POWER INTERFACE
RFID CONNECTOR PIN
(P/N 515 177 223)
installed
A ECM ground
B 12 - 15 Vdc
C 5 Vdc
D 12 Vdc
Key Not Read

Possible causes:
– Damaged RFID chip
– No voltage at RFID-D connector
– No voltage at RFID-C connector
Condition can be duplicated with a magnet on the
D.E.S.S. post.
2 mmr2017-034
Subsection XX (ROTAX ELECTRONIC REVERSE (RER))
ROTAX ELECTRONIC REVERSE (RER)

SERVICE TOOLS
DIAGNOSTIC CABLE .................................................................... 710 000 851 ............................................. 2
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 2–3
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................................. 2
MPI-2 INTERFACE CARD .............................................................. 529 036 018 ............................................. 2
MPI-3 INTERFACE CARD .............................................................. 529 036 353 ............................................. 2
POWER INTERFACE ..................................................................... 515 177 223 ............................................. 2

OPTIONAL MALE-FEMALE EXTENSION SERIAL CABLE ............ (DB9) ............................................. 2
GENERAL If the following condition are not meet, the RER

function is disabled and nothing takes place when
The main components of the RER system are: the RER button is pressed.
– RPM between 1000 and 4300 RPM
– Throttle lever released (TPS opening below 2%)
– Vehicle speed below 25 km/h (16 MPH).
NOTE: Refer to E-TEC DIRECT FUEL INJECTION
subsection for crankshaft position sensor (CPS)
testing.
TROUBLESHOOTING
DIAGNOSTIC TIPS
RER Does Not Respond When
mmr2017-035-001
1. RER Switch
Depressing RER Button
2. Crankshaft position sensor (CPS) Check the following:
3. ECM
– RER fuse condition
The ECM receives signals from the CPS for for- – Check if the vehicle is properly configured in
ward and reverse engine rotation. B.U.D.S. (with Mechanical Reverse check box
The ECM recognizes a signal sent by the RER not selected)
switch. – TESTING RER SWITCH SIGNAL WITH B.U.D.S.
When the RER switch is activated and the engine
is running at or near idle speed, the ECM cuts Engine Stops after Pressing RER
off ignition, therefore causing the engine RPM to Button
drop off gradually. This confirms that RER control circuits function
When the engine reaches a predetermined low normally. Check the following:
RPM (approximately 450 RPM), the ECM initiates – CPS
an ignition spark that is greatly advanced in timing, – Engine compression, refer to TOP END subsec-
creating a thrust which reverses engine rotation. tion.
– Reed valves leaking, refer to applicable TOP
END subsection
mmr2017-035 1
– RAVE valve adjustment or sticking, refer to RER SWITCH

RAVE subsection
– Drive belt adjustment, refer to DRIVE SYSTEM Testing RER Switch Signal with BUDS2
AND BRAKE subsection 1. Connect vehicle to BUSD2.Download from
– ECM KNOWLEDGE CENTER. Refer to COMMUNI-
– Stator, refer to MAGNETO SYSTEM subsection CATION TOOLS AND B.U.D.S. subsection for
proper connection instructions.
– Capacitor, refer to CHARGING SYSTEM sub-
section. REQUIRED TOOLS
Ensure 55V system is in good condition at idle. MPI-2 INTERFACE CARD
(P/N 529 036 018)
RER Functions Erratically or
MPI-3 INTERFACE
1. Check engine compression.
CARD (P/N 529 036 353)
NOTE: A low compression resulting in loss of en-
gine power may cause the RER to function errat- DIAGNOSTIC CABLE (P/N 710
ically, leading you to believe the problem is in the 000 851)
electronic control system.
POWER INTERFACE
2. Low compression may be due to the following (P/N 515 177 223)
items:
– REED valves leaking or broken 12 V BATTERY SUPPLY CABLE
– RAVE valves sticking (P/N 529 035 997)
– Worn engine parts. OPTIONAL MALE-FEMALE
3. Check piston condition through the intake and EXTENSION SERIAL CABLE
exhaust ports. (P/N (DB9))
NOTE: Look for scoring on piston skirts. Scored
NOTE: A 12 volt battery is required to activate the
piston skirts or other mechanical problems result-
electrical system.
ing in excessive friction which may cause the RER
to function erratically. 2. In BUDS2, select the Scan button.
4. Also check the following: 3. Select the Measurements tab.
– RER switch for intermittent operation, refer 4. Raise track and start the engine.
to TESTING RER SWITCH CONTINUITY in 5. Press vehicle RER button and look for the
this subsection START/RER Button status to change.
– Loose (intermittent) electrical connections
If the START/RER Button status changes, it
– Drive belt adjustment, refer to DRIVE SYS- indicates the RER switch, ECM and wiring are
TEM AND BRAKE subsection functioning properly. Test CPS. Refer to E-TEC
– ECM. DIRECT FUEL INJECTION subsection.
If theSTART/RER Button status does not change,
PROCEDURES carry out the RER switch tests that follow.
REQUIRED TOOLS NOTE: When the B.U.D.S. RER test is carried
out with engine running and reverse engages,
FLUKE 115 MULTIMETER the RER light on the ECM Monitoring page and
(P/N 529 035 868) the reverse light on the Cluster Monitoring page
should both turn ON.
ECM ADAPTER TOOL (P/N 529
036 166) Testing RER Switch Continuity
1. Measure continuity of RER switch as per fol-
lowing table.
M o d e ls w i t h m u l t i f u n c t i o n s w it c h o n h a n d l e b a r
2. Disconnect the RER switch (SH) connector.
2 mmr2017-035
SWITCH SH (RER) CONNECTOR SPECIFICATION

RESISTANCE
POSITION CONNECTOR
RER-2 Chassis ground 12 Vdc
Continuity (0.4
Released SH-1 SH-2 No voltage
max.)
when switch
Press and Continuity (0.4 is released
SH-8 SH-2
held max.) RER-1 Chassis ground 12 volts when
switch is
M o d e l s w it h c o n s o l e s w i t c h e s pressed and
3. Disconnect the RER connector. held
SWITCH RER If no voltage is present at RER-1 when switch is
RESISTANCE
POSITION CONNECTOR pressed and held, replace switch.
Release RER-1 RER-2 O.L. If no voltage is present at RER-2, repair the wire
Press and Continuity (0.4 between RER fuse and RER-2 connector.
RER-1 RER-2
hold max.)
Testing RER Switch Signal to ECM
If continuity test fails, replace switch.
M o d e ls w i t h e l e c t r ic s t a r t e r
If continuity tests were good, measure voltage as
1. If applicable, ensure the (SD) starter solenoid
per TESTING RER SWITCH CIRCUIT.
connector is disconnected.
Testing RER Switch Circuit A l l m o d e ls
M o d e l s w it h m u l t if u n c t io n s w i t c h o n h a n d l e b a r 2. Disconnect ECMB connector and install the
ECM ADAPTER TOOL (P/N 529 036 166).
1. Backprobe SH2 connector pins as per table.
2. Lift track and idle vehicle. 3. Test wire continuity between the RER fuse and
the ECMB connector as follows.
(SH) CONNECTOR SPECIFICATION
ECMB
RER FUSE (F1) RESISTANCE
SH-1 Chassis ground 0 CONNECTOR
Chassis ground RER switch
when switch pressed
is released FB-H ECMB-A3 and held
START / RER Continuity
SH-2 12 volts when
SIGNAL (0.2 max.)
switch is
pressed and RER switch
held FB-H ECMB-A3 released
Infinite (OL)
Unswitched
SH-8 Chassis ground
12 Vdc
If continuity test is good, try a new ECM.
If chassis ground SH-1 and 12 volts SH-8 mea- If test fails, repair or replace wiring.
surements are good but START / RER SIGNAL
SH-2 measurements are incorrect, replace switch. BEEPER (REVERSE ALARM)
If chassis ground is not measured, repair the wire The reverse alarm (beeper) is integrated in the
between chassis ground and SH connector. gauge cluster and is also used for emitting the
If 12 votls is not measured, repair the wire be- vehicle beep codes. Refer to applicable GAUGE
tween RER fuse and SH connector. subsection for the testing procedure.
Testing RER Switch Circuit

M o d e l s w it h c o n s o l e s w i t c h e s
2. Backprobe RER connector pins as per table.
3. Lift track and idle vehicle.
mmr2017-035 3
Subsection XX (LIGHTS)
LIGHTS
SERVICE TOOLS
POWER INTERFACE ..................................................................... 515 177 223 ............................................. 1
GENERAL
Refer to WIRING HARNESS AND CONNECTORS
for electrical connector locations.
WARNING
must be strictly adhered to. Locking devices
must be replaced with new ones when re-
moved (e.g.: locking tabs, elastic stop nuts,
self-locking fasteners, cotter pins, etc.).
SYSTEM TESTING mmr2017-036-006
All vehicle lights are powered from the primary 4. Turn bulb socket to unlock and remove bulb.
12 Vdc circuit. This circuit is powered from and NOTE: Ensure bulb seal stays in place.
controlled by the ECM when the engine reaches
800 RPM. Refer to POWER DISTRIBUTION AND
GROUNDS subsection for more information on
how power is distributed to various systems.
For models without a battery, connect the follow-
ing tools in order to provide electrical power to the
vehicle.
REQUIRED TOOLS
– POWER INTERFACE (P/N 515 177 223)
– 12 V BATTERY SUPPLY CABLE
(P/N 529 035 997)
– 12-volt battery
mmr2017-036-008
1. Bulb socket
PROCEDURES 2. Bulb seal
Installing Headlight Bulb

HEADLIGHTS
NOTICE Never touch glass portion of a halo-
Removing Headlight Bulb gen bulb with bare fingers, it shortens its oper-
1. Remove gauge and trim. Refer to BODY sub- ating life. If glass is touched, clean it with iso-
section. propyl alcohol which will not leave a film on
2. Remove front glove box. Refer to BODY sub- the bulb.
section. Reverse removal procedure.
3. Unplug electrical connector.
Measuring Headlight Input Voltage
1. Disconnect headlight connector(s).
2. Provide electrical power to the headlights for
testing.
mmr2017-036 1
3. Read voltage at headlight connector as follows. Aiming Headlight Beam

WIRE COLOR Beam aiming is correct when center of high beam
SWITCH is 25 mm (1 in) below the headlight horizontal cen-
(HEADLIGHT VOLTAGE
POSITION
CONNECTOR) ter line, scribed on a test surface, 381 cm (12 ft
6 in) away.
LO beam GY/OG BK Battery
voltage 1. Place the vehicle on a flat surface perpendicu-
HI beam GY/WH BK (Vdc) lar to test surface (wall or screen) and 381 cm
(12 ft 6 in) away from it.
If voltage is inadequate, carry out the following to 2. Ask rider to sit on vehicle seat, or apply equiv-
find the source of the problem: alent weight on the vehicle.
– Test headlights dimmer switch.
3. Select high beam.
– Test wiring harness and connectors.
– Test primary 12 Vdc system. Refer to CHARG- 4. Measure headlight center distance from
ING SYSTEM. ground. Scribe a line at this height on test
surface (wall or screen). Light beam center
Testing Headlight Dimmer with BUDS2 should be 25 mm (1 in) below scribed line.
The headlight dimmer switch status can be mon-
itored using BUDS2.
Testing Headlight Dimmer Switch

Continuity 1 90°
1. Disconnect the applicable connector depending
on gauge, refer to following tables. A
2. Test switch circuits on applicable connector on
switch side as per table.
B
MODELS WITH COMPACT DIGITAL GAUGE
SWITCH DIMMER
SPECIFICATION mmr2010-024-010_a
POSITION PINS
TYPICAL
2 4 Close to 0 1. Headlight center line
HIGH A. 381 cm (12 ft 6 in)
2 1 Infinite (OL) B. 25 mm (1 in) below center line
2 4 Infinite (OL)
LOW 1 2
2 1 Close to 0
MODELS WITH ANALOG/DIGITAL GAUGE

SWITCH
SH PINS SPECIFICATION 3 A
POSITION
A02E07A
12 7 Close to 0 1. Headlight horizontal

HIGH 2. Light beam (high beam) (projected on the wall)
6 7 Infinite (OL) 3. Light beam center
7 A. 25 mm (1 in)
12 Infinite (OL)
LOW
6 7 Close to 0 Adjusting Beam
Open the front storage compartment.
If tests were good, switch is functioning properly.
Turn knob to adjust the beam height.
If any test failed, check wiring and connections go-
NOTE: Avoid reaching extreme adjustments as
ing to switch.
the headlight assembly might move out of posi-
If test of wiring and connections was good, re- tion.
place switch.
2 mmr2017-036
mmr2017-036-003
mmr2017-036-005
TAILLIGHT / BRAKE LIGHT

Replacing Taillight
mmr2017-036-004
Replace taillight.
Installation is the reverse of removal. However
pay attention to the following.
mmr2017-036-001
TIGHTENING TORQUE
Taillight retaining screw 0.4 N•m (4 lbf•in)
mmr2017-036-002
mmr2017-036 3
Subsection XX (GAUGE (ANALOG/DIGITAL))
GAUGE (ANALOG/DIGITAL)
SERVICE TOOLS
12 V BATTERY SUPPLY CABLE .................................................... 529 035 997 ......................................... 2, 4
POWER INTERFACE ..................................................................... 515 177 223 ......................................... 2, 4
mmr2017-037-001_a
mmr2017-037 1
GENERAL GAUGE DESCRIPTION

bleshooting step. Refer to DIAGNOSTIC AND
WARNING
SYSTEM TESTING mmr2017-037-001
MULTIFUNCTION ANALOG/DIGITAL GAUGE (PREMIUM)

For models without a battery, connect the follow- 1. Speedometer
ing tools in order to provide electrical power to the 2. Tachometer (RPM)
3. Gauge Multifunction Digital Display
vehicle. 4. Gauge Pilot Lamps
REQUIRED TOOLS
Mode and Set Buttons
(P/N 529 035 997)
– 12-volt battery
mmr2017-037-002
1. MODE button
2. SET button
The mode and set buttons allow you to toggle

through the different gauge functions and set-
tings.
INDICATOR LAMPS
INDICATOR LAMP(S) STATE DESCRIPTION
All indicator lamps On All indicator lamps are activated during WOW TEST
Steady on Parking brake engaged.
Blnking slowly Unit in reverse position.
On Headlights in the HIGH beam position.
2 mmr2017-037
On Charging system fault
Blink 4 times then steady on Engine management system fault
Blink 4 times then steady on Engine overheat 85°C (185°F)????

Blinking Major engine overheat100°C (212°F)????
On Engine temperature displayed
On Heated grip temperature displayed
On Heated throttle lever temperature displayed
On Fuel level displayed

On (red indicator lamp) Low fuel
On Low Engine Oil Pressure Indicator
Blink 2 times Good key

D.E.S.S. Blinking slowly Not able to read the key
Blinking rapidly Wrong key read / key not programmed to vehicle
INDICATOR LAMP DESCRIPTION ECM Overheat

Charging System Fault The indicator lamp comes on at 80°C (176°F) and
power limitation will occur at 85°C (185°F).
There is a charging system fault. Refer to CHARG-
ING SYSTEM subsection. Fuel Level Indication
Overheat Indicator Lamp A bar gauge located in the RH side of the display
indicates the amount of fuel in the fuel tank.
Overheat indicator lamp may come on for three
different reasons: engine overheat, muffler over- When there is approximately 12 L (3.2 U.S. gal.),
heat or ECM overheat. The multifunction gauge the indicator lamp will come ON to advise you that
will display the active problem. a low fuel condition exists.
Engine Overheat Check Engine Light

The indicator lamp comes on at 85°C (185°F) and The check engine light comes ON when a fault is
power limitation will occur at 95°C (203°F). Ma- detected by the engine management system.
jor engine overheat condition occurs when engine The check engine light may be accompanied by
temperature reaches 100°C (212°F), the overheat the applicable scrolling fault message in the mul-
indicator light will begin to blink. tifunction display.
Muffler Overheat To scroll through active fault codes, refer to DIS-
The indicator lamp comes on at 750°C (1,382°F) PLAYING "P" CODES in this subsection .
and power limitation will happen at 800°C
(1,472°F). Major muffler overheat condition Low Injection Oil Level Indicator
occurs when the muffler temperature reaches When this indicator is ON, it indicates a low injec-
800°C (1,472°F). tion oil level condition. Look for a message in the
multifunction display. Add oil to oil tank.
mmr2017-037 3
TROUBLESHOOTING
SYSTEM TESTING
For models without a battery, connect the follow-
vehicle.
REQUIRED TOOLS
(P/N 529 035 997)
mmr2017-037-003
– 12-volt battery 1. Clock displayed
1. In BUDS2, select the Settings page.

PROCEDURES
2. Activate the clock (models with battery).
GAUGE Changing Gauge Units of Measurement
Gauge Self Test Function The gauges are factory preset to indicate in im-
perial units and can be changed using the BUDS2
Gauge self test only runs if the gauge has been software.
off for more than 30 seconds.
To change the gauge units of measurement in
On ECM wake-up, the gauge will perform a self- BUDS2:
test. All indications should come ON and gauge
pointers will cycle once. You will have a few sec- 1. Provide electrical power to the gauge.
onds to ensure the indications (LEDs and LCDs) 2. In BUDS2, select the Setting page.
are functioning correctly. 3. Select Imperial or Metric in the Cluster Units
NOTE: This test only validates the gauge opera- field.
tion of the LEDs, LCDs in the gauge digital display NOTE: Speedometer, odometer and trip meter
and the pointers. It does not test the actual circuit will have their units (kilometer or miles) changed
functions related to each indication. simultaneously.
If the self test does not take place, test gauge in-
put power. Adjusting Speedometer and Tachometer
Pointer
Gauge Setup 1. In BUDS2, select the Settings page.
Activating Clock 2. Click on Clockwise or Counterclockwise but-
ton to align gauge pointer with the zero (0).
The gauge has an internal clock that can display
the time of day in the lower digital display (when NOTE: Because of the fine tuning of the pointer,
selected). the button must be pressed several times before
perceiving pointer movement.
NOTE: The internal clock is only available if the ve-
hicle is equipped with a battery, such as an electric Displaying “P” Codes
starter kit.
1. To activate P CODE mode, push and hold the
“M” button for 2 seconds.
2. As you hold the “M” button, quickly turn ON
and OFF the high beams a few times. The
gauge will enter P CODE mode.
3. While in P CODE mode, use the “M” or “S”
button to scroll over available failure codes.
4. Push and hold the “M” button to exit P CODE
mode.
4 mmr2017-037
A NO ACTIVE P CODE message is displayed if 4. Measure voltage as per following table.

there are no P CODES in memory.
GAUGE CONNECTOR VOLTAGE
Testing Gauge With BUDS2 Pin 9 Battery voltage
The GAUGE SELF TEST can be duplicated using
BUDS2 5. If there is no voltage read, test input wire con-
tinuity. Refer to WIRING DIAGRAM for circuit
1. Connect vehicle to BUDS2 Refer to COMMU- details.
2. In BUDS2,choose the Functions page. Testing Gauge Beeper
3. Select WOW Test. To test beeper, perform the following test with
BUDS2
Testing Gauge Power(Main 12 Vdc) 1. Connect vehicle to BUDS2 Refer to COMMU-
If the gauge does not come on when the engine NICATION TOOLS AND B.U.D.S.
is started, carry out the following test. 2. In BUDS2, choose the Functions page.
1. Remove multifunction gauge. 3. Activate the Cluster Buzzer Test.
2. Disconnect the gauge connector. You should hear a few beeps.
3. Set multimeter to Vdc. – If you do not hear the beeper, replace gauge.
4. Start engine.
Testing Gauge Buttons with BUDS2
5. Measure voltage with the chassis ground as per
following table. Using the BUDS2 software, select the Measure-
ments page.
Press the ’m’ and ’s’ buttons on the left multifunc-
Approximately 14.75 tion switch.
Pin 8
Vdc
6. If gauge main power input test was as speci-

fied, test the gauge ground circuit.
7. If no voltage was read, test wiring continuity.
Refer to WIRING DIAGRAM for details.
mmr2017-037-100
Testing Gauge Ground
If the indicator light(s) come ON in BUDS2, the
1. Set multimeter to selection.
gauge button(s) is(are) functioning correctly.
2. Measure for continuity of gauge ground wire to
If the indicator light(s) do not come ON, check
chassis ground as per following table.
button(s) and wiring continuity, refer to WIRING
GAUGE CONNECTOR RESISTANCE DIAGRAM. If they are in good condition, replace
Pin 11
gauge.
Close to 0
If ground test failed, check vehicle ground. Refer

Removing Gauge
to POWER DISTRIBUTION subsection. 1. Remove glove box.
If gauge power input test and ground circuit con- 2. Remove gauge trim.
tinuity tests are good, replace gauge.
Testing Clock 12 Vdc Input

(If electric starter kit is installed)
If the clock function in the premium gauge does
not hold the proper time of day when the engine
is not running, carry out the following test.
1. Remove multifunction gauge.
2. Disconnect the gauge connector.
mmr2017-037 5
mmr2017-037-004 mmr2017-037-007
3. Unplug gauge connector. Installing Gauge

TIGHTENING TORQUE
1 N•m ± 0.2 N•m
Gauge retaining screws
Configuring Gauge
Using BUDS2, configure gauge options as per
customer preferences
– Language
– Units
mmr2017-037-005
Summerization Function
4. Remove retaining screws. Like other engines, the E-TEC has to be properly
lubricated at storage for internal parts protection.
The E-TEC system offers a built-in engine storage
lubrication function (summerization) that can be
initiated by the operator.
To engage procedure, do the following:
1. Place the vehicle in a well ventilated area.
2. Start the engine and let it run at idle speed until
it reaches its operating temperature (watch the
coolant temperature on the display or verify that
the rear heat exchanger becomes warm).
3. Push the SET (S) button to select odometer
mode.
mmr2017-037-006
NOTE: The storage mode does not function in
5. Remove gauge. other modes (trip A, trip B and hr trip).
4. Hold the SET button while repeatedly pressing
the HI/LOW beam switch until PRESS/HOLD
_S_ FOR OIL INJECTION appears on the dis-
play.
5. Release all buttons when gauge displays
PRESS/HOLD _S_ FOR OIL INJECTION ap-
pears.
6. Again, press and hold the SET (S) button for 2 -
3 seconds.
6 mmr2017-037
NOTE: The gauge will display oil injection when

the storage procedure is initiated.
mmr2017-037-101
7. When gauge displays oil injection, release but-

ton and wait for the lubrication function to end.
Do not touch anything during engine lubrication
cycle.
The engine lubrication function takes approxi-
mately 1 minute. During this time, engine RPM
may increase slightly and the oil pump will "oil
flood" the engine.
At the end of engine lubrication function, the ECM
will stop the engine.
8. Remove tether cord cap from engine cut-off
switch.
NOTICE Do not start the engine during stor-
age period.
mmr2017-037 7
Subsection XX (GAUGE COMPACT DIGITAL)
GAUGE COMPACT DIGITAL

SERVICE TOOLS
12 V BATTERY SUPPLY CABLE .................................................... 529 035 997 ........................................... 2
POWER INTERFACE ..................................................................... 515 177 223 ........................................... 2
mmr2017-056-099_a
1
GENERAL GAUGE DESCRIPTION

The compact digital gauges is a heated, backlit
LCD gauge.
WARNING
self-locking fasteners, cotter pins, etc.). mmr2017-056-005
COMPACT DIGITAL GAUGE

SYSTEM TESTING 1. Gauge button
2. Gauge Digital Display
For models without a battery, connect the follow- The button allow you to toggle through the differ-
ing tools in order to provide electrical power to the ent gauge functions and settings.
vehicle.
REQUIRED TOOLS
(P/N 529 035 997)
– 12-volt battery
INDICATOR LAMPS
All indicator lamps On All indicator lamps are activated during WOW TEST
Parking brake engaged
Flashing
Brake applied while throttle lever
4 Beeps
depressed
Flashing slowly
Unit in reverse position.
Beeping slowly
On
Headlights in the HIGH beam position.
4 beeps
On
Charging system fault
4 Beeps
On Engine management system fault
On Temperature: cold
On Level: empty
2

On
Overheat condition
4 Beeps
Flashing
Major overheat condition
Beeping rapidly
On Engine temperature displayed
On Level: full
On Heated grip temperature displayed
On Heated throttle lever temperature displayed
On Temperature: hot
On Fuel level displayed

Flashing
Low fuel
Long beep
On Low oil indicator
Rev Limit Scrolling Limp home mode active
INDICATOR LAMP DESCRIPTION ECM Overheat

Charging System Fault The indicator lamp comes on at 80°C (176°F) and
power limitation will occur at 85°C (185°F).
There is a charging system fault. Refer to CHARG-
ING SYSTEM subsection. Fuel Level Indication
Overheat Indicator Lamp A bar gauge located in the RH side of the display
indicates the amount of fuel in the fuel tank.
Overheat indicator lamp may come on for three
different reasons: engine overheat, muffler over- When there is approximately 6 L (1.6 U.S. gal.),
heat or ECM overheat. The multifunction gauge the indicator lamp will come ON to advise you
will display the active problem. that a low fuel condition exists.
Engine Overheat Check Engine Light

The indicator lamp comes on at 85°C (185°F) and The check engine light comes ON when a fault is
power limitation will occur at 95°C (203°F). Ma- detected by the engine management system.
jor engine overheat condition occurs when engine The check engine light may be accompanied by
temperature reaches 100°C (212°F), the overheat the applicable scrolling fault message in the mul-
indicator light will begin to blink. tifunction display.
Muffler Overheat To scroll through active fault codes, refer to DIS-
The indicator lamp comes on at 750°C (1,382°F) PLAYING "P" CODES in this subsection .
and power limitation will happen at 800°C
(1,472°F). Major muffler overheat condition Low Injection Oil Level Indicator
occurs when the muffler temperature reaches When this indicator is ON, it indicates a low injec-
800°C (1,472°F). tion oil level condition. Look for a message in the
multifunction display. Add oil to oil tank.
3
PROCEDURES 3. Press and hold the button on the gauge while

cycling high beams on and off 5 times.
GAUGE Active fault codes will scroll across gauge display.
Gauge Self Test Function 4. Press the button to scroll multiple fault codes.
On ECM wake-up, the gauge will perform a self- 5. Hold the button to exit the function.
test. All indications should come ON and cycle
once. You will have a few seconds to ensure the Testing Gauge With BUDS2
indicator (lights are functioning correctly. The GAUGE SELF TEST can be duplicated using
NOTE: This test only validates the gauge opera- BUDS2
tion of the gauge digital display. It does not test 1. Connect vehicle to BUDS2 Refer to COMMU-
the actual circuit functions related to each indica- NICATION TOOLS AND BUDS2 subsection.
tion. 2. In BUDS2,choose the Functions page.
If the self test does not take place, proceed with 3. Select WOW Test.
the TESTING GAUGE POWER.
Testing Gauge Power (Main 12 Vdc)
Gauge Setup
If the gauge does not come on when the engine
Changing Gauge Units of Measurement is started, carry out the following test.
The gauges are factory preset to indicate in im- 1. Remove multifunction gauge.
perial units and can be changed using the BUDS2 2. Disconnect the gauge connector.
software.
1. Provide electrical power to the gauge.
4. Start engine.
2. In BUDS2, navigate to the Settings page.
5. Measure voltage with the chassis ground as per
3. Change the units of measurement as per owner following table.
preferences.
NOTE: Speedometer, odometer and trip meter
will have their units (kilometer or miles) changed Approximately 14.75
Pin 2
simultaneously. Vdc
Displaying “P” Codes 6. If gauge main power input test was as spec-
ified, carry out the gauge GROUND CIRCUIT
CONTINUITY TEST.
1. Provide electrical power to the gauge.
7. If no voltage was read, test wiring continuity.
2. Cycle through the gauge displays until both Refer to WIRING DIAGRAM for details.
RPM and speed are displayed.
Testing Gauge Ground
1. Set multimeter to selection.
2. Measure for continuity of gauge ground wire to
chassis ground as per following table.
GAUGE CONNECTOR RESISTANCE
Pin 8 Close to 0
If ground test failed, check vehicle ground. Refer

to POWER DISTRIBUTION subsection.
If gauge power input test and ground circuit con-
tinuity tests are good, replace gauge.
IndicatorLight_RPMKmh
TYPICAL RPM AND SPEED DISPLAYED
4
Testing Gauge Beeper

To test beeper, perform the following test with
BUDS2
1. Connect vehicle to BUDS2 Refer to COMMU-
NICATION TOOLS AND BUDS2
2. In BUDS2, choose the Functions page.
3. Activate the Cluster Buzzer Test.
You should hear 4 short beeps.
– If you do not hear the beeper, replace gauge.
Testing Gauge Button mmr2017-056-004
Using the BUDS2 software, select the Measure- 4. Remove retaining screws.
ments page.
Press button on the gauge and activate the heater
and hi/lo beam buttons on the console.
If the indicator light(s) come ON in BUDS2, the
gauge button(s) is(are) functioning correctly.
If the indicator light(s) do not come ON, check but-
ton(s) and wiring continuity. Refer to WIRING DI-
AGRAM for details. If they are in good condition,
replace gauge.
Removing Gauge
1. Remove glove box.
2. Remove gauge trim. mmr2017-056-002
5. Remove gauge.
mmr2017-056-001
3. Unplug gauge connector. mmr2017-056-003
Installing Gauge
TIGHTENING TORQUE
1 N•m ± 0.2 N•m
Gauge retaining screws
5
Configuring Gauge
Using BUDS2, configure gauge options as per
owner preferences
– Language
– Units
– Throttle lever heating ratio. Refer to ACCES-
SORIES subsection for more information.
Summerization Function
Like other engines, the E-TEC has to be properly
lubricated at storage for internal parts protection.
The E-TEC system offers a built-in engine storage
lubrication function (summerization) that can be
initiated by the operator.
To engage procedure, do the following:
1. Place the vehicle in a well ventilated area.
2. Start the engine and let it run at idle speed until
it reaches its operating temperature (watch the
coolant temperature on the display or verify that
the rear heat exchanger becomes warm).
3. Push the gauge button to select odometer
mode.
NOTE: The storage mode does not function in
other modes (trip A, trip B and hr trip).
4. Hold thegauge button while repeatedly
pressing the HI/LOW beam switch until
PRESS/HOLD BUTTON FOR OIL INJECTION
appears on the display.
5. Release all buttons when gauge displays
PRESS/HOLD BUTTON FOR OIL INJECTION
appears.
6. Again, press and hold the gauge button for 2 -
3 seconds.
NOTE: The gauge will display oil when the stor-
age procedure is initiated.
7. When gauge displays OIL, release button and
wait for the lubrication function to end.
Do not touch anything during engine lubrication
cycle.
The engine lubrication function takes approxi-
mately 1 minute. During this time, engine RPM
may increase slightly and the oil pump will "oil
flood" the engine.
At the end of engine lubrication function, the ECM
will stop the engine.
8. Remove tether cord cap from engine cut-off
switch.
NOTICE Do not start the engine during stor-
age period.
6
Subsection XX (ACCESSORIES)
ACCESSORIES
SERVICE TOOLS
12 V BATTERY SUPPLY CABLE .................................................... 529 035 997 ........................................... 1
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................................... 6
POWER INTERFACE ..................................................................... 515 177 223 ........................................... 1
GENERAL NOTE: The heating intensity is displayed via the

gauge with the activation of the heated throttle
On multifunction analog/digital gauge, heated lever switch.
grips and heated throttle lever are limited at 50%
output when idling. The switch selection sends a signal to the gauge
to increase or decrease heat.
WARNING
SYSTEM TESTING
mmr2017-038-001
For models without a battery, connect the follow- HEATER SWITCH - MODELS WITH CONSOLE SWITCH
vehicle.
REQUIRED TOOLS
(P/N 529 035 997)
– 12-volt battery
SYSTEM DESCRIPTION (HEATED

THROTTLE LEVER)
mmr2017-038-002
HEATER SWITCH - MODELS WITH MULTIFUNCTION SWITCH
Power to the heated throttle lever is controlled The gauge then applies the appropriate amount of
through the gauge. current to the heater according to the selection.
A three position switch allows the selection vari- To turn OFF the heaters, select heat down until
ous heat levels, which are displayed in the gauge. there is no more indication on the bar graph.
NOTE: The heated handlebar grips and the When released, the 3 position switch springs back
heated throttle lever are controlled by the same to the center neutral position.
3 position switch when used with the console
switch. Refer to SETTING THE HEATED THROT-
TLE LEVER RATIO.
mmr2017-038 1
SYSTEM DESCRIPTION (HEATED SETTING THE HEATED

HANDLEBAR GRIPS) THROTTLE LEVER RATIO
On models where one switch simultaneously con-
trols the heated grip temperature and the throttle
lever, use BUDS2 to set the heated throttle grip
The grip heat is controlled through the gauge. ratio.
A three position switch allows the selection of var- A higher ratio will increase the heated throttle
ious heat levels, which are displayed in the gauge. temperature compared to the heated grips.
NOTE: The heated handlebar grips and the A lower ratio will lower the heated throttle tem-
heated throttle lever are controlled by the same perature compared to the heated grips.
3 position switch when used with the console 1. Connect BUDS2. Refer to COMMUNICATION
switch. Refer to SETTING THE HEATED THROT- TOOLS AND BUDS subsection.
TLE LEVER RATIO. 2. Navigate to the settings page.
3. Change the Heated Throttle Lever Ratio.
4. Write the changes to the cluster.
PROCEDURES
HEATED THROTTLE LEVER
mmr2017-038-001
HEATER SWITCH - MODELS WITH CONSOLE SWITCHES
mmr2017-038-005
On multifunction analog/digital gauge heaters are

limited to 50% under 2000 RPM.
For troubleshooting:
– Start engine and rev above 800 RPM for at least
2 seconds
mmr2017-038-006
– Use BUDS2 to activate the applicable heater.
HEATER SWITCH - MODELS WITH MULTIFUNCTION SWITCH
NOTE: On models with console switches, there
NOTE: The heating intensity is displayed via the is only one switch that controls both the heated
gauge with the activation of the heated grips grips and heated throttle lever. Refer to SYS-
switch. TEM DESCRIPTION and SETTING THE HEATED
The gauge then applies the appropriate amount of THROTTLE LEVER RATIO.
current to the heater according to the selection.
To turn OFF the heaters, select heat down until
there is no more indication on the bar graph.
When released, the switch springs back to the
center neutral position.
2 mmr2017-038
Testing Heated Throttle Lever Switch RESISTANCE

STR 6P CONNECTOR
with BUDS2 @ 20°C (68°F)
Heating elements are permanently connected to STR 6P-5 STR 6P-2 1.73 - 4.22
ground. Positive voltages are supplied by gauges.
1. Provide electrical power to the gauge for test- 1. If readings are out of specifications, replace
ing. throttle lever.
2. Using BUDS2, select the Measurements page. 2. If heating element readings are within specifica-
tions, check wiring and connections to gauge.
3. Alternately increase or decrease heat using
heated throttle lever switch. 3. Reconnect connectors.
4. Look for the applicable value to change to con-
firm the gauge receives the signal. HEATED HANDLEBAR GRIPS
If test is good, refer to TESTING GAUGE HEATED
THROTTLE LEVER POWER OUTPUT in this sub-
section.
If test failed, refer to TESTING THROTTLE LEVER
HEAT SWITCH in this subsection.
Testing Gauge Heated Throttle Lever
Power Output
1. Provide electrical power to the gauge for test-
ing.
2. Using BUDS2, select the Functions page..
3. In BUDS2, turn on the heated throttle grip. mmr2017-038-004
4. Touch throttle lever to confirm it heats up.

5. Backprobe gauge no. MG connector as per fol- Testing Handlebar Heated Grip Switch
lowing table. with BUDS2
MODELS WITH COMPACT DIGITAL GAUGE
Heating elements are permanently connected to
ground. Positive voltages are supplied by gauges.
TERMINAL SPECIFICATION
1. Provide electrical power to the gauge for test-
2.7 to 14.5 Vdc ing.
MG-7 depending on heated
2. Using the BUDS2, navigate to the Measure-
throttle lever ratio
ments page.
MODELS WITH ANALOG/DIGITAL GAUGE 3. Press on the vehicle handle grip heat switch to
alternately increase or decrease heat.
TERMINAL SPECIFICATION
4. In BUDS2, look for the applicable to change.
MG-4 12 Vdc
If test is good, proceed with TESTING GAUGE
6. If test is good, the gauge output to throttle lever HEATER GRIPS POWER OUTPUT WITH BUDS2
heater is good. Proceed with TESTING THROT- in this subsection.
TLE LEVER HEATING ELEMENT in this subsec- If test failed, proceed with TESTING HANDLEBAR
tion. GRIP HEAT SWITCH in this subsection.
7. If the test failed, replace the gauge.
Testing Gauge Heater Grips Power
Testing Throttle Lever Heating Element Output with BUDS2
Refer to WIRING HARNESS AND CONNECTORS 1. Provide electrical power to the gauge for test-
subsection for connector location. ing.
2. Using the BUDS2, navigate to the Functions
page.
3. In BUDS2, turn the heated grips on.
mmr2017-038 3
MODELS WITH COMPACT DIGITAL GAUGE Removing Heater Element

TERMINAL SPECIFICATION NOTICE Heater wire routing may vary sig-
MG-1 12 Vdc
nificantly due to different type handlebars and
vehicles. Its highly important to take note of
MODELS WITH ANALOG/DIGITAL GAUGE exact positioning of grip heaters, locking ties,
and wire routing before removing them from
TERMINAL SPECIFICATION the handlebars. Failure to properly route wires
MG-5 12 Vdc may lead to equipment damage or failure.
1. Disconnect the connector, Refer to WIRING
4. If test is good, the gauge heater to handlebar
DIAGRAM AND CONNECTORS subsection for
grip heater is good. Proceed with TESTING
connector location.
HANDLEBAR GRIP HEATING ELEMENT in this
subsection. 1.1 STR 4P for left hand handlebar heater
5. If the test failed, replace the gauge. 1.2 STR 6P for right hand handlebar heater
Use procedures for MOLEX connectors in the
Testing Handlebar Grip Heating WIRING DIAGRAM AND CONNECTORS subsec-
Element tion.
If you cannot feel the temperature increase of a 2. Cut locking ties securing heater wires to han-
hand grip heating element, carry out the following dlebars.
steps.
3. Pull wires from harness protective sheath, mul-
1. Disconnect heated grip connector. tifunction switch housing or throttle lever hous-
2. Test heating elements on either side as per fol- ing.
lowing specifications. 4. Cut and remove black electrical tape from
Refer to WIRING HARNESS AND CONNECTORS heater element and remove heater from cork
subsection for connector location. insulator.
RESISTANCE 5. If damaged, remove cork insulator from handle-
RIGHT HEATED GRIP bar and clean all adhesive residue from the han-
@ 20°C (68°F)
dlebar.
STR 6P-4 STR 6P-1 5.3 - 6.6
Installing Heated Grips Heater Element
RESISTANCE
LEFT HEATED GRIP 1. Measure 159 mm (6.25 in) from the end of the
@ 20°C (68°F)
handlebar, and across the top of the bend in the
STR 6P-3 STR 6P-1 5.3 - 6.6 bar. Trace a reference line with a marker at that
point on the handlebar.
3. If readings are out of specifications, replace ap-
plicable handle grip heating element.
4. If heating element readings are within specifi-
cations, check wiring and connections.
5. Reconnect connectors.
mbg2008-009-013_b
TYPICAL — MEASURING FOR HEATER POSITION

1. Trace reference line
2. Align the edge of the cork insulator with the ref-

erence line centered with the handlebar folding
axis as illustrated.
4 mmr2017-038
mbg2008-009-017_b
mbg2008-009-014_a
TYPICAL — CORK INSULATOR ALIGNMENT TYPICAL

1. Electrical tape application (4x)
3. Apply firm pressure to cork insulator to assure NOTE: It is highly important to apply tape so that it
proper adherence to handlebar. fully secures the electrical wire connections. This
4. Align the film heater element with the cork in- will ease installation of the rubber hand grip and
sulator and center of handlebar folding axis as prevent undue stress to the connections.
illustrated.
mbg2008-009-018_b
mbg2008-009-016_b
TYPICAL — IMPORTANT
TYPICAL — HEATER ALIGNMENT 1. Tape application over wire connections
1. Heater wire position (LH front, RH rear)
7. Install rubber hand grip, refer to STEERING
5. Apply firm pressure to heater to assure proper SYSTEM subsection for detail.
adherence to cork insulator.
8. Route wiring as noted during the removal pro-
NOTE: The same heater element is used for both cedure.
the LH and RH sides. Therefore, the electrical
wiring will be in front of the handlebar on the LH 9. Insert wire in housing, refer to WIRING DIA-
side, and behind the handlebar (towards driver) GRAM for wire color and pin number locations.
on the RH side.
6. Apply two turns of black electrical tape at each
of the four locations illustrated so that it cov-
ers the edges of the heater element and pre-
vents snagging and damage to the element dur-
ing rubber grip installation.
mmr2017-038 5
mmr2017-038-008
mbg2008-009-020_b
TYPICAL - SUMMIT HEATER WIRE ROUTING
TYPICAL
1. Heater wire terminals
2. Insertion through back of connector NOTICE Ensure LH heater wires are properly
routed through multifunction switch housing
10. Install locking ties to secure the heater wire as to prevent them from being pinched when
it was routed originally.. installing housing cover. Pinched or damaged
wires may result in a short circuit.
WARNING
To ensure RH heater wires does not prevent 11. Provide electrical power to the heaters for
smooth operation of throttle lever, it must be testing.
passed straight through the housing without 12. Using the hand grip heat switch, turn on the
any slack, and secured with a locking tie on hand grip heaters and ensure they are func-
the emergency engine cut-off switch hous- tioning correctly.
ing.
TESTING THROTTLE LEVER
HEAT SWITCH
NOTE: On models with the compact digital
gauge, there is only one switch that controls both
the heated grips and heated throttle lever.
1. Using the FLUKE 115 MULTIMETER (P/N 529 035
868), select the position.
2. Test throttle lever heat switch and circuits as
per table.
Models with console switches
mmr2017-038-700
TYPICAL -MXZ HEATER WIRE ROUTING
mmr2017-038-001
6 mmr2017-038
THROTTLE LEVER HEAT SWITCH TEST Models with console switches

SWITCH
TERMINAL RESISTANCE
SELECTION
GRIP-6 GRIP-8 Close to 0
UP
GRIP-6 GRIP-5 Infinite (OL)
DOWN
Models with multifunction switches
mmr2017-038-001
HEATED GRIP HEAT SWITCH TEST

SWITCH
TERMINAL RESISTANCE
SELECTION
UP
DOWN
mmr2017-038-002
THROTTLE LEVER HEAT SWITCH TEST Models with multifunction switches

SWITCH
TERMINAL RESISTANCE
SELECTION
SH-1 SH-9 Close to 0
UP
SH-1 SH-3 Infinite (OL)
DOWN
SH-1 SH-3 Close to 0
If continuity test is as per specification, check

wiring to gauge connector.
If continuity test is out of specification, check
switch circuit as per wiring diagram. If good, mmr2017-038-006
replace switch.
HEATED GRIP HEAT SWITCH TEST
TESTING HANDLEBAR HEATED SWITCH
TERMINAL RESISTANCE
GRIP SWITCH SELECTION
NOTE: On models with the compact digital SH-1 SH-10 Close to 0
gauge, there is only one switch that controls both UP
the heated grips and heated throttle lever.
1. Test throttle lever heat switch and circuits as DOWN
per table. SH-1 SH-4 Close to 0
If continuity test is as per specification, check

wiring to gauge connector.
mmr2017-038 7
If continuity test is out of specification, check

switch circuit as per wiring diagram. If good,
replace switch.
8 mmr2017-038
Subsection XX (DRIVE BELT)
DRIVE BELT
SERVICE TOOLS
TENSIOMETER.............................................................................. 414 348 200 ........................................... 5
3.3 ± 0.2 N•m

(29 ± 2 lbf•in)
mmr2017-039-100_a
mmr2017-039 1
GENERAL
DRIVE BELT APPLICATION
Always use the drive belt specified in the BRP
PARTS CATALOG as applicable to vehicle and en-
gine model.
TROUBLESHOOTING
VEHICLE CREEPS FORWARD AT IDLE
1. Improper drive belt height (too high)
mmr2013-034-002_a
- Refer to ADJUSTING THE DRIVE BELT HEIGHT 1. Belt guard tab
procedure in this subsection. 2. Front support slot
ENGINE STALLS WHEN ENGAGING RER 2. Push drive belt guard toward engine then to-
1. Improper drive belt height (too high)
ward front of vehicle.
- Refer to ADJUSTING THE DRIVE BELT HEIGHT
PROCEDURES
DRIVE BELT GUARD
NOTE: Belt guard is purposely made slightly over-
size to maintain tension on its pins and retainers
preventing undue noise and vibration.
Removing the Drive Belt Guard

1. Remove LH side panel.
2. Remove retaining pin.
mmr2013-034-006_a
3. Position rear portion of the drive belt guard over

the retainer and secure it using the retaining
pin.
mmr2017-039-001_a
3. Lift rear portion of guard then release from front

tabs.
Installing the Drive Belt Guard

mmr2017-039-002
1. Insert belt guard tab in front support slot.
2 mmr2017-039
DRIVE BELT GUARD SUPPORT

Removing the Drive Belt Guard
Support
1. Remove the drive belt guard.
2. Remove screws securing the support to vehi-
cle.
mmr2013-034-005_a
1. PULLEY expander to be installed here - on Adjuster hub
5. Open the driven pulley by screwing the tool in.

6. Remove the belt by slipping it over the top of
the driven pulley, then out of the drive pulley.
mmr2017-039-003_a
Inspecting the Drive Belt

Installing the Drive Belt Guard Support
Inspect belt for:
– Cracks
– Fraying
TIGHTENING TORQUE – Abnormal wear (uneven wear, wear on one
Drive belt guard support 3.3 N•m ± 0.2 N•m side, missing cogs, torn fabric).
Torx screw (29 lbf•in ± 2 lbf•in) If abnormal wear is noted, the probable cause
Hexagonal flange 10 N•m ± 2 N•m could be:
elastic nut (89 lbf•in ± 18 lbf•in) – Pulley misalignment
– Excessive RPM with frozen track
DRIVE BELT – Fast starts without warm-up period
– Scratched or rusty sheave
Removing the Drive Belt – Oil on belt
1. Remove tether cord cap from engine cut-off – Distorted spare belt.
switch.
Check drive belt width. Replace the drive belt if
2. Remove LH side panel. its width is under minimum recommended speci-
3. Remove drive belt guard, refer to REMOVING fication.
THE DRIVE BELT GUARD. DRIVE BELT WIDTH
4. Insert the driven pulley expander provided in
NEW WEAR LIMIT
the tool kit in the threaded hole on the adjuster
hub as illustrated. 38.3 mm (1.508 in) 35.9 mm (1.413 in)
Installing the Drive Belt

1. If necessary, open the driven pulley, refer to RE-
MOVING THE DRIVE BELT.
2. Insert drive belt in the drive pulley, then pull it
over the driven pulley.
NOTICE Do not force or use tools to pry the
belt into place, as this could cut or break the
cords in the belt.
mmr2017-039 3
NOTE: The maximum drive belt life span is ob-

tained when the belt is installed with the arrows
on the belt pointing in the direction of rotation.
mmr2017-039-004 mmr2013-034-010_a
1. Suspension adjustment tool

3. Unscrew and remove the driven pulley ex-
pander from the driven pulley. NOTE: The adjustment ring has left hand treads.
4. Rotate the driven pulley several times to prop- Repeat step 5 until the lowest portion of the cogs
erly set the belt between the sheaves. on the external surface of drive belt is even with
5. Adjust drive belt height. Refer to ADJUSTING the driven pulley edge.
THE DRIVE BELT HEIGHT procedure.
6. Install drive belt guard, refer to INSTALLING
THE DRIVE BELT GUARD.
7. Install LH side panel.
Adjusting the Drive Belt Height

1. Remove tether cord cap from engine cutout
switch.
2. Remove LH side panel.
3. Remove drive belt guard, refer to REMOVING mmo2012-006-905_a
THE DRIVE BELT GUARD. PRELIMINARY SETTING
1. Lowest portion of cogs even with external surface of drive belt
4. Loosen the clamping screw.
NOTE: Turning the adjustment ring counterclock-
wise lowers the belt in the pulley. Turning the ring
clockwise raises the belt in the pulley.
6. Tighten the adjustment ring clamping screw.
TIGHTENING TORQUE
Adjustment ring 5.5 N•m ± 0.5 N•m
clamping screw (49 lbf•in ± 4 lbf•in)
mmr2013-034-009_a
1. Adjustment ring
2. Clamping screw
5. Using the suspension adjustment tool provided

in the tool kit, turn the adjustment ring 1/4 turn
at a time then rotate the driven pulley to prop-
erly set the belt between the pulley sheaves.
4 mmr2017-039
mmr2009-133-003_b
DEFLECTION SETTING
1. Bottom O-ring
5. Place upper O-ring to 0 kgf (0 lbf).
mmo2012-004-903_a
1. Clamping screw mmr2009-133-003_a
LOAD READING
7. Install belt guard, refer to INSTALLING THE 1. Upper O-ring
DRIVE BELT GUARD.
6. Apply pressure until bottom O-ring (deflection)
8. Install LH side panel.
is flush with edge of rule.
9. Start engine and check if vehicle creeps.
9.1 If vehicle does not creep, adjustment is
complete.
9.2 If vehicle creeps, check the drive belt de-
flection.
Reverse Activation
Reverse may not activate or may be harder to acti-
vate if the belt is positioned too high in the driven
pulley. If reverse activation does not work prop-
erly, ensure the drive belt is properly adjusted. mmr2013-034-011_a
Adjust the drive belt lower in the driven pulley if TYPICAL

needed. 1. Upper O-ring — load
2. Bottom O-ring — deflection
3. Reference rule
Verifying the Drive Belt Deflection
7. Read drive belt load. Compare result with the
1. Make sure drive belt height is adjusted (prelim-
following table.
inary setting).
2. Position a reference rule on drive belt. DRIVE BELT DEFLECTION
3. Use the TENSIOMETER (P/N 414 348 200) as ex- DRIVE BELT LOAD
11.30 kgf (25 lbf)
plained below. READING
4. Set deflection as per following table using bot- 8. If deflection is within specification, drive belt is
tom O-ring. properly adjusted.
DRIVE BELT DEFLECTION 9. If deflection is out of specification, try the fol-
DRIVE BELT 32 mm ± 5 mm lowing:
DEFLECTION SETTING (1.26 in ± .2 in) – Lower drive belt height from initial setting.
– Try another drive belt.
10. If proper load still cannot be obtained, check
the following:
– Inspect engine supports.
– Inspect countershaft and bearing.
– Inspect chassis for damages.
mmr2017-039 5
Subsection XX (pDRIVE PULLEY WITH CLICKER)
pDRIVE PULLEY WITH CLICKER

SERVICE TOOLS
CIRCLIP INSTALLER/REMOVER ................................................... 529 036 375 ......................................... 4–5
CLUTCH HOLDER......................................................................... 529 036 369 ....................................... 3, 12
DRIVE PULLEY OPENING TOOL .................................................. 529 036 378 ......................................... 4, 8
DRIVE PULLEY SUPPORT ............................................................ 529 036 371 ..................................... 4–5, 7
GREASE INJECTOR ...................................................................... 529 036 376 ........................................... 10
PDRIVE PULLER ........................................................................... 529 036 370 ......................................... 3–4
PULLEY SPRING COMPRESSOR TOOL....................................... 529 036 373 ................................. 4–5, 7–8
REMOVING AXLE TOOL............................................................... 529 036 372 ..................................... 4, 6–8
SERVICE PRODUCTS
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ........................................... 10
5 ± 1 N•m
(44 ± 9 lbf•in)
5 ± 0.5 N•m
(44 ± 4 lbf•in)
NEW Synthetic grease
5 ± 0.5 N•m
(44 ± 4 lbf•in)
31.5 ± 3.5 N•m

(23 ± 3 lbf•ft)
See tightening
sequence
NEW
mmc2016-001-100_a
mmr2017-040 1
GENERAL Ramp cam should be adjusted so that actual

maximum engine RPM in vehicle matches the
The pDrive pulleys are lubrication-free drive pul- maximum horsepower RPM given in TECHNICAL
leys. Only the needle bearings inside the rollers SPECIFICATIONS.
need to be lubricated when replaced.
To adjust, modify ramp end position by turning
Always refer to appropriate PARTS CATALOG for ramp cams (3x).
replacement parts.
The ramp and the right lever have a notch while
NOTICE Never use any type of impact ramp cam has 5 positions numbered 1 to 5.
wrench for drive pulley removal and installa-
tion. The use of impact wrench could damage
the drive pulley and modify the calibration.
Some drive pulley components (like the spring and
ramps) can be changed to improve vehicle perfor-
mance in high altitude regions. A Service Bulletin
provides information about calibration according
to altitude.
NOTICE Such modifications should only be
performed by experienced mechanics since
they can greatly affect vehicle performance.
Verify spring specifications before installation.
Do not only refer to the spring color code.
WARNING mmc2016-001-118_a
Any drive pulley repairs must be performed 1. Ramp notch

2. Right lever notch
by an authorized Ski-Doo dealer. Subcompo- 3. Cam position (here #3 - factory setting, no number)
nent installation and assembly tolerances re-
quire strict adherence to procedures detailed. Each number modifies maximum engine RPM by
about 200 RPM.
During assembly/installation, use torque values as Lower numbers decrease engine RPM in steps of
in the exploded view. 200 RPM and higher numbers increase it in steps
Clean threads before applying a threadlocker. Re- of 200 RPM.
fer to SELF-LOCKING FASTENERS and LOCTITE For example: Ramp cam is set at position 3 and is
APPLICATION at the beginning of this manual for changed to position 5. So maximum engine RPM
complete procedure. is increased by about 400 RPM.
WARNING
tic stop nuts, cotter pins, etc.).
ADJUSTMENT
The drive pulley is factory calibrated to transmit
maximum engine power at a predefined RPM.
Factors such as ambient temperature, altitude
or surface condition may vary this critical engine
RPM thus affecting snowmobile efficiency.
This adjustable drive pulley allows setting maxi-
mum engine RPM in the vehicle to maintain ma-
ximum power. The adjustment has an effect on
high RPM only.
2 mmr2017-040
MODIFYING THE RAMP CAM

SETTING
7
6
1 2 5
4
3
mmc2016-001-117_a
mmc2016-001-119_a
1. Desired cam position (here #2)
1. Pivot
2. Axle retaining screw
3. Left lever TIGHTENING TORQUE
4. Ramp
5. Cam 5 N•m ± 1 N•m
6. Right lever Pivot
7. Axle
1. Loosen the pivot. NOTICE Always adjust all 3 cams and make
sure they are all set at the same number.
PROCEDURES
DRIVE PULLEY
Removing the Drive Pulley
REQUIRED TOOLS
CLUTCH HOLDER
(P/N 529 036 369)
PDRIVE PULLER
(P/N 529 036 370)
mmc2016-001-116_a
1. Remove drive belt. Refer to DRIVE BELT sub-
1. Pivot
section.
2. Move right lever aside to be able to turn the 2. Remove the drive pulley bolt.
cam.
2.1 Secure the drive pulley with the clutch
3. Turn cam to the desired position. holder.
2.2 Using a breaker bar, remove the drive pul-
ley bolt and its conical spring washer.
mmr2017-040 3
REQUIRED TOOLS
CIRCLIP
INSTALLER/REMOVER
(P/N 529 036 375)
REMOVING AXLE TOOL

(P/N 529 036 372)
DRIVE PULLEY
OPENING TOOL
(P/N 529 036 378)
Separating Fixed and Sliding Sheaves

mmc2016-001-147_a
1. Clutches holder To separate fixed sheave from sliding sheave,

2. Drive pulley bolt screw puller into fixed sheave shaft about 13 mm
(1/2 in).
3. Remove the drive pulley from engine.
Raise drive pulley and hold it by the sliding sheave
3.1 Make sure the clutches holder is properly
while knocking on puller head to disengage fixed
installed.
sheave.
3.2 Screw the pDrive puller in place of the
drive pulley bolt. NOTICE NEVER tap on spider.
3.3 Tighten the pDrive puller until pulley is dis-
engaged from the crankshaft end.
NOTICE These pulleys have metric threads.
Do not use a puller with ANS (American Na-
tional Standard) or IS (International Standard)
type threads. Always tighten puller by hand to
ensure that the drive pulley has the same type
of threads (metric vs ANS or IS) prior to fully
tightening.
Disassembling the Drive Pulley

REQUIRED TOOLS
mmc2016-001-102_a
PDRIVE PULLER 1. Puller screwed 13 mm (1/2 in) in fixed sheave
(P/N 529 036 370) 2. Sliding sheave
3. Fixed sheave
DRIVE PULLEY
SUPPORT (P/N 529 NOTE: No component marking is required before
036 371) disassembly. This drive pulley features factory ap-
posed index marks as references.
NOTICE Never use any type of torch to heat
PULLEY SPRING spider.
COMPRESSOR TOOL
(P/N 529 036 373) Removing the Damper
1. Secure the drive pulley support in a vice.
2. Install the drive pulley over the support.
4 mmr2017-040
mmc2016-001-103_a mmc2016-001-106_a
1. DRIVE PULLEY SUPPORT (P/N 529 036 371) 1. CIRCLIP INSTALLER/REMOVER (P/N 529 036 375)
3. Remove the damper.
mmc2016-001-107_a
1. Handle of thePULLEY SPRING COMPRESSOR TOOL

mmc2016-001-104 (P/N 529 036 373)
Removing the Spring
mmc2016-001-105_a
mmc2016-001-108_a
PULLEY SPRING COMPRESSOR
1. Threaded shaft of the
1. Remove the circlip
TOOL (P/N 529 036 373)
mmr2017-040 5
Removing the Roller

1. Remove axle retaining screw.
mmc2016-001-109
Removing the Spider

1. Remove the threaded shaft.
mmc2016-001-112
2. Remove the axle.
mmc2016-001-110
NOTICE Remove the threaded shaft to avoid

damaging the bushings inside the spider. mmc2016-001-113_a
1. REMOVING AXLE TOOL (P/N 529 036 372)

2. Remove the spider. Step 1: Screw the tool into the axle
Step 2: Push axle to the right side
3. Remove the roller and its thrust washers.
mmc2016-001-114_a
mmc2016-001-111
6 mmr2017-040
Removing the Ramp (without Spider) Removing the Ramp (Spider Installed)
1. Remove axle retaining screw. 1. Lower the sliding sheave.
1.1 Secure the drive pulley support in a vice.
1.2 Install the drive pulley over the support.
1.3 Install the drive pulley opening tool.
mmc2016-001-122
2. Remove the axle.
mmc2016-001-103_a
1. DRIVE PULLEY SUPPORT (P/N 529 036 371)
mmc2016-001-123_a

2. Axle
Step 1: Screw the tool into the axle
3. Remove ramp assembly. mmc2016-001-105_a

TOOL (P/N 529 036 373)
mmc2016-001-124_a
mmr2017-040 7
4. Remove ramp assembly.
mmc2016-001-115_a
1. DRIVE PULLEY OPENING TOOL (P/N 529 036 378) mmc2016-001-125_a
2. Handle of the PULLEY SPRING COMPRESSOR TOOL

(P/N 529 036 373) Removing the Torque Rollers
mmc2016-001-128_a
mmc2016-001-120
3. Remove the axle.
mmc2016-001-148_a

Step 2: Push axle towards the center of the pulley
mmc2016-001-121_a

2. Axle
8 mmr2017-040
Assembling the Drive Pulley

Torque Rollers
Position torque rollers as illustrated.
mmc2016-001-129_a
Replacing the Sliding Sheave Bushing

In case of worn out bushing, it is advisable to re-
place whole sliding sheave assembly as replacing
just the bushing may reduce drive pulley perfor- mmc2016-001-139
mance.
Position the flat sides of the axle head inside the
Cleaning the Drive Pulley slot of the mounting lug.
NOTE: Parts must be at room temperature before Install a new spring pin.
cleaning.
Clean pulley sheaves and shaft with fine steel
wool and dry cloth.
Using a paper towel with PULLEY FLANGE
CLEANER (P/N 413 711 809), clean the follow-
ing components.
– Crankshaft tapered end
– Taper inside fixed sheave of drive pulley
– Crankshaft threads
– Retaining screw threads.
NOTICE Avoid contact between cleaner and
crankshaft seal because damage may occur.
Remove all hardened oil deposits that are baked
mmc2016-001-140
on crankshaft and pulley tapered surfaces with
coarse or medium steel wool and/or sand paper Ramp
no. 600.
Assemble the ramp as illustrated. Do not torque
NOTICE Do not use any other type of abra- the pivot yet.
sive.
Reclean mounting surfaces with paper towel and
cleaning solvent.
Wipe off the mounting surfaces with a clean, dry
paper towel.
NOTICE Mounting surfaces must be free of
any oil, cleaner or towel residue.
mmr2017-040 9
REQUIRED SERVICE PRODUCT

ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021)
REQUIRED TOOL
GREASE INJECTOR
3 (P/N 529 036 376)
2
NOTE: A threaded end is required on the grease
1 gun for using the grease injector.
5 4
mmc2016-001-141_a
1. Ramp
2. Cam
3. Right lever
4. Left lever
5. Pivot
Install the ramp assembly on the sliding sheave.
mmc2016-001-143_a
1. GREASE INJECTOR (P/N 529 036 376)
Install roller.
mmc2016-001-142_a
TIGHTENING TORQUE
5 N•m ± 0.5 N•m
Axle screw
(44 lbf•in ± 4 lbf•in) mmc2016-001-114_a
Position the cam to factory setting or to the de-

sired position.
NOTICE Make sure all cams are set at the
same number.
FACTORY SETTING
3
Cam number
(position without number)
TIGHTENING TORQUE
8 N•m ± 2 N•m
Pivot mmc2016-001-144_a
Roller
Lubricate the roller bearing.
10 mmr2017-040
TIGHTENING TORQUE
5 N•m ± 0.5 N•m
Roller axle screw
Spider 1
Install the spider on the sliding sheave by aligning
the indexing marks.
– Spider - the arrow on the arms #1, just above
the roller.
– Sliding sheave - the dot on the external side of
the sheave.
2
mmc2016-001-153_a
ROLLER - GOOD INSTALLATION

1. Torque rollers
2. Spur of the spider leg
mmc2016-001-149_a
2
mmc2016-001-152_a
ROLLER - WRONG INSTALLATION

1. Torque rollers
mmc2016-001-151_a
FINAL POSITION
1. Arrow - spider arm
2. Dot - sliding sheave
NOTICE During installation of the spider,

make sure to position the three spurs of spider
legs between torque rollers and ensure that mmc2016-001-154_a
ramps are positioned inside the openings of RAMP POSITIONING
the spider.
Damper
Install the damper using the following sequence.
mmr2017-040 11
6. Using a torque wrench, tighten the drive pulley

bolt. Refer to TIGHTENING THE DRIVE PUL-
LEY for the completed procedure.
Tightening the Drive Pulley
Tighten the drive pulley bolt.
TIGHTENING TORQUE
120 N•m
Drive pulley bolt First torque
(89 lbf•ft)
Before starting engine, perform drive pulley ad-

justment. Refer to ADJUSTMENT, at the begin-
ning of this subsection.
mmc2016-001-146_a Install drive belt and guard.
TIGHTENING TORQUE
Raise the rear of the vehicle and support it with a
mechanical stand.
31.5 N•m ± 3.5 N•m
Damper screws
(23 lbf•ft ± 3 lbf•ft) WARNING
Ensure that the track is free of particles which
Sliding Sheave and Fixed Sheave Assembly could be thrown out while track is rotating.
Index sliding sheave with fixed sheave by aligning Keep hands, tools, feet and clothing clear of
index marks. track. Ensure nobody is standing near the ve-
– Sliding sheave - the arrow on the spider arms hicle.
#1, just above the roller.
– Fixed sheave- the dot on the external side of the Accelerate the vehicle at low speed (maximum
sheave. 32 km/h (20 MPH) and apply the brake, repeat
5 times.
Drive Pulley Installation Tighten the drive pulley bolt again.
REQUIRED TOOLS TIGHTENING TORQUE
120 N•m
CLUTCH HOLDER Drive pulley bolt Final torque
(89 lbf•ft)
(P/N 529 036 369)
WARNING
1. Clean mounting surfaces as described in DRIVE After 10 hours of operation the transmission
PULLEY CLEANING above. system of the vehicle must be inspected
NOTICE Do not apply antiseize or any lubri- to ensure drive pulley bolt is still properly
torqued.
cant on crankshaft and drive pulley tapers.
2. Install drive pulley on crankshaft end.
NOTE: The drive pulley can be installed in one
position only. Drive pulley and crankshaft are
indexed.
3. Install a NEW conical spring washer with its
concave side towards drive pulley.
4. Install drive pulley bolt.
NOTICE Always use BRP genuine parts for
conical spring washer and bolt.
5. Secure the drive pulley with the clutch holder.
12 mmr2017-040
Subsection XX (pDRIVE PULLEY WITHOUT CLICKER)
pDRIVE PULLEY WITHOUT CLICKER

SERVICE TOOLS
CIRCLIP INSTALLER/REMOVER ................................................... 529 036 375 ......................................... 4–5
CLUTCH HOLDER......................................................................... 529 036 369 ....................................... 3, 12
DRIVE PULLEY OPENING TOOL .................................................. 529 036 378 ......................................... 4, 8
DRIVE PULLEY SUPPORT ............................................................ 529 036 371 ......................................... 4, 7
GREASE INJECTOR ...................................................................... 529 036 376 ........................................... 10
PDRIVE PULLER ........................................................................... 529 036 370 ......................................... 3–4
PULLEY SPRING COMPRESSOR TOOL....................................... 529 036 373 ................................. 4–5, 7–8
REMOVING AXLE TOOL............................................................... 529 036 372 ..................................... 4, 6–8
SERVICE PRODUCTS
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ........................................... 10
mmr2017-057 1
5 ± 0.5 N•m
(44 ± 4 lbf•in)
NEW Synthetic grease
5 ± 0.5 N•m
(44 ± 4 lbf•in)
31.5 ± 3.5 N•m

(23 ± 3 lbf•ft)
See tightening
sequence
NEW
mmr2017-057-100_a
2 mmr2017-057
GENERAL PROCEDURES
The pDrive pulleys are lubrication-free drive pul-
leys. Only the needle bearings inside the rollers DRIVE PULLEY
need to be lubricated when replaced. Removing the Drive Pulley
Always refer to appropriate PARTS CATALOG for
REQUIRED TOOLS
replacement parts.
NOTICE Never use any type of impact CLUTCH HOLDER
wrench for drive pulley removal and installa- (P/N 529 036 369)
tion. The use of impact wrench could damage
the drive pulley and modify the calibration. PDRIVE PULLER
(P/N 529 036 370)
Some drive pulley components (like the spring and
ramps) can be changed to improve vehicle perfor- 1. Remove drive belt. Refer to DRIVE BELT sub-
mance in high altitude regions. A Service Bulletin section.
provides information about calibration according
to altitude. 2. Remove the drive pulley bolt.
2.1 Secure the drive pulley with the clutch
NOTICE Such modifications should only be holder.
performed by experienced mechanics since
they can greatly affect vehicle performance. 2.2 Using a breaker bar, remove the drive pul-
Verify spring specifications before installation. ley bolt and its conical spring washer.
Do not only refer to the spring color code.
WARNING
Any drive pulley repairs must be performed
by an authorized Ski-Doo dealer. Subcompo-
nent installation and assembly tolerances re-
quire strict adherence to procedures detailed.
During assembly/installation, use torque values as

in the exploded view.
complete procedure.
WARNING mmc2016-001-147_a
1. Clutches holder
Torque wrench tightening specifications 2. Drive pulley bolt
Locking devices must be replaced with new 3. Remove the drive pulley from engine.
ones when removed (e.g.: locking tabs, elas- 3.1 Make sure the clutches holder is properly
tic stop nuts, cotter pins, etc.). installed.
3.2 Screw the pDrive puller in place of the
drive pulley bolt.
3.3 Tighten the pDrive puller until pulley is dis-
engaged from the crankshaft end.
mmr2017-057 3
NOTICE These pulleys have metric threads.

Do not use a puller with ANS (American Na-
tional Standard) or IS (International Standard)
type threads. Always tighten puller by hand to
ensure that the drive pulley has the same type
of threads (metric vs ANS or IS) prior to fully
tightening.
Disassembling the Drive Pulley

REQUIRED TOOLS
PDRIVE PULLER
(P/N 529 036 370) mmc2016-001-102_a
DRIVE PULLEY 1. Puller screwed 13 mm (1/2 in) in fixed sheave

2. Sliding sheave
SUPPORT (P/N 529 3. Fixed sheave
036 371)
NOTE: No component marking is required before
disassembly. This drive pulley features factory ap-
posed index marks as references.
PULLEY SPRING
COMPRESSOR TOOL NOTICE Never use any type of torch to heat
(P/N 529 036 373) spider.
Removing the Damper
1. Secure the drive pulley support in a vice.
CIRCLIP 2. Install the drive pulley over the support.
INSTALLER/REMOVER
(P/N 529 036 375)
REMOVING AXLE TOOL

(P/N 529 036 372)
DRIVE PULLEY
OPENING TOOL
(P/N 529 036 378)
Separating Fixed and Sliding Sheaves

To separate fixed sheave from sliding sheave,
screw puller into fixed sheave shaft about 13 mm
(1/2 in).
Raise drive pulley and hold it by the sliding sheave mmc2016-001-103_a
while knocking on puller head to disengage fixed 1. DRIVE PULLEY SUPPORT (P/N 529 036 371)
sheave.
3. Remove the damper.
NOTICE NEVER tap on spider.
NOTE: To racing purpose only: Some dampers
might be installed with shims for initial opening
setup of the pulley.
4 mmr2017-057
mmc2016-001-104 mmc2016-001-107_a
PULLEY SPRING COMPRESSOR TOOL

1. Handle of the
Removing the Spring (P/N 529 036 373)
mmc2016-001-105_a

TOOL (P/N 529 036 373)
mmc2016-001-108_a
1. Remove the circlip
mmc2016-001-106_a
1. CIRCLIP INSTALLER/REMOVER (P/N 529 036 375)

mmc2016-001-109
NOTE: To racing purpose only: A shim may be

added between the spring and the cover to modify
the compression of the spring. Refer to the chart
in the CALIBRATION SECTION.
mmr2017-057 5
Removing the Spider

1. Remove the threaded shaft.
mmc2016-001-112
2. Remove the axle.
mmc2016-001-110
NOTICE Remove the threaded shaft to avoid

damaging the bushings inside the spider.
2. Remove the spider.
mmc2016-001-113_a

3. Remove the roller and its thrust washers.
mmc2016-001-111
Removing the Roller

mmc2016-001-114_a
Removing the Ramp (without Spider)

6 mmr2017-057
Removing the Ramp (Spider Installed)

1. Lower the sliding sheave.
1.1 Secure the drive pulley support in a vice.
1.2 Install the drive pulley over the support.
1.3 Install the drive pulley opening tool.
mmr2017-057-050_a
2. Remove the axle.
mmc2016-001-103_a
1. DRIVE PULLEY SUPPORT (P/N 529 036 371)

1
1
2
mmr2017-057-051_a

2. Axle
mmc2016-001-105_a
TOOL (P/N 529 036 373)
mmr2017-057-052_a
mmr2017-057 7
mmc2016-001-115_a
1. DRIVE PULLEY OPENING TOOL (P/N 529 036 378)

2. Handle of the PULLEY SPRING COMPRESSOR TOOL mmr2017-057-055_a
(P/N 529 036 373)
Removing the Torque Rollers
mmc2016-001-128_a
mmr2017-057-053_a TYPICAL
3. Remove the axle.
1
1
2
mmc2016-001-148_a
TYPICAL
mmr2017-057-054_a Step 1: Screw the tool into the axle
Step 2: Push axle towards the center of the pulley
2. Axle
8 mmr2017-057
Assembling the Drive Pulley

Torque Rollers
Position torque rollers as illustrated.
mmc2016-001-129_a
TYPICAL
Replacing the Sliding Sheave Bushing

In case of worn out bushing, it is advisable to re-
place whole sliding sheave assembly as replacing mmc2016-001-139
just the bushing may reduce drive pulley perfor- TYPICAL
mance.
Position the flat sides of the axle head inside the
Cleaning the Drive Pulley slot of the mounting lug.
NOTE: Parts must be at room temperature before Install a new spring pin.
cleaning.
Clean pulley sheaves and shaft with fine steel
wool and dry cloth.
Using a paper towel with PULLEY FLANGE
CLEANER (P/N 413 711 809), clean the follow-
ing components.
– Crankshaft tapered end
– Taper inside fixed sheave of drive pulley
– Crankshaft threads
– Retaining screw threads.
NOTICE Avoid contact between cleaner and
crankshaft seal because damage may occur.
Remove all hardened oil deposits that are baked
mmc2016-001-140
on crankshaft and pulley tapered surfaces with
TYPICAL
coarse or medium steel wool and/or sand paper
no. 600. Ramp
NOTICE Do not use any other type of abra- Install the ramp on the sliding sheave.
sive.
Reclean mounting surfaces with paper towel and
cleaning solvent.
Wipe off the mounting surfaces with a clean, dry
paper towel.
NOTICE Mounting surfaces must be free of
any oil, cleaner or towel residue.
mmr2017-057 9
mmc2016-001-114_a
mmr2017-057-056_a
TIGHTENING TORQUE
5 N•m ± 0.5 N•m
Axle screw
Roller
Lubricate the roller bearing.
REQUIRED SERVICE PRODUCT
ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021)
mmc2016-001-144_a
REQUIRED TOOL TIGHTENING TORQUE

GREASE INJECTOR 5 N•m ± 0.5 N•m
(P/N 529 036 376) Roller axle screw
NOTE: A threaded end is required on the grease Spider

gun for using the grease injector.
Install the spider on the sliding sheave by aligning
the indexing marks.
– Spider - the arrow on the arms #1, just above
the roller.
– Sliding sheave - the dot on the external side of
the sheave.
mmc2016-001-143_a
1. GREASE INJECTOR (P/N 529 036 376)
Install roller.
mmc2016-001-149_a
TYPICAL
10 mmr2017-057
mmc2016-001-151_a mmc2016-001-152_a
TYPICAL - FINAL POSITION ROLLER - WRONG INSTALLATION

1. Arrow - spider arm 1. Torque rollers
2. Dot - sliding sheave 2. Spur of the spider leg
NOTICE During installation of the spider,

make sure to position the three spurs of spider
legs between torque rollers and ensure that
ramps are positioned inside the openings of
the spider.
mmc2016-001-154_a
RAMP POSITIONING
Damper
Install the damper using the following sequence.
2
mmc2016-001-153_a
ROLLER - GOOD INSTALLATION

1. Torque rollers
mmc2016-001-146_a
mmr2017-057 11
TIGHTENING TORQUE WARNING

31.5 N•m ± 3.5 N•m Ensure that the track is free of particles which
Damper screws
(23 lbf•ft ± 3 lbf•ft) could be thrown out while track is rotating.
Keep hands, tools, feet and clothing clear of
Sliding Sheave and Fixed Sheave Assembly track. Ensure nobody is standing near the ve-
Index sliding sheave with fixed sheave by aligning hicle.
index marks.
Accelerate the vehicle at low speed (maximum
– Sliding sheave - the arrow on the spider arms
32 km/h (20 MPH) and apply the brake, repeat
#1, just above the roller.
5 times.
– Fixed sheave- the dot on the external side of the
sheave. Tighten the drive pulley bolt again.
TIGHTENING TORQUE
Drive Pulley Installation
120 N•m
REQUIRED TOOLS Drive pulley bolt Final torque
(89 lbf•ft)
CLUTCH HOLDER WARNING

(P/N 529 036 369)
After 10 hours of operation the transmission
system of the vehicle must be inspected
1. Clean mounting surfaces as described in DRIVE to ensure drive pulley bolt is still properly
PULLEY CLEANING above. torqued.
NOTICE Do not apply antiseize or any lubri-
cant on crankshaft and drive pulley tapers.
2. Install drive pulley on crankshaft end.
NOTE: The drive pulley can be installed in one
position only. Drive pulley and crankshaft are
indexed.
3. Install a NEW conical spring washer with its
concave side towards drive pulley.
4. Install drive pulley bolt.
NOTICE Always use BRP genuine parts for
conical spring washer and bolt.
5. Secure the drive pulley with the clutch holder.
6. Using a torque wrench, tighten the drive pulley
bolt. Refer to TIGHTENING THE DRIVE PUL-
LEY for the completed procedure.
Tightening the Drive Pulley
Tighten the drive pulley bolt.
TIGHTENING TORQUE
120 N•m
Drive pulley bolt First torque
(89 lbf•ft)
Before starting engine, perform drive pulley ad-

justment. Refer to ADJUSTMENT, at the begin-
ning of this subsection.
Install drive belt and guard.
Raise the rear of the vehicle and support it with a
mechanical stand.
12 mmr2017-057
Subsection XX (DRIVEN PULLEY AND COUNTERSHAFT)
DRIVEN PULLEY AND COUNTERSHAFT

SERVICE TOOLS
COUNTERSHAFT ADAPTER ......................................................... 529 036 424 ............................................. 9
COUNTERSHAFT BEARING INSTALLER ...................................... 529 036 066 ........................................... 10
COUNTERSHAFT BEARING REMOVER ....................................... 529 036 065 ............................................. 9
COUNTERSHAFT SUPPORT ......................................................... 529 036 067 ............................................. 9
DRIVEN PULLEY SPRING COMPRESSOR ................................... 529 036 182 ............................................. 3
UPPER GEAR RETAINING TOOL .................................................. 529 036 110 ............................................. 2
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 7
LOCTITE 609 ................................................................................. 413 703 100 ........................................... 10
LOCTITE 7649 (PRIMER) .............................................................. 293 800 041 ........................................... 10
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ............................................. 8
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ......................................... 6, 9
17 ± 1 N•m
(150 ± 9 lbf•in) Loctite 243
31.5 ± 3.5 N•m

(23 ± 3 lbf•ft)
NEW Loctite 7649 (Primer)
+
Loctite 609
17 ± 1 N•m 4.3 ± 0.7 N•m

(150 ± 9 lbf•in) (35 ± 3.5 lbf•in)
Loctite 243

mmr2017-041-100_a
mmr2017-041 1
GENERAL
ues and the service products as in the exploded
views.
complete procedure.
WARNING
Torque wrench tightening specifications mmr2017-041-002
Locking devices (e.g.: locking tabs, elastic 4. Remove the upper gear screw and the conical
stop nuts, cotter pins, etc.) must be replaced spring washer.
with new ones. NOTE: Slightly tilt the bolt to avoid dropping
washer inside chaincase.
WARNING
Never start engine when the pulley guard is
removed.
PROCEDURES
DRIVEN PULLEY
Removing the Driven Pulley
NOTE: The driven pulley is removed with the
countershaft.
1. Remove the muffler. Refer to EXHAUST SYS-
TEM subsection. mmr2017-041-003
2. Remove the filling plug on the chaincase cover. 5. Install the gear retaining tool on countershaft
end.
REQUIRED TOOL
UPPER GEAR
RETAINING TOOL
(P/N 529 036 110)
mmr2017-041-001
3. Release drive chain tension by unscrewing ten-

sioner adjustment screw.
mmr2008-042-104_a
TYPICAL
1. Upper gear retaining tool
6. Remove the drive belt. Refer to DRIVE BELT

subsection.
2 mmr2017-041
7. Behind driven pulley, remove nut securing the

countershaft bearing flange.
mmr2017-041-005
2. Unscrew the adjuster hub clockwise using the

suspension adjustment tool provided in the ve-
mmr2017-041-004
hicle tool kit.
8. Pull out bearing flange. NOTE: The adjuster hub has LH treads.
9. Pull the driven pulley to disengage countershaft
and upper gear.
NOTE: If necessary, tap the upper gear retaining
tool with a plastic hammer.
mmr2013-034-010_a
1. Suspension adjustment tool shown
REQUIRED TOOL
mmr2008-042-106
TYPICAL DRIVEN PULLEY

SPRING COMPRESSOR
10. Unscrew countershaft from the upper gear re- (P/N 529 036 182)
taining tool. Do not remove tool.
NOTE: While countershaft is removed from vehi- 3. Install the threaded adapter of the spring com-
cle, the upper gear retaining tool maintains the pressor on the countershaft.
drive chain and the upper gear in position inside
chaincase.
Driven Pulley Disassembly

Removing Cam and Spring
1. Loosen the clamping screw.
mmr2008-042-110_a
1. Threaded adapter
mmr2017-041 3
4. Install the external sleeve over the threaded

adapter and secure sleeve with the tool screw.
mmr2013-036-006_a
mmr2008-042-111_a 1. Heat cam screws

1. External sleeve
2. Driven pulley spring compressor screw 8. Remove and discard cam screws.
5. Tighten the tool screw to compress the cam. 9. Unscrew the tool screw completely.
6. Install the tool in a vice. 10. Remove cam, spring stoppers and spring.
Removing the Sliding Sheave
1. Remove the cam and spring. Refer to proce-
dure in this subsection.
2. Remove the countershaft bearing. Refer to pro-
cedure in this subsection.
3. Remove sliding sheave.
mmr2008-042-112_a
1. Driven pulley spring compressor

2. Driven pulley
7. Using a heat gun, heat cam screws to break the

thread locker.
mmr2009-083-004_a
1. Fixed sheave
2. Sliding sheave
3. Countershaft
Removing the Fixed Sheave

The fixed sheave and countershaft are sold as an
assembly. They are not available separately.
Removing the Driven Pulley Rollers
1. Move sliding and fixed sheaves apart.
2. Remove spring pins used to lock pivot screws.
2.1 Use tap wrench to start removing spring
pin.
4 mmr2017-041
2.2 Once spring pin is accessible to pliers, pull

pin out using pliers.
mmr2012-043-003
PIVOT SCREW REMOVAL
mmr2013-036-021_a
1. Fixed sheave outer face

2. Roller
3. Spring pin location
3. Identify pivot screws location before removal.

4. Remove pivot screw and ribbed lock washer;
keep both for reuse.
NOTICE Make sure not to damage or lose
pivot screws. If screws need to be replaced,
replace fixed sheave assembly.
mmr2012-043-004_a
1. Ribbed lock washer
5. Remove roller.
6. Proceed with removal of other roller.
IMPORTANT: For proper fit, each pivot screw
must be reinstalled where originally mounted in
the fixed sheave.
Inspecting the Driven Pulley

mmr2008-042-107_a Inspecting Cam and Spring
1. Pivot screw
2. Sliding sheave 1. Verify contact surfaces of cam for visible dam-
3. Fixed sheave ages. Ensure circlip properly locks the inner
bushing. Replace part if necessary.
2. Using a dial bore gauge, measure the inner di-
ameter of cam bushing. Measuring point must
be at least 5 mm (1/4 in) from bushing edge.
mmr2017-041 5
– Bent, twisted or otherwise damaged counter-

shaft
– Defective splines and threads at the end of
countershaft.
Inspecting the Driven Pulley Roller
1. Check the rollers for flat spots, cracks or other
visible damages. Replace if necessary (as a
set).
2. Measure inner and outer diameter of rollers.
mmr2008-044-011_a
A. Inner diameter of cam bushing
CAM BUSHING SERVICE LIMIT

Inner diameter 41.5 mm (1.634 in)
3. Replace the cam if the inner diameter of bush-

ing is out of specification.
Inspecting the Sliding Sheave
mmr2008-044-009_a
1. Inspect pulley sheave for marks or scratches. A. Inner diameter
2. Ensure circlip properly locks the inner bushing. B. Outer diameter
Replace part if necessary.
DRIVEN PULLEY
3. Using a dial bore gauge, measure the inner di- SERVICE LIMIT
ROLLER
ameter of sliding sheave bushing. Measuring
Inner diameter 8.5 mm (.335 in)
point must be at least 5 mm (1/4 in) from bush-
ing edge. Outer diameter 21.5 mm (.846 in)
3. Measure the roller thickness.
mmr2008-044-022_a
A. Inner diameter of sliding sheave bushing mmr2008-044-010_a
A. Thickness of roller
SLIDING SHEAVE
SERVICE LIMIT
BUSHING DRIVEN PULLEY
SERVICE LIMIT
Inner diameter 41.5 mm (1.634 in) ROLLER
Thickness 14.75 mm (.581 in)
4. Replace the sliding sheave if the inner diameter
of bushing is out of specification. 4. If a roller is out of specifications, replace both
Inspecting the Fixed Sheave rollers at the same time.
Replace fixed sheave and countershaft if one of Cleaning the Driven Pulley
the following problem is detected:
Use the PULLEY FLANGE CLEANER (P/N 413 711
– Marks or scratches on pulley sheave 809) and a clean rag to clean pulley sheaves.
6 mmr2017-041
Cleaning Cam and Spring

During break-in period, teflon from bushing moves
to cam or countershaft surface. A teflon over
teflon running condition occurs, leading to low
friction. So it is normal to see gray teflon deposit
on cam or countershaft. Do not remove this de-
posit.
When a dust deposit has to be removed from the
cam or the countershaft, use dry cloth to avoid
removing transferred teflon.
Driven Pulley Assembly

Installing the Driven Pulley Roller
mmr2013-036-007_a
NOTE: Exceptionally, do NOT clean threaded 1. Pivot screw
hole to avoid changing the screw position when 2. Ribbed lock washer (concave side towards fixed sheave)
3. Roller
torqued.
1. Using a hand wire brush, clean pivot screw IMPORTANT: For proper fit, each pivot screw
threads. must be reinstalled where originally mounted in
IMPORTANT: Do not use a thread die to clean the fixed sheave.
pivot screw of threadlocker as this may alter the 4. Torque pivot screw as specified.
screw threads.
TIGHTENING TORQUE
NOTE: Pivot screw and ribbed lock washer must
17 N•m ± 1 N•m
be reused if in good condition. If damaged, re- Pivot screws
place fixed sheave assembly.
2. Apply the following threadlocker to the pivot NOTE: Spring pin hole in the fixed sheave and
screw threads. pivot screw must perfectly line up when torque
is applied.
SERVICE PRODUCT
LOCTITE 243 (BLUE) NOTICE If not properly aligned, spring pin
Pivot screw threads will not insert in pivot screw hole and spring
(P/N 293 800 060)
pin threads in fixed sheave will be damaged.
3. Insert roller in fixed sheave, thread in pivot
screw with ribbed lock washer.
NOTE: The ribbed locked washer must be in-
stalled with the concave side towards the fixed
sheave.
mmr2013-036-10_a
1. Hole in pivot screw

2. Spring pin
5. Install spring pin.
mmr2017-041 7
Installing Cam and Spring When installing sliding sheave, make sure to align
1. Install a spring stopper, the spring, the other its arrow with the arrow on cam.
spring stopper and the cam.
mmr2008-044-013_a
mmr2008-042-114_a
1. Spring stopper SLIDING SHEAVE ARROW
2. Spring
3. Cam
2. Align the arrow on the cam with the arrow on

the fixed sheave.
NOTE: On completion of cam installation, the ar-
row on the cam should have moved clockwise (ap-
proximately 30°).
mmr2008-044-014_b
CAM ARROW
Installing the Driven Pulley

1. Using sand paper (600-grit or 1000-grit) or steel
wool, remove any rust on bearing shoulder of
countershaft bearing support.
mmr2008-044-014_a
3. Install the driven pulley spring compressor

sleeve and tighten the tool screw until the
cam is completely pressed against the sliding
sheave.
4. From the back of the sliding sheave, install
4 new cam screws.
5. Torque cam screws as specified.
TIGHTENING TORQUE
31.5 N•m ± 3.5 N•m
Cam screw
mmr2017-041-006_a
6. Remove the tool. BEARING SUPPORT SHOULDER
Installing the Sliding Sheave 2. Apply a thin layer of LOCTITE 767 (ANTISEIZE LU-
BRICANT) (P/N 293 800 070) on bearing shoulder.
The assembly of sliding sheave is the reverse of
the disassembly. However, pay attention to the 3. Insert countershaft through countershaft bear-
following. ing support.
8 mmr2017-041
4. Fasten the end of countershaft to upper gear REQUIRED TOOL

retaining tool.
COUNTERSHAFT
5. Align countershaft splines with upper gear BEARING REMOVER
splines. (P/N 529 036 065)
6. Using the upper gear retaining tool as a puller, COUNTERSHAFT
Engage countershaft splines in upper gear ADAPTER (P/N 529
splines. Ensure countershaft bearing is in- 036 424)
stalled properly in countershaft bearing sup-
port.
7. Remove the upper gear retaining tool.
8. Install the upper gear screw and the conical
spring washer.
NOTE: The conical spring washer must be in-
stalled with its concave side towards upper gear.
9. Torque upper gear screw.
10. Install chaincase filler plug. mmr2017-041-007_a
1. Countershaft adapter
11. On LH side, install the bearing flange. Torque 2. Countershaft bearing remover
nut as specified.
Tighten the screw at the end of tool to extract the
TIGHTENING TORQUE bearing. Discard bearing.
15.5 N•m ± 1.5 N•m
Bearing flange nut Installing the Countershaft Bearing
1. Remove the adjuster hub from the cam.
12. Install the adjuster hub onto the countershaft
end and temporarily tighten. 2. Insert the countershaft support in the counter-
shaft.
13. Install and adjust drive belt. Refer to DRIVE
BELT subsection. REQUIRED TOOL
14. Install all other removed parts. COUNTERSHAFT SUPPORT (P/N 529 036 067)
COUNTERSHAFT
The countershaft and the fixed sheave are sold as
an assembly. They are not available separately.
Removing and Installing the

Countershaft
Refer to DRIVEN PULLEY in this subsection for
the procedures.
COUNTERSHAFT BEARING mmr2008-042-115_a
Removing the Countershaft Bearing 1. Countershaft support
Remove the driven pulley. Refer to procedure in NOTICE The countershaft support is manda-
this subsection. tory to avoid damaging the countershaft
Install the bearing remover on countershaft. threaded end and the cam during bearing
installation.
3. Using PULLEY FLANGE CLEANER (P/N 413 711
809), clean residues on countershaft bearing
surface.
4. Check countershaft bearing surface for wear.
mmr2017-041 9

on countershaft bearing surface and let dry 5
minutes.
6. Apply LOCTITE 609 (P/N 413 703 100) on primer.
mmr2008-044-020_a
1. Apply Loctite 7649 (Primer) before Loctite 609 in this region
7. Using a press and the bearing installer, install

the new bearing on countershaft.
REQUIRED TOOL
COUNTERSHAFT BEARING INSTALLER
(P/N 529 036 066)
mmr2008-044-021_a
1. Countershaft bearing installer

2. New bearing
NOTICE Use a press only, never tap on coun-

tershaft bearing installer with an hammer to
avoid damaging bearing and countershaft.
8. Clean the surplus Loctite with a rag to avoid
having Loctite on sliding sheave bushing.
COUNTERSHAFT BEARING
SUPPORT
For countershaft bearing support removal and
installation, refer to COUNTERSHAFT BEARING
SUPPORT in FRAME.
10 mmr2017-041
Subsection XX (BRAKE)
BRAKE
SERVICE TOOLS
CALIPER PULLER ......................................................................... 529 036 145 ............................................. 6
PROTECTIVE CAP ......................................................................... 529 036 150 ............................................. 6
SERVICE PRODUCTS
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ............................................. 6
XPS SYNTHETIC GREASE............................................................. 293 550 010 ............................................. 9
mmr2017-042 1
0.4 ± 0.2 N•m 9 ± 1 N•m

27 ± 1 N•m (4 ± 2 lbf•in) (8 ± 9 lbf•in)
(20 ± 1 lbf•ft)
NEW
XPS
Brake synthetic
fluid grease
6 ± 1 N•m
(53 ± 9 lbf•in)
10 ± 2 N•m
(89 ± 18 lbf•in)
35 ± 1 N•m
(26 ± 1 lbf•ft) 9 ± 1 N•m
(80 ± 9 lbf•in)
Brake fluid 24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
NEW NEW
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
NEW
10 ± 2 N•m
(89 ± 18 lbf•in)
mmr2017-042-100_a
2 mmr2017-042
GENERAL PROCEDURES
and service products as in the exploded view. BRAKE PADS
Clean threads before applying a threadlocker. Re- Inspecting the Brake Pads
fer to SELF-LOCKING FASTENERS and LOCTITE 1. Measure brake pad lining thickness.
complete procedure. SERVICE LIMIT
Brake pad thickness A 1 mm (1/32 in)
WARNING
Torque wrench tightening specifications NOTICE Brake pads must always be replaced
must be strictly adhered to. in pairs.
tic stop nuts, cotter pins, etc.).
Hoses or cables removed or disconnected must

be installed and routed as per factory specifica-
tions.
NOTICE Locking ties removed must be re-
placed as per factory specifications. mmr2008-043-105_a
1. Groove on pad lining

WARNING
2. Also inspect the brake disc, refer to INSPECT-
Never apply any product to brake fittings, ING THE BRAKE DISC in this subsection.
The use of thread sealant or Teflon tape
could cause brake system failure. Replacing the Brake Pads
WARNING Removing the Brake Pads
A contaminated brake disc or pad reduces 1. Place the vehicle on a level surface.
braking efficiency. Discard contaminated 2. Cover the plastic parts under and near master
pads and clean contaminated disc with a cylinder in the event that brake fluid would be
high quality brake degreasing agent. spilled.
3. Remove reservoir cover with its diaphragm
NOTICE Avoid spilling brake fluid on plastic, seal.
rubber or painted parts. Protect these parts
with a rag when servicing the brake system.
NOTICE Wipe up any brake fluid spillage.
NOTICE To avoid serious damage to the
brake system, use only DOT 4 brake fluid from
a sealed container. Do not use brake fluid
taken from an old or already opened contain-
ers, or mix different fluids for topping up the
system.
NOTICE Sealing washers must be discarded
and replaced with NEW ones every time a mmr2015-137-019_a
Banjo fitting is unscrewed. 1. Reservoir cover

2. Diaphragm
Dispose of brake fluid as per your local environ- 4. Open the LH side panel.
mental regulation.
5. Remove the LH toe hook.
mmr2017-042 3
mmr2017-042-001 mmr2017-042-004
6. Remove the disc brake protective cover. 11. Remove brake pads.
11.1 Remove the external pad first.
mmr2017-042-002
7. Remove the clip securing brake pad pin. mmr2017-042-005
8. Unscrew and remove the brake pad pin. 11.2 Pull the brake disc outward and remove
the internal pad.
mmr2017-042-003_a
1. Clip mmr2017-042-006
2. Brake pad pin
Installing the Brake Pads
9. Using a flat screwdriver, depress caliper pistons
into their bores. The installation is the reverse of the removal.
NOTICE Pay attention to avoid scratching 1. Install new brake pads with tabs facing upward.
brake disc.
2. Install brake pad pin and tighten to specifica-
10. Remove the circlip securing brake disc to drive tion.
axle.
4 mmr2017-042
TIGHTENING TORQUE 2. Refer to CHAINCASE subsection and carry the

following steps.
10 N•m ± 2 N•m
Brake pad pin 2.1 Remove chaincase cover.
2.2 Loosen drive chain.
3. Install spring clip on brake pad pin. If the clip
2.3 Remove lower sprocket.
seems loose, replace it with a new one.
3. Open LH side panel.
NOTE: Make sure anti-rattle spring ends on brake
pads tabs are correctly installed as per following 4. Remove drive belt guard support. Refer to
pictures. DRIVE BELT subsection.
5. Remove the LH toe hook.
NOTE: If the caliper is not replaced, omit steps 5
and 6 concerning the brake system draining and
brake hose removal.
6. Drain the brake system, refer to PERIODIC
7. Remove the Banjo fitting and discard the seal-
ing washers.
mmr2015-137-006
CORRECT
mmr2017-042-007
8. Remove the brake pads., Refer to procedure in

this subsection.
9. Lift the rear of vehicle and release track tension
completely.
mbg2009-004-007_a
10. Turn track to align brake disc slots with caliper
INCORRECT (RIGHT SIDE SPRING CLIP)
bracket screws.
4. Operate the brake lever several times to bring 11. Remove caliper screws (4) behind brake disc.
the brake pads into contact with the disc brake.
5. Check brake fluid level in master cylinder and
refill if necessary.
6. Reinstall the diaphragm and the cover.
7. Ride the vehicle a few minutes to make sure
the repair is successful.
CALIPER
Removing the Caliper
1. Open the RH side panel.
mmr2017-042-008
mmr2017-042 5
12. Pull the assembly (brake disc, caliper, bearing, NOTICE Never use an impact tool to operate
and drive axle) from LH side in order to make caliper puller. The caliper or the puller could
room for the caliper puller. break.
16. When brake disc is out of splines, remove it.
17. Remove caliper.
NOTICE Do not let caliper hang by the hose
and do not stretch or twist the hose.
Inspecting the Caliper

1. Check caliper pistons for:
– Proper operation
– Rust
– Scratches
mbg2009-004-002_a
– Leaks.
TYPICAL 2. Check caliper bracket for:
– Cracks
REQUIRED TOOL
– Rust on bearing shoulder (clean with a steel
wood).
CALIPER PULLER (P/N 529 3. Replace caliper if required.
036 145)
Installing the Caliper
1. Using your fingers or a small piece of wood,
PROTECTIVE CAP (P/N 529 push both pistons into their bores.
036 150)
2. Clean brake caliper bearing shoulder with fine
steel wool.
13. Install the caliper puller on the brake caliper
through brake disc slots. 3. Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070) on drive axle splines and on
NOTE: Make sure puller tabs are correctly en- bearing shoulder of caliper bracket.
gaged on caliper.
14. Install the protective cap between caliper
puller bolt and plastic cap in drive axle end.
mmr2017-042-009
DRIVE AXLE SPLINES
mmr2009-084-002_a
TYPICAL
1. Caliper puller
2. Protective cap
3. Caliper bracket
4. Brake disc
15. Tighten caliper puller bolt to separate caliper

from drive axle bearing.
6 mmr2017-042
6. Align brake disc splines with drive axle splines

and push brake disc onto drive axle.
7. Push the caliper bracket over the drive axle
bearing.
mmr2008-043-113_a
1. Caliper bracket
2. Bearing shoulder
4. Insert brake disc in the caliper. The brake disc

collar must be inserted in the caliper bracket. mmr2017-042-011
8. Align caliper bracket holes with bearing flange

holes and install caliper screws.
mmr2008-043-114_a
mmr2017-042-012_a
1. Brake disc collar TUNNEL IS TRANSPARENT FOR CLARITY
2. Caliper bracket 1. Bearing flange (inside frame)
5. Ensure bearing flange is properly locked in the 9. HAND TIGHTEN each caliper bracket screw
frame. Tabs must be properly inserted in frame evenly in a criss-cross pattern until bracket is
slots. correctly positioned against frame.
NOTICE Never use an air tool to tighten
caliper screws. The caliper bracket could
crack.
10. Install the brake pads. Refer to procedure in
this subsection.
11. Install the brake disc circlip.
12. Tighten the brake caliper screws to specifica-
tion.
mmr2017-042-010
VIEW FROM OUTSIDE FRAME
mmr2017-042 7
TIGHTENING TORQUE MASTER CYLINDER

Caliper screws
24.5 N•m ± 3.5 N•m Removing the Master Cylinder
NOTE: If the master cylinder is not replaced, omit
13. Apply brake fluid on Banjo fitting threads. the steps concerning brake system draining and
brake hose removal.
14. Install the Banjo fitting with two new sealing
washers. 1. Drain brake system., Refer to PERIODIC MAIN-
15. Tighten Banjo fitting to specification.
2. Remove the Banjo fitting and discard the seal-
TIGHTENING TORQUE ing washers.
35 N•m ± 1 N•m
Banjo fitting
16. Fill and bleed the brake system. Refer to PE-

RIODIC MAINTENANCE PROCEDURES sub-
section.
17. Install all other removed parts.
18. Check the operation of the brake carefully be-
fore riding the snowmobile.
BRAKE DISC
Inspecting the Brake Disc (Not mmr2017-042-013
Removed)
3. Remove screws and clamp securing master
1. Remove the disc brake protective cover.
cylinder to handlebar.
2. Check for scoring, cracking or bending, replace
as required.
3. Measure brake disc thickness. If the brake disc
is out of specification, replace it with a new one.
NOTICE Brake disc should never be ma-
chined.
BRAKE DISC SPECIFICATION
Minimum thickness 4.5 mm (.177 in)
Inspecting the Brake Disc (Removed)

1. Check brake disc splines and drive axle splines mmr2017-050-015
for wear or other damages. Replace defective
parts. 4. Remove master cylinder.
Removing and Installing the Brake NOTICE Do not let master cylinder hang by
Disc the hose and do not stretch or twist the hose.
Follow procedures for caliper removal and instal- Inspecting the Master Cylinder
lation.
1. Discard all remaining fluid inside master cylin-
der reservoir.
2. Check if the reservoir cap seal is brittle, hard or
damaged. Replace as necessary.
3. If the reservoir is damaged or leaking, replace
master cylinder.
8 mmr2017-042
4. Check if brake lever is bent, cracked or other- BRAKE LEVER

wise damaged. Replace brake lever if required.
Lubricating the Brake Lever
Installing the Master Cylinder After using brake cleaner in the brake lever
1. Place the master cylinder on the handlebar. area or after adding brake oil in reservoir, check
brake lever pivot lubrication. Add XPS SYNTHETIC
2. Install master cylinder retaining clamp with its
GREASE (P/N 293 550 010) on brake lever pivot as
arrow pointing toward the front of vehicle.
necessary.
Replacing the Brake Lever

Lubricate brake lever pivot using XPS SYNTHETIC
GREASE (P/N 293 550 010).
mmr2017-050-017
3. Install master cylinder clamp screws and

tighten loosely.
4. With the handlebar in the straight ahead posi- mmr2009-130-001_a
tion, place the reservoir parallel to the ground. TYPICAL

1. Lubricate brake lever pivot
5. Tighten master cylinder clamp screws to spec-
ification. Tighten the pivot nut of brake lever to specifica-
tion.
TIGHTENING TORQUE
TIGHTENING TORQUE
Master cylinder clamp 9 N•m ± 1 N•m
screws (80 lbf•in ± 9 lbf•in) 6 N•m ± 1 N•m
Brake lever pivot nut
6. Install the Banjo fitting with two new sealing
washers.
BRAKE LIGHT SWITCH
7. Tighten Banjo fitting to specification.
TIGHTENING TORQUE
Testing the Brake Light Switch
Resistance
27 N•m ± 1 N•m
Banjo fitting
BODY subsection.
8. Fill and bleed the brake system. Refer to PERI- 2. Disconnect the brake light switch connector lo-
ODIC MAINTENANCE PROCEDURES subsec- cated on the ECM.
tion.
9. Install brake light switch.
10. Install steering cover.
mmr2017-042 9
mmr2017-042-014 mmr2017-042-015_a
3. Validate switch operation with an ohmmeter as 4. Cut all locking ties securing switch wires.
follows.
LH HANDLEBAR CONNECTOR (4-PIN)
SWITCH WIRE RESISTANCE
Released Infinite (OL)
Pin 2
Squeezed and and pin 4 Close to 0
held
If readings do not correspond to the above speci-

fications, replace switch.
If readings correspond to the above specifica-
tions, check fuse, wiring and connectors going to
switch. Repair or replace defective part(s). mmr2017-050-014
Removing the Brake Light Switch 5. Remove switch wires from connector. Refer to
WIRING HARNESS AND CONNECTORS.
BODY subsection. NOTE: Check wires location for reinstallation.
2. Disconnect the brake light switch connector lo- Installing the Brake Light Switch
cated on the ECM.
Plug switch wires into connector as per following
tables.
LH HANDLEBAR CONNECTOR (4-PIN)
WIRE CONNECTOR
GRAY Pin 4
BROWN Pin 2
Check if switch is working properly.

Install new locking ties.
mmr2017-042-014
3. Slip a small screwdriver between brake light BRAKE HOSE

switch and master cylinder housing and sepa-
rate them.
Replacing the Brake Hose
1. Remove the console. Refer to BODY subsec-
tion.
10 mmr2017-042
2. Drain the brake system, refer to PERIODIC

3. Remove Banjo fittings at both ends of hose.
Refer to REMOVING THE MASTER CYLINDER
and REMOVING THE CALIPER.
4. Remove fasteners that secure the hose clamps
to the frame.
NOTICE Take care not to overdrill the lower
clamp rivet. The fuel tank could be damaged.
Install new sealing washer.
TIGHTENING TORQUE
2.3 N•m ± 0.2 N•m
Middle clamp nut
35 N•m ± 1 N•m
Caliper Banjo fitting
Master cylinder Banjo 27 N•m ± 1 N•m
fitting (20 lbf•ft ± 1 lbf•ft)
mmr2017-042 11
Subsection XX (CHAINCASE)
CHAINCASE
SERVICE TOOLS
BEARING PULLER/PUSHER ......................................................... 529 036 111 ........................................... 5
BEARING PULLER/PUSHER ......................................................... 529 036 112 ........................................... 5

SNAP-ON SEAL PULLER .............................................................. YA105 ........................................... 6
SERVICE PRODUCTS
LOCTITE 5900 ............................................................................... 293 800 066 ........................................... 11
mmr2017-043 1
0.9 ± 0.1 N•m

48 ± 6 N•m
(35 ± 4 lbf•
lbf•po
po)
NEW
6 ± 1 N•m
(53 ± 9 lbf•in)
NEW
NEW
16 ± 2 N•m
(142 ± 18 lbf•in)
6 ± 1 N•m
(53 ± 9 lbf•in)
See tightening
procedure
Loctite 5900

mmr2017-043-100_a
2 mmr2017-043
GENERAL
ues and service products as in the exploded view.
complete procedure.
WARNING
must be strictly adhered to. mmr2017-043-024_a
ones when removed (e.g.: locking tabs, elas- 6. Disconnect speed sensor connector.
tic stop nuts, cotter pin, etc.).

PROCEDURES
CHAINCASE
Chaincase Disassembly
Removing the Chaincase Cover mmr2017-043-001
1. Apply parking brake.

7. Remove the RH side toe hook and the screw
2. Remove the muffler. Refer to EXHAUST SYS- securing the cover to the footrest.
TEM subsection.
3. Remove the filler plug on the chaincase cover.
mmr2017-043-002
mmr2017-041-001
8. Remove chaincase cover screws.
4. Place a container under vehicle in line with

chaincase to catch chaincase oil.
5. Remove the drain plug on the bottom of the
chaincase.
mmr2017-043 3
mmr2017-043-003 mmr2017-043-006
9. Pull on bottom of chaincase cover to drain oil. NOTE: The following steps are required only if the
10. Wait a moment then remove the cover com- tensioner or the slider is defective.
pletely. 4. Remove the circlip securing the slider to ten-
sioner.
Removing the Chain Tensioner
1. Remove the hair pin from behind the chaincase.
mmr2017-043-007
1. Circlip
2. Tensioner
mmr2017-043-004 3. Slider
2. Remove the tensioner adjustment screw. Removing the Drive Chain and Sprocket
NOTE: Prior to removing the drive chain, check
the drive chain deflection.
1. Remove the upper sprocket screw and its con-
ical spring washer.
mmr2017-043-005
3. Remove tensioner.
mmr2017-043-008
2. Remove the lower sprocket circlip.
4 mmr2017-043
mmr2017-043-009 mmr2017-043-012
3. Remove the upper sprocket, lower sprocket 3. Install the appropriate bearing extractor:
and drive chain simultaneously.
BEARING REQUIRED TOOL
BEARING PULLER/PUSHER
Countershaft
(P/N 529 036 111)
BEARING PULLER/PUSHER
Drive axle
(P/N 529 036 112)
529036111
COUNTERSHAFT
mmr2017-043-010
4. Remove the countershaft spacer.
529036112
DRIVE AXLE
4. Install the extractor/installer tool behind the

bearing.
mmr2017-043-011
Removing the Chaincase Bearing

1. Remove countershaft or drive axle, depending
which bearing is replaced. Refer to the ap-
propriate subsection, DRIVEN PULLEY AND
COUNTERSHAFT or DRIVE AXLE.
2. Remove snap ring securing bearing into chain-
case. mmr2008-044-114_a
TYPICAL
1. Extractor/installer tool
5. Install the extractor cup over bearing.

mmr2017-043 5
6. Tighten the extractor/installer tool screw to re-

move the bearing.
mmr2017-043-013
4. Remove the Huck rivets. Refer to FRAME sub-

section for proper removal procedure.
mmr2008-044-115_a
TYPICAL
1. Extractor cup
2. Tighten to remove bearing
7. Using a seal puller such as the SNAP-ON SEAL

PULLER (P/N YA105), remove and discard the oil
seal.
mmr2017-043-014
5. Remove nuts beside the footrest.
mmr2008-044-116
TYPICAL
Removing the Chaincase Housing

1. Remove the drive axle. Refer to DRIVE AXLE
subsection.
2. Remove the countershaft. Refer to DRIVEN
PULLEY AND COUNTERSHAFT subsection.
3. Remove the screw securing the coolant reser-
voir.
mmr2017-043-015
6. Remove the screw above the tensioner.
6 mmr2017-043
If a problem is detected, replace drive chain and

sprockets as an assembly.
Check the drive chain deflection.
If the deflection is greater than 38 mm (1-1/2 in)
without the chain tensioner, replace the drive
chain.
Inspecting the Chaincase Bearing
Check for worn or defective bearings.
Chaincase Assembly
mmr2017-043-016
Installing the Chaincase Housing
7. Using 2 large pry bars inserted between chain- The installation is the reverse of the removal pro-
case and frame, pry chaincase out of vehicle. cedure. However, pay attention to the following.
8. Remove the rewind starter rope guide screws. Have the following parts in hands:
PARTS TO INSTALL CHAINCASE
QTY FASTENERS PART NUMBER
1 Mounting plate kit 861805514
M6 elastic
5 233261434
flanged nut
Remove the clinch studs from the frame.
mmr2017-043-017
Inspecting the Chaincase

Inspecting the Chaincase Cover
Check the cover for cracks or other damages. Re-
place it if necessary.
Check if O-ring inside cover is brittle, hard or dam-
aged. Replace it if necessary. mmr2017-043-025_a
Inspecting the Chain Tensioner

Use a suitable box to support the frame around
Check chain tensioner slider for wear or other the stud head and hit the stud from the outside
damages. Replace if necessary. with a hammer.
Check threads of tensioner adjustment screw for Install the mounting plate underneath the frame.
damages or wear.
Replace screw if necessary and check chaincase
for damages.
Inspecting the Drive Chain and Sprockets
Visually inspect the drive chain and sprockets for:
– Wear
– Cracks
– Damages teeth
– Missing links.
mmr2017-043 7
mmr2008-044-117_a
mmr2017-043-026
TYPICAL
UNDERNEATH FRAME 1. Extractor/installer tool
2. Oil seal lips on this side
Install 5 elastic flanged nuts to secure chaincase
on mounting plate. Install the extractor cup inside frame.
Tighten fasteners as per the following sequence.
mmr2008-044-118_a
TYPICAL
1. Extractor cup
mmr2017-043-018_a
Tighten the extractor/installer tool screw to install
Proceed with drive chain adjustment. Refer to PE- the oil seal.
RIODIC MAINTENANCE PROCEDURES subsec- Install the large washer and the extractor/installer
tion. tool screw inside frame.
Refill chaincase with recommended oil. Refer to
REPLACING THE CHAINCASE OIL in PERIODIC
Installing Chaincase Bearing
Install the new oil seal on the extractor/installer
tool. Position the lips toward bearing.
mmr2008-044-119_a
TYPICAL
1. Large washer
2. Extractor/installer tool screw
In chaincase, install new bearing and the

extractor/installer tool.
8 mmr2017-043
mmr2008-044-120_a
TYPICAL
1. Bearing mmr2017-043-003_a
2. Extractor/installer tool
TIGHTENING TORQUE
Tighten the extractor/installer tool screw to install
the bearing. Same 10 N•m ± 2 N•m
Screws 1 chaincase (89 lbf•in ± 18 lbf•in)
Install new snap ring.
to 8 New 15 N•m ± 1 N•m
Installing the Drive Chain and Sprockets chaincase (133 lbf•in ± 9 lbf•in)
The installation is the reverse of the removal pro- 24.5 N•m ± 3.5 N•m
cedure. However, pay attention to the following. Screw 9
Make sure to install sprockets with their inscrip- 16 N•m ± 2 N•m
tions outward. Screw 10
Install the conical spring washer on the upper
sprocket with its concave side toward sprocket. Refill chaincase with recommended oil. Refer to
CHAINCASE OIL REPLACEMENT in PERIODIC
Installing the Chain Tensioner MAINTENANCE PROCEDURES subsection.
The installation is the reverse of the removal pro- Reinstall all other removed parts.
If the tensioner has been disassembled, make SPEED SENSOR (VSS)
sure circlip turns freely and slider moves easily.
The speed sensor is a hall effect sensor.
Proceed with drive chain adjustment. Refer to PE-
RIODIC MAINTENANCE PROCEDURES subsec- Speed Sensor Location
tion.
The speed sensor is mounted in the chaincase
Installing the Chaincase Cover cover.
cedure. However, pay attention to the following. Testing the Speed Sensor Signal
Ensure cover seal is positioned correctly in its 1. Ensure speed sensor is properly connected.
groove. 2. Wake up ECM.
Install new sealing washer with screw no.10. See 3. Back-probe VSS connector as per table and test
next illustration. for proper specification.
Tighten chaincase cover screws in accordance NOTICE Be careful not to damage connector
with the following sequence. seals when back probing.
SPEED SENSOR (VSS)
SPECIFICATION
CONNECTOR
Pin 2 Ground
Pin 3 5 Vdc reference voltage
If test failed, check wiring harness going to ECM.

4. Lift and support rear of vehicle.
mmr2017-043 9
5. Back-probe VSS connector as per table and test Replacing the Speed Sensor
for proper specification. The sensor can be replaced with the chaincase
6. Rotate track/driven pulley. cover as an assembly. In such a case, refer to
CHAINCASE subsection.
SPEED SENSOR SIGNAL TEST
To replace sensor only, proceed as follows.
SPEED SENSOR
CONNECTOR VOLTAGE Removing the Speed Sensor
ROTATE (SENSOR SIDE)
DRIVEN 1. Remove chaincase cover. Refer to procedure in
PULLEY Alternate this subsection.
Pin 1 Pin 2 7 Vdc and
2. Heat the upper end of the speed sensor protec-
0 Vdc
tive plate with a heat gun.
If reference voltage and ground are available at
sensor, but no signal, replace sensor.
NOTE: During chaincase disassembly, ensure
magnets are intact on shaft.
mmr2017-043-019_a
3. Use a flat screwdriver to pry out the end of the

protective plate from chaincase cover.
mmr2017-043-100
Air gap between magnets and sensor must be as

specified.
mmr2017-043-019_b
NOTICE Use care when prying out the plate

not to damage the chaincase cover.
mmr2017-043-101 4. Heat the next section of the plate.
A. VSS Air gap 5. Pry out the heated section using the flat screw-
AIR GAP SPECIFICATION
driver.
6. Repeat steps 4 and 5 until the protective plate
no. A Measure between
3 mm (.118 in) is completely removed.
magnet and sensor
7. Remove the speed sensor.
8. Use the flat screwdriver to remove the remain-
ing sealant from the chaincase cover.
10 mmr2017-043
NOTICE Do not apply excessive pressure

when removing the remaining sealant not to
damage the chaincase cover.
9. Rub the sealant using a scouring pad.
Installing the Speed Sensor
Make sure surface is clean and free of grease.
The assembly must be watertight.
PRODUCT REQUIRED
LOCTITE 5900 (P/N 293 800 066)
mmr2017-043-022_a
1. Apply 3 beads of sealant in the chaincase cover

as per the following illustration. 4. Place the protective plate in position and firmly
push in order to evacuate all the surplus sealant.
Keep pressure for at least 1 minute.
5. Wipe off all the sealant surplus.
6. Once cleaned up, inspect all the circumference
for sealant lacks.
NOTE: Sealant must be visible all around.
7. Place some adhesive tape on the protective
plate to maintain a pressure for at least 24
hours.
NOTE: Wait for at least 1 hour before exposing
vehicle to cold temperature.
mmr2017-043-020_a
8. Reinstall chaincase cover. Refer to procedure in
this subsection.
2. Install the speed sensor in the chaincase cover.
mmr2017-043-021
3. Apply sealant all around the protective plate bed

on the chaincase cover.
Follow the pattern shown on the next picture.
mmr2017-043 11
Subsection XX (DRIVE AXLE)
DRIVE AXLE
SERVICE PRODUCTS
NEW
Suspention grease
Suspention grease
NEW
mmr2017-044-100_a
mmr2017-044 1
GENERAL
and service products as in the exploded view.
complete procedure.
WARNING
must be strictly adhered to. mmr2017-043-009
ones when removed (e.g.: locking tabs, elas- 5. Remove lower gear and drive chain.
tic stop nuts, cotter pins, etc.). 6. Remove the caliper. Refer to BRAKE subsec-
tion.
PROCEDURES 7. From underneath of vehicle, turn the LH bear-
ing flange counterclockwise to unlock it from
DRIVE AXLE frame.
Removing the Drive Axle
1. Remove the rear suspension. Refer to REAR
SUSPENSION subsection.
2. Remove the chaincase cover. Refer to CHAIN-
CASE subsection.
3. Release tension from drive chain by unscrew-
ing the tensioner adjustment screw.
mmr2017-044-001_a
8. Release drive axle sprockets from track and at

the same time, push the drive axle towards left
side until it comes out of the chaincase.
9. Move the drive axle towards the right side to
remove it from vehicle.
mmr2017-041-002
Inspecting the Drive Axle
4. Remove the lower sprocket circlip. Check if bearing turns smoothly and freely. Re-
place bearing if necessary.
Check if bearing seals are damaged. Replace
bearing if necessary.
Check if the bearing flange is cracked, bent or oth-
erwise damaged. Replace if required.
Replace drive axle if one of the following situa-
tions is detected:
– Cracked, worn or damaged drive axle
– Worn or damaged drive axle splines
2 mmr2017-044
– Worn or damaged sprockets NOTE: Ensure bearing flange is properly locked.

– Worn bearing journal. Tabs must be properly inserted in frame slots.
Removing the Drive Axle Bearing

1. Use a 3-jaw pullerto remove the drive axle bear-
ing.
mmr2017-042-010
VIEW FROM OUTSIDE FRAME
Install the caliper and the disc brake. Refer to

BRAKE subsection for the specific procedure.
Install all other removed parts. Refer to appropri-
mmr2008-045-104
ate subsections.
2. Remove the bearing flange.
MAGNETIC CAPS
Installing the Drive Axle Bearing
Removing the Magnetic Cap
1. Install bearing flange on drive axle with locking
tabs outwards. 1. For the LH cap, remove brake disc protective
cover. Refer to BRAKE subsection.
2. For the RH cap, remove the chaincase cover.
Refer to CHAINCASE subsection.
3. By screwing a large screw in the middle of the
cap, pry or pull the magnetic cap out of drive
axle end.
4. To remove the other cap, push through axle
with a long metal bar or wood stick.
5. Discard the magnetic cap.
Installing the Magnetic Cap

1. Apply SUSPENSION GREASE (P/N 293 550 033) on
O-ring.
mmr2017-044-003_a
2. Insert new magnetic cap in drive axle, Push un-
2. Using a press and a suitable pipe, push the til caps is secure into groove.
bearing onto drive axel. NOTE: Cap should have outside contour face
5 mm (.197 in) inwards.
NOTICE Always push the bearing by inner
race.
Installing the Drive Axle

Insert drive axle and lock the bearing flange on
frame.
mmr2017-044 3
mmr2017-044-005_a
5 MM (.197IN) INWARDS
3. Install all other removed parts.
4 mmr2017-044
Subsection XX (TRACK)
TRACK
SERVICE TOOLS
TRACK CLEAT INSTALLER............................................................ 529 036 044 ........................................... 1
PROCEDURES Place new cleat in position on the track.

Secure cleat with the cleat installer.
TRACK REQUIRED TOOL
Inspecting the Track
Visually inspect track for: TRACK CLEAT
– Cuts and abnormal wear INSTALLER (P/N 529
– Broken rods 036 044)
– Broken or missing track cleats
– Perforations in the track Bend cleat and push tabs into rubber.
– Tears in the track (particularly around traction
product holes)
– Lugs that are broken or torn off, exposing por-
tion of rods
– Delamination of the rubber
– Missing track guide(s).
If track is damaged or rods are broken, replace
track. For damaged or missing cleats, replace by
new ones.
WARNING
Do not operate a snowmobile with a cut, torn mmr2008-046-101_a
or damaged track. TYPICAL
1. Narrow-cleat installer
Replacing a Track Cleat Reopen narrow-cleat installer.
Raise rear of vehicle off the ground.
Position cleat tabs on open end of tool.
Lift snow guard.
Squeeze tabs until they are indented in rubber.
Rotate track to expose a cleat to be replaced.
Remove cleat from track using plastic hammer Removing the Track
and a big screwdriver. Remove rear suspension from vehicle. Refer to
REAR SUSPENSION.
Remove drive axle. Refer to DRIVE AXLE subsec-
tion.
Remove track.
Installing the Track

Reverse the removal procedure.
NOTE: When installing the track, respect rotation
direction indicated by an arrow on track thread.
mmr2008-046-201_a
TYPICAL
1. Cleat
mmr2017-045 1
Subsection XX (TRACK)
mmr2008-046-200_a
1. Arrow pointing forwards
Adjusting and aligning the Track

Refer to PERIODIC MAINTENANCE PROCE-
DURE subsection to adjust and align the track.
2 mmr2017-045
Subsection XX (FRONT SUSPENSION)
FRONT SUSPENSION
SERVICE TOOLS
BALL JOINT EXTRACTOR............................................................. 529 035 827 ............................................. 4
BALL JOINT INSTALLER SUPPORT ............................................. 529 036 398 ............................................. 7
BALL JOINT INSTALLER............................................................... 529 036 399 ............................................. 7
BALL JOINT REMOVER SUPPORT .............................................. 529 036 400 ............................................. 7
SPRING COMPRESSOR ............................................................... 529 036 184 ............................................. 3
SUSPENSION ARM SUPPORT ..................................................... 529 035 637 ............................................. 5
NEW
NEW
NEW
NEW
31.5 ± 3.5 N•m

(23 ± 3 lbf•ft)
NEW
15 ± 2 N•m NEW
NEW (133 ± 18 lbf•in) 19 ± 2 N•m
(168 ± 18 lbf•in)
NEW
NEW
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)
MX Z X MX Z TNT
Renegade X Renegade
Summit SP Summit X Adrenaline
mmr2017-046-100_a
mmr2017-046 1
GENERAL Spring Preload Adjustment

The procedure explained below is the same for Cam Type Adjustment
the RH and LH sides unless otherwise noted. Using the suspension adjustment tool (included in
During assembly/installation, use torque values the vehicle tool kit), turn the cam to increase or
and service products as in the exploded view. decrease spring preload.
complete procedure.
WARNING
Torque wrench tightening specifications mmr2017-046-016_a
must be strictly adhered to. 1. Increase preload

2. Decrease preload
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced Ring Type Adjustment
with new ones.
Grab and turn the spring to increase or decrease
spring preload.
Check for loose, bent, worn out, rusted or oth-
erwise damaged components. Replace the faulty
components.
ADJUSTMENT
SPRINGS
Front spring preload has an effect on front suspen-
sion firmness.
Front spring preload also has an effect on the mmr2017-046-001_a
steering behavior. 1. Increase preload

2. Decrease preload
ACTION RESULT
Firmer front suspension PROCEDURES
Higher front end
Increasing SHOCK ABSORBER
preload More precise steering
Removing the Shock Absorber
More bump absorption capability
1. Remove the side panel. Refer to BODY subsec-
Softer front suspension tion.
Decreasing Lower front end 2. Lift the front of vehicle until skis are off the
preload Lighter steering ground.
3. Remove the shock absorber upper bolt.
Less bump absorption capability
WARNING
Adjust both springs to the same preload.
Uneven adjustment can cause poor handling
and loss of stability, and/or control, and in-
crease the risk of an accident.
2 mmr2017-046
mmr2017-046-002_a mmr2017-046-004
4. Remove the shock absorber lower bolt, nut, TIGHTENING TORQUE

and spacers. Front shock absorber 31.5 N•m ± 3.5 N•m
retaining nuts (23 lbf•ft ± 3 lbf•ft)
SPRING
Removing the Spring
1. Secure the SPRING COMPRESSOR (P/N 529 036
184) in a vise.
mmr2017-046-003
5. Remove the shock absorber. 529036184
SPRING COMPRESSOR
Inspecting the Shock Absorber
2. Position the shock absorber in the tool and in-
Refer to REAR SUSPENSION (RMOTION) sub- stall the spring compressor hooks.
section.
Installing the Shock Absorber

For installation, reverse the removal procedure,
however, pay attention to the following.
Install upper bolt first while shock absorber lower
mount is not engaged into the bracket.
Install shock absorber with body up and valve (if
equipped) towards outside.
mmr2010-033-012_a
TYPICAL
1. Spring compressor hooks
3. Tighten the spring compressor tool screw until

the spring is sufficiently compressed to remove
spring stopper.
4. Release the spring compressor tool screw.
5. Remove spring from shock absorber.
Inspecting the Spring

Inspect spring for apparent damage.
mmr2017-046 3
When the adjustment is at the lowest preload, en-

sure that adjustment cam and spring stopper are
not loose. They must be under spring pressure.
Otherwise, the spring stopper might fall off.
Installing the Spring

UPPER SUSPENSION ARM

Inspecting the Upper Suspension Arm
1. Check suspension arm for distortion or dam- mmr2017-046-006
age. Replace if necessary.

5.2 Use the extractor to detach ball joint from
2. Lift the front of vehicle until skis are off the
ski leg.
ground.
3. Move suspension arm from side to side. REQUIRED TOOL
4. Lower vehicle to the ground.

5. Move suspension up and down. BALL JOINT EXTRACTOR
6. There should be no noticeable looseness. Re- (P/N 529 035 827)
place bushings and/or sleeves if necessary.
NOTE: A play of 2 mm (.079 in) is acceptable
when the suspension arm is moved forward and 6. Remove upper suspension arm.
backward.
Installing the Upper Suspension Arm
7. Check sleeves inside suspension arm attach-
ments for wear or damage. The installation is the reverse of the removal pro-
Removing the Upper Suspension Arm NOTICE Make sure not to invert LH and RH
1. Lift the front of vehicle until skis are off the arm.
ground.
2. Remove muffler and tuned pipe. Refer to EX-
3. Remove shock absorber. See procedure in RE-
MOVING THE SHOCK ABSORBER in this sub-
section.
4. Remove the upper suspension arm bolts.
msi2016-010-004_a
RH UPPER ARM INSTALLED ON LH SIDE
mmr2017-046-005
5. Detach ball joint from ski leg as follows.

5.1 Remove nut securing ball joint to ski leg.
4 mmr2017-046
msi2016-010-003_a
mmr2012-048-100_a
LH UPPER ARM INSTALLED ON LH SIDE
TYPICAL
1. Press rod
UPPER BALL JOINT 2. Socket
3. Suspension arm
4. Suspension arm support
Inspecting the Upper Ball Joint
Check both upper ball joints for damage, pitting, Installing the Upper Ball Joint
looseness and roughness. If so, replace with a The installation is the reverse of the removal pro-
new one. cedure. However, pay attention to the following.
Removing the Upper Ball Joint 1. Press ball joint into the suspension arm.
1. Remove the UPPER SUSPENSION ARM, see REQUIRED TOOLS
procedure in this subsection. Shop press
2. Remove circlip securing ball joint to suspension
arm. SUSPENSION ARM
SUPPORT (P/N 529
035 637)
Suitable socket
mmr2017-046-007
3. Press ball joint out of the suspension arm.

REQUIRED TOOLS
mmr2012-048-101_a
Shop press
TYPICAL
1. Socket
SUSPENSION ARM 2. Ball joint
SUPPORT (P/N 529 3. Suspension arm
4. Suspension arm support (P/N 529 035 637)
035 637)
2. Reinstall the circlip. If it seems loose, replace it
Suitable socket
with a new one.
mmr2017-046 5
LOWER SUSPENSION ARM

Inspecting the Lower Suspension Arm
1. Check suspension arm for distortion or dam-
age. Replace if necessary.
ground.
3. Detach shock absorber and stabilizer bar link
from lower suspension arm.
4. Move suspension arm from side to side.
5. Lower vehicle to the ground. mmr2017-046-008_a
6. Move suspension up and down.

8. Remove lower suspension arm from vehicle.
7. There should be no noticeable loose. Replace
bushings and/or sleeves if necessary. Installing the Lower Suspension Arm
NOTE: A play of 2 mm (.079 in) is acceptable The installation is the reverse of the removal pro-
when the suspension arm is moved forward and cedure. However, pay attention to the following.
backward.
1. Install a wear plate over bushings.
8. Check sleeves inside suspension arm attach-
2. Position the wear plate on top.
ments for wear or damage.
3. Fold all tabs against bushings.
Removing the Lower Suspension Arm
ground.
2. Remove the tune pipe. Refer to EXHAUST
SYSTEM subsection.
3. Remove shock absorber lower bolt.
4. Detach stabilizer bar link from lower suspension
arm. Refer to STABILIZER BAR further in this
subsection.
5. Remove lower ball joint nut.
mmr2008-047-120_a
1. Wear plate
2. Wear plate tabs
3. Bushings
4. Lower suspension arm
Install all other removed parts.
LOWER BALL JOINT

Inspecting the Lower Ball Joint
Inspect ball joint end for damage. Ensure it's mov-
ing freely, a 0.3 mm (.012 in) axial play is accept-
able. Replace ball joints as required.
mmr2017-046-014
Removing the Lower Ball Joint
6. Using a suitable ball joint remover, detach lower 1. Remove the LOWER SUSPENSION ARM, see
ball joint from ski leg. procedure in this subsection.
7. Remove suspension arm screws from inside 2. Remove circlip securing ball joint to suspension
the vehicle. arm.
6 mmr2017-046
mmr2017-046-010_a
mmr2015-141-009_a
1. Ball joint installer support
2. Ball joint installer
3. Use a shop press and the specified tools to
press the ball joint out of the lower suspension 2. Reinstall the circlip. If the circlip seems loose,
arm. replace it with a new one.
REQUIRED TOOLS 3. Install the LOWER SUSPENSION ARM on ve-
hicle, see procedure in this subsection.
BALL JOINT REMOVER
SUPPORT (P/N 529 036 400) SKI LEG
Suitable box Removing the Ski Leg
1. Remove ski from ski leg.
2. Detach tie-rod end from ski leg.
mmr2017-046-009_a
1. Ball joint remover support

2. Suitable box
mmr2015-141-010_a
Installing the Lower Ball Joint
1. Use a press and the specified tools to press the 3. Remove upper and lower ball joints from ski
ball joint into the suspension arm end. leg. Refer to UPPER BALL JOINT and LOWER
BALL JOINT in this subsection.
REQUIRED TOOLS
Installing the Ski Leg
BALL JOINT INSTALLER
SUPPORT (P/N 529 036 398) The installation is the reverse of the removal pro-
cedure.
BALL JOINT INSTALLER
(P/N 529 036 399) STABILIZER BAR
Removing the Stabilizer Bar
1. Remove bolts and nuts securing stabilizer links
to lower suspension arms.
mmr2017-046 7
TIGHTENING TORQUE
19 N•m ± 2 N•m
Stabilizer bar link nut
mmr2017-046-011
LH SIDE SHOWN
2. Remove stabilizer lever bolts and nuts.
mmr2017-046-017
FLAT SIDE FACING OUTWARDS
mmr2017-046-012
LH SIDE SHOWN
3. Remove stabilizer levers and plastic bushings

from stabilizer bar.
4. Slide stabilizer bar out of vehicle from the LH
side.
mmr2017-046-013_a
Installing the Stabilizer Bar

Ensure to install the flat side outwards.
Install the screw with the head upwards.
8 mmr2017-046
Subsection XX (REAR SUSPENSION (rMOTION))
REAR SUSPENSION (rMOTION)

SERVICE TOOLS
RMOTION MASTER CYLINDER KEY............................................ 529 036 254 ........................................... 19
RMOTION SOCKET....................................................................... 529 036 255 ........................................... 19
RMOTION SUSPENSION TOOL ................................................... 529 036 234 ..................................... 14, 27
SHOCK ABSORBER SUPPORTS .................................................. 529 036 186 ........................................... 25

BENCH SCALE .............................................................................. Salter ........................................... 25
Brecknell PS
400
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 17
mmr2017-047 1
RAILS
NEW
NEW
5 ± 0.5 N•m
(44 ± 4 lbf•in) 70 ± 10 N•m
(52 ± 7 lbf•ft)
2.5 ± 0.2 N•m

11 ± 1 N•m
NEW
24.5 ± 3.5 N•m 24.5 ± 3.5 N•m
(18 ± 3 lbf•ft) (18 ± 3 lbf•ft)
NEW
48 ± 6 N•m
(35 ± 4 lbf•ft)
NEW
16.5 ± 1.5 N•m NEW
NEW 10 ± 2 N•m
(146 ± 13 lbf•in)
120 ± 10 N•m (89 ± 18 lbf•in)
(89 ± 7 lbf•ft)
NEW
48 ± 6 N•m
(35 ± 4 lbf•ft)
NEW
48 ± 6 N•m
(35 ± 4 lbf•ft)
QAS

mmr2017-047-099
2 mmr2017-047
WHEELS (3 IDLER WHEELS LAYOUT)
NEW
16.5 ± 1.5 N•m
(146 ± 13 lbf•in)
NEW
48 ± 6 N•m
(35 ± 4 lbf•ft)

en_mmr2017-047-199
mmr2017-047 3
FRONT ARM
48 ± 6 N•m
(35 ± 4 lbf•ft)
NEW
NEW
48 ± 6 N•m
(35 ± 4 lbf•ft)
NEW
48 ± 6 N•m
(35 ± 4 lbf•ft)

mmr2017-047-299
4 mmr2017-047
REAR ARM (MODELS WITHOUT ADJUSTABLE REAR SHOCK)
NEW
24.5 ± 3.5 N•m
48 ± 6 N•m (18 ± 3 lbf•ft)
(35 ± 4 lbf•ft)
NEW
36 ± 2 N•m NEW
(27 ± 1 lbf•ft)
24.5 ± 3.5 N•m
NEW (18 ± 3 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
NEW
85 ± 10 N•m
(63 ± 7 lbf•ft)
Suspension
grease

mmr2013-042-101_a
mmr2017-047 5
REAR ARM (MODELS WITHOUT QUICK ADJUST SYSTEM)
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
NEW
48 ± 6 N•m
(35 ± 4 lbf•ft)
NEW
0,8 ± 0.2 N•m 24.5 ± 3.5 N•m
NEW (7 ± 2 lbf•in) (18 ± 3 lbf•ft)
36 ± 2 N•m
(27 ± 1 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
NEW
85 ± 10 N•m
(63 ± 7 lbf•ft)
Suspension
grease

mmr2013-042-103_a
6 mmr2017-047
REAR ARM (MODELS WITH QUICK ADJUST SYSTEM)
3 ± 0.5 N•m 24.5 ± 3.5 N•m 24.5 ± 3.5 N•m 3 ± 0.5 N•m
(27 ± 4 lbf•in) (18 ± 3 lbf•ft) NEW (18 ± 3 lbf•ft) (27 ± 4 lbf•in)
3 ± 0,5 N•m
(27 ± 4 lbf•in)
3 ± 0.5 N•m
(27 ± 4 lbf•in)
0.8 ± 0.2 N•m

(7 ± 2 lbf•in)
NEW
1.8 ± 0.2 N•m
(16 ± 2 lbf•in)
NEW
48 ± 6 N•m
(35 ± 4 lbf•ft) 24.5 ± 3.5 N•m
(18 ± 3 lbf•in)
NEW
36 ± 2 N•m
(27 ± 1 lbf•ft)
NEW NEW
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
NEW
36 ± 2 N•m
(27 ± 1 lbf•ft)
NEW
Suspension
85 ± 10 N•m grease
(63 ± 7 lbf•ft)

mmr2013-042-104_a
mmr2017-047 7
GENERAL Stopper Strap

and service products as in the exploded views.
complete procedure.
WARNING
tabs, cotter pins, etc.) must be replaced.
mmr2017-047-013
NOTICE Hoses, cables and locking ties re- Stopper strap length has an effect on the amount
of weight the center spring has to carry especially
during acceleration, therefore on the front end up-
lift.
ADJUSTMENT Stopper strap length also has an effect on center
spring travel.
REAR SUSPENSION NOTICE Whenever stopper strap length is
ADJUSTMENTS changed, track tension must be checked.
ACTION RESULT
Lighter ski pressure
under acceleration
Increasing stopper strap
More center spring travel
length
More bump absorption
capability
Heavier ski pressure
under acceleration
Decreasing stopper strap
Less center spring travel
length
Less bump absorption
capability
mmr2013-042-001_a
ADJUSTABLE COMPONENTS Stopper strap could be set to position 1, 2, 3, 4

1. Stopper strap
2. Center spring and 5. Below are illustrations for position 1, 2, 3.
3. Rear spring Smaller numbers correspond to a longer strap set-
4. Rear shock absorber
5. Coupling blocks (RH side shown) ting.
NOTICE Whenever adjusting rear suspen-
sion, check track tension and adjust if neces-
sary.
8 mmr2017-047
mmr2015-142-039_a mmr2015-142-038_a
STOPPER STRAP POSITION 1 (1ST HOLE, LONGEST) STOPPER STRAP POSITION 2 (2ND HOLE)
1. 1st hole from end 1. Free hole
2. Towards rear 2. 2nd hole from end
3. Tip of strap touching strap axis 3. Towards rear
4. Two holes left open between screw head and nut 4. Tip of strap touching strap axis
5. Towards front 5. Two holes left open between screw head and nut
6. Towards front
mmr2017-047 9
ACTION RESULT
Lighter steering
More bump absorption
capability
Increasing preload Better deep snow starts
Better deep snow
performance and
handling
Heavier steering
Less bump absorption
Decreasing preload
capability
Better trail handling
mmr2015-142-040_a
STOPPER STRAP POSITION 3 (3RD HOLE)

1. Free holes
2. 3rd hole from end
3. Towards rear
4. Tip of strap touching strap axis
5. Two holes left open between screw head and nut
6. Towards front
Always install stopper strap bolt as close as pos- mmr2013-042-003_a
sible to the lower shaft. TYPICAL- RING TYPE SHOWN

1. Spring preload adjustment ring
Decreasing the stopper strap length may reduce 2. Increase preload
3. Decrease preload
comfort. If too much weight transfer is felt, try to
correct it by adjusting the coupling blocks first. Al- Rear Spring
ways install stopper strap bolt as close as possible
to the lower shaft. Rear spring preload has an effect on comfort, ride
height and load compensation.
When operating the snowmobile in deep snow,
it may be necessary to vary stopper strap length Also, adjusting rear spring preload shifts more or
and/or riding position, to change the angle at less weight to the snowmobile front end. As a re-
which the track rides on the snow. Operator's sult, more or less weight is applied to the skis.
familiarity with the various adjustments as well This has an effect on performance in deep snow,
as snow conditions will dictate the most efficient steering effort and handling.
combination. Slight suspension bottoming occurring under the
Generally, a longer stopper strap setting gives bet- worst riding conditions indicates a good choice of
ter performance in deep snow on a flat landscape. spring preload.
Center Spring
Center spring preload has an effect on steering
effort, handling and bump absorption.
Also, since center spring preload adjustment puts
more or less pressure on the front of the track, it
has an effect on the performance in deep snow.
10 mmr2017-047
ACTION RESULT CAUTION Never set preload cams directly

Firmer rear suspension from position 5 to 1 or directly from position 1
to 5.
Higher rear end
Increasing preload More bump absorption WARNING
capability Both rear spring preload must be set at the
Heavier steering
same position. Otherwise vehicle behavior
may be unpredictable and suspension may
Softer rear suspension become warped.
Lower rear end
The adjustment cams have 5 different settings, 1
Less bump absorption being the softest.
Decreasing preload capability
Lighter steering
Better performance and
handling in deep snow
Refer to the following to determine if preload is

correct.
A
B mmr2013-042-005_a
rMOTION WITHOUT QUICK ADJUST SYSTEM — LH SIDE

1. Position 1
2. Position 2
3. Position 3
4. Position 4
mmo2006-003-022_a
5. Position 5
6. Adjustment nut
TYPICAL — PROPER ADJUSTMENT
A. Suspension fully extended
B. Suspension has collapsed with operator, passenger(s) and load
added
C. Distance between dimension “A” and “B”, see table below
C WHAT TO DO
50 mm to 75 mm
No adjustment required
(2 in to 3 in)
More than Adjusted too soft.
75 mm (3 in) Increase preload
Less than Adjusted too firm.
50 mm (2 in) Decrease preload
If the specification is unattainable with the origi-

nal springs, refer to the applicable SPRING CHART
bulletin for other available springs.
rMotion Without Quick Adjust System
To increase spring preload using tool, always turn
the left side adjustment cam in a clockwise direc-
tion, and the right side cam in a counterclockwise
direction.
mmr2017-047 11
RESULT ON BIG
TURNING ACTION AND SMALL
BUMPS
Increasing Firmer
Clockwise compression compression
damping force damping
Decreasing Softer
Counter
compression compression
Clockwise
damping force damping

To adjust, turn the adjuster button located on the
oil reservoir on shock clockwise to increase com-
pression damping force and counterclockwise to
mmr2013-042-004_a decrease compression damping force.
rMOTION WITHOUT QUICK ADJUST SYSTEM— RH SIDE
1. Position 1
2. Position 2
3. Position 3
4. Position 4
5. Position 5
6. Adjustment nut
rMotion with Quick Adjust System

Turn the LH side knob to adjust preload accord-
ingly.
mmr2013-042-007_a
TYPICAL — rMOTION WITHOUT QUICK ADJUST SYSTEM

1. Compression damping adjustment button

Turn the RH side knob to adjust the shock com-
mmr2013-042-006_a
pression speed.
TYPICAL — rMOTION WITH QUICK ADJUST SYSTEM
1. LH side knob to adjust spring preload
Rear Shock Absorber

Rear Shock Compression Damping
NOTE: Both low and high speed compression
damping are adjusted simultaneously.
Low speed compression damping controls how
the shock absorber reacts to a low suspension ve-
locity (slow compression strokes, in most cases
when riding at lower speeds).
High speed compression damping controls how
the shock absorber reacts to a high suspension mmr2013-042-008_a
velocity (quick compression strokes, in most TYPICAL — rMOTION WITH QUICK ADJUST SYSTEM
cases when riding at higher speeds). 1. Knob to adjust low/high speed compression damping
12 mmr2017-047
Rear Shock Mounting Position

Two rear shock mounting positions are available:
high performance and sport.
Factory setting is set to lowest mounting position
(high performance) which will suit most opera-
tors riding preferences. The sport mounting hole
adjustment allows for another range of softer set-
tings, but all other rear suspension adjustments
should be performed before changing the rear
shock mounting position.
mmr2013-042-010_a
COUPLING BLOCK — RIGHT SIDE VIEW

(“R” — RIGHT EMBOSSED ON BLOCK)
1. Position 1 (minimum)
2. Position 2
3. Position 3
4. Position 4 (maximum)
5. Release button
Coupling Blocks Setting

POSITION USE
More ski lift during acceleration -
1
and best comfort
mmr2013-042-009_a 2 Intermediate setting
REAR SHOCK MOUNTING POSITION 3 Intermediate setting
1. High performance position
2. Sport position
Less ski lift during acceleration -
4
and some comfort loss
Coupling Blocks
Coupling blocks adjustment has an effect on vehi-
cle handling during acceleration only. MAINTENANCE
NOTE: A high coupling block setting will reduce For rear suspension lubrication, mechanism and
both comfort and transfer under acceleration. stopper strap inspection, refer to PERIODIC
To adjust, push on release button under cam and MAINTENANCE PROCEDURES.
turn coupling block to the desired setting.
PROCEDURES
WARNING
NOTE: Parts can be replaced without suspension
Both blocks must be set at the same posi- removal, unless otherwise noted.
tion. Otherwise vehicle behavior may be
unpredictable and suspension may become
warped.
mmr2017-047 13
SUSPENSION ASSEMBLY
mmr2013-042-012_a
1. Retaining screw
2. Connecting rod
mmr2017-047-012
REQUIRED TOOL
Removing Suspension Assembly RMOTION SUSPENSION
1. Lift rear of vehicle and support it off the ground. TOOL (P/N 529 036 234)
2. Completely loosen track tension by unscrewing
both adjustment screws.
mmr2013-042-011_a
1. Adjustment screw

mmr2013-042-013_a
3. Remove quick adjuster control modules, refer 1. rMotion suspension tool to be installed here
to:
– SHOCK DAMPING QUICK ADJUSTER SYS- 6. Remove front arm retaining bolts.
TEM
– SPRING PRELOAD QUICK ADJUSTER SYS-
TEM.
All Models
4. Lower the rear of vehicle just enough to support
suspension.
5. Remove rear arm connecting rods retaining
screws.
mmr2013-042-020_a
TYPICAL
1. Front arm bolt
2. Chaincase
14 mmr2017-047
7. Lift rear of vehicle until front arm as enough Adjust track tension, refer to PERIODIC MAINTE-
clearance to pass underneath tunnel. NANCE PROCEDURES subsection.
Install quick adjuster control modules, refer to:
– SHOCK DAMPING QUICK ADJUSTER SYS-
1 TEM
TEM.
SHOCK DAMPING QUICK

ADJUSTER SYSTEM
A33F5VA
TYPICAL
1. Enough clearance
8. Remove suspension assembly from vehicle.
mmr2017-047-011
Removing Shock Damping Quick

Adjuster Control Module
1. Remove the following parts:
– Knob
– Retaining clamp
– Support.
A33F5WA
TYPICAL — REMOVE SUSPENSION
Installing Suspension Assembly

Installation is the reverse of removal procedure.
Pay attention to the following.
Install suspension into track with front portion
first.
Tighten new screws to specification.
UPPER SUSPENSION ARM FASTENERS
TIGHTENING TORQUE mmr2012-050-005_a
48 N•m ± 6 N•m CONTROL MODULE

Front arm bolts 1. Knob screw
(35 lbf•ft ± 4 lbf•ft) 2. Clamp
3. Clamp screws
Rear arm connecting 61 N•m ± 9 N•m 4. Support
rod screws (45 lbf•ft ± 7 lbf•ft) 5. Support screws
mmr2017-047 15
2. Remove front fasteners from hose guard.

3. Remove hose from its retainer tab and rotate
hose guard outwards around rear rivet.
mmr2012-050-005_a
CONTROL MODULE
1. Knob screw
2. Clamp
3. Clamp screws
4. Support
5. Support screws

1. Pivot outwards
2. Front fasteners 5 N•m ± 1 N•m
Support screws
4. Remove shock remote reservoir as follows: 2.5 N•m ± 0.5 N•m
– Rotate. Clamp screws
– Pass through tunnel opening. 0.4 N•m ± 0.1 N•m
Knob screw
3. Secure rear shock hose to hose guard bracket.
mmr2012-050-008_a
Step 1: Rotate
Step 2: Pass through tunnel opening mmr2013-042-301_a
1. Hose
2. Hose guard
Installing Shock Damping Quick 3. Hose guard bracket
Adjuster Control Module
1. Align the hose guard front holes with the sup-
port front holes.
NOTE: No rivet needed at front of hose guard.
2. Install parts as follows:
16 mmr2017-047
SPRING PRELOAD QUICK

ADJUSTER SYSTEM
mmr2013-042-304_a
mmr2017-047-010 1. Pivot outwards

2. Front fasteners
Removing Spring Preload Quick 4. Pass control cylinder through the opening in the
Adjuster Control Module tunnel.
This procedure removes only the control module
from the tunnel, without disconnecting the hose Installing Spring Preload Quick
and will not necessitate bleeding the system. Adjuster Control Module
1. Remove the following parts: 1. Align the hose guard front holes with the sup-
– Knob port front holes.
– Retaining clamp 2. Install parts as follows:
– Support.
mmr2012-050-006_a
mmr2012-050-006_a
SPRING PRELOAD QUICK ADJUSTER CONTROL MODULE
1. Knob
SPRING PRELOAD QUICK ADJUSTER CONTROL MODULE 2. Clamp
1. Knob 3. Clamp screws
2. Clamp 4. Support
3. Clamp screws 5. Support screws
4. Support
5. Support screws
TIGHTENING TORQUE
2. Remove front fasteners from hose guard. 5 N•m ± 1 N•m
Support screws
3. Remove hose from its retainer tab and rotate (44 lbf•in ± 9 lbf•in)
hose guard outwards around rear rivet. 2.5 N•m ± 0.5 N•m
Clamp screws
Knob screw
1.5 N•m ± 0.5 N•m
(apply LOCTITE 243
(BLUE) (P/N 293 800 060)
mmr2017-047 17
3. Secure rear shock hose to hose guard bracket. CAUTION Spring support are spring
loaded.
mmr2013-042-303_a
1. Hose
2. Hose guard
3. Hose guard bracket
mmr2012-050-015_a
Removing Spring Preload Quick 1. Spring

2. Spring support
Adjuster System 3. Spring support bolt
This procedure removes the following parts as an
5. Move spring supports with spring ends over the
assembly and does not necessitate bleeding the
idler wheel supports and let them sit on the
system:
track.
– Control module
NOTE: If the springs are still loaded, completely
– Hose
loosen track tension in order to make room to un-
– Actuator. load springs.
1. Support the rear of vehicle just enough to re- 6. Move the other end of the springs off the spring
move load on the rear suspension. adjuster actuator.
2. Remove control module, refer to SPRING 7. Remove hose retainer from shock assembly.
PRELOAD QUICK ADJUSTER SYSTEM.
3. Remove idler wheels to access spring support
screws.
mmr2013-042-305_a
1. Shock
2. Hose
3. Retaining screw
mmr2013-042-022_a 4. Hose retainer
1. Idler wheel to be removed (on each side)
8. Remove actuator from rear arm.
4. Firmly hold the spring supports and remove
9. Remove spring adjuster assembly.
spring support bolts.
18 mmr2017-047
Disassembling Spring Preload Quick

Adjuster System
NOTE: System bleeding is required whenever the
hose is disconnected.
NOTICE Thoroughly clean parts before disas-
sembly. Work on a clean surface.
1. Set controller to the minimum preload.
2. Remove the banjo bolt(s) retaining the hose.
3. Drain fluid.
Replacing Spring Preload Quick

Adjuster System Seals
NOTE: System bleeding is required whenever the
hose is disconnected. rmr2013-042-210
REMOVE BANJO BOLT

NOTICE Thoroughly clean parts before disas-
sembly. Work on a clean surface. 3. Remove banjo bolt, washers and hose from
cylinder.
1. Remove quick adjuster assembly from vehicle.
Refer to REMOVING THE SPRING PRELOAD
QUICK ADJUSTER CONTROL MODULE.
rmr2013-042-204_a
rmr2013-042-213
QUICK ADJUSTER ASSEMBLY 1. Banjo bolt

2. Washer
3. Hose fitting
REQUIRED TOOL 4. Cylinder body
RMOTION MASTER REQUIRED TOOL

CYLINDER KEY (P/N 529
036 254) RMOTION MASTER
CYLINDER KEY (P/N 529
2. Use retainer tool to hold cylinder while remov- 036 254)
ing banjo bolt.
RMOTION SOCKET
(P/N 529 036 255)
4. Hold cylinder body with tool and unscrew end

cap using the rMotion socket.
mmr2017-047 19
rmr2013-042-211 rmr2013-042-208_a
REMOVE END CAP REMOVE PISTON ROD
5. Remove end cap. 8. Replace external seals if worn out or damaged.
rmr2013-042-207_a
1. Cylinder Body front seal

2. Cylinder body rear seal
3. Knob seal
rmr2013-042-205_a 9. Installation is the reverse of removal.

1. End cap
2. Cylinder body Bleeding and Reassembling Spring
6. At other end of cylinder, unscrew piston rod us- Preload Quick Adjuster System
ing same tools. NOTE: Actuator, control module and hose have to
be separated from each other before carrying out
bleeding procedure.
1. Fully extend the actuator by hand.
2. Add fluid in the actuator, see table.
ACTUATOR FILLING
FLUID TYPE QUANTITY
Approximately 40 ml
ATF Dexron III
(1.35 U.S. oz)
3. Maintain actuator with threaded hole upwards

rmr2013-042-206_a
and:
1. Cylinder body
2. Piston rod 3.1 Compress the actuator by precisely
15 mm (19/32 in).
7. Remove piston rod.
20 mmr2017-047
3.2 Fill until fluid reaches the top of the

threads.
3.3 Install hose with new sealing washers as
shown.
mmr2012-050-018_a
1. Notches
2. Hose
NOTE: The hose must on be the opposite side of

the decal on the control cylinder.
TIGHTENING TORQUE
24.5 N•m ± 3.5 N•m
mmr2012-050-016_b Banjo bolt
1. Hose (18 lbf•ft ± 3 lbf•ft)
2. Sealing washers
9. Verify system operation. The actuator full
stroke should be 22 mm (7/8 in).
Installing Spring Preload Quick

Adjuster System
Installation is the reverse of removal procedure,
however, pay attention to the following:
Set the preload to the minimum using the control
cylinder adjustment rod first.
REAR AXLE
mmr2012-050-017_a
A. 5°
TIGHTENING TORQUE
24.5 N•m ± 3.5 N•m
Banjo bolt
4. With the hose open end up, compress the ac-

tuator by precisely 8 mm (5/16 in).
NOTE: Fluid should reach the open end of the
hose.
5. Unscrew the control cylinder adjustment rod
until it stops. mmr2017-047-009
6. Using a small diameter punch through the M10 Removing Rear Axle
threaded hole, push the control cylinder piston
all the way back. 1. Lift rear of vehicle and support it off the ground.
7. With the threaded hole up, fill control cylinder 2. Remove rear idler wheel caps.
until fluid reaches the top of the threads.
8. Install the hose on the control cylinder as
shown.
mmr2017-047 21
mmr2013-042-021_a
TYPICAL - RH SIDE SHOWN

mmr2012-050-031_a
1. Rear idler wheel
1. RH rear idler wheel cap 2. Seal
3. Rear axle
4. Wheel spacer
3. Loosen rear axle screws (one each side).
7. Pull out the rear axle.
Installing Rear Axle

Installation is reverse of removal procedure. How-
ever, pay attention to the following.
Make sure to position all parts correctly.
mmr2012-050-032_b
1. RH rear axle screw

mmr2008-048-011_a
4. Completely loosen track tension by unscrewing TYPICAL - 3 IDLER WHEELS LAYOUT
both adjustment screws. 1. Idler wheels
2. Seals
3. Wheel spacers
4. Rear axle
5. Rear axle spacer
6. Washer
mmr2009-089-008_a
mmr2012-050-032_a TYPICAL - 4 IDLER WHEELS LAYOUT

1. Idler wheels
1. RH adjustment screw 2. Seals
3. Wheel spacers
5. Remove both rear axle screws. 4. Rear axle
5. Rear axle spacer
6. Remove rear idler wheels, seals and wheel
spacers. Position wheel spacers with a flat side up and a
groove facing tensioner screw.
22 mmr2017-047
SHOCK ABSORBERS
mmr2008-048-200_a
TYPICAL
1. Wheel spacer
2. Groove mmr2017-047-008
3. Flat side
4. Tensioner screw
Removing Rear Shock Absorber
When tightening rear axle, make sure each wheel 1. Lift rear of vehicle and support it off the ground.
spacer protuberance is engaged into rail slot.
2. Carry out REMOVING THE SHOCK DAMPING
QUICK ADJUSTER CONTROL MODULE, Refer
to procedure in this subsection.
All Models
3. Remove the upper bolt.
NOTE: It may be necessary to lower the vehicle
and slightly compress suspension to remove load.
mmr2012-050-011_a
1. Wheel spacer protuberance

2. Rail slot
Adjust track tension. Refer to PERIODIC MAIN-

mmr2012-050-012_a
TYPICAL
2. Upper bolt
4. Remove the lower bolt.
mmr2017-047 23
mmr2008-048-017_a
TYPICAL
1. Stopper strap
2. Stopper strap bolt
mmr2012-050-012_b
TYPICAL 3. Remove idler wheels to access lower retaining

2. Lower bolt bolt.
4. Remove shock retaining bolts.
5. Remove rear shock absorber from the vehicle.
Installing Rear Shock Absorber

REAR SHOCK ABSORBER POSITIONING
rMotion quick with Body up
adjust system hose on RH side
rMotion quick without Body up
adjust system reservoir downwards
Install new shock absorber retaining nuts and

tighten to specified torque.
TIGHTENING TORQUE
Shock absorber retaining 24.5 N•m ± 3.5 N•m mmr2013-042-022_b
bolts (18 lbf•ft ± 3 lbf•ft) TYPICAL
1. Center shock absorber
2. Retaining bolts
Carry out INSTALLING THE SHOCK DAMPING 5. Remove shock absorber from vehicle.
QUICK ADJUSTER CONTROL MODULE.
Inspecting Shock Absorber
Removing Center Shock Absorber NOTE: All types of shock absorbers are covered
1. Lift the rear of vehicle and support it off the in this topic, refer to TECHNICAL SPECIFICA-
ground. TIONS to identify the shock absorber relating to
2. Unfasten stopper strap. the vehicle model.
NOTE: Unless otherwise noted, shock absorber
must be at normal room temperature (21°C ± 2°C
(70°F ± 36°F)) during inspection.
MC Hydraulic Shock
1. Perform a visual inspection of the shock:
– The shock must be exempt of any dent or
scratch, especially on the rod.
– Small dent on the shock body may not affect
any performance or reliability of this shock.
24 mmr2017-047
– Any defect on the rod, as small as it is, can 2. Completely push down shock rod into the body
lead to seal failure and oil leak. and check result as per table.
– If such defect (on rod) is detected, the shock HPG SHOCK RESULT
must be replaced, and this will not be cover
under warranty. The rod should
All except 551 mm
completely get in the
2. Secure the shock body end in a vise, clamping (21-11/16 in) rear shock
shock body
on eyelet, with its rod upward.
551 mm (21-11/16 in) The stroke must be at
NOTICE Do not clamp directly on shock rear shock least 138 mm (5-7/16 in)
body.
NOTE: For the HPG Variable Rate Shock, it
1 should be stiff for approximately the first 25 mm
(1 in), then softer for about 50 mm (2 in), and
stiffer again. This stiff/soft/stiff phenomenon
shows the normal operation of VR shock.
3. Release shock from completely collapsed posi-
tion and check result as per table.
A14F0BA
HPG SHOCK EXCEPT VARIABLE RATE

1. Shock body eyelet
– The shock should extend unassisted.
3. Examine shock for leaks. Extend and compress
the piston at least 5 complete strokes with its – The rod must come out at a steady speed.
rod upward.
HPG VARIABLE RATE SHOCK
4. Check that shock moves smoothly and with uni-
form resistance over its entire stroke. – The shock should extend unassisted.
– Rod must come out slowly first, than faster and
NOTE: For the first 5 complete strokes, it could
finally slow again for the last 25 mm (1 in).
be normal to note uneven resistance.
5. Check the following conditions that will denote 4. Proceed with TESTING SHOCK ABSORBER
a defective shock: COMPRESSION. See procedure in this sub-
– A skip or a hang back when reversing stroke section.
at mid travel. 5. If any faults are present, replace shock.
– Seizing or binding condition except at ex-
treme end of either stroke. Testing Shock Absorber Compression
– Oil leakage. 1. Ensure shock absorber is at normal room tem-
– A gurgling noise, after completing one full perature (21°C ± 2°C (69.8°F ± 35.6°F).
compression and extension strokes. 2. Remove spring from shock absorber (if applica-
6. If suspecting a shock is freezing, place shock ble).
in a freezer (temperature below 0°C (32°F)) for 3. Place a BENCH SCALE (P/N SALTER BRECKNELL
4 hours. PS 400) (or an equivalent) on a suitable drill
7. Push down on rod and note its resistance. If press.
shock is frozen it will be much more difficult to
REQUIRED TOOL
compress than one in normal condition.
8. If any faults are present, replace shock. SHOCK ABSORBER
SUPPORTS (P/N 529
All HPG™ Shock (Including KYB PRO Series) 036 186)
1. Perform a visual inspection of the shock:
– The shock must be exempt of any dent or 4. Install the shock absorber support onto drill
scratch, especially on the rod. press.
– Any defect on the rod, as small as it is, can 5. Set bench scale units to kg.
lead to seal failure and oil leak.
– If such defect is detected, the shock must be
replaced and this will not be covered under
warranty.
mmr2017-047 25
mmr2010-034-004_a
mmr2010-034-002_a
1. Shock body upwards
1. Drill press
2. Bench scale 10. Set the drill press displacement to 10 mm
3. Shock absorber supports (.394 in) using locking nut.
6. Press TARE to reset digits (must indicate zero).
mmr2010-034-003_a
1. Units indicator lamp

2. TARE button
3. Digits
mmr2010-034-005
7. Install shock absorber into support with shock
body upwards. 11. Compress shock absorber by 10 mm (.394 in)
8. Adjust drill press table height in order to set the and hold it in position.
upper shock support flush with the shock body 12. Read load recorded on the bench scale.
end.
9. Ensure shock absorber is aligned with drill
press axis.
mmr2010-034-006
13. Load reading must be as per the following ta-

ble.
26 mmr2017-047
ROD SERVICE rMotion with Quick Adjust System

MODEL
DIAMETER RANGE 3. Remove quick adjuster control modules, refer
Every HPG 24 kgf ± 4 kgf to:
12.5 mm (1/2 in)
(Plus/Plus R) (53 lbf ± 9 lbf) – SHOCK DAMPING QUICK ADJUSTER SYS-
All KYB PRO 39 kgf ± 5 kgf
TEM
16 mm (5/8 in) – SPRING PRELOAD QUICK ADJUSTER SYS-
Series (86 lbf ± 11 lbf)
TEM.
Installing Center Shock Absorbers All Models
Installation is reverse of removal procedure. How- 4. Remove rear arm connecting rod retaining
ever, pay attention to the following. screws.
CENTER SHOCK ABSORBER POSITIONING
Body up
HPG Plus
Valve upwards
Body up
KYB PRO
Reservoir on the RH side
mmr2013-042-012_a
1. Connecting rod retaining screw

2. Connecting rod
REQUIRED TOOL
mmr2013-042-029_a
BOTTOM OF SHOCK ABSORBER RMOTION SUSPENSION

1. Washers location
TOOL (P/N 529 036 234)
REAR SPRINGS
mmr2017-047-007
Removing Rear Springs mmr2013-042-013_a
1. rMotion suspension tool to be installed here

1. Support the rear of vehicle just enough to re-
move load on the rear suspension. 5. Remove idler wheels to have access to spring
2. Set rear spring preload to the minimum. support screws.
mmr2017-047 27
9.3 Pull connecting rod off the rear arm.
mmr2013-042-022_a
1. Idler wheel to be removed (on each side)
6. Firmly hold the spring supports and remove mmr2013-042-038_b
spring support bolts. 1. Retaining screw

2. Bolt
CAUTION Spring support are spring 10. Remove upper idler wheels and hardware.
loaded. 11. Remove rear spring from suspension.
Installing Rear Springs

Make sure that spring end is in cam adjuster or
actuator spring support.
mmr2012-050-015_a
1. Spring
2. Spring support
3. Spring support bolt
7. Move spring supports with spring ends over the

idler wheel supports and let them sits on the
track.
mmr2012-050-033_a
NOTE: If the springs are still loaded, completely
MODELS WITHOUT QUICK-ADJUST
loosen track tension in order to make room to un- 1. Rear spring
load springs. 2. Cams
8. Raise and support the rear of vehicle just

enough to clear the rear arm connecting rods.
NOTICE rMotion with Quick Adjust system:
Avoid stretching the hoses.
9. Remove connecting rods from the rear arm.
9.1 Loosen bolt.
9.2 Remove circlip.
28 mmr2017-047

Install quick adjuster control modules, refer to:
– SHOCK DAMPING QUICK ADJUSTER SYS-
TEM
TEM.
SLIDER SHOES
mmr2012-050-022_a
QUICK-ADJUST MODELS
1. Actuator spring support
2. Rear spring
Install spring supports upwards.
mmr2017-047-006
Removing Slider Shoes

mmr2012-050-015_a
1. Spring
2. Spring support
Install rear arm connecting rod inserts with the

shoulder outwards.
mmr2012-050-032_a
1. RH adjustment screw
3. Remove nut and screw of each runner.
mmr2013-042-039_a
1. Connecting rod
2. Insert with the shoulder outwards
3. Support
4. Washer
5. Retaining screw
mmr2017-047 29
7. Using locking pliers, pull slider shoe through

track window to remove.
A33F5RA
TYPICAL - REMOVE NUT AND SCREW OF EACH RUNNER
4. At the rear of vehicle, align a track window with

slider shoe. A33F5UA
TYPICAL - PULL ON SLIDER SHOE TO REMOVE
Installing Slider Shoes

1
Make sure to insert slider shoe end with hole first.
2
FRONT ARM
A33F5SA
TYPICAL
1. Track window
2. Slider shoe
5. Lubricate widow edges.

6. Using a pry bar or a screwdriver, push slider
shoe rearward until it comes in contact with
track.
mmr2017-047-005
Removing Front Arm

1. Proceed with REMOVING THE SUSPENSION
ASSEMBLY. Refer to procedure in this subsec-
tion.
2. Unfasten stopper strap.
3. Remove the following fasteners:
– Center shock to front arm
– Front arm to rocker
– Front arm to rail.
A33F5TA
TYPICAL - PUSH ON SLIDER SHOE
30 mmr2017-047
REAR ARM
mmr2013-042-023_a
TYPICAL
1. Stopper strap bolt mmr2017-047-004
2. Center shock to front arm bolt
3. Front arm to rocker bolt WITH QAS
4. Front arm to rail screw
4. Remove front arm from suspension assembly.
Installing Front Arm

Install front arm to rail fasteners as shown.
mmr2017-047-015
WITHOUT QAS
Removing Rear Arm

1. Remove rear springs, refer to REMOVING
REAR SPRINGS in this subsection.
NOTE: On Quick Adjust models, set the spring
preload actuator aside.
mmr20123-042-050_a
1. Front arm
– Rear shock to rear arm
2. Insert (shoulder inward) – Rear arm to throttle rods
3. Front arm to rail screw
4. Washer – Coupling blocks retaining screws.
Install stopper strap on the LH side of the vehicle.
NOTICE Incorrect stopper strap installation
would cause suspension parts interference.
mmr2017-047 31
mmr2012-050-027_a
mmr2013-042-027_a
1. Convex side out
MODELS WITHOUT QUICK ADJUST SYSTEM 2. Spring between wheel and plastic cover
1. Rear shock to rear arm bolt
2. Coupling blocks retaining screw Install rear arm connecting rod inserts with the
3. Rear arm to throttle rods bolt
shoulder outwards.
Install circlip.
mmr2012-050-026_a
mmr2013-042-039_a
QUICK ADJUST SYSTEM 1. Connecting rod
1. Rear shock to rear arm bolt 2. Shoulder outwards
2. Coupling blocks retaining screw 3. Support
3. Rear arm to throttle rods bolt 4. Washer
5. Retaining screw
3. Remove rear arm from the vehicle.
Installing Rear Arm

Place rear arm grease fitting towards the front of
the vehicle.
All Models
Install coupling block with new socket screws.
Install upper idler wheels as shown.
mmr2012-050-023_a
1. Connecting rod
2. Shoulder outwards
Install new connecting rod retaining screws.
32 mmr2017-047
Lubricate rear arm pivot. Refer to PERIODIC Lubricate pivot arm. Refer to PERIODIC MAINTE-
MAINTENANCE PROCEDURES subsection. NANCE PROCEDURES subsection.
PIVOT ARM COUPLING BLOCKS
mmr2017-047-003 mmr2017-047-001
Removing Pivot Arm Replacing Coupling Blocks

1. Lift rear of vehicle and support it off the ground. LH and RH coupling blocks are different. There is
2. Completely loosen track tension by unscrewing a molded “R” (RH side) or “L” (LH side) on the
both adjustment screws. back face of the coupling blocks.
3. Set the rear springs preload to the minimum.
4. Remove rear spring supports.
– Coupling blocks retaining screws
– Pivot arm to rails bolt.
mmr2013-042-025_a
1. Side identification
Install new coupling block screws.

mmr2017-047-002
TYPICAL
Set the coupling blocks to the same position on
1. Coupling block screw both sides.
2. Pivot arm to rails bolt
FACTORY BLOCK
6. Carefully remove pivot arm from rear arm. MODELS
POSITION
All models 1
Installing Pivot Arm
The installation is the reverse of the removal pro- Fit riveted pin through coupling block.
Install new coupling block screws.
Install pivot arm with the grease fitting towards
front of the vehicle.
mmr2017-047 33
mmr2013-042-037_a
TYPICAL
1. Riveted pin
2. Spring pin
IDLER WHEELS AND SUPPORTS

Replacing Idler Wheels
Refer to the exploded views at the beginning
of this subsection for parts layout and fasteners
tightening torque.
STOPPER STRAP
tightening torque.
NOTICE Incorrect stopper strap installation
would cause suspension parts interference.
34 mmr2017-047
Subsection XX (REAR SUSPENSION (tMOTION))
REAR SUSPENSION (tMOTION)

SERVICE TOOLS
SHOCK ABSORBER SUPPORTS .................................................. 529 036 186 ........................................... 12

BENCH SCALE SUCH AS SALTER BRECKNELL .......................... PS 400 ........................................... 12
mmr2017-048 1
RAILS AND IDLER WHEELS
NEW
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
NEW
If equipped
9 ± 3 N•m
(80 ± 27 lbf•in)
NEW
NEW
24.5 ± 3.5 N•m NEW
(18 ± 3 lbf•ft)
NEW
If equipped
5 ± 0.5 N•m
(44 ± 4 lbf•in) 14.5 ± 1.5 N•m
NEW (128 ± 13 lbf•in)
2.5 ± 0.2 N•m NEW
(22 ± 2 lbf•in)
mmr2017-048-099
2 mmr2017-048
FRONT ARM
24.5 ± 3.5 N•m

48 ± 6 N•m (18 ± 3 lbf•ft)
(35 ± 4 lbf•ft)
NEW
NEW
NEW
70 ± 10 N•m
(52 ± 7 lbf•ft)
NEW
48 ± 6 N•m
(35 ± 4 lbf•ft)
NEW
48 ± 6 N•m
(35 ± 4 lbf•ft)
NEW 3 ± 0.2N•m
(27 ± 2 lbf•in)
70 ± 10 N•m
(52 ± 7 lbf•ft)
24.5 ± 3.5 N•m Suspension
(18 ± 3 lbf•ft)
synthetic grease
NEW
With 3 in.
profile track
With 2.5 in. NEW
profile track 48 ± 6 N•m
(35 ± 4 lbf•ft)
NEW
7 ± 1 N•m
(62 ± 9 lbf•in)
mmr2017-048-100_a
mmr2017-048 3
REAR ARM
2 ± 0.1 N•m
(18 ± 1 lbf•in)
NEW
NEW
48 ± 6N•m
(35 ± 4 lbf•ft)
NEW
36 ± 2 N•m
(27 ± 1 lbf•ft)
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
NEW
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
NEW
32 ± 4 N•m
(24 ± 3 lbf•ft)
NEW
3 ± 0.2N•m
(27 ± 2 lbf•in)
Suspension
synthetic grease
NEW = Component must be replaced when removed

mmr2015-142-102_a
4 mmr2017-048
GENERAL ACTION RESULT

NOTE: Refer to TECHNICAL SPECIFICATIONS to Lighter ski pressure
identify the snowmobile suspension type. under acceleration
Increasing stopper strap
During assembly/installation, use torque values length
More center spring travel
and service products as in the exploded views. More bump absorption
Clean threads before applying a threadlocker. Re- capability
fer to SELF-LOCKING FASTENERS and LOCTITE Heavier ski pressure
APPLICATION at the beginning of this manual for under acceleration
complete procedure. Decreasing stopper strap
Less center spring travel
length
WARNING Less bump absorption
Torque wrench tightening specifications capability
Locking devices when removed (e.g.: locking NOTE: Stopper strap could be set to position 1,
tabs, cotter pins, etc.) must replaced. 2, 3, 4 and 5. Below are illustrations for position
1, 2, 3. Smaller numbers correspond to a longer
strap setting.
ADJUSTMENT
REAR SUSPENSION
ADJUSTMENTS
mmr2017-048-006
ADJUSTABLE COMPONENTS
1. Rear springs
2. Center spring
3. Stopper strap
NOTICE Whenever adjusting rear suspen-

sion, check track tension and adjust if neces-
sary.
mmr2015-142-039_a
Stopper Strap STOPPER STRAP POSITION 1 (1ST HOLE, LONGEST)

1. 1st hole from end
Stopper strap length has an effect on the amount 2. Towards rear
3. Tip of strap touching strap axis
of weight the center spring has to carry especially 4. Two holes left open between screw head and nut
during acceleration, therefore on the front end up- 5. Towards front
lift.
Stopper strap length also has an effect on center
spring travel.
NOTICE Whenever stopper strap length is
changed, track tension must be checked.
mmr2017-048 5
mmr2015-142-038_a
STOPPER STRAP POSITION 2 (2ND HOLE)

mmr2015-142-040_a
1. Free hole
2. 2nd hole from end STOPPER STRAP POSITION 3 (3RD HOLE)
3. Towards rear 1. Free holes
4. Tip of strap touching strap axis 2. 3rd hole from end
5. Two holes left open between screw head and nut 3. Towards rear
6. Towards front 4. Tip of strap touching strap axis
5. Two holes left open between screw head and nut
6. Towards front
NOTE: Always install stopper strap bolt as close

as possible to the lower shaft.
When operating the snowmobile in deep snow or
hill climbing, it may be necessary to vary stopper
strap length and/or riding position, to change the
angle at which the track rides on the snow. Oper-
ator's familiarity with the various adjustments as
well as snow conditions will dictate the most effi-
cient combination.
Generally, a longer stopper strap setting gives bet-
ter performance on a flat landscape and a shorter
setting will improve handling in steep hill climbing
and deep snow conditions.
STOPPER STRAP SETTING
POSITION USE
1 Not used
Boon docking:
– Better boon docking
manoeuvrability
2
– Better bump absorption
– Better deep snow starts (forward
and reverse)
6 mmr2017-048
STOPPER STRAP SETTING Also, adjusting rear spring preload shifts more or
less weight to the snowmobile front end. As a re-
POSITION USE sult, more or less weight is applied to the skis.
Factory setting: Best overall setting This has an effect on performance in deep snow,
3
(General use) steering effort and handling.
Hill climb: Slight suspension bottoming occurring under the
4 – Better track attack angle for hill worst riding conditions indicates a good choice of
climbing spring preload.
Steep hill climb: ACTION RESULT
– Better track attack angle for hill Firmer rear suspension
5 climbing
– Less transfer Increasing Higher rear end
– Lower ride height preload More bump absorption capability
Heavier steering
Center Spring
Softer rear suspension
Center spring preload has an effect on steering
effort, handling and bump absorption. Lower rear end
Also, since center spring preload adjustment puts Decreasing Less bump absorption capability
more or less pressure on the front of the track, it preload
Lighter steering
has an effect on the performance in deep snow.
Better deep snow performance
ACTION RESULT and handling
Lighter steering
Refer to the following to determine if preload is
More bump absorption capability correct.
Increasing
preload Better deep snow starts
Better deep snow performance
and handling
Heavier steering
Decreasing
Less bump absorption capability
preload
Better trail handling
mmr2015-142-003_a
PROPER ADJUSTMENT
A. Suspension fully extended
B. Suspension has collapsed with operator, passenger and load
added
C. Distance between dimension “A” and “B”, see table below
”C” WHAT TO DO
65 mm to 100 mm
No adjustment required
(2.5 in to 4 in)
mmr2017-048-007
More than Adjusted too soft.
1. Decrease preload 100 mm (4 in) Increase preload
2. Increase preload
Less than Adjusted too firm.
65 mm (2.5 in) Decrease preload
Rear Springs
Rear spring preload has an effect on comfort, ride If the specification is unattainable with the origi-
height and load compensation. nal springs, refer to the applicable SPRING CHART
bulletin for other available springs.
mmr2017-048 7
NOTICE To increase spring preload, always

turn the left side adjustment cam in a clockwise
direction, and the right side cam in a counter-
clockwise direction.
CAUTION Never set preload cams directly

from position 5 to 1 or directly from position 1
to 5.
The adjustment cams have 5 different settings, 1
being the softest.
mmr2015-142-005_a
3.2 Replace this bolt with a longer one and a

nut.
3.3 Screw in by approximately 7 turns.
3.4 Hold the bolt and tighten locking nut.
mmr2015-142-004_a
MAINTENANCE
For rear suspension lubrication, mechanism and
stopper strap inspection, refer to PERIODIC
MAINTENANCE PROCEDURES.
For shock absorbers inspection, refer to SHOCK
ABSORBERS in this subsection.
1. Long bolt
2. Locking nut
NOTE: Many parts can be changed with rear sus-
pension in place. When specified, refer to SUS- 3.5 Remove the bolt on the other side then
PENSION ASSEMBLY to remove rear suspension unlock nut and remove the long bolt.
from vehicle.
4. Remove bolts retaining front arm to tunnel the
same way rear arm bolts have been removed.
SUSPENSION ASSEMBLY
NOTE: Discard the front arm bolts.
Removing Suspension Assembly
2. Completely loosen track tension.
3. Remove and discard rear arm bolts from chas-
sis. Use the following procedure to remove
bolts easily.
3.1 Remove one of the bolts securing the rear
arm to frame.
8 mmr2017-048
mmr2017-048-001
Step 1: Loosen axle nut

Step 2: Unscrew adjustment screws
mmr2015-142-007_a
4. Remove rear axle nut, screw, washers and slid-

5. Lift rear of vehicle until front arm as enough ers.
clearance to pass underneath tunnel.
5. Pull out the rear axle.
6. Remove suspension.
Installing Rear Axle
Installing Suspension Assembly The installation is the reverse of the removal pro-
Installation is the reverse of removal procedure. cedure. However, pay attention to the following.
Bearing circlip faces outward.
Inspect track thoroughly before reinstalling sus-
pension. Refer to PERIODIC MAINTENANCE
PROCEDURES subsection.
Install suspension into track with front portion
first.
Install new front and rear arm bolts.
Tighten bolts to specified torque.
TIGHTENING TORQUE
Front and rear arm 48 N•m ± 6 N•m
upper bolts (35 lbf•ft ± 4 lbf•ft)
Adjust track tension, refer to PERIODIC MAINTE- mmr2017-048-004

REAR AXLE
Removing Rear Axle
2. Loosen rear axle nut.
mmr2017-048-003
When tightening rear axle, make sure each wheel

spacer protuberance is engaged into runner slot.
mmr2017-048 9
mmr2017-048-005 mmr2015-142-033_a
Adjust track tension. Refer to PERIODIC MAIN- Installing Ice Scratchers

TENANCE PROCEDURES subsection. The installation is the reverse of the removal pro-
ICE SCRATCHERS Make sure spring end is well inserted in holder.
Removing Ice Scratchers
CAUTION Always remove ice scratchers

from hooks before working on rear suspen-
sion.
mmr2015-142-034_a
1. Ice scratcher spring

2. Spring holder
Tighten retaining nuts to specification.
mmr2015-142-031_a
TIGHTENING TORQUE
24.5 N•m ± 3.5 N•m
Spring retaining nuts
Removing Ice Scratcher Hooks
CAUTION Always remove ice scratchers

from hooks before working on rear suspen-
sion.
1. Remove hook retaining nut.
mmr2015-142-032_a
Remove spring holder nuts.
10 mmr2017-048
SHOCK ABSORBERS
Removing Rear Shock Absorber
NOTE: If necessary, to ease shock removal, un-
fasten stopper strap to release shock pressure.
2. Remove bolts and nuts from shock.
mmr2015-142-035_a
2. Remove hook counter nut.
mmr2015-142-011_a
Removing Center Shock Absorber

mmr2015-142-036_a 1. Lift the rear of vehicle and support it off the
ground.
Installing Ice Scratcher Hooks 2. Unfasten stopper strap(s).
Hand tighten counter nut first.
mmr2015-142-012_a
3. Remove lower and upper shock absorber nuts

mmr2015-142-037_a
and bolts.
Tighten hook retaining nut to specification.

TIGHTENING TORQUE
9 N•m ± 3 N•m
Hook retaining nut
mmr2017-048 11
– Any defect on the rod, as small as it is, can

lead to seal failure and oil leak.
– If such defect is detected, the shock must be
replaced and this will not be covered under
warranty.
2. Completely push down shock rod into the body
and check result as per table.
HPG SHOCK RESULT
The rod should
All except 551 mm
completely get in the
(21-11/16 in) rear shock
mmr2017-048-009
shock body
551 mm (21-11/16 in) The stroke must be at
4. Remove shock absorber from vehicle. rear shock least 138 mm (5-7/16 in)
3. Release shock from completely collapsed posi-

tion and check result as per table.
HPG SHOCK
– The shock should extend unassisted.
– The rod must come out at a steady speed.
4. Proceed with COMPRESSION TESTING

SHOCK ABSORBERS. See procedure in this
subsection.
5. If any faults are present, replace shock.
mmr2017-048-011
Compression Testing Shock Absorbers

5. Remove bushings and shock shaft from shock
1. Ensure shock absorber is at normal room tem-
absorber.
perature (21°C ± 2°C (70°F ± 36°F)).
2. Remove spring from shock absorber (if applica-
ble).
3. Place a BENCH SCALE SUCH AS SALTER BRECK-
NELL (P/N PS 400) (or an equivalent) on a suitable
drill press.
4. Install SHOCK ABSORBER SUPPORTS (P/N 529
036 186) onto drill press.
mmr2017-048-010
Inspecting Shock Absorbers

NOTE: Unless otherwise noted, shock absorber
must be at normal room temperature (21°C ± 2°C
(70°F ± 36°F)) during inspection.
1. Perform a visual inspection of the shock: 529036186
– The shock must be exempt of any dent or

scratch, especially on the rod.
12 mmr2017-048
mmr2010-034-004_a
mmr2010-034-002_a
1. Shock body upwards
1. Drill press
2. Bench scale 10. Set the drill press displacement to 10 mm
3. Shock absorber supports (.394 in) using locking nut.
5. Set bench scale units to kg (or lb).
6. Press TARE to reset digits (must indicate (0)
zero).
mmr2010-034-003_a
1. Units indicator lamp mmr2010-034-005

2. TARE button
3. Digits
11. Compress shock absorber by 10 mm (.394 in)
7. Install shock absorber into support with shock and hold it in position.
body upwards. 12. Read load recorded on the bench scale.
8. Adjust drill press table height in order to set the
upper shock support flush with the shock body
end.
9. Ensure shock absorber is aligned with drill
press axis.
mmr2010-034-006
13. Load reading must be as per the following ta-

ble.
mmr2017-048 13
ROD DIAMETER SERVICE RANGE

24 kgf ± 4 kgf
12.5 mm (1/2 in)
(53 lbf ± 9 lbf)
Installing Rear Shock Absorber

To ease shock installation, secure upper side of
shock first.
Install new shock absorber retaining nuts and
tighten to specification.
TIGHTENING TORQUE
mmr2015-142-015_a
Rear shock absorber 24.5 N•m ± 3.5 N•m BOTTOM OF SHOCK ABSORBER
fasteners (18 lbf•ft ± 3 lbf•ft) 1. Lower screw
2. Washers location
3. Spacers
4. Shock shaft
Installing Center Shock Absorber 5. Nut
Tighten nut to the specification.
1. Position the adjustment ring upwards and the TIGHTENING TORQUE
valve towards the tunnel. Center shock absorber 70 N•m ± 10 N•m
lower nut (52 lbf•ft ± 7 lbf•ft)
REAR SPRINGS
Removing Rear Springs
3. Decrease springs preload by turning cams ac-
cordingly.
mmr2015-142-014_a
2. Using new nut, install shock shaft to runners.

3. Position washers in proper position.
mmr2015-142-004_b
LH SIDE SHOWN
4. Firmly hold the spring support and unscrew its

retaining bolt (one each side).
14 mmr2017-048
WARNING Installing Rear Springs

Supports are spring loaded. Installation is the reverse of removal procedure.
1. Respect THIS SIDE OUT inscription on top idler
wheels.
2. Make sure that spring end is in cam adjuster.
mmr2015-142-016_a

2. Spring support
3. Spring
mmr2015-142-004_c
5. Remove screws and washers from rear arm top LH SIDE SHOWN
axle. Refer to REMOVING SUSPENSION AS-
SEMBLY for procedure to remove the bolts. 3. Install spring supports upwards.
6. Loosen set screw from locking rings.
7. Remove locking rings.
8. Remove upper idler wheels.
9. Remove springs.
mmr2015-142-018_a
SLIDER SHOES
Removing Slider Shoes
mmr2015-142-017_a 1. Lift rear of vehicle and support it off the ground.
LH SIDE SHOWN
1. Locking ring 2. Completely loosen track tension.
2. Set screw
3. Upper idler wheel 3. Remove nut and screw of each runner.
4. Rear spring
mmr2017-048 15
6. Using locking pliers, pull slider shoe through

track window to remove.
NOTE: If necessary, lubricate track window to fa-
cilitate slider shoe removal.
A33F5RA
TYPICAL
4. At the rear of vehicle, align a track window with

slider shoe.
A33F5UA
TYPICAL - PULL ON SLIDER SHOE TO REMOVE
Installing Slider Shoes

1
2 cedure. However, pay attention to the following.
Make sure to insert slider shoe end with hole first.
FRONT ARM
Removing Front Arm
1. Proceed with REMOVING SUSPENSION AS-
A33F5SA SEMBLY, see procedure in this subsection.
TYPICAL 2. Remove nut and bolt securing rocker to front
1. Track window
2. Slider shoe arm.
5. Using a pry bar or a screwdriver, push slider

shoe rearward until it comes in contact with
track.
mmr2015-142-019_a
3. Remove the front arm lower bolt, nut and wash-

ers. Discard retaining nut.
A33F5TA
TYPICAL - PUSH ON SLIDER SHOE
16 mmr2017-048
mmr2015-142-020_a
4. Remove the shock absorber upper nut and bolt. mmr2015-142-007_a
7. Remove front arm.
Installing Front Arm

1. Install new nuts.
2. Install new front arm upper bolts.
mmr2015-142-021_a
5. Unfasten stopper strap(s).
mmr2015-142-023_a
1. Front arm lower bolt

2. Nut
3. Spacer washers
4. Washers
3. See front arm exploded view for proper tighten-

mmr2015-142-012_a
ing torque.
6. Remove and discard front arm upper bolts.
REAR ARM
Removing Rear Arm
2. Completely loosen track tension.
3. Proceed with REMOVING REAR SPRINGS, see
mmr2017-048 17
4. Remove the rear shock absorber upper bolt and

nut.
5. Remove nut and bolt securing throttle rods to
rear arm.
mmr2015-142-026_a
1. Rear arm stroke limiter

2. Pivot arm stroke limiter
2. Install new nuts and tighten to specification.

Assemble rear arm fasteners as per following il-
mmr2015-142-024 lustrations.
6. Remove bolt, nut and washer holding rear arm
to pivot arm.
mmr2015-142-027
mmr2015-142-025
Installing Rear Arm

1. At installation, rear arm stroke limiter must be
at rear.
mmr2015-142-028_a
SOME PARTS REMOVED FOR CLARITY PURPOSES

1. Throttle rod upper bolt
2. Washers
3. Bushings
4. Axle
5. Throttle rod upper nut
18 mmr2017-048
TIGHTENING TORQUE Installing Pivot Arm

24.5 N•m ± 3.5 N•m The installation is the reverse of the removal pro-
Rear arm throttle rod nut cedure. However, pay attention to the following.
32 N•m ± 4 N•m Assemble pivot arm fasteners as per following il-
Rear arm to pivot arm nut lustrations, with grease fitting towards front of ve-
hicle.
PIVOT ARM
Removing Pivot Arm
3. Remove bolt, nut and washer retaining rear arm
to pivot arm.
mmr2015-142-027
mmr2015-142-027
4. Remove bolt, nut and 4 washers retaining pivot

arm to runners.
mmr2015-142-030_a
PARTS REMOVED FOR CLARITY PURPOSE

1. Pivot arm lower screw
2. Washers
3. Axle
4. Pivot arm nut
Tighten pivot arm nuts to specification.

TIGHTENING TORQUE
24.5 N•m ± 3.5 N•m
Pivot arm lower nut
32 N•m ± 4 N•m
Pivot arm upper nut
mmr2015-142-029
Lubricate pivot arm. Refer to PERIODIC MAINTE-
NOTE: Make sure inner washers are properly re-
moved from assembly to avoid losing them.
5. Carefully remove pivot arm from rear arm.
mmr2017-048 19
STOPPER STRAP
tightening torque.
20 mmr2017-048
Subsection XX (STEERING SYSTEM (PITMAN ARM))
STEERING SYSTEM (PITMAN ARM)

SERVICE PRODUCTS
SKIS
Trail and Crossover Models
Suspension
NEW grease
NEW
NEW 8 ± 1 N•m
mmr2017-049-102_a
mmr2017-049 1
Mountain Models
3 ± 0.5 N•m
NEW
(27 ± 4 lbf•in)
NEW
Suspension
grease
NEW
NEW 8 ± 1 N•m
(71 ± 9 lbf•in)

mmr2017-049-103_a
2 mmr2017-049
STEERING COLUMN AND TIE-RODS
NEW
12.5 ± 2.5 N•m
(111 ± 22 lbf•in)
Suspension
grease
Suspension
grease
NEW
NEW
NEW
18.5 ± 3.5 N•m
NEW (164 ± 31 lbf•in)

mmr2017-049-100_a
mmr2017-049 3
HANDLEBAR
Loctite 243
14 ± 2 N•m
(124 ± 18 lbf•in)
European models
Mountain models
If equipped
3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

mmr2017-049-101_a
4 mmr2017-049
GENERAL
When removing or replacing a part of the steering
mechanism, perform the steering alignment, refer
to ALIGNING THE STEERING in this subsection.
views.
complete procedure. mmr2017-050-047_a
TYPICAL
WARNING 1. Same reference point
A. Equal distance on each side
must be strictly adhered to. 4. Ensure track is properly aligned.
tabs, elastic stop nuts, cotter pins, etc.) must 5. Verify if skis are in straight-ahead position by
be replaced. placing a straight edge against track and mea-
suring distance between front and rear ski
bridges and straight edge.
NOTICE Hoses, cables and locking ties re- 6. With skis in straight ahead position, adjust the
moved during a procedure must be reinstalled toe-out.
at the same location. 7. Measure the distance between front and rear
ski bridges in line with arrows on skis.
ADJUSTMENT 8. Use the following illustration and this equation
to determine the steering adjustment.
ALIGNING THE STEERING
Ski alignment is performed by adjusting the length
of left and right tie-rods.
1. Leave the vehicle on the ground on its own
weight.
2. Attach ski handles together with a bungee cord.
mmr2017-049-001_a
STEERING ALIGNMENT
mmr2008-049-025_a Toe-out A – B = 5 mm (.197 in)
TYPICAL
1. Bungee cord 9. If adjustment is needed, loosen tie-rod jam nuts
then turn tie-rods to change their length.
3. Position handlebar so that it is straight ahead
position by measuring from the extremities of NOTE: There is no jam nut on the inner tie-rods.
the grips to the rear most edge of the tunnel, 10. Tighten jam nuts to specification.
as shown.
NOTE: The reference point must be the same to
each side.
mmr2017-049 5
TIGHTENING TORQUE
18.5 N•m ± 3.5 N•m
Jam nut
mmr2017-050-045
WARNING
The maximum tie-rod end length (A) not en- mmr2017-049-002
gaged in the tie rod must not exceed 34 mm
(1.339 in). Installing the Ski Runner
cedure. Pay attention to the following.
tighten ski runner nuts to specification.
TIGHTENING TORQUE
8 N•m ± 1 N•m
Runner nut
SKIS
Inspecting the Ski
mmr2017-050-037_a
DURES subsection.
Removing the Ski
PROCEDURES 1. Lift front of vehicle and support it off ground.
SKI RUNNER 2. Unscrew nut then pull ski bolt out.
Inspecting the Ski Runner

DURES subsection.
Removing the Ski Runner
1. Lift the front of vehicle and support it off the
ground.
2. Unscrew the ski runner nuts then remove ski
runners.
mmr2017-049-003
3. Remove ski from vehicle.
Installing the Ski

Make sure bushings are installed in ski holes.
Install the ski stopper. Position indicator in front
and make sure the bump in the ski is in the groove
of the ski stopper.
6 mmr2017-049
mmr2017-050-006_a mmr2017-050-008
1. Ski stopper NARROWER STANCE — RIGHT SKI SHOWN

2. Bushings
Mountain Models
mmr2017-050-009
WIDER STANCE — RIGHT SKI SHOWN
mbl2015-002-013_a Trail and Crossover Models

LH SIDE SHOWN
1. Ski stopper Install ski on ski leg as per the following illustra-
2. M10 x 130 screw tions.
3. M10 flat washer
4. M10 flanged nut
5. Ski axel
6. Narrow adjustment
7. Wide adjustment
Install the spacer inside for the narrower stance

and outside for the wider stance.
WARNING
Proceed to the same setting for both skis.
mbl2016-002-002_a
1. Ski stopper
2. M10 x 130 screw
3. M10 flat washer
4. M10 flanged nut
5. Ski leg bushings
6. Ski leg sleeve
7. Ski leg stopper
mmr2017-049 7
2. Place a rivet in position and insert it into ski and

ski handle. Repeat the procedure for the other
side.
mbl2017-002-001_a
LATERAL SKI KEEL TOWARDS OUTSIDE (IF EQUIPPED) -

CORRECT
mmr2006-098-009_a
1. C-clamp
2. Rivet
3. Handle
3. When both rivets are installed, use the short

10 mm socket to push rivet heads against the
ski.
mbl2017-002-002_a
LATERAL SKI KEEL TOWARDS INSIDE (IF EQUIPPED) - NOT

CORRECT
All Models
TIGHTENING TORQUE
48 N•m ± 6 N•m
Ski nut
mmr2006-098-010_a
SKI HANDLES 1. C-clamp

2. 10 mm socket
Removing the Ski Handle
1. Remove ski from vehicle. SKI FLOTATION EXTENSION
2. Using a 9 mm (3/8 in) drill bit, remove ski handle (MOUNTAIN MODELS)
rivets. Only drill the head of rivet. Do not try to Condition Utilization
drill all the way through the rivet. Angle the drill
bit to reduce the chance of spinning the rivet in The key to the adjustable nose is to reduce the
the ski. tip-hop that can slow down the vehicle.
3. Remove handle from ski. In snow conditions with less than 41 cm (16 in) of
fresh powder, specially when there is a crust, the
4. Place handle in hot water for 10 minutes then narrow tip stays in the snow - which helps to main-
using a punch, drive the inner part of rivet out tain a carve. Also, when side hilling, and crossing
of handle. a snowmobile rut, the narrow shape moves the
impact point - where a change in snow density
Installing the Ski Handle acts to tip-up the ski - more towards the spindle.
1. To install rivets, use a C-clamp and a short This reduces kick back by 50% compared to the
10 mm socket. wider configuration, minimizing its impact on the
attitude of the snowmobile holding a side hill.
8 mmr2017-049
In snow conditions with more than 41 cm (16 in) HANDLEBAR GRIP

of fresh powder, the wider tip configuration is de-
sirable, as it increases flotation and will bring the NOTE: To verify or replace heating elements, re-
nose of the snowmobile up. fer to ACCESSORIES subsection.
Removing the Ski Flotation Extension Removing the Handlebar Grip

1. Remove nuts and screws securing the exten- Remove grips by pulling while using compressed
sion to ski. air, which will inflate or loosen the fit between the
grip and handlebar.
mmr2017-049-004
mmr2015-143-007
2. Slide the extension off the ski.
Installing the Handlebar Grip
Insert the handlebar grip on handlebar while blow-
ing compressed air to inflate or loosen the fit be-
tween grip and handlebar.
MULTIFUNCTION SWITCH
Removing the Multifunction Switch
(Mountain models)
BODY subsection.
2. Disconnect the multifunction switch connector
mmr2017-049-005_a
(2-pin connector).
Installing the Ski Flotation Extension
1. Install extension nuts towards up and tighten to
specification.
TIGHTENING TORQUE
3 N•m ± 0.5 N•m
Extension nuts
SKI LEG
To replace a ski leg, refer to FRONT SUSPENSION mmr2017-049-014
subsection. 3. Cut locking ties securing multifunction switch

harness.
mmr2017-049 9
mmr2017-049-006 mmr2017-050-014
4. Remove multifunction switch screws. 4. Unscrew master cylinder from handlebar.
mmr2017-049-007 mmr2017-050-015
5. Remove multifunction switch from vehicle. 5. Remove master cylinder.

Removing the Multifunction Switch NOTICE Do not let master cylinder hang by
(Trail and Crossover models) the hose and do not stretch or twist the hose.
1. Remove the gauge support. Refer to BODY 6. Remove multifunction switch screws.
subsection.
2. Disconnect the multifunction switch connector.
mmr2017-050-016
7. Remove multifunction switch from vehicle.

mmr2017-050-013
3. Cut locking ties securing multifunction switch Installing the Multifunction Switch
harness. (Mountain models)
10 mmr2017-049
Install the multifunction switch clamp with the ar-

row towards rear.
Tighten multifunction switch screws to specifica-
tion as per the following sequence.
TIGHTENING TORQUE
Multifunction switch 2.4 N•m ± 0.2 N•m
mmr2017-049-021_a
MOUNTAIN MODELS
Place the master cylinder on the handlebar.

Install master cylinder retaining clamp with its ar-
row pointing toward the front of vehicle.
mmr2017-049-007_a
Turn handlebar completely from side to side mak-

ing sure it does not exert unwanted tension on
handlebar wires.
Installing the Multifunction Switch

(Trail and Crossover Models)
cedure. However, pay attention to the following. mmr2017-050-017
Tighten the multifunction switch screws to speci-

Install master cylinder clamp screws and tighten
fication, as per the following sequence.
loosely.
TIGHTENING TORQUE With the handlebar in the straight ahead position,
Multifunction switch 2.4 N•m ± 0.2 N•m place the reservoir parallel to the ground.
screw (21 lbf•in ± 2 lbf•in) Tighten master cylinder clamp screws to specifi-
cation.
TIGHTENING TORQUE

handlebar wires.
THROTTLE LEVER HOUSING

Removing the Throttle Lever Housing
mmr2017-050-016_a 1. Remove the upper body module. Refer to
TRAIL AND CROSSOVER MODELS BODY subsection.
2. Cut the harness locking ties.
mmr2017-049 11
mmr2017-049-008 mmr2017-050-021
3. Disconnect the LH heater element connector 8. Pull the heater element wire out of the throttle
(6-pin connector). lever housing.
mmr2017-049-009 mmr2017-050-022_a
4. Remove the heater element wire terminals 9. Remove throttle cable circlip.
from connector. Refer to WIRING HARNESS
AND CONNECTORS subsection.
NOTICE Take note of exact positioning of
multifunction wire before removing it from the
connector.
5. Disconnect throttle cable from throttle lever.
6. Remove both throttle lever pivot screws.
mmr2017-050-023
10. Remove the throttle cable from the housing.

11. Loosen throttle lever housing retaining screw.
mmr2017-050-020
7. Loosen the emergency stop switch screw and

slide the switch towards center of handlebar.
12 mmr2017-049
mmr2017-050-024 mmr2017-050-027_a
12. Insert a flat screwdriver between the housing Installing the Throttle Lever Housing
and the clamp to release the tab.
Tighten throttle lever pivot screws to specifica-
tion.
TIGHTENING TORQUE
Throttle lever retaining 1.5 N•m ± 0.2 N•m

handlebar wires.
mmr2017-050-025_a THROTTLE LEVER

1. Tab
Removing the Throttle Lever
13. Slide the clamp out of the housing 1. Remove the upper body module. Refer to
BODY subsection.
mmr2017-050-026
14. Remove throttle lever housing from handlebar.

mmr2017-049-008
3. Disconnect the LH heater element connector.
mmr2017-049 13
HANDLEBAR
Removing the Handlebar
NOTE: If the handlebar must be changed, re-
move all components (handlebar grip, throttle
lever housing, etc.) before removing it from ve-
hicle.
1. Remove handlebar retaining clamp screws.
mmr2017-049-009
4. Remove throttle lever heater wire terminals

from connector. Refer to CONNECTOR IN-
FORMATION subsection.
throttle lever heater before removing it from
the connector.
mmr2017-049-010
6. Remove throttle lever pivot screws.
2. Remove handlebar from handlebar extension.
Inspecting the Handlebar

1. Inspect the handlebar for:
– Damages
– Cracks
– Bending.
2. Replace if any of these problems is detected.
WARNING
Do not try to repair a defective handlebar.
mmr2017-050-020
3. Check handlebar clamps for cracks or distor-
7. Remove throttle lever and heater wires. tion, replace if necessary.
Installing the Throttle Lever Installing the Handlebar

The installation is the reverse of the removal pro- The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. cedure. However, pay attention to the following.
Tighten throttle lever pivot screws to specifica- Position the handlebar with clamps, as per the fol-
tion. lowing table.
TIGHTENING TORQUE HANDLEBAR
MODEL
POSITION
Throttle lever pivot 1.5 N•m ± 0.2 N•m
screws (13 lbf•in ± 2 lbf•in) Mountain 0
Trail and crossover +1
handlebar wires.
14 mmr2017-049
mmr2017-049-013 mmr2017-049-012
HANDLEBAR POSITION - MOUNTAIN MODEL SHOWN

3. Remove handlebar extension from vehicle.
Tighten handlebar clamps screws to specification.
TIGHTENING TORQUE
Inspecting the Handlebar Extension
1. Check handlebar extension for:
24.5 N•m ± 3.5 N•m
Clamp screws – Cracks
– Bending
Ensure handlebar clamps are parallel with handle- – Other damages.
bar extension. 2. Replace if any of these problems is detected.
WARNING
Do not try to repair a defective handlebar ex-
tension.
Installing the Handlebar Extension

Position the extension with the steering column,
as per the following table.
HANDLEBAR
mmr2017-049-011_a MODEL EXTENSION POSITION
A. Must be equal on each side ANGLE
Turn handlebar completely from side to side mak- Mountain 180°

ing sure it does not exert unwanted tension on Trail and crossover 159°
handlebar wires.
HANDLEBAR EXTENSION
Removing the Handlebar Extension
1. Proceed with REMOVING THE HANDLEBAR,
see procedure in this subsection.
2. Remove screws retaining the extension to
steering column.
mmr2017-049-015_a
MOUNTAIN MODELS
mmr2017-049 15
mmr2017-049-020_a mmr2017-049-016
TRAIL AND CROSSOVER MODELS STEERING COLUMN
Ensure extension clamps are parallel with handle-

bar extension.
mmr2017-050-035
SKI LEG
mmr2017-049-019_a 3. Cut the locking tie on the steering boot.

A. Must be equal on each side
WARNING
Handlebar and it's components must not get
in contact with anything (windshield, fuel
tank cap, etc.) when steering is turned.
TIE-RODS
NOTE: The same procedure is applied on RH and
LH side.
Inspecting the Tie-Rod

Check tie-rod ends for looseness. If play is exces-
sive, replace tie-rod.
Check if the tie-rod is bent, cracked or otherwise mmr2017-050-059
damaged. Replace if necessary.

4. Remove tie-rod with ring from vehicle.
Removing the Tie-Rod
1. Remove the tuned pipe. Refer to EXHAUST
SYSTEM subsection.
2. Remove the tie-rod end nuts and screws from
the steering column and ski leg.
16 mmr2017-049
mmr2017-050-036 mmr2017-050-038_a
Installing the Tie-Rod Install the washer and the nut, and tighten to
specification.
Adjust the length of all tie-rod end to specification
without tightening the jam nuts.
mmr2017-050-039
mmr2017-050-037_a
TIE-ROD LENGTH (A)

30 mm (1.181 in)
WARNING
The maximum tie-rod end length (A) not en-
(1.339 in).
Install tie-rod with the groove on ski leg side.
mmr2017-050-057
TIGHTENING TORQUE
48 N•m ± 6 N•m
Outer tie-rod end nut
24.5 N•m ± 3.5 N•m
Inner tie-rod end nut
Ensure the new locking tie is fully seated and the

head is positioned upwards.
mmr2017-049 17
NOTICE To avoid bellows damage, make

sure locking tie head is positioned upwards.
mmr2017-049-022
REARWARD POSITION COLUMN
6. Remove nuts and screws securing the steering

column lower support.
mmr2017-050-702_a
1. Head up
2. Fully seated
Perform the steering alignment, refer to ALIGN-

ING THE STEERING in this section.
STEERING COLUMN
Removing the Steering Column
SYSTEM subsection.
mmr2017-049-018
2. Remove the rear console. Refer to BODY sub-
section. 7. Pull steering column from top.
3. Remove HANDLEBAR EXTENSION from steer-
ing column. Refer to the procedure in this sub-
Inspecting the Steering Column
section. Check if steering column is:
4. Remove the inner tie-rod end nuts and screws. – Cracked
Refer to TIE-RODS in this subsection. – Bent
5. Remove nuts and screws securing steering col- – Twisted
umn upper support. – Otherwise damaged.
Replace steering column if necessary.
WARNING
Do not try to repair a defective steering col-
umn.
Installing the Steering Column

cedure. However, pay attention to the followings.
1. Apply SUSPENSION GREASE (P/N 293 550 033) on
vibration dampers before installing upper and
lower supports.
mmr2017-049-017
FRONTWARD POSITION COLUMN

2. Install new elastic nuts on the steering column
retaining screws.
18 mmr2017-049
3. Tighten nuts to specification.

TIGHTENING TORQUE
Upper steering column 12.5 N•m ± 2.5 N•m
support nut (111 lbf•in ± 22 lbf•in)
Lower steering column 23.5 N•m ± 3.5 N•m
support nut (17 lbf•ft ± 3 lbf•ft)
mmr2017-049 19
Subsection XX (STEERING SYSTEM (RACK))
STEERING SYSTEM (RACK)

SERVICE PRODUCTS
XPS BRAKES AND PARTS CLEANER (USA) ................................. 219 701 705 ........................................... 8
XPS BRAKES AND PARTS CLEANER ........................................... 219 701 776 ........................................... 8
XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 8
SKIS (WITH ADJUSTABLE RUNNER)
NEW
9 ± 1 N•m
(80 ± 9 lbf•in)
XPS
NEW Synthetic
24.5 ± 3.5 N•m grease
(18 ± 3 lbf•ft)
NEW
Suspension
grease
NEW
mmr2017-050-100_a
mmr2017-050 1
SKIS (WITHOUT ADJUSTABLE RUNNER)
Suspension
NEW grease
NEW
NEW 8 ± 1 N•m
mmr2017-049-102_a
2 mmr2017-050
STEERING COLUMN AND TIE-RODS
NEW
12.5 ± 2.5 N•m
(111 ± 22 lbf•in)
NEW
Suspension
grease
Loctite 243
1.8 ± 0.2 N•m
(16 ± 2 lbf•in)
NEW
Suspension
grease NEW
NEW
NEW
European models
18.5 ± 3.5 N•m

(164 ± 31 lbf•in)
NEW
NEW NEW

mmr2017-050-101_a
mmr2017-050 3
GENERAL
When removing or replacing a part of the steering
mechanism, perform the steering alignment, refer
to STEERING ALIGNMENT in this subsection.
views.
complete procedure. mmr2017-050-047_a
1. Same reference point

WARNING A. Equal distance on each side
must be strictly adhered to. 4. Ensure track is properly aligned.
Locking devices when removed (e.g.: locking 5. Verify if skis are in straight-ahead position by
tabs, elastic stop nuts, cotter pins, etc.) must placing a straight edge against track and mea-
be replaced. suring distance between front and rear ski
bridges and straight edge.
6. With skis in straight ahead position, adjust the
toe-out.
at the same location. 7. Measure the distance between front and rear
ski bridges in line with arrows on skis.
ADJUSTMENT 8. Adjust the steering alignment as per the follow-
ing illustration and specification.
ALIGNING THE STEERING
Ski alignment is performed by adjusting the length
of left and right tie-rods.
1. Leave the vehicle on the ground on its own
weight.
2. Attach ski handles together with a bungee cord.
mmr2017-050-046_a
STEERING ALIGNMENT
Toe-out A - B = 5 mm (.197 in)
mmr2008-049-025_a
1. Bungee cord 9. If adjustment is needed, loosen tie-rod jam nuts

then turn tie-rods to change their length.
3. Position handlebar so that it is straight ahead
position by measuring from the extremities of NOTE: There is no jam nut on the inner tie-rods.
the grips to the rear most edge of the tunnel, 10. Tighten jam nuts to specification.
as shown.
TIGHTENING TORQUE
NOTE: The reference point must be the same to
each side. 18.5 N•m ± 3.5 N•m
Jam nut
4 mmr2017-050
With Adjustable Ski (Pilot TS)

1. Remove the ski.
mmr2017-050-045
2. Remove the pin.
WARNING
(1.339 in).
mmr2017-050-001
Installing the Ski Runner

cedure. Pay attention to the following.
mmr2017-050-037_a
Without Adjustable Ski (Pilot TS)
Tighten ski runner nuts to specification.
PROCEDURES TIGHTENING TORQUE
8 N•m ± 1 N•m
SKI RUNNER Runner nut
Inspecting the Ski Runner
With Adjustable Ski (Pilot TS)
DURES subsection.
Removing the Ski Runner
Without Adjustable Ski (Pilot TS)
1. Lift the front of vehicle and support it off the
ground.
2. Unscrew the ski runner nuts, then remove the
ski runner.
mmr2017-050-002_a
1. Towards front
2. Towards rear
SKIS
Inspecting the Ski
DURES subsection.
mmr2017-050-007 Removing the Ski
1. Lift front of vehicle and support it off ground.
mmr2017-050 5
2. Unscrew nut then pull ski bolt out. Install ski on ski leg as per the following illustra-
tions.
mmr2017-050-003
3. Remove ski from vehicle.

mbl2016-002-002_a
Installing the Ski WITHOUT ADJUSTABLE SKI (PILOT TS)

1. Ski stopper
Make sure bushings are installed in ski holes. 2. M10 x 130 screw
3. M10 flat washer
Install the ski stopper. Position indicator in front 4. M10 flanged nut
and make sure the bump in the ski is in the groove 5. Ski leg bushings
6. Ski leg sleeve
of the ski stopper. 7. Ski leg stopper
mmr2017-050-006_a mbl2016-002-008_a
WITHOUT ADJUSTABLE SKI (PILOT TS) WITH ADJUSTABLE SKI (PILOT TS)
1. Ski stopper 1. Ski screw
2. Bushings 2. Nut
3. Washer
mmr2017-050-005_a
mbl2017-002-001_a
WITH ADJUSTABLE SKI (PILOT TS)
1. Ski stopper LATERAL SKI KEEL TOWARDS OUTSIDE (IF EQUIPPED) -
2. Bushings CORRECT
6 mmr2017-050
Disassembling the Adjustable Ski

Mechanism
1. Remove the adjusting knob and the indicator
screws.
NOTE: There are two O-rings on the indicator
screw.
mbl2017-002-002_a
LATERAL SKI KEEL TOWARDS INSIDE (IF EQUIPPED) - NOT

CORRECT
TIGHTENING TORQUE
48 N•m ± 6 N•m
Ski nut
ADJUSTABLE SKI MECHANISM

Removing the Adjustable Ski mmr2017-050-050_a
Mechanism 1. Adjusting knob screw

2. Indicator screw
1. Remove the ski and the runner.
2. Slide the sleeve out of the ski leg. 2. Slide the adjusting screw and the adjusting
shaft out of the body.
mmr2017-050-010
3. Remove the mechanism from the ski leg.

mmr2017-050-051_a
3. Remove the screw from the shaft.
mmr2017-050-011
mmr2017-050 7
mmr2017-050-052 mmr2017-050-054
4. Clean the screw and the shaft inner threads Inspecting the Adjustable Ski
with XPS BRAKES AND PARTS CLEANER (USA) Mechanism
(P/N 219 701 705) or XPS BRAKES AND PARTS
CLEANER (P/N 219 701 776) and a small brush. Inspect the mechanism body for cracks. Replace
if required.
Inspect the adjusting screw and shaft for:
– Thread damages
– Bending.
Replace if required.
Inspect the sleeve for:
– Cracks
– Spline damages
Replace if required.
Inspect the ball bearing. It should turn freely and
smoothly. If bearing needs to be replaced, replace
the mechanism assembly.
Assembling the Adjustable Ski

mmr2017-050-701_a Mechanism
5. Remove the snap ring. The assembly is the reverse of the disassembly
procedure. However, pay attention to the follow-
ing.
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) on
screw thread and shaft inner thread.
mmr2017-050-053_a
6. Slide the sleeve out of the body.
8 mmr2017-050
2. Using a 9 mm (3/8 in) drill bit, remove ski handle

rivets. Only drill the head of rivet. Do not try to
drill all the way through the rivet. Angle the drill
bit to reduce the chance of spinning the rivet in
the ski.
3. Remove handle from ski.
4. Place handle in hot water for 10 minutes then
using a punch, drive the inner part of rivet out
of handle.
Installing the Ski Handle

1. To install rivets, use a C-clamp and a short
10 mm socket.
mmr2017-050-700_a
2. Place a rivet in position and insert it into ski and
ski handle. Repeat the procedure for the other
Install a new knob screw.
side.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Adjusting knob screw
24.5 N•m ± 3.5 N•m
Indicator screw
Installing the Adjustable Ski

Mechanism
The installation is the reverse of the removing pro-
Install rubber grommet on nut first. Align flat
against flat. mmr2006-098-009_a
Ensure all bushings, and the grommet are in place 1. C-clamp

2. Rivet
and fully seated. 3. Handle
3. When both rivets are installed, use the short

10 mm socket to push rivet heads against the
ski.
mmr2017-050-012
SKI HANDLES
Removing the Ski Handle mmr2006-098-010_a
1. C-clamp
1. Remove ski from vehicle. 2. 10 mm socket
mmr2017-050 9
SKI LEG 3. Cut locking ties securing multifunction switch

harness.
To replace a ski leg, refer to FRONT SUSPENSION
subsection.
HANDLEBAR GRIP
NOTE: To verify or replace heating elements, re-
fer to LIGHTS, GAUGE AND ACCESSORIES sub-
section.
Removing the Handlebar Grip

Remove grips by pulling while using compressed
air, which will inflate or loosen the fit between the
grip and handlebar.
mmr2017-050-014
4. Unscrew master cylinder from handlebar.
mmr2015-143-007
Installing the Handlebar Grip

mmr2017-050-015
Insert the handlebar grip on handlebar while blow-
ing compressed air to inflate or loosen the fit be- 5. Remove master cylinder.
tween grip and handlebar.
NOTICE Do not let master cylinder hang by
the hose and do not stretch or twist the hose.
MULTIFUNCTION SWITCH
6. Remove multifunction switch screws.
Removing the Multifunction Switch
1. Remove the gauge support. Refer to BODY
subsection.
2. Disconnect the multifunction switch connector.
mmr2017-050-016
7. Remove multifunction switch from vehicle.
mmr2017-050-013
10 mmr2017-050
Installing the Multifunction Switch Turn handlebar completely from side to side mak-
The installation is the reverse of the removal pro- ing sure it does not exert unwanted tension on
cedure. However, pay attention to the following. handlebar wires.
Tighten the multifunction switch screws to speci-
fication, as per the following sequence. THROTTLE LEVER HOUSING
TIGHTENING TORQUE Removing the Throttle Lever Housing
Multifunction switch 2.4 N•m ± 0.2 N•m 1. Remove the upper body module. Refer to
screw (21 lbf•in ± 2 lbf•in) BODY subsection.
mmr2017-050-016_a
mmr2017-050-018
Place the master cylinder on the handlebar.

3. Disconnect the RH heater element connector.
Install master cylinder retaining clamp with its ar-
row pointing toward the front of vehicle.
mmr2017-050-019
mmr2017-050-017 4. Remove the heater element wire terminals

from connector. Refer to WIRING HARNESS
Install master cylinder clamp screws and tighten AND CONNECTORS subsection.
loosely.
With the handlebar in the straight ahead position,
place the reservoir parallel to the ground. multifunction wire before removing it from the
connector.
Tighten master cylinder clamp screws to specifi-
cation. 5. Disconnect throttle cable from throttle lever.
TIGHTENING TORQUE 6. Remove both throttle lever pivot screws.
mmr2017-050 11
mmr2017-050-020 mmr2017-050-023
7. Loosen the emergency stop switch screw and 10. Remove the throttle cable from the housing.
slide the switch towards center of handlebar. 11. Loosen throttle lever housing retaining screw.
mmr2017-050-021
mmr2017-050-024
8. Pull the heater element wire out of the throttle

12. Insert a flat screwdriver between the housing
lever housing.
and the clamp to release the tab.
mmr2017-050-022_a
mmr2017-050-025_a
9. Remove throttle cable circlip. 1. Tab
13. Slide the clamp out of the housing
12 mmr2017-050
mmr2017-050-026 mmr2017-050-018
14. Remove throttle lever housing from handlebar. 3. Disconnect the LH heater element connector.
mmr2017-050-027_a mmr2017-050-019
4. Remove throttle lever heater wire terminals

Installing the Throttle Lever Housing
from connector. Refer to CONNECTOR IN-
The installation is the reverse of the removal pro- FORMATION subsection.
Tighten throttle lever pivot screws to specifica-
throttle lever heater before removing it from
tion.
the connector.
TIGHTENING TORQUE
Throttle lever retaining 1.5 N•m ± 0.2 N•m
screw (13 lbf•in ± 2 lbf•in) 6. Remove throttle lever pivot screws.

handlebar wires.
THROTTLE LEVER
Removing the Throttle Lever
BODY subsection.
mmr2017-050-020
7. Remove throttle lever and heater wires.
mmr2017-050 13
Installing the Throttle Lever Installing the Handlebar

The installation is the reverse of the removal pro- The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. cedure. However, pay attention to the following.
Tighten throttle lever pivot screws to specifica- Position the handlebar at +2 with clamps.
tion.
TIGHTENING TORQUE
Throttle lever pivot 1.5 N•m ± 0.2 N•m

handlebar wires.
HANDLEBAR
Removing the Handlebar
NOTE: If the handlebar must be changed, re- mmr2017-050-048
move all components (handlebar grip, throttle

lever housing, etc.) before removing it from ve- Tighten handlebar clamps screws to specification.
hicle. TIGHTENING TORQUE
1. Remove handlebar retaining clamp screws. 24.5 N•m ± 3.5 N•m
Clamp screw
Ensure handlebar clamps are parallel with handle-

bar extension.
mmr2017-050-028
2. Remove handlebar from handlebar extension.
Inspecting the Handlebar mmr2017-050-029_a
1. Inspect the handlebar for: A. Must be equal on each side

– Damages
– Cracks ing sure it does not exert unwanted tension on
– Bending. handlebar wires.
2. Replace if any of these problems is detected.
HANDLEBAR EXTENSION
WARNING
Do not try to repair a defective handlebar.
Removing the Handlebar Extension
1. Proceed with REMOVING THE HANDLEBAR,
3. Check handlebar clamps for cracks or distor- see procedure in this subsection.
tion, replace if necessary. 2. Remove screws retaining the extension to
steering column.
14 mmr2017-050
Ensure extension clamps are parallel with handle-

bar extension.
mmr2017-050-030
3. Remove handlebar extension from vehicle.
Inspecting the Handlebar Extension mmr2017-050-031_a
A. Must be equal on each side

1. Check handlebar extension for:
– Cracks WARNING
– Bending Handlebar and it's components must not get
– Other damages. in contact with anything (windshield, fuel
2. Replace if any of these problems is detected. tank cap, etc.) when steering is turned.
WARNING TIE-RODS
Do not try to repair a defective handlebar ex- NOTE: The same procedure is applied on RH and
tension. LH side.
Installing the Handlebar Extension Inspecting the Tie-Rod
The installation is the reverse of the removal pro- Check tie-rod ends for looseness. If play is exces-
cedure. However, pay attention to the following. sive, replace tie-rod.
Position the extension in order to have the handle- Check if the tie-rod is bent, cracked or otherwise
bar horizontal. damaged. Replace if necessary.
Removing the Tie-Rod

SYSTEM subsection.
2. Remove the tie-rod end nuts and screws from
the steering rack and ski leg.
mmr2017-050-049_a
Torque handlebar extension retaining screws to

specification.
TIGHTENING TORQUE
24.5 N•m ± 3.5 N•m
Clamp screw
(18 lbf•ft ± 3 lbf•ft) mmr2017-050-033
STEERING RACK - STEERING COLUMN REMOVED FOR

CLARITY
mmr2017-050 15
mmr2017-050-035 mmr2017-050-037_a
SKI LEG
TIE-ROD LENGTH (A)
3. Cut the locking tie on the steering boot.
30 mm (1.181 in)
WARNING
(1.339 in).
Install tie-rod with the groove on ski leg side.
mmr2017-050-059
4. Remove tie-rod with ring from vehicle.
mmr2017-050-038_a
Install the washer and the nut, and tighten to

specification.
mmr2017-050-036
Installing the Tie-Rod

Adjust the length of all tie-rod end to specification
mmr2017-050-039
without tightening the jam nuts.
16 mmr2017-050
2. Remove the rear console. Refer to BODY sub-

section.
3. Remove HANDLEBAR EXTENSION from steer-
ing column. Refer to the procedure in this sub-
section.
4. Remove nuts and screws securing steering col-
umn upper support.
mmr2017-050-057
TIGHTENING TORQUE
48 N•m ± 6 N•m
Outer tie-rod end nut
24.5 N•m ± 3.5 N•m
Inner tie-rod end nut mmr2017-050-040
5. From inside engine compartment, remove the
Ensure the new locking tie is fully seated and the steering column pitman arm nut.
head is positioned upwards.
NOTE: Use an Allen key to lock the ball joint.
NOTICE To avoid bellows damage, make
sure locking tie head is positioned upwards.
mmr2017-050-041
6. Remove nuts, stopper plate and screws secur-

ing the steering column lower support.
mmr2017-050-702_a
1. Head up
2. Fully seated
Perform the steering alignment, refer to ALIGN-

ING THE STEERING in this section.
STEERING COLUMN
Removing the Steering Column
SYSTEM subsection.
mmr2017-050 17
STEERING RACK
Inspecting the Steering Rack
Remove the tuned pipe. Refer to EXHAUST SYS-
TEM subsection.
Check if steering rack component are:
– Cracked
– Bent
– Twisted
– Otherwise damaged.
Check steering rack for looseness.
Check if stopper plate is deformed or otherwise
damaged.
mmr2017-050-058
Replace component if necessary.
7. Pull steering column from top.
Removing the Steering Rack
Inspecting the Steering Column 1. Remove the tuned pipe. Refer to EXHAUST
Check if steering column is: SYSTEM subsection.
– Cracked 2. Remove inner tie-rod end nuts and screws.
– Bent 3. Remove the nuts, stopper plate and screws as
– Twisted per the following illustrations.
– Otherwise damaged.
Replace steering column if necessary.
WARNING
Do not try to repair a defective steering col-
umn.
Check if stopper plate is deformed or otherwise

damaged.
Replace stopper plate as necessary.
Installing the Steering Column

cedure. However, pay attention to the followings.
1. Apply SUSPENSION GREASE (P/N 293 550 033) on mmr2017-050-058
vibration dampers before installing upper and INSIDE ENGINE COMPARTMENT
lower supports.
2. Install new elastic nuts on the steering column
retaining screws.
3. Tighten nuts to specification.
TIGHTENING TORQUE
Upper steering column 12.5 N•m ± 2.5 N•m
support nut (111 lbf•in ± 22 lbf•in)
Lower steering column 23.5 N•m ± 3.5 N•m
support nut (17 lbf•ft ± 3 lbf•ft)
18 mmr2017-050
mmr2017-050-043
INSIDE ENGINE COMPARTMENT
mmr2017-050-044
Installing the Steering Rack

cedure.
mmr2017-050 19
Subsection XX (BODY)
BODY
SERVICE TOOLS
SUPERTANIUM DRILL BIT 3/16"................................................... 529 031 800 ........................................... 9
10 9 8
13 11
12
14
15
16
7
6
5
1 4
2 3
mmr2017-051-100_a
1. Hood 9. Battery cover

2. Bottom pan 10. Seat
3. Side bottom pan 11. Console
4. Side panel 12. Gauge support
5. Side wind deflector 13. Windshield
6. Lateral hood 14. Storage compartment cover
7. Snow guard 15. Windshield support
8. Taillight cover 16. Headlight trim
mmr2017-051 1
GENERAL MATERIAL NON-COMPATIBLE CLEANING

TYPE PRODUCTS
CLEANING ANY PETROLEUM BASE
CLEANING PRODUCTS
Cleaning the Seat
It is recommended to clean the seat with a solu- XP-S ATV Finishing Spray
(P/N 219 701 704)
tion of warm soapy water, using a soft clean cloth. Polypropylene
XP-S ATV Cleaning
NOTICE Avoid use of harsh detergents such Kit (P/N 219 701 713)
as strong soaps, degreasing solvents, abrasive (it contains the above XP-S
cleaners, paint thinners, etc. that may cause ATV Finishing Spray)
damage to the seat cover.
Cleaning the Plastic

Clean the vehicle thoroughly, removing all dirt and
grease accumulation.
To clean use a soft clean cloth and either soapy
water or isopropyl alcohol.
To remove grease, oil or glue use isopropyl alco-
hol.
NOTICE Do not apply isopropyl alcohol or
acetone directly on decals.
Follow these recommendations to protect the
glossy finish of polypropylene parts.
Apply a non abrasive wax on glossy finish only.
Non Compatible Cleaning Products
NOTICE Polypropylene is not compatible vbs2012-006-002_a
with PETROLEUM BASE PRODUCTS. Contact DO NOT USE ON POLYPROPYLENE

with petroleum base products, such as clean-
ers or lubricants will permanently alter the Compatible Cleaning Products
glossy finish of polypropylene parts. MATERIAL COMPATIBLE CLEANING
NOTICE The following products must not be TYPE PRODUCT
applied on the plastic components used on the XPS ATV Wash
vehicles: Polypropylene (P/N 219 701 702)
– Gasoline Soapy water
– Brake fluid
– Kerosene
– Diesel fuel
– Lighter fluid
– Varsol
– Naphtha
– Acetone
– Strong detergents
– Abrasive cleaners
– Waxes containing an abrasive or a cleaning
agent in their formula.
2 mmr2017-051
DECAL
Replacing the Decal
1. To remove a decal; heat old decal with a heat
gun (low temperature) and peel off slowly.
2. Using isopropyl alcohol, clean the surface and
dry thoroughly.
NOTICE Do not apply isopropyl alcohol or
solvent directly on decals. Use only in a well
ventilated area.
3. Just before beginning to affix the new decals,
wipe the surface with a clean damp cloth and
allow to dry.
vbs2012-006-001
SAFE FOR POLYPROPYLENE 4. Use a pallet to affix the decal. Always work
from the center towards the edges.
REPAIRING BODY PARTS NOTICE Do not remove the pre-mask yet.
The very first step before repairing plastic materi- 5. Once the decal is correctly affixed, carefully
als is to find out exactly which type of material is make a final pass with the pallet. Apply enough
involved. pressure to make sure the glue sticks well on
On the inner surface of each part, the production the surface.
date, part number, and material code are molded 6. Remove the pre-mask.
in.
PLASTIC PARTS SIDE PANEL
CODE MATERIAL Removing the Side Panel
PP Polypropylene 1. Release all lock devices.
EMA+PA Surlyn
NOTICE Some repair products are not com-

patible with certain plastics.
WARNING
Polycarbonate windshields must never be re-
paired by welding or otherwise.
The following company provides a complete line

of products to repair plastic materials:
CREST INDUSTRIES, INC.
mmr2017-051-002
Trenton, MI 48183
Phone: 734 479-4141 2. Open side panel.
Toll Free: 1 800 822-4100
Fax: 734 479-4040 3. Lift the side panel up and towards front.
E-Mail: info@crestauto.com
www.crestauto.com
PROCEDURES
NOTE: The same procedure applies for RH and
LH side. Most of the time, only one side is de-
scribed in this subsection.
mmr2017-051 3
WINDSHIELD
mmr2017-051-003_a
NOTICE Make sure to place panels in a safe

place to avoid scratching. mmr2017-051-005
Installing the Side Panel Removing the Windshield

The installation is the reverse of the removal pro- Place your hands on each side of windshield.
cedure.
Pull the windshield until its pins come out of rub-
ber grommets then pull in the center to remove
REWIND STARTER HANDLE center pin from grommet.
HOUSING
Installing the Windshield
Removing the Rewind Starter Handle
Housing dure.
1. Open RH side panel.
Lubricate the grommets using soapsuds.
2. Remove screw retaining housing to bracket.
NOTICE Do not lubricate grommets with any
type of grease.
Secure windshield by inserting the windshield
pins into the grommets.
NOTE: Make sure not to push grommets through
gauge support holes.
mmr2017-051-004
3. Remove rewind starter handle. Refer to

REWIND STARTER subsection.
Installing the Rewind Starter Handle
Housing
Installation is the reverse of removal procedure. mbl2009-010-202_a
Pay attention to the following. TYPICAL

1. Windshield tab
2. Gauge support front grommet
TIGHTENING TORQUE
Rewind starter handle 2.3 N•m ± 0.2 N•m
housing screw (20 lbf•in ± 2 lbf•in)
4 mmr2017-051
WARNING
Make sure that handlebar turns freely in both
directions. Make sure that there is no contact
at any time between handlebar wind deflec-
tors (if so equipped) and windshield.
STORAGE COMPARTMENT
COVER
mmr2017-051-008_a
Installing the Storage Compartment

Cover
cedure.
NOTICE Ensure windshield is NOT installed.
Otherwise, the storage cover could be dam-
aged during installation.
mmr2017-051-006
GAUGE SUPPORT
Removing the Storage Compartment
Cover
1. Remove windshield.
2. Open storage cover until it is almost vertical.
mmr2017-051-009
Removing the Gauge Support

1. Remove the windshield. Refer to procedure in
this subsection.
mmr2017-051-007_a
2. Open the storage compartment cover
3. Pull out storage cover. 3. Remove the gauge support screws.
mmr2017-051 5
mmr2017-051-010 mmr2017-051-012
TRAIL AND CROSSOVER MODELS SHOWN

3. Loosen the air intake hose clamp.
4. Pull out gauge support from bottom grommets.
5. Remove the multifunction gauge from support.
Refer to GAUGE subsection.
Installing the Gauge Support

dure.
TIGHTENING TORQUE
2.3 N•m ± 0.2 N•m
Gauge support screw
UPPER BODY MODULE mmr2017-051-013
4. Remove the upper body module retaining

screws.
mmr2017-051-011
Removing the Upper Body Module mmr2017-051-014_a
1. Refer to procedures in this subsection and re-

5. Pull on the rear end of both lateral hood until
move:
their tabs come out of the rear console.
– Side panels
– Gauge support
– Storage compartment and its cover.
2. Disconnect the MAPTS and headlight connec-
tors.
6 mmr2017-051
HOOD
mmr2017-051-015_a
6. Remove the upper body module.

6.1 Grab the upper body module in the gauge mmr2017-051-018
support section.
Removing the Hood
6.2 Pull the module forward.
1. Remove the upper body module. Refer to pro-
6.3 Remove the module from the vehicle. cedure in this subsection.
Installing the Upper Body Module 2. Remove both sides air deflector and air intake
filter.
Ensure to engage rear hood tabs in rear console.
mmr2017-051-019
3. Remove the front push nut under the hood.

mmr2017-051-016
Ensure to connect the air intake hose.

TIGHTENING TORQUE
Upper body module 2.3 N•m ± 0.2 N•m
mmr2017-051-020
4. Remove hood screws.
mmr2017-051 7
mmr2017-051-021_a mmr2017-051-023_a
5. Pull out hood. 3. Pull out headlight housing and trim.
Installing the Hood Installing the Headlight Module

The installation is the reverse of removal proce- The installation is the reverse of removal proce-
dure. dure.
Install a new push nut. TIGHTENING TORQUE
TIGHTENING TORQUE Headlight hexagonal 1.8 N•m ± 0.2 N•m
1.8 N•m ± 0.2 N•m
Hood hexagonal screw
(16 lbf•in ± 2 lbf•in) 2.3 N•m ± 0.2 N•m
Headlight Torx screw
2.3 N•m ± 0.2 N•m
Hood Torx screw
CONSOLE
HEADLIGHT MODULE
mmr2017-051-024
mmr2017-051-022
Removing the Console
Removing the Headlight Module 1. Remove UPPER BODY MODULE. Refer to pro-
1. Remove the hood. Refer to procedure in this cedure in this subsection.
subsection. 2. Remove the seat. Refer to SEAT subsection.
2. Remove the headlight trim fasteners. 3. Cut harness locking ties.
4. Remove console nuts.
8 mmr2017-051
mmr2017-051-041_a mmr2017-051-029
5. Remove fuel tank cap. 3. Drill out rivets from front bumper.
6. Lift up the console and unplug all connectors. REQUIRED TOOL
7. Install fuel tank cap. SUPERTANIUM DRILL BIT 3/16" (P/N 529 031 800)
Installing the Console 4. Remove front bumper screws.
cedure.
TIGHTENING TORQUE
2.3 N•m ± 0.2 N•m
Console nut
FRONT BUMPER
Removing the Front Bumper
mmr2017-051-027_a
5. Pull out bumper towards front.
Installing the Front Bumper

cedure.
Ensure the small surface of the bumper extrusion
is facing downwards.
mmr2017-051-026
1. Remove tuned pipe. Refer to EXHAUST SYS-

TEM subsection.
2. Detach TCM from bumper.
mmr2017-051-040_a
mmr2017-051 9
TIGHTENING TORQUE
5 N•m ± 0.5 N•m
Front bumper nut
FRONT BOTTOM PAN
mmr2017-051-029
6. Remove FRONT BUMPER. See procedure in

this subsection.
If the front bottom pan does not need to be re-
placed, the bumper may remain attached to bot-
tom pan.
7. Remove bottom pan screws.
mmr2017-051-028
Removing the Front Bottom Pan

1. Lift front of vehicle until skis are off the ground.
2. Place the front portion of frame on a wooden
box to support it securely.
mmr2017-051-030_a
8. Remove front shock absorbers. Refer to

FRONT SUSPENSION subsection.
9. Drill out all rivets retaining bottom pan.
NOTE: Refer to FRAME for proper procedure
mmr2008-050-103 when drilling rivets retaining plastic parts.
3. Remove the upper body module. Refer to pro-
cedure in this subsection.
4. Remove tuned pipe. Refer to EXHAUST SYS-
TEM subsection.
5. Detach TCM from bumper.
mmr2017-051-031_a
LH SIDE SHOWN — SOME PARTS REMOVED FOR CLARITY

PURPOSE
10 mmr2017-051
10. Remove bottom pan.
Installing the Front Bottom Pan

cedure.
TIGHTENING TORQUE
1.8 N•m ± 0.2 N•m
Bottom pan screw
SIDE BOTTOM PAN

mmr2017-051-033_a
1. Vent tube
mmr2017-051-032
mmr2017-051-035
Removing the Side Bottom Pan
1. Remove the side panel. Refer to procedure in 5. To remove the LH side bottom pan, remove the
this subsection. screws.
3. Place the front portion of frame on a wooden
box to support it securely.
NOTE: Ensure to clear side bottom pans so they
can move freely.
mmr2017-051-034_a
6. To remove the RH side bottom pan, drill out all

rivets
NOTE: Refer to FRAME for proper procedure
when drilling rivets retaining plastic parts.
mmr2008-050-103 NOTICE Be careful not to drill through muf-
fler.
4. Disconnect vent tube from side bottom pan,
and remove the screws.
mmr2017-051 11
mmr2017-051-036_a mmr2017-051-039
RH SIDE SHOWN FOAM REMOVED FOR CLARITY
Installing the Side Bottom Pan Replacing the Seat Cover

The installation is the reverse of the removal pro- Remove seat.
cedure. Remove the old seat cover. Check the foam and
TIGHTENING TORQUE replace it if necessary.
2.8 N•m ± 0.2 N•m Install the new seat cover with staples.
Side bottom pan screw
(25 lbf•in ± 2 lbf•in) NOTICE Ensure to use the proper length sta-
ples. Extra long staples would pierce the ex-
SEAT posed side of the leatherette.
Removing and Installing the Seat NOTE: For an easier installation, it is highly rec-
ommended to use an electric tacker.
1. While pushing in the center of the seat towards
front, pull on both sides, to unlock, and slide Ensure that the seat rest firmly against a hard sur-
rearwards. face such as a piece of wood. This is done to get
the staples completely pushed in place.
mmr2017-051-037_a
1
The Installation is the reverse of the removal pro- A35H0HA
cedure.
TYPICAL
Ensure the seat is locked. 1. Piece of wood
2. Tacker
After seat cover installation, cut all around the ex-

cess of material.
12 mmr2017-051
REAR BUMPER
TIGHTENING TORQUE
16 N•m ± 2 N•m
Rear bumper screws
TAIL LIGHT HOUSING

Drill out the rivets.
mmr2017-051-038
Pull housing towards rear.
mmr2017-051 13
Subsection XX (FRAME)
FRAME
SERVICE TOOLS
RADIATOR INSTALLATION GAUGES............................................ 529 036 422 ........................................... 13
SUPERTANIUM DRILL BIT 3/16"................................................... 529 031 800 ........................................... 4
SUSPENSION MODULE
NEW
NEW
15 ± 1 N•m
(133 ± 9 lbf•in)
See installation
sequence
mmr2017-052-100_a
mmr2017-052 1
ENGINE MODULE
NEW
NEW
1 / 4
4 / 4
2 / 4
33 ± 3 N•m
NEW = Component must be replaced when removed. 3 / 4 (24 ± 2 lbf•ft)
mmr2017-052-101_a
2 mmr2017-052
TUNNEL MODULE
30 ± 2 N•m
(22 ± 1 lbf•ft)
NEW
NEW Summit
Except
Mountain
Summit X
Renegade
MX Z
Except Mountain
NEW
Except Mountain
If equipped
mmr2017-052-102_a
mmr2017-052 3
GENERAL
ues and the service products as in the exploded
views.
complete procedure.
WARNING
must be strictly adhered to. mmr2009-092-002_a
Locking devices (e.g.: locking tabs, elastic TYPICAL

1. 11 mm socket over a rivet head
stop nuts, cotter pins, etc.) must be replaced 2. Rivet heads
with new ones.
3. Drive out remaining rivet using a punch.
Check for loose, bent, worn out, rusted or oth-
erwise damaged components. Replace the faulty Removing a Pop Rivet
components. Stavex, Avibulb, and Hemlock rivets are standard
pop rivets. They are installed with standard man-
PROCEDURES ual or pneumatic tool.
1. Drill rivet head sufficiently to cut through it.
RIVETS NOTE: To drill a Hemlock rivet, remove the rivet-
For proper drilling instructions and to prevent pre- ing nail using a punch first.
mature wear, follow the procedures as detailed. Important: It is highly recommended to support
the frame locally around a Hemlock rivet when
NOTICE When removing rivets, do not en- punching its nail out.
large or deform the rivet holes in the frame.
Removing a Self-Percing Rivet

Henrob and Thomson rivets are self-piercing riv-
ets. They are installed with specific robotized
equipment.
1. Using a grinding disk, grind the rivet end.
mmr2017-052-031
HEMLOCK RIVET
RECOMMENDED TOOL
SUPERTANIUM DRILL BIT 3/16" (P/N 529 031 800)
mmr2017-052-030_a
1. Thomson rivet NOTICE Drill only sufficiently to cut rivet

2. Henrob rivet
head. Do not drill into frame material, or part
2. Support the frame around the rivet head with a secured using the rivet. When rivet is used
socket on the opposite side to avoid warpage. to secure a plastic part, use pliers to avoid
rotation of rivet with drill bit and heating or
melting of the plastic part.
4 mmr2017-052
2. Using a small punch, drive out the remaining NOTE: Paint takes approximately 15 minutes to
rivet end. dry following application.
5. Apply a thin coat of clear.
Removing a HUCK Rivet
NOTE: Immediately after the clear coat applica-
Huck rivet is a 2 parts type rivet. It is installed with tion, apply a thin coat of HR50 blending solvent
a specific pneumatic tool. around the painted area.
1. Using a cut-off tool, cut the rivet retainer with- 6. Allow clear coat to dry.
out touching the retainer's shoulder.
NOTE: Clear coat takes approximately 2 hours to
dry following application.
REAR BUMPER
Refer to BODY subsection for rear bumper re-
moval and installation procedure.
REAR FRAME MEMBER

Removing the Rear Frame Member
mmr2008-051-125_a
1. Rivet retainer's shoulder 1. Refer to BODY subsection to remove the fol-

2. Cutter wheel lowing:
3. Rivet retainer
– Seat
NOTE: Apply a thin layer of grease on cutter – Upper body module
wheel to increase its durability. – Rear console.
2. Break the rivet retainer's shoulder using a 2. Remove fasteners as per the following illustra-
chisel. tions.
3. Use a small punch to drive out the rivet stem.
FRAME
Cleaning the Frame
Clean frame and tunnel with appropriate cleaners
and rinse with high pressure hose.
NOTE: For bare aluminum frames use only alu-
minum cleaner and follow instructions on con-
tainer.
NOTICE Never direct high-pressure water jet
towards decals. They will peel off.
mmr2017-052-001
Welding the Frame

No welding is permitted unless it is specified on a
BRP bulletin.
Repairing the Frame

NOTE: The following is specific information for
aluminum chassis painting. Use common paint-
ing techniques.
1. Sand the area to be painted.
2. Clean and dry the area.
3. Apply a thin layer of paint of the appropriate
color. mmr2017-052-002
4. Allow paint to dry before re-coating.

mmr2017-052 5
3. Remove rear frame member.
Installing the Rear Frame Member

NOTE: Install all screws and nuts before tighten-
ing them.
Refer to exploded view for proper tightening
torque.
FRONT SUSPENSION MODULE mmr2017-052-007_a
6. Remove the front suspension assembly in the

following manner:
6.1 Detach tie-rod ends from steering column.
6.2 Remove upper shock absorber screws.
6.3 Remove screw that secures stabilizer link
to lower arm.
mmr2017-052-003
Removing the Front Suspension

Module
2. Place a wooden box under the engine module
to support the frame securely.
mmr2017-046-011
3. Refer to the appropriate subsection and re-
move: 6.4 Remove upper and lower suspension
– Engine arms screws and nuts. Refer to FRONT
– Steering column. SUSPENSION subsection.
4. Detach the brake hose clamp next of the upper 6.5 Remove front suspension assembly from
steering column support. vehicle.
5. Detach side frame members from upper steer- 7. Remove the stabilizer bar. Refer to FRONT
ing column support. SUSPENSION subsection.
8. Remove the front bottom pan. Refer to BODY
subsection.
NOTE: Keep the front bumper installed on front
bottom pan.
9. Cut locking ties that secure vents and electrical
harness to module tubes.
6 mmr2017-052
mmr2017-052-004_a mmr2017-052-006
RH SIDE SHOWN
10. If the suspension module needs to be re-
placed, remove: 13. Remove the front suspension module.
– Steering rack / lower steering column sup-
port Installing the Front Suspension
– Tie rod boots.
Module
Refer to STEERING SYSTEM subsection. The installation is the reverse of the removal pro-
11. Remove the following pop rivets. Refer to RE-
MOVING A POP RIVET at the beginning of this Refer to exploded view for proper tightening
subsection. torque.
Important: It is highly recommended to support Install fasteners as per the following sequence.
punching its nail out.
mmr2017-052-025_a
mmr2017-052-005 ENGINE MODULE

RH SIDE SHOWN
12. Remove screws securing front suspension

module to frame.
mmr2017-052-008
mmr2017-052 7
Removing the Engine Module

1. Remove the FRONT SUSPENSION MODULE,
see procedure in this subsection.
2. Remove RH side bottom pan. Refer to BODY
subsection.
3. Remove the RH side engine rubber mount. Re-
fer to ENGINE.subsection.
4. Detach side frame members from engine mod-
ule.
mmr2017-052-011_a
8. Remove the electrical ground screw located be-

tween the chaincase and the engine mount.
mmr2017-052-009_a
5. Remove toe hook fasteners, if equipped.
mmr2017-052-012
9. Remove rivets as per the following illustrations.

Refer to REMOVING A POP RIVET in this sub-
section.
Important: It is highly recommended to support
mmr2017-052-010
6. Remove the chaincase cover. Refer to CHAIN-

CASE subsection.
7. Remove the screw that secure the chaincase to
the engine module.
mmr2017-052-013
LH SIDE
8 mmr2017-052
mmr2017-052-014 mmr2017-052-016
RH SIDE
Engine Module Installation
10. Remove nuts and screws securing the engine
module to the tunnel. The installation is the reverse of the removal pro-
Assemble LH and RH side frame member before
to fix on the tunnel module.
If the HUCK rivets were removed, replace with
the following parts.
NEW FASTENERS
Torx screw M6 x 20 (P/N 250000712)
Hexagonal flanged
(P/N 233261414)
elastic stop nut M6
NOTE: Install the 3 bottom screws with heads

mmr2017-052-015_a
downwards and the 2 upper screws with heads
towards the engine.
Install all screws and rivets in there hole before
tightening and riveting.
Refer to exploded view for proper tightening
torque. Use standard tightening torque when not
specified.
TUNNEL MODULE
mmr2017-052-022
VIEW FROM INSIDE THE TUNNEL
11. Remove the engine module.

12. If only one of the two side members is re-
placed, remove HUCK rivets as per the proce-
dure in this subsection.
mmr2017-052-017
mmr2017-052 9
Removing the Tunnel Module – Rear bumper

1. Drain cooling system, Refer to COOLING SYS- – Taillight
TEM DRAINING in PERIODIC MAINTENANCE – Snowguard.
PROCEDURES subsection.
2. Place a wooden box under the engine module
to support the frame.
move:
– Driven pulley and countershaft
– Fuel tank
– Primary air intake silencer
– LH bottom pan
– Track
4. Remove the remaining drive belt guard bracket
screw. mmr2017-052-023_a
8. Move the plastic bracket, electrical harness,

and fuel hoses aside to clear the tunnel.
9. Loosen the coolant hose clamps and discon-
nect hoses.
mmr2017-052-018_a
5. Disconnect the starter cable from the solenoid,

if equipped.
6. Disconnect and remove the electric harness
from the plastic bracket. mmr2017-052-021
10. Remove rivets as per the following illustra-

tions. Refer to REMOVING A POP RIVET in
this subsection.
mmr2017-052-019
7. If the tunnel is replaced, remove:

– Chaincase
– The plastic bracket
– Devices that retain the battery cable, if
equipped
10 mmr2017-052
mmr2017-052-013 mmr2017-052-022
LH SIDE VIEW FROM INSIDE THE TUNNEL
12. Separate the tunnel module from the rest of

the frame.
13. Remove the tunnel protectors under the tun-
nel, if equipped.
mmr2017-052-014
RH SIDE
11. Remove nuts and screws securing the engine

module to the tunnel.
mmr2017-052-024
Installing the Tunnel Module

Refer to exploded views or appropriate subsec-
tions for proper tightening torque.
mmr2017-052-015_a
mmr2017-052 11
HEAT EXCHANGER
mmr2017-052-041_a
4. Position the new heat exchanger.

mmr2017-052-028
5. Install M6 screws and nuts loosely in the Hem-
lock rivet holes.
Replacing the Heat Exchanger
NOTE: M6 screws will not fit in self-piercing rivet
1. Remove the tunnel. Refer to the procedure in holes.
this subsection.
Do not remove the chaincase.
2. Remove the tunnel rear cap. Refer to RIVETS
in this subsection.
mmr2017-052-033_a
FRONT RIVET HOLES
mmr2017-052-029_a
1. Avibulb rivets (pop rivets)

2. Hemlock rivets (pop rivets)
3. Remove the following rivets.
mmr2017-052-040_a
MID-LENTGH RIVET HOLES

1. Install M6 screws and nuts here
2. Rear mounting hole for rear frame member
mmr2017-052-032_a
12 mmr2017-052
mmr2017-052-034_a mmr2017-052-036
REAR RIVET HOLES 2 LINQ KIT FRAME - INSTALL ON FRONT HOLES
6. Install the gauge kit loosely with the appropriate

screws, as per the following illustrations.
NOTICE It is imperative to use the gauge kit
and to follow each steps of this procedure to
avoid drive axle misalignment.
REQUIRED TOOL
RADIATOR
INSTALLATION
GAUGES (P/N 529
036 422)
mmr2017-052-037
CYLINDRICAL GAUGES LENGHT
REAR SUSPENSION FRONT ARM GAUGE
Rear suspension hole
419.2 mm (16-1/2 in)
gauges
Tail gauge 426.4 mm (16-25/32 in)
The gauge kit fits all tunnel sizes.
mmr2017-052-038
REAR SUSPENSION REAR ARM GAUGE
mmr2017-052-035
1 LINQ KIT FRAME
mmr2017-052-039
TAIL GAUGE
mmr2017-052 13
7. Install the drive axle. Refer to DRIVE AXLE sub-

section.
NOTE: It is not required to install the chain and the
brake disc.
8. Tighten gauges and M6 screws with standard
torque.
9. Enlarge self-piercing rivet holes.
REQUIRED TOOL
Drill bit6.35 mm (1/4 in)
10. Install Hemlock rivets in enlarged holes. mmr2017-052-026
FRAME MEMBER IS TRANSPARENT FOR CLARITY

REQUIRED PARTS
5. Remove countershaft bearing support screws.
Hemlock rivets 293150119
11. Install the tunnel rear cap.
mmr2017-052-027
6. Remove the countershaft bearing support.

mmr2017-052-029_a
1. Avibulb 4.76 mm (3/16 in) rivets Installing the Countershaft Bearing

2. Hemlock 6.4 mm (1/4 in) rivets
Support
12. Remove the M6 screws and nuts, and install The installation is the reverse of the removal pro-
Hemlocks rivets. cedure. However, pay attention to the following.
13. Remove all gauges and the drive axle. IF INSTALLED ON THE SAME FRAME MEMBER
14. Reassemble the vehicle. M8 Hexagonal flange
207683044
screw
COUNTERSHAFT BEARING IF INSTALLED ON A NEW FRAME MEMBER
SUPPORT
M8 Hexagonal flange
210283040
Removing the Countershaft Bearing self-tapping screw
Support
Refer to exploded view for tightening torque and
sequence.
move:
– Driven pulley and countershaft
– LH side bottom pan.
2. Disconnect the Rave valve cable. Refer to
RAVE subsection in ENGINE.
3. Install a shim between the engine bottom end
and the engine module.
4. Remove both engine mount screws.
14 mmr2017-052
Subsection XX (ENGINE)
ENGINE
ENGINE
Engine type Rotax 850 E-TEC
Number of cylinder 2
Bore 82 mm (3.228 in)
Stroke 80.4 mm (3.165 in)
Displacement 849 cm³ (51.81 in³)
Compression ratio 12.50 ± 0.3
Combustion chamber volume 37.00 cc ± 0.93
Maximum power engine speed 7900 ± 100 RPM
Color Yellow
3D RAVE spring Valve springs Wire diameter 0.7 mm (.0276 in)
Minimum free length 35 mm (1.378 in)
Piston ring type Semi-trapezoidal
0.4 mm to 0.6 mm
New
Ring end gap (.016 in to .024 in)
Service limit 1 mm (.039 in)
Engine compression specification Service limit 7.5 bar (109 PSI)
0.135 mm to 0.161 mm
New
Piston/cylinder wall clearance (.0053 in to .0063 in)
Service limit 0.200 mm (.0079 in)
1.75 mm to 1.82 mm
Piston projection
(.069 in to .072 in)
Cylinder head warpage Service limit 0.5 mm (.0197 in)
New (max.) 0.03 mm (.0012 in)
Cylinder taper
New (max.) 0.010 mm (.0004 in)
Cylinder out of round
MAG: 0.05 mm (.002 in)
Crankshaft deflection Max.
PTO: 0.06 mm (.0024 in)
0.152 mm to 0.352 mm
Connecting rod big end axial play New
(.006 in to .0139 in)
COOLING SYSTEM
Ethyl glycol and distilled
water (50%/50%).
Use BRP LONG LIFE
Coolant Type ANTIFREEZE (P/N 219
702 685) or coolant
specifically formulated
for aluminum engines
Thermostat opening temperature 37°C (99°F)
mmr2017-053 1
Subsection XX (ENGINE)
FUEL SYSTEM
E-TEC direct injection
Fuel delivery with integrated auxiliary
injection system
Throttle body 2x 52 mm
Idle speed (not adjustable) 1200 ± 200 RPM
ELECTRICAL SYSTEM
Lighting system output 1340 W @ 6000 RPM
Ignition type Inductive
NGK ILKR8Q7 (engine
Make and type and spark plug threads
are indexed)
Spark plug
Not adjustable
Gap 0.6 mm to 0.7 mm
(.024 in to .028 in)
28°
Ignition timing BTDC @ 3500 RPM
5.98 mm (.235 in)
2 mmr2017-053
Subsection XX (VEHICLES)
VEHICLES
COOLING SYSTEM
Ethyl glycol and distilled
water (50%/50%).
Use BRP LONG LIFE
Type
ANTIFREEZE or coolant
specifically formulated for
Coolant aluminum engines
MX Z 6.8 L (7.2 qt (U.S. liq.))
Quantity Renegade 7.1 L (7.5 qt (U.S. liq.))
Summit 7.5 L (7.9 qt (U.S. liq.))
Radiator cap opening pressure 110 kPa (16 PSI)
LUBRICATION SYSTEM
Electronic oil injection
Oil injection pump type
pump
Type XPS synthetic 2-stroke oil
Injection oil
Quantity 3.4 L (3.6 qt (U.S. liq.))
FUEL SYSTEM
Fuel pump In-tank electrical fuel pump
Premium unleaded gasoline
Type (fuel which may contain up
to 10% MAX ethanol
Fuel
91 Pump Posted AKI
Inside North America
Octane rating (R+M)/2)
Outside North America 95 (RON)
Fuel tank capacity 36 L (9.5 U.S. gal.)
ELECTRICAL SYSTEM
Battery 12 V, 18 A•h
Headlamp 2 x 60/55 W (H-13)
Taillight and stoplight 2.6 W / 139m W LED
START/RER/CLOCK (F1) 5 A
LOADS (F2) 25 A
Fuses
BATTERY (F3) 30 A
ACCESSORIES (F4) 7.5 A
DRIVE SYSTEM
Type XPS synthetic chaincase oil
Chaincase oil
Quantity 350 ml (12 U.S. oz)
mmr2017-054 1
DRIVE SYSTEM
MX Z 27/45
Renegade 25/45
Chain drive ratio
Summit (154") 19/45
Summit (165") 21/51
Pitch 9.530 mm (.375 in)
Type Silent
MX Z 110/13
Chain
Links qty/ Renegade 108/13
plate qty Summit (154") 112/13
Summit (165") 116/13
Drive pulley type pDrive
MX Z
3600 ± 100 RPM
Renegade
Clutch Summit (High Altitude
3800 ± 100 RPM
engagement Calibration)
Summit (Sea Level
3600 ± 100 RPM
Calibration)
MX Z Blue/Violet
Renegade Blue/Blue
Drive pulley calibration Spring Summit (High Altitude
color code Violet/Violet
Calibration)
Summit (Sea Level
Blue/Yellow
Calibration)
Blue/Blue 108 mm (4.252 in)
Spring Blue/Violet 100.3 mm (3.949 in)

length Blue/Yellow 123 mm (4.843 in)
Violet/Violet 106.7 mm (4.201 in)
Screw length 14 mm (.551 in)
MX Z
Drive pulley calibration 868
Ramp Renegade
Summit 967 adjustable
Clicker
Drive pulley calibration Summit 3
position
2 mmr2017-054
DRIVE SYSTEM
Type QRS
MX Z
Green/Green
Renegade
Spring Summit (High Altitude
Blue/Blue
color code Calibration)
Summit (Sea Level
Not applicable
Calibration)
Blue/Blue 124.3 mm (4.894 in)
Driven pulley type
Spring Green/Green 98.5 mm (3.878 in)
length
Summit (Sea Level
88.8 mm (3.496 in)
Calibration)
Spring preload 0
MX Z 47°/44°
Cam angle Renegade 44°/42°
Summit 40° - XTIs
Not adjustable
Z
20.9 mm (.823 in)
Pulley distance Not adjustable
X 41.1 mm ± 1.8 mm
(1.618 in ± .071 in)
Not adjustable
New
3 mm (.118 in)
Offset Y-X Not adjustable
After break-in 2 mm ± .5 mm
(.079 in ± .02 in)
Width 38.3 mm (1.508 in)
Drive belt
Wear limit 35.9 mm (1.413 in)
MX Z
8
Drive sprocket number of teeth Renegade
Summit 6
MX Z
183 mm (7.2 in)
Drive sprocket diameter Renegade
Summit 166 mm (6.5 in)
mmr2017-054 3
DRIVE SYSTEM
MX Z
381 mm (15 in)
Width Renegade
Summit 406.4 mm (16 in)
MX Z 326.9 cm (129 in)
Renegade 348.7 cm (137 in)
Length
Track 3 923 mm (154 in)
Summit
4 178 mm (165 in)
MX Z
31.75 mm (1.25 in)
Profile Renegade
height 63.5 mm (2.5 in) or
Summit
76.2 mm (3 in)
Deflection 3.2 cm (1.26 in)
Track adjustment 6.0 kgf to 8.5 kgf
Force
(13 lbf to 19 lbf)
BRAKE SYSTEM
Brake lining minimum thickness 1 mm (.039 in)
Brake disk minimum thickness 4.5 mm (.177 in)
Type DOT 4
Brake fluid
SUSPENSION
FRONT
Suspension type RAS 3
MX Z
233 mm (9.17 in)
Suspension maximum travel Renegade
Summit SP HPG
Shock absorber type
All other HPG Plus
Stabilizer bar type Link
REAR
MX Z
rMotion
Suspension type Renegade
Summit tMotion
MX Z TNT
27.2 cm (10.7 in)
MX Z X
Suspension maximum travel
Renegade 27 cm (10.6 in)
4 mmr2017-054
SUSPENSION
MX Z TNT
MX Z X
HPG Plus
Renegade X
Center Summit X
Renegade Adrenaline
HPG
Summit SP
Shock absorber type
MX Z TNT
HPG Plus
Summit X
MX Z X
Rear KYB PRO 36 EA
Renegade X
Renegade Adrenaline
HPG
Summit SP
Stroke limiter standard position 3
STEERING SYSTEM
MX Z
Aluminum with J-Hooks
Renegade
Handlebar
Aluminum with J-Hooks
Summit
and Grab handle
MX Z TNT
120 mm (4.7 in)
Renegade Adrenaline
Riser block height MX Z X
Adjustable - 120 mm (4.7 in)
Renegade X
MX Z TNT
Pilot 5.7
Renegade Adrenaline
Ski type MX Z X Pilot 5.7
Renegade X Pilot TS (optional)
Summit Pilot DS3
Toe-out 5 mm (.197 in)
WEIGHT AND DIMENSIONS

MX Z TNT 214 kg (471 lb)
MX Z X 215 kg (475 lb)
Renegade 220 kg (486 lb)
Mass (dry) Summit SP (154") 200 kg (441 lb)
Summit SP (165") 203 kg (448 lb)
Summit X (154") 197 kg (434 lb)
Summit X (165") 200 kg (441 lb)
MX Z 301 cm (118.5 in)
Renegade 311 cm (122.4 in)
Overall length
Summit (154") 3 422 mm (134.7 in)
Summit (165") 3 555 mm (140 in)
mmr2017-054 5
WEIGHT AND DIMENSIONS

MX Z
121.7 cm (47.9 in)
Overall width Renegade
Summit 1 057 mm (41.6 in)
MX Z
122.2 cm (48.1 in)
Overall height Renegade
Summit 1 379 mm (54.3 in)
MX Z
106 cm (41.7 in)
Ski stance Renegade
Summit 89.5 cm (35.2 in)
MATERIAL
Frame Aluminum
Side bottom pan, Front bottom pan, gauge support, gauge support cover,
side panel, rear console, windshield support, glove box cover and headlamp Polypropylene
surrounding
Rear lateral hood, front hood and top side panel Surlyn
6 mmr2017-054
Subsection XX (WIRING DIAGRAM INFORMATION)
WIRING DIAGRAM INFORMATION

GENERAL
WIRING DIAGRAM LOCATION
Wiring diagrams are found in the WIRING DIAGRAM BOOKLET.
WIRING DIAGRAM WITH COLORED LINES

The wiring diagram on the KNOWLEDGE CENTER is in color.
Color Definition
NOTE: To find the color of the wire on the vehicle skip to WIRE COLORS AND SIZES in this subsection.
The following colors refer to the color of the line drawn in the wiring diagram.
LINE COLOR LINE TYPE FUNCTION DEFINITION
Thick Unswitched 12 V Hot at all times
Red
Thin 3.3 and 5 V Sensor reference voltage
Orange Thick 55 - 60 V High voltage
Blue Thin Analog signal Variable voltage
Cyan Thin Digital signal Pulsed or constant digital (on/off)
Condition must be met to
Pink Thick 12V switched
activate circuit
Data communication between
Green Thin dotted Communication modules using a protocol (CAN,
LIN, & other)
Controls a circuit by providing an
Brown Thick Power control
on/off control to activate the circuit
Alternative current exiting
Yellow Thick AC Volts
the magneto
A ground that is in permanent
Thick Permanent ground
contact
Black
A ground that is controlled
Thin Module (analog/digital) ground
by a module
WIRING DIAGRAM CODES

The wiring diagrams use the following codes.
mmr2015-147-002_a
1. Wiring diagram index

2. Power condition
3. Voltage of a powered circuit
4. Connector code
5. Connector pin
mmr2017-055 1
Wiring Diagram Index

The wiring diagram is separated by rows (letters)
and columns (numbers).
mmr2015-147-006_a
FROM JT WH/RD (-B-2)
In following example, the 60V goes to the IGN_M

connector pin 3 in section (-B-4).
mmr2015-147-007_a
TO ING_M-3 (-B-4)
mmr2015-147-004_a
WIRING DIAGRAM INDEX WIRE COLORS AND SIZES

Power Condition (12V Circuits Only)
The wiring diagram indicates when a circuit is
powered:
– S: Switched. Certain conditions must be met;
– U: Unswitched (hot at all times).
Voltage of Powered Circuit

Voltage references are approximate for a powered
circuit in good condition. mmr2015-147-003_a
1. Wire color
INDICATED VOLTAGE APPROXIMATION 2. Wire gauge (AWG)
12V Battery voltage The first color of a wire is the main color, second
5V Regulated 4.95 - 5V color is the stripe.
60V Regulated 55 - 60V
Example: YE/BK is a YELLOW wire with a BLACK
stripe.
Connector Code COLOR CODE
The wire connects to the indicated connector. BG — BEIGE OG — ORANGE
See image at the beginning of this subsection. BK — BLACK RD — RED
Connector Pin BU — BLUE VT — VIOLET
The wire is the indicated pin in the connector. BN — BROWN WH — WHITE
NOTE: Could be identified by either a number or GN — GREEN YE — YELLOW
by a letter depending on the type of connector
GY — GRAY PK — PINK
used.
LT prefix means a "light" color. E.g: LT GN = Light
FOLLOWING A CIRCUIT green.
To follow a circuit, search the in section of the

wiring diagram shown in the wiring diagram index. SPLICES IN WIRING HARNESS
In this example, the 60V comes from JT WH/RD Splices in wiring harness are indicated on the
in section (-B-2). wiring diagram as follows.
NOTE: The arrow indicates the direction of the
power in the circuit.
2 mmr2017-055
mmr2012-057-010_a
1. JT: Splice indication

2. Spliced wire color
3. Splice number on the wire
Refer to SPLICE INFORMATION subsection for

more details.
mmr2017-055 3
1 2 3 4 5 6 7 8 9 10
2017 550 FAN COOLED

HEADLAMP 1
A A
HL1
A
GY/VT-16 LOW BEAM
B
BK-16 GROUND
C
GY-16 HIGH BEAM
ACCESSORY
(-H-3)
ACC
2
RD/WH-18
1
JT BK 1
BK-18
HEADLAMP 2
HL2
(-H-2)
A
GY/VT-16 LOW BEAM
B
JT BK 2 BK-16 GROUND
C
GY-16 HIGH BEAM
STARTER SWITCH
(-H-3)
JT GY/VT
JT GY
REGULATOR
REG OFF
JT RD/WH JT BK 1
B 5
RD/WH-14 RUN B
TAILLIGHT
4 (-B-6)
REGULATOR JT RD/YE
GENERATOR STARTER START TL
3 A (-B-2) 3
BK-14 GEN RD/WH-18 REG-4 REGULATOR RD/YE-14 RD/YE-16 12 VOLTS
2 YE RD 2 B 2
RD-18 RD-18 WH-18 BRAKE LAMP
1 1 C 1
BK-18 RD/BN-18 BK-16 GROUND
YE BK
D
(-H-2)
(-H-2)
RD/GN-18
MAGNETO
JT BK 3 JT BK 3
(-H-1)
JT BK 3
C C
TETHER SWITCH
TETHER
1
BK/YE-18
2
BK-18
LB
(-H-2)
START/RER SWITCH
JT BK 2
C
BG-20
D
RD/GY-20
E
ECM-3W GY/VT-16 HEATING LEVER SWITCH
3 F
BK/YE-18 RD/OG-16
2 G
RD/BN-18 BN-20
1 H
BK-18 BN/YE-20
D D
(-H-3)
STARTER SOLENOID
SD LA HEATING GRIP SWITCH
JT bk/ye
A
JT BK 2 A
RD/GN-18 RD/YE-20
STEERING HARNESS
B ECM-2W B
BK-18
2 SH3 OG/VT-20
13 C
TRIGGER COIL 9 O'CLOCK 1
RD/YE-18 RD/YE-20 OG/VT-20
(-H-1)
12 D
GY/VT-16 GY/VT-16 OG-20
BATTERY FUSE 11 E
FA : 30A
RD/YE-16 RD/OG-16 OG-20 DIMMER SWITCH
JT BK 3 10 F
ECM-4W GY-16 GY-16 GY-16
4
TRIGGER COIL 11 O'CLOCK

FA
3 8
BK-18 BG-20
RD-6
2
BG/BK-20 BUZZER
6
RD/WH-14
BK/YE-20 BK/YE-20
1
BG-20 RER
RD-14
5
BG/RD-20 RD/GY-20
JT RD/YE 4
E RD/YE-18 RD/OG-16 E
WH-18
3
WH-20
GD
1 BN
BN-20
2
BK-18 BK-20
2 BN/YE
BN/YE-20 THROTTLE LEVER WARMER
1
BK-18 BK-20
3 YE/BK
(-H-4)
(-H-4)
(-H-4)
BK-20
4 BK
BK-20
5 OG/VT
JT BK 1 JT BK 1 JT BK 1 OG/VT-20 RIGHT GRIP WARMER
6 OG
OG-20
MULTIFUNCTION GAUGE
7 BK
MG MG BK/YE-20
8 BK
BK-20
EMERGENCY ENGINE CUT OFF SWITCH
4 21
BG-20 BK/YE-20
HANDLEBAR GROUND
1 16
BG/BK-20 GY-20
BK-20
FUEL LEVEL SENSOR
FLS 20
1 15
BG/RD-20 GG
SIGNAL BU-20
F OG-20
1 OG F
2 12
GROUND BK/GN-20
OG/VT
2
OG/VT-20 LEFT GRIP WARMER
JT BK 3 BK
BK-20
SPEED SENSOR 4 BN
RD/OG-16
VSS WH-20
5 GY
BRAKE SWITCH
1 7
12 VOLTS RD/BK-20
COMMUNICATION
2 10
GROUND BK/RD-20 COM
3 6
SIGNAL GN/WH-20
8 5
RD/YE-20 RD/YE-18
OIL LEVEL SENSOR

3
OLS BK-18
B 14 23 2
LT BU-20 WH/BK-20
A 24 1
BK-20 WH/BG-20
11
(-H-2)
BK-20
G G
JT BK 3
(-H-2)
(-H-3)
LINE TYPES
55 / 60 VOLTS
JT BK 2 JT BK 1
12 VOLTS SWITCHED
12 VOLTS UNSWITCHED
5 OR 3.3 VOLTS
DIGITAL SIGNAL
Link
POWER CONTROL
ANALOG SIGNAL
COMMUNICATION
JT BK 3 JT BK 2 JT BK 1
A-D GROUND
BK-14 BK-14 BK-14
POWER GROUND
AC VOLTAGE
BK-14
BK-18
BK-20
BK-16
BK-16
BK-20
BK-18
BK-18
CHASSIS
H H
(-G-6)
(-G-4)
(-G-4)
(-C-2)
(-D-2)
(-C-6)
(-D-4)
(-B-3)
(-A-8)
(-B-8)
(-B-3)
(-B-8)
(-E-7)
(-E-7)
(-E-7)
GEN-1
HL1-B
REG-3
COM-3
TL-1
ACC-1
TETHER-2
ECM-3W-1
MG-11
SH3-1
SH3-2
SH3-8
SD-B
OLS-A
HL2-B
REF: 515177979 REV:

1 2 3 4 5 6 7 8 9 10
2017 550F SKANDIC WT
219100863-002
1 2 3 4 5 6 7 8 9 10
LINE TYPES
2017 REV-XS 600 ACE iTC

55 / 60 VOLTS
12 VOLTS SWITCHED
12 VOLTS UNSWITCHED
2017 REV-XS 900 ACE iTC

5 OR 3.3 VOLTS
F4 DIGITAL SIGNAL
A RY2 RY3 A
POWER CONTROL
Link
IGNITION COILS
RY3 RY2 RY1
F3
: ACCESSORY RELAY : LIGHTING RELAY HEADLAMP START BUTTON : MAIN RELAY FUEL INJECTORS ECM
BRAKE LIGHT CLOCK FUEL PUMP MULTIFUNCTION GAUGE
2017 REV-XS 1200 iTC

F A : 40A
ACCESSORY
F2 :20A
TAIL LIGHT
F5: 20A
COOLING FAN
F4: 15A
STARTER SOLENOID
F1: 10A
CAPS
F6: 10A
E-REVERSE
F3 :30A ANALOG SIGNAL
15 10 20
COMMUNICATION
F2 F6 A-D GROUND
MAIN FUSE
30
87
30
87
30
87
85
86
85
86
85
86
RY1
FUSEBOX
POWER GROUND
FA
FB
F1 F5
WITH : STARTER SOLENOID
SD AC VOLTAGE
B2
B1
A6
A5
B3
A4
A3
B4
A1
A2
B5
B6
D5
D6
D1
D2
D4
D3
C6
C5
C2
C1
C4
C3
B (-E-2)
CONTROL BY ECM OG/BK-18
RCM : REVERSE CONTROL MODULE

CTRL ECMB-L4
OG/WH-20
RD/WH-12
RD/WH-14
RD/WH-14
RD/WH-14
RD/WH-14
RD/WH-14
RD/WH-14
RD/WH-14
OG/GN-20
RD/GN-14
RD/GN-14
RD/GN-14
RD/GN-14
OG/BU-20
RD/BN-14
RD/BU-16
RD/OG-14
VT/BU-14
RD-12
RD/GY-18
VT/GN-14 VT/OG-14
A (-B-9)
12 VOLTS
RD/YE-14
VT/BU-18 S12V JT VT/BU
CFM : COOLING FAN MODULE JT RD/WH 1 JT RD/WH 2 JT RD/GN (-G-2)

RD/WH-12 RD/BU-16 S12V RCM-5
SD+
ACS : AIR CONTROLED SUSPENSION JT RD/GY
RD/GY-18
(-F-6)
S12V MG-8
(-D-2)
RD/GY-20 S12V RFID-D
B DRIVER B
HARNESS INTER CONNECTION
ACCESSORY
HIC
RD-6
(-D-6) ACC1 4
12 VOLTS FOR CAPS
BAT+ RD/WH-16 U12V COM-5
RD/YE-18
2
12 VOLTS
RD/GY-18
(-G-2) 3
RCM-6 S12V VT/OG-18 12 VOLTS FOR REVERSE RELAYS
1
BK-18 GROUND JT VT/BU 2
VT/BU-18 12 VOLTS FOR INJECTORS
(-C-3)
1
VT/BU-18 12 VOLTS FOR IGNITION COILS
(-B-3)
JT BK 3 VT/BU-18 S12V SD-A
JT RD/YE
PASSENGER (-E-2)
VT/BU-18 S12V FP-C
ACCESSORY
RECTIFIER/REGULATOR ACC2
2
REG RD/YE-18 12 VOLTS
1 1 JT RD/BN (-F-6)
RD/WH-12 BK-18 GROUND RD/BN-20 U12V MG-9
(-F-2)
RD/BN-16 U12V CFM-4
(-C-2)
3 JT BK 1 JT BK 2 JT BK 3 JT BK 4 (-F-7)
BK-12 BK-14 BK-14 BK-14 RD/BN-20 U12V SH1-H
JT BK 1
BK-16
BK-18
BK-18
BK-18
BK-18
BK-16
BK-16
BK-18
BK-18
BK-20
BK-18
BK-16
BK-16
BK-18
BK-18
C C
JT RD/OG (-E-8)
RD/OG-18 S12V HL-D
(-G-6) (-F-7)
RD/YE-16 S12V ACS-3 RD/OG-16 S12V SH1-G
GND
(-D-8)
(-H-2)
(-H-2)
(-H-2)
(-H-3)
(-H-7)
(-H-6)
(-G-7)
(-G-7)
(-B-6)
(-C-6)
(-E-6)
(-E-8)
(-E-8)
(-F-2)
(-G-6)
(-D-8)
BK-12 RD/OG-18 S12V TL-3
(-G-7)
RD/OG-20 S12V SH2-H
HL-A
TL-1
MG-11
SH2-A
HL-E
SH1-A
SH1-B
COM-3
RCM-1
ACS-1
CFM-1
ECMB-M3
ECMB-M2
ACC2-1
ACC1-1
ECMB-L1
CHASSIS
ECMB
J2
OG/WH-20
TAIL LIGHT
G1
OG/GN-20 TL
H2 (-C-9) 3 3
OG/BU-20 JT RD/OG TAIL LIGHT RD/OG-18 RD-18 12 VOLTS
M4 2 2
RD/GY-18 WH-18 WH-18 BRAKE
1 1
BK-18 BK-18 GROUND
RF IDENTIFICATION KEY
(-C-2)
D RFID D
(-B-9) D
JT RD/GY S12V RD/GY-20 12 VOLTS COMMUNICATION
B2 C
JT BK 1
WH/GY-20 DATA CONNECTOR
E4 B
BK/WH-20 CONTACT COM
F2 A 6
BK/GN-20 GROUND RD/GY-18 12 VOLTS
HEADLAMP
(-B-5) 5
JT RD/WH 1 U12V RD/WH-16 12 VOLTS HL LAMP A
A2 4 A
WH/VT-20 WH/VT-20 ECM POWER IN BK-16 BK-16 GROUND
3 B
BK-16 GROUND GY/OG-16 GY/OG-16 LOW BEAM
C2 JT WH/BK 2 C
WH/BK-20 WH/BK-20 CAN LO GY/WH-16 GY/WH-16 HIGH BEAM
C1 JT WH/BG 1 (-C-9) D 2
WH/BG-20 WH/BG-20 CAN HI JT RD/OG S12V RD/OG-18 RD/OG-18 12 VOLTS
E 1
LAMP B
BK-16 BK-16 GROUND
(-C-3)
L4 (-A-3)
BK-16 GROUND
OG/BK-18 SD CTRL SD-B AUXILIARY
(-C-4)
(-C-4)
GY/OG-16 LOW BEAM
JT BK 2
LIGHT
C3
GY/WH-16 HIGH BEAM
WH-20 JT BK 4 JT BK 4
C4
E BK/YE-20 E
D1
BG-20
FUEL PUMP
FP
(-F-6) D
JT BK/RD LEVEL (-) BK/RD-20 FUEL LEVEL GROUND
BRAKE SWITCH
(-C-9) C
JT VT/BU S12V VT/BU-18 12 VOLTS
4
RD-20 GY
MULTIFUNCTION GAUGE
87a
(-F-6) B
30
87
85
86
MG-15 LEVEL (+) BU-20 FUEL LEVEL SIGNAL

3
M1
BN/PK-18
A
CONTROL
MG WH-20 BN
LEFT GRIP WARMER
2
OG-20 OG
24
CAN HI WH/BG-20
RD/VT-18
RD/VT-18
STEERING HARNESS CONNECTOR 1

OG/YE-18
1
BK-20 BK
23
CAN LO WH/BK-20 SH1
RD
COOLING FAN MODULE

16 JT GY/WH M
CFM HIGH BEAM GY/WH-20 GY/WH-16 GY/WH-17
(-C-9) 4 JT RD/VT JT WH L HANDLEBAR GROUND
JT RD/BN S12V RD/BN-16 RD/VT-18 WH-18 WH-20
BK-20
FAN HEATED LEVER OUTPUT 4
OG/RD-20
K
OG/RD-20 RIGHT GRIP WARMER
J4 2 B 5 J JT OG
OG/YE-20 OG/YE-18 SWITCHED 12 VOLTS HEATED GRIPS OUTPUT OG-20 OG-20
F BK-16
1
BK-18
A
GROUND JT RD/BN U12V
(-C-9)
RD/BN-20
H
RD/VT-20 OG-20
1
OG F
8 (-B-9) (-C-9) G JT RD 2
S12V RD/GY-18 S12V JT RD/GY JT RD/OG S12V RD/OG-16 RD-17 OG/RD-20 BN
(-C-3)
THROTTLE LEVER WARMER

9 (-C-9) F 3
CLOCK (U12V) RD/BN-20 U12V JT RD/BN GY/OG-16 GY/OG-17 BK-20 BK
THROTTLE ACCELERATOR SENSOR 15 (-E-2) E 4
JT BK 3 FUEL LEVEL SIGNAL BU-20 LEVEL + FP-B BK/YE-20 BK/YE-20 BK-20 YE/BK
TAS BK/RD-20
(-E-2)
BK/BU-20
5
BK
LEVEL - FP-D
J3 A
VT/BN-20 5 VOLTS 6
C
BG-20 BG-20 BK/YE-20 BK
B3 B
BK/BN-20 GROUND VEHICULE SPEED SENSOR JT BK/BU
B
BK-18 BK/BU-20 EMERGENCY ENGINE CUT OFF SWITCH
A3 C
WH/BN-20 SIGNAL 2 VSS BK-18
A
BK-20
JT BK
K1 D REVERSE RELAY FORWARD RELAY 7 1
VT/BU-20 5 VOLTS 12 VOLTS RD/BK-20 12 VOLTS
(-C-4)
(-C-4)
JT BK/RD DIMMER SWITCH
K3 E 12 2
BK/BU-20 GROUND GROUND BK/RD-20 BK/RD-20 GROUND
GY/WH-17
E1 F 6 3
WH/BU-20 SIGNAL 1 SPEED SIGNAL INPUT GN/WH-20 SIGNAL JT BK 4 JT BK 4
GY/OG-17
87a
87a
85
86
30
87
85
86
30
87
RD-17
ECO MODE SWITCH
ECO
87a
START / RER SWITCH

AIR CONTROLLED SUSPENSION MODULE
D3 A
YE-20 UP ACS BK/BU-20
BK/BU-18
BG/RD-18
G G
VT/OG-18
VT/OG-18
RD/VT-18
RD/VT-18
BG/YE-18
RD/YE-18
A1 B (-C-6) 3
BK-18
BK-18
BK/GY-20 GROUND JT RD/YE S12V RD/YE-16 12 VOLTS RD/VT-20 BACK LIGHT

REVERSE MOTOR
E3 C 14 2
YE/RD-20 DOWN RV ACS WH/OG-20 DATA BG-20
1 1
RD/YE-18 BK-16 GROUND
REVERSE CONTROL MODULE
(-C-2)
2
RCM BK/BU-18
HIC-3 S12V
(-B-9)
VT/OG-18
6
VT/OG-18
JT VT/OG SH2
(-C-9) H
JT RD/VT JT BK 1 JT RD/OG S12V RD/OG-20 RD/OG-20
(-B-9) 5
FB-C3 S12V RD/BU-16 RD/VT-18
18 G
SET YE/GN-20 YE/GN-20
F1 4
BG/RD-20 BG/RD-18 GRIP UP
19 F
GRIP UP OG/WH-20 OG/WH-20 BACK LIGHT
L3 3
BG/YE-18 BG/YE-18 GRIP DOWN SET
21 E
GRIP DOWN OG/VT-20 OG/VT-20
BACK LIGHT
LEVER UP MODE
20 D
JT BK LEVER UP BN-20 BN-20
REVERSE POSITION SWITCH BK-16
1
BK-18 LEVER DOWN
RPS2- LEVER DOWN 22
BN/YE-20
C
BN/YE-20
(-C-3)
H3
GN/BG-20
10 B
MODE YE/BN-20 YE/BN-20
H1
BK/OG-20
11 A
JT BK 2 BK-18 BK-20 BK-20
RPS1-
(-C-3)
(-C-3)
L1
BK-18
H H
M2
BK-18
M3
JT BK 4 JT BK 3
BK-18
(-C-2)
(-C-2)
(-C-2)
219100863-003 REF: 515177990 REV:

1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
LINE TYPES
2017 TUNDRA 600 ACE

55 / 60 VOLTS
12 VOLTS SWITCHED
12 VOLTS UNSWITCHED
5 OR 3.3 VOLTS
F4 DIGITAL SIGNAL
A RY2 RY3 A
IGNITION COILS
POWER CONTROL
Link
RY3 RY2 RY1
F3
: ACCESSORY RELAY : LIGHTING RELAY HEADLAMP START BUTTON : MAIN RELAY FUEL INJECTORS ECM
BRAKE LIGHT CLOCK FUEL PUMP MULTIFUNCTION GAUGE
F A : 40A
ACCESSORY
F2 :20A
TAIL LIGHT
F5: 20A
COOLING FAN
F4: 15A
STARTER SOLENOID
F1: 10A
CAPS
F6: 10A ANALOG SIGNAL
15 10 20
COMMUNICATION
F2 F6 A-D GROUND
MAIN FUSE
30
87
30
87
30
87
85
86
85
86
85
86
RY1
FUSEBOX
POWER GROUND
FA
FB
STARTER SOLENOID F1 F5
SD AC VOLTAGE
B2
B1
A6
A5
B3
A4
A3
B4
A1
A2
B5
B6
D5
D6
D1
D2
D4
D3
C6
C5
C2
C1
B (-E-2)
CONTROL BY ECM OG/BK-18 CTRL ECMB-L4
OG/WH-20
RD/WH-12
RD/WH-14
RD/WH-14
RD/WH-14
RD/WH-14
RD/WH-14
RD/WH-14
RD/WH-14
OG/GN-20
RD/GN-14
RD/GN-14
RD/GN-14
OG/BU-20
RD/BN-14
RD/OG-14
VT/BU-14
RD-12
RD/GY-18
VT/GN-14 VT/OG-14
A (-B-9)
12 VOLTS
RD/YE-14
VT/BU-18 S12V JT VT/BU
JT RD/WH 1 JT RD/WH 2 JT RD/GN

RD/WH-12
SD+
JT RD/GY (-F-6)
RD/GY-18 S12V MG-8
(-D-2)
RD/GY-20 S12V RFID-D
B DRIVER B
HARNESS INTER CONNECTION
ACCESSORY
HIC
RD-6
(-D-6) ACC1 4
12 VOLTS FOR CAPS
BAT+ RD/WH-16 S12V COM-5
RD/YE-18
2
12 VOLTS
RD/GY-18
1
BK-18 GROUND JT VT/BU 2
VT/BU-18 12 VOLTS FOR INJECTORS
(-C-3)
1
VT/BU-18 12 VOLTS FOR IGNITION COILS
(-B-3)
JT BK 3 VT/BU-18 S12V SD-A
JT RD/YE
(-E-2)
VT/BU-18 S12V FP-C
RD/YE-16 S12V
RECTIFIER/REGULATOR
REG
1 JT RD/BN (-F-6)
RD/WH-12 RD/BN-20 U12V MG-9
(-F-2)
RD/BN-16 U12V CFM-4
3 JT BK 1 JT BK 2 JT BK 3 JT BK 4 (-F-7)
BK-12 BK-14 BK-14 BK-14 RD/BN-20 U12V SH1-H
BK-16
BK-18
BK-18
BK-18
BK-16
BK-16
BK-18
BK-18
BK-20
BK-18
BK-16
BK-18
BK-18
C C
JT RD/OG (-F-7)
RD/OG-16 S12V SH1-G
(-D-8)
GND RD/OG-18 S12V TL-3
(-D-8)
(-H-2)
(-H-2)
(-H-2)
(-H-7)
(-H-6)
(-G-7)
(-G-7)
(-B-6)
(-E-6)
(-E-8)
(-E-8)
(-F-2)
(-G-7)
BK-12 RD/OG-20 S12V SH2-H
HL-A
TL-1
MG-11
SH2-A
HL-E
SH1-A
SH1-B
COM-3
CFM-1
ECMB-M3
ECMB-M2
ECMB-L1
ACC1-1
CHASSIS
ECMB
J2
OG/WH-20
TAIL LIGHT
G1
OG/GN-20 TL
H2 (-C-9) 3
OG/BU-20 JT RD/OG TAIL LIGHT RD/OG-18 12 VOLTS
M4 2
RD/GY-18 WH-18 BRAKE
1
BK-18 GROUND
(-C-2)
D RFID D
(-B-9) D
JT RD/GY S12V RD/GY-20 12 VOLTS COMMUNICATION
B2 C
JT BK 1
WH/GY-20 DATA CONNECTOR
E4 B HL1
BK/WH-20 CONTACT COM JT GY/OG A
LOW BEAM
GY/OG-16
F2 A 6
BK/GN-20 GROUND RD/GY-18 12 VOLTS
B
BK-16 GROUND
(-B-5) 5
JT RD/WH 1 U12V RD/WH-16 12 VOLTS JT GY/WH C
GY/WH-16 HIGH BEAM
A2 4
WH/VT-20 WH/VT-20 ECM POWER IN
3
BK-16 GROUND HL2
C2 JT WH/BK 2 A
WH/BK-20 WH/BK-20 CAN LO GY/OG-16 LOW BEAM
C1 JT WH/BG 1 B
WH/BG-20 WH/BG-20 CAN HI BK-16 GROUND
C
GY/WH-16 HIGH BEAM
(-C-3)
L4 (-A-3)
OG/BK-18 SD CTRL SD-B
(-C-4)
(-C-4)
JT BK 2
C3
WH-20 JT BK 4 JT BK 4
C4
E BK/YE-20 E
D1
BG-20
FUEL PUMP
FP
(-F-6) D
JT BK/RD LEVEL (-) BK/RD-20 FUEL LEVEL GROUND
BRAKE SWITCH
(-C-9) C
JT VT/BU S12V VT/BU-18 12 VOLTS
4
RD-20 GY
MULTIFUNCTION GAUGE
87a
(-F-6) B
30
87
85
86
MG-15 LEVEL (+) BU-20 FUEL LEVEL SIGNAL

3
M1
BN/PK-18
A
CONTROL
MG WH-20 BN
LEFT GRIP WARMER
2
OG-20 OG
24
CAN HI WH/BG-20
RD/VT-18
RD/VT-18

OG/YE-18
1
BK-20 BK
23
CAN LO WH/BK-20 SH1
RD
COOLING FAN MODULE

16 JT GY/WH M
CFM HIGH BEAM GY/WH-20 GY/WH-16 GY/WH-16
(-C-9) 4 JT RD/VT JT WH L HANDLEBAR GROUND
JT RD/BN S12V RD/BN-16 RD/VT-18 WH-18 WH-20
BK-20
FAN HEATED LEVER OUTPUT 4
OG/RD-20 OG/RD-20
K
J4 2 B 5 J JT OG
OG/YE-20 OG/YE-18 SWITCHED 12 VOLTS HEATED GRIPS OUTPUT OG-20 OG-20 OG-20
F BK-16
1
BK-18
A
GROUND JT RD/BN U12V
(-C-9)
RD/BN-20
H
RD/VT-20 OG-20
1
OG F
8 (-B-9) (-C-9) G JT RD 2
S12V RD/GY-18 S12V JT RD/GY JT RD/OG S12V RD/OG-16 RD-16 OG/RD-20 BN
(-C-3)

9 (-C-9) F 3
CLOCK (U12V) RD/BN-20 U12V JT RD/BN GY/OG-16 GY/OG-16 BK-20 BK
THROTTLE ACCELERATOR SENSOR E 4
JT BK 3 BK/YE-20 BK/YE-20 BK-20 YE/BK
TAS BK/BU-20
5
BK
J3 A
VT/BN-20 5 VOLTS (-E-2) 6
15 C
FUEL LEVEL SIGNAL BU-20 LEVEL + FP-B BG-20 BG-20 BK/YE-20 BK
B3 B
BK/BN-20 GROUND (-E-2) JT BK/BU
B
BK/RD-20 LEVEL - FP-D BK-18 BK/BU-20 EMERGENCY ENGINE CUT OFF SWITCH
A3 C
WH/BN-20 SIGNAL 2 JT BK
A
BK-18 BK-20
K1 D
VT/BU-20 5 VOLTS
(-C-4)
(-C-4)
DIMMER SWITCH
K3 E
BK/BU-20 GROUND
GY/WH-16
E1 F
WH/BU-20 SIGNAL 1 JT BK 4 JT BK 4
GY/OG-16
VEHICULE SPEED SENSOR
RD-16
VSS
7 1 START / RER SWITCH
12 VOLTS RD/BK-20 12 VOLTS
JT BK/RD BK/BU-20
12 2
G ECO MODE SWITCH GROUND BK/RD-20 BK/RD-20 GROUND G
RD/VT-20 BACK LIGHT
6 3
ECO SPEED SIGNAL INPUT GN/WH-20 SIGNAL
BG-20
D3 A
YE-20 UP
A1 B
BK/GY-20 GROUND STEERING HARNESS CONNECTOR 2
E3 C
YE/RD-20 DOWN SH2
(-C-9) H
JT RD/OG S12V RD/OG-20 RD/OG-20
18 G
GRIP UP
19 F
GRIP UP OG/WH-20 OG/WH-20 BACK LIGHT
GRIP DOWN SET
REVERSE POSITION SWITCH GRIP DOWN 21
OG/VT-20
E
OG/VT-20
RPS2-
BACK LIGHT
LEVER UP MODE
H3 20 D
GN/BG-20 LEVER UP BN-20 BN-20
LEVER DOWN
H1 22 C
BK/OG-20 LEVER DOWN BN/YE-20 BN/YE-20
RPS1- MODE 10
YE/BN-20
B
YE/BN-20
11 A
BK-18 BK-20 BK-20
(-C-3)
(-C-3)
L1
BK-18
H H
M2
BK-18
M3
JT BK 4 JT BK 3
BK-18
(-C-2)
(-C-2)
(-C-2)
219100863-004 REF: 515177991 REV:

1 2 3 4 5 6 7 8 9 10
2017 Expedition LE 900 ACE
2017 Expedition SE 900 ACE
2017 Skandic SWT 600 ACE
2017 Skandic SWT 900 ACE
2017 Skandic WT 900 ACE
219001869-005
1 2 3 4 5 6 7 8 9 10
2017 600 CARB. HEADLAMP 1

HL1
A
GY/VT-16 LOW BEAM
B
R1 : HEADLAMP/ACCESSORY BK-16 GROUND
A GY-16
C
HIGH BEAM
A
DPM VALVE
(-H-2)
ACCESSORY
HEADLAMP TAIL LIGHT ACCESSORY
FD : 15 A FC : 20A
ACC
87a
30
87
85
86
2
RD/YE-18 12 VOLTS JT BK 1
R1
1
BK-18 GROUND
FD
FC
HEADLAMP 2
85
86
30
87
(-H-2)
HL2
B
OG/WH-20
RD/BU-14
RD/BU-14
RD/BN-14
A
GY/VT-16 LOW BEAM
RD/BN-14
RD/BN-14
RD/YE-20
RD/YE-14
JT BK 1 B
BK-16 GROUND
C
GY-16 HIGH BEAM
(-H-2)
JT RD/BN
(-F-6)
RD/YE-16 S12V COM-6 JT BK 1
RD/YE-16
(-F-6) TL
S12V COM-5 (-B-5) 3
(-B-8)
JT RD/YE S12V RD/YE-16 12 VOLTS
RD/YE-16 S12V TL-3
2
WH-18 BRAKE
B B
JT RD/YE
1
BK-16 GROUND
(-H-2)
(-D-7)
RD/YE-18 S12V SH3-13
(-E-7)
JT RD/BU 1
RD/YE-18 S12V SH3-4 JT BK 2
(-G-7)
RD/YE-18 S12V MG-8
(-D-7)
RD/YE-20 S12V SH3-11
(-E-7)
RD/GY-20 U12V SH3-5
R2 : CHARGING RELAY
(-E-7)
C BG-20 START/RER SH3-8 C
OG/BK-20
BG-20
87a
87
30
86
85
RELAY
R2
STARTER SOLENOID
ECM ECM
87
30
86
85
LB
A
JT GY/VT
JT GY
SD
OG/WH-18
BATTERY FUSE START/RER BUTTON FUSE

RD/WH-14
RD/BU-14
FA: 30A FB: 5A

START/RER SWITCH
CONFIGURATION CONNECTOR ENGINE CONTROL MODULE IGN-(+)
14 33
CFG RD/BU-18 WH/BU-18
C
BG-20
1 26
JT RD/WH
OG/BK-20 OG/BK-20 OG/BK-20

IGN-(-)
FA
FB
D
JT BG RD/GY-20
2 8 15
BG-20 BG-20 BG-20 BK/BU-18
A
E
SD+ 3 JT RD/GY 34
GY/VT-16 HEATING LEVER SWITCH
RD-14 RD/WH-14 RD/WH-14 RD/GY-18 RD/GY-18 RD/GY-20
F
JT OG/WH RD/OG-16
4 28
OG/WH-18 OG/WH-20 OG/WH-20
G
BN-20
RD-6
H
BN/YE-20
6
RD/BU-16 RD/BU-16
JT RD/BU 7
RD/BU-16 RD/BU-16
BAT+ LA HEATING GRIP SWITCH
ENGINE
D RD/YE-20
A D
STEERING HARNESS
B
SH3 OG/VT-20
(-B-5) 13 C
JT RD/YE S12V RD/YE-18 RD/YE-20 OG/VT-20
12 D
GY/VT-16 GY/VT-16 OG-20
(-B-5) 11 E
FD-B S12V RD/YE-20 RD/OG-16 OG-20 DIMMER SWITCH
10 F
GY-16 GY-16 GY-16
JT BG (-C-5) 8
START/RER BG-20 BG-20
23 6
BK/YE-20 BK/YE-20
ENGINE CHASSIS CHASSIS (-C-5) 5
JT RD/GY S12V RD/GY-20 RD/GY-20
CRANKSHAFT POSITION SENSOR (-B-5) 4
JT RD/YE S12V RD/YE-18 RD/OG-16
CPS 3 GD
WH-18 WH-20
4 35 1 BN
TRIGGER COIL 1 SIGNAL (8 O'CLOCK) BU/YE-18 BN-20
2
BK-20 BK-20
3 36 2 BN/YE
E TRIGGER COIL 2 SIGNAL (10 O'CLOCK) GN/YE-18 BN/YE-20 THROTTLE LEVER WARMER E
1
BK-20 BK-20
2 18 3 YE/BK
TRIGGER COIL 2 GROUND (10 O'CLOCK)
(-H-3)
(-H-3)
GY/YE-18 BK-20
1 17 4 BK
TRIGGER COIL 1 GROUND (8 O'CLOCK) WH/YE-18 BK-20
5 OG/VT
JT BK 1 JT BK 1 OG/VT-20 RIGHT GRIP WARMER
6 OG
DIGITALLY ENCODED OG-20
SECURITY SYSTEM BK/YE-20

7 BK
DESS BK-20
8 BK
DATA 3 WH/GY-20 24
JT BK/GN
2 1
GROUND BK/GN-20 BK/GN-20 HANDLEBAR GROUND
CONTACT 1 BK/WH-20 6 GND

BK-20
GG
1 OG
OG-20
COOLANT TEMP. SENSOR 2 OG/VT
OG/VT-20 LEFT GRIP WARMER
CTS COMMUNICATION JT BK
BK-20
3 BK
F GROUND 2 F
BK/GN-18 COM 4 BN
RD/OG-16
1 21 (-B-5) 6
SIGNAL BG/OG-18 JT RD/YE S12V RD/YE-16 SWITCHED 12 VOLTS GY
5
(-B-5) WH-20 BRAKE SWITCH
5
JT RD/YE S12V RD/YE-16 SWITCHED 12 VOLTS
(-G-2) 4
JT RD/BU 2 S12V RD/BU-16 UNSWITCHED 12 VOLTS
3
BK-16 GROUND
JT WH/BK 2
25 WH/BK-20 WH/BK-20 CAN LO
JT WH/BG 1
7 WH/BG-20 WH/BG-20 CAN HI
OIL LEVEL SENSOR
(-H-2)
OLS
A 27
SIGNAL LT BU-20
B
GROUND BK-20 JT BK 2 MG
16 16
BK-18
(-B-5) 8
(-H-2)
(-H-3)
JT RD/YE S12V RD/YE-20
23
JT BK 2 JT BK 1 WH/BK-20
G 24
G
WH/BG-20
RECTIFIER / REGULATOR
LINE TYPES
REG 55 / 60 VOLTS
3 JT RD/BU 2
RD/BU-14
FUEL LEVEL SENSOR 12 VOLTS SWITCHED
FLS 12 VOLTS UNSWITCHED
5 (-F-6) 1 15
BK-14 RD/BU-16 U12V COM-4 SIGNAL BU-20 5 OR 3.3 VOLTS
2
GROUND BK/RD-20 DIGITAL SIGNAL
POWER CONTROL
Link
ANALOG SIGNAL
SPEED SENSOR
COMMUNICATION
GND VSS A-D GROUND
JT BK 2 JT BK 1 1 7
BK-14 12 VOLTS RD/BK-20 POWER GROUND
2 JT BK/RD 12
GROUND BK/RD-20 BK/RD-20 AC VOLTAGE
BK-16
BK-20
BK-16
BK-18
BK-16
BK-16
BK-20
BK-20
BK-20
BK-18
3 6
CHASSIS SIGNAL GN/WH-20
H BK-20
11 H
(-G-3)
(-G-6)
(-G-4)
(-H-7)
(-A-5)
(-B-7)
(-B-8)
(-A-7)
(-E-7)
(-E-7)
(-H-3)
ACC-1
TL-1
COM-3
HL2-B
SH3-2
SH3-1
MG-11
ECM-16
OLS-B
HL1-B
JT BK 1
REF: 515177981 REV:

1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
2017 600RS
LINE TYPES
55 / 60 VOLTS
A 12 VOLTS SWITCHED A
12 VOLTS UNSWITCHED
5 OR 3.3 VOLTS
ACCESSORY
87a
DIGITAL SIGNAL
30
87
85
86
LIGHTING
F1 :20A
R1
Link
ACCESSORY POWER CONTROL
85
86
30
87
ACC ANALOG SIGNAL
2
RD/YE-18 COMMUNICATION
F1
1
A-D GROUND
B
BK-18
OG/WH-18
RD/WH-14
RD/BU-14
RD/BU-14
POWER GROUND
RD/WH-14
RD/YE-14
AC VOLTAGE
(-G-4)
JT RD/WH JT RD/YE
JT BK 2
RD/YE-16
RD/YE-18
B HL LAMP A B
(-E-5)
(-F-5)
E
BK-16 BK-16 GROUND
S12V
S12V
D
28
RD/YE-18 GY/OG-16 LOW BEAM
OG/WH-18
C
14
GY/WH-16 GY/WH-16 HIGH BEAM
RD/BU-18
MG-8
COM-5
B
GY/OG-16 RD/OG-18 12 VOLTS
A
LAMP B
BK-16 BK-16 GROUND
EMERGENCY ENGINE STOP SWITCH BK-16 GROUND
KILL AUXILIARY
JT BK/YE GY/OG-16 LOW BEAM
2
BK/YE-18 BK/YE-18
23
ENGINE CONTROL MODULE LIGHT
(-G-4)
(-G-4)
1
BK-18
POWERJET 1 GY/WH-16 HIGH BEAM
ECM RD/WH-18
2
(-G-4)
13 1
JT BK 1 JT BK 1
BN/BU-18
JT BK 2
ENGINE CUT-OFF SWITCH
TETHER
2
BK/YE-18 POWERJET 2 TL
1 2 3 3
C BK-18 RD/WH-18 RD/YE-18 RD-18 12 VOLTS C
(-G-4)
29 1 2 2
BN/OG-18 WH-18 WH-18 BRAKE
1 1
BK-18 BK-18 GROUND
JT BK 2
THROTTLE POSITION SENSOR
TPS
(-G-3)
1 22
VT/BN-20
2 4
BG/BN-20 JT BK 3
3 JT BK/GN 1
BK/GN-20 BK/GN-20
BRAKE SWITCH
6
BK/GN-20
4
RD-20 GY
IGN-(+)
EXHAUST TEMPERATURE SENSOR 33 3
WH/BU-18 SH1 WH-20 BN
EGTS LEFT GRIP WARMER
JT RD/BU
2
OG-20 OG
t° A
BK/GN-20 IGN-(-)
15 1
BK/BU-18 BK-20 BK
B 5
BG/GY-20
JT GY/WH M
GY/WH-16 GY/WH-17
HANDLEBAR GROUND
COOLANT TEMPERATURE SENSOR WH-18
L
WH-20
D CTS BK-20 D
K RIGHT GRIP WARMER
OG/RD-20 OG/RD-20
t° 1 21
BG/OG-18 JT OG
J
OG-20 OG-20
2
BK/GN-18
10 H 1
BG-20 BG-20 RD/VT-20 OG-20 OG
JT RD
AIR TEMP. SENSOR RD/YE-16
G
RD-17 OG/RD-20
2
BN
ATS GY/OG-16
F
GY/OG-17 BK-20
3
BK
t° 2
BK/GN-20
4
YE/BK
RES
BK/YE-20 BK-20
1 19
VT/WH-20
5
BK/BU-20
COMMUNICATION
C 6
COM BK-18 BG-20 BK/YE-20
B JT BK/BU
BK-18 BK/BU-20
(-B-6) 5 A JT BK
JT RD/YE S12V RD/YE-16 BK-18 BK-20
(-G-4)
(-F-3) 4
JT RD/BU S12V RD/BU-18 DIMMER SWITCH
3
BK-16 JT BK 2 GY/WH-17
CRANKSHAFT POSITION SENSOR
(-G-5)
(-G-5)
(-G-5)
25 JT WH/BK 2
WH/BK-20 WH/BK-20 CAN LO GY/OG-17
CPS 7 JT WH/BG 1
CAN HI
E 1 35
WH/BG-20 WH/BG-20 RD-17 E
BU/YE-18 JT BK 1 JT BK 1 JT BK 1
START / RER SWITCH
(-G-3)
2 17
WH/YE-18
BK/BU-20
JT BK 2 RD/VT-20
BG-20
16
BK-18
(-G-4)
JT BK 2
MG MG
23 16
WH/BK-20 GY/WH-20
(-E-5)
RD/BU-18 S12V COM-4
24
WH/BG-20
F 4
OG/RD-20 F
RECTIFIER / REGULATOR
(-B-6) 8 5
REG FUEL LEVEL SENSOR
JT RD/YE S12V RD/YE-18 OG-20
1
FLS
2 1 15
BU-20
3 2
RD/BU-14 BK/RD-20
4
5
BK-14 SPEED SENSOR
VSS
PW2 PW1 1 7 SH2
RD/BK-20
2 2
RD/BU-14 JT BK/RD
2 12
BK/RD-20 BK/RD-20
1 1
BK-14
3 6 19 F
GN/WH-20 GRIP UP OG/WH-20
21 E
GRIP DOWN OG/YE-20
11 20 D
BK-18 LEVER UP BN-20
22 C
LEVER DOWN BN/YE-20
G G
JT BK 3 JT BK 2 JT BK 1 A
BK-14 BK-14 BK-14 BK-20
GND
BK-18
BK-16
BK-18
BK-18
BK-18
BK-20
BK-18
BK-16
BK-16
BK-18
BK-18
BK-18
(-B-7)
(-C-7)
(-C-3)
(-C-3)
(-C-7)
(-C-7)
(-E-5)
(-E-6)
(-E-3)
(-E-7)
(-E-7)
(-E-7)
HL-A
TL-1
HL-E
SH1-A
SH1-B
COM-3
KILL-1
SH1-C
ACC-1
RES-B
ECM-16
TETHER-1
H H
219100863-007 REF: 515177994 REV:

1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
2017 REV-XS, REV-XM 600 HO E-TEC LINE TYPES

55 / 60 VOLTS
12 VOLTS SWITCHED
12 VOLTS UNSWITCHED
A 5 OR 3.3 VOLTS A
J1A DIGITAL SIGNAL
ACCESSORY POWER CONTROL
ACC 1
15
RD/OG-20
Link
ANALOG SIGNAL
2
RD/OG-18 12 volts COMMUNICATION
1 RF IDENTIFICATION KEY
BK-18 Ground A-D GROUND
RFID
POWER GROUND
(-H-2)
D
RD/OG-20 12 VOLTS
11 C
AC VOLTAGE
WH/GY-20 DATA
JT BK 3 23 B
BK/WH-20 CONTACT
5 A
BK/GN-20 GROUND
30
WH-20
9
BK/YE-20
28
RD/GN-18
B B
CRANK POSITION SENSOR COMMUNICATION
RD/OG-18
(-C-8) CPS CONNECTOR
S12V HL-D
7 2
(-F-7)
WH/YE-18 GROUND COM
RD/OG-16 S12V SH1-G
6 1 (-E-3) 6
(-G-7)
BU/YE-18 SIGNAL JT RD/OG 2 S12V RD/OG-16 12 VOLTS
RD/OG-20 S12V SH2-H (-E-3) 5
JT RD/OG 2 S12V RD/OG-16 12 VOLTS
4
RD/BU-18 ECM POWER IN
JT RD/OG 1
3
BK-16 GROUND
HEADLAMP
13 JT WH/BK 2
WH/BK-20 WH/BK-20 CAN LO HL LAMP A
14 JT WH/BG 1 A
(-E-6)
WH/BG-20 WH/BG-20 CAN HI BK-16 BK-16 GROUND
RD/OG-18 S12V MG-8
B
(-H-2)
GY/OG-16 GY/OG-16 LOW BEAM
JT RD/GN
KNOCK SENSOR
C
J1B-9
KS GY/WH-16 GY/WH-16 HIGH BEAM

RD/OG-18
33 2 (-B-3) D
YE/BU-20 SIGNAL JT BK 3 JT RD/OG 1 S12V RD/OG-18 RD/OG-18 12 VOLTS
CONTROL
12 VOLTS
C 34 1 E LAMP B C
BG/BU-20 GROUND BK-16 BK-16 GROUND
BK-16 GROUND
(-E-4)
(-D-7)
AUXILIARY
(-H-5)
(-H-5)
GY/OG-16 LOW BEAM
LIGHT
THROTTLE POSITION SENSOR GY/WH-16 HIGH BEAM
TPS
ACC 2 1
WH/BN-20
3
SIGNAL
JT BK 1 JT BK 1
2
RD/GN-18
OG/BK-18
RD/OG-18
2
BK/OG-20 GROUND
1
BK-18 JT VT/BN
STARTER RELAY
10 1
VT/BN-20 VT/BN-20 5 VOLTS (-C-1)
SD-A SOLENOID RD/GN-18
B
3D-RAVE POSITION SENSOR

SD
(-H-2)
ACS ERF
CONTROL BY ECM
12 VOLTS FROM START BUTTON
FA : 25A FB: 5A FC: 15 A 3

VT/BN-20 5 VOLTS
BATTERY CHARGING
START/RER CLOCK
JT BK 3 18 2
WH/BU-20 SIGNAL
1
BK/OG-20 GROUND
FC
FA
FB
(-F-4) AIR TEMPERATURE SENSOR

A
RD/OG-20 S12V ER-2

TAIL LIGHT
D (-D-8) ATS D
RD/WH-14
RD/WH-14
TL-3 TL
RD/VT-20
S12V
20 2
SIGNAL
RD/OG-16
VT/WH-20 VT/WH-20
RD/YE-16
RD-14
(-D-3) 3 B
JT BK/OG JT RD/OG 2 S12V RD/OG-16 RD-18 12 VOLTS
27 1
BK/OG-20 BK/OG-20 GROUND
2 C
WH-18 WH-18 BRAKE
JT RD/VT
COOLANT TEMPERATURE SENSOR 1 A

BK-16 BK-18 GROUND
MULTIFUNCTION GAUGE
(-F-6)
CTS
MG
JT RD/OG 2
2
S12V
GROUND
(-H-2)
BK/OG-18
19 1 24
BG/OG-18 SIGNAL WH/BG-20
RD/VT-20
RD/VT-20
23 JT BK 3
WH/BK-20
ACS-3
EXHAUST TEMPERATURE SENSOR

ENGINE (-B-6)
(-E-7)
(-E-6)
RD/OG-16 S12V COM-5 EGTS

(-B-6) 12 2
U12V
U12V
RD/OG-16 S12V COM-6 J2 BG/GY-20 BG/GY-20 SIGNAL (-C-3)

8
RD/OG-18 S12V JT RD/OG 1
1
BK/OG-20 GROUND (-E-2)
15 9
RD/OG-18 RD/VT-20 U12V JT RD/VT BRAKE SWITCH
SH1-H
MG-9
RD/OG-18
16 OIL LEVEL SENSOR RD-20
4
GY
OLS 3
WH-20 BN
29 A LEFT GRIP WARMER
LT BU-20 LT BU-20 CONTACT
6 2
RD/WH-18 OG-20 OG
B
E JT RD/WH BK/OG-20 GROUND STEERING HARNESS CONNECTOR 1 E
14 1
RD/WH-18 BK-20 BK
SH1
16 JT GY/WH M
BK/OG-18 GY/WH-20 GY/WH-16 GY/WH-16
MAGNETO
4 JT WH L HANDLEBAR GROUND
MO BG/BK-18 WH-18 WH-20
BK-20
CHASSIS 6
YE-16
1 4
OG/RD-20
K
MAGNETO
J1B JT OG
PC1
5 3 5 J
OG-16 OG-20 OG-20
4 2 (-E-2) H 1
BN-16 JT RD/VT U12V RD/VT-20 RD/VT-20 OG-20 OG
9 (-C-1)
PC2
OG/BK-18 SOLENOID SD-B JT RD
3 10 OIL PUMP (-B-3) G 2
BN/WH-16 JT RD/OG 1 S12V RD/OG-16 RD-16 OG/RD-20 BN
2
OG/WH-16
11 OP GY/OG-16
F
GY/OG-16 BK-20
3
(-G-2) BK
B
JT WH/RD +55V WH/RD-18 55 VOLTS 4
1200W 1 9 E
YE/WH-16 BK/YE-20 BK/YE-20 BK-20 YE/BK
23 A 15 (-F-2)
GN/YE-18 CONTROL BU-20 LEVEL + FP-B
5
BK/BU-20 BK
(-F-2)
BK/RD-20 LEVEL - FP-D JT RD/GN C 6
RD/GN-18 BG-20 BK/YE-20 BK
10
RD/BU-18 JT BK/BU
B
FUEL PUMP 3D RAVE VALVE VEHICULE SPEED SENSOR
A JT BK
FP ER VSS BK-18 BK-20
(-H-5)
(-H-5)
F PUMP CONTROL A
BN/PK-18
4
JT RD/OG 2 S12V
(-D-3) 2
12 VOLTS 7
RD/BK-20
1
12 VOLTS DIMMER SWITCH
F
B (-F-7) 22 1 12 JT BK/RD 2
FUEL LEVEL SIGNAL BU-20 LEVEL + MG-15 BN/GN-20 CONTROL BK/RD-20 BK/RD-20 GROUND GY/WH-16
C 6 3 JT BK 1 JT BK 1
55 VOLTS WH/RD-18 GN/WH-20 SIGNAL GY/OG-16
INJECTOR (MAG)
D (-F-7)
FUEL LEVEL GROUND BK/RD-20 LEVEL - JT BK/RD INJ_M RD-16
8 2
BU-18 INJECTOR CONTROL START / RER SWITCH
AIR CONTROLLED SUSPENSION
12 (-G-2) 1
WH/RD-18 JT WH/RD +55V WH/RD-18 55 VOLTS ACS BK/BU-20
JT WH/RD 13 (-D-2) 3
WH/RD-18 FC-B S12V RD/YE-16 12 VOLTS RD/VT-20 BACK LIGHT
INJECTOR (PTO)
14 2
INJ_P WH/OG-20 DATA BG-20
1 2 1
WH/RD-12
GN-18 INJECTOR CONTROL BK-16 GROUND

(-F-4) (-G-2) 1 STEERING HARNESS CONNECTOR 2
55 VOLTS
(-H-2)
WH/RD-18 +55V OP-B JT WH/RD +55V WH/RD-18
(-F-4) SH2
WH/RD-18 +55V INJ_M-1
CAPACITOR IGNITION COIL (MAG) JT RD/OG 1 S12V
(-B-3) H
RD/OG-20
(-G-4)
WH/RD-18 +55V INJ_P-1 CAP+ BK-18
5
IGN_M 18 JT BK 3 G
(-G-4) (-G-2)
S YE/GN-20 YE/GN-20
7 3
WH/RD-18 +55V IGN_M-3 BK-18 JT WH/RD +55V WH/RD-18 55 VOLTS GRIP UP
{
19 F
(-G-4)
↑ OG/WH-20 OG/WH-20 BACK LIGHT
8 26 2
WH/RD-18 +55V IGN_P-3 BK-18 OG/BU-18 IGNITION CONTROL GRIP DOWN SET
21 E
BACK LIGHT
G 1
↓ OG/YE-20 OG/VT-20 G
BK-18 GROUND LEVER UP MODE
{
20 D
(-H-2)
↑ BN-20 BN-20
LEVER DOWN
22 C
↓ BN/YE-20 BN/YE-20
3 B
JT BK 3 M YE/BN-20 YE/BN-20
BK-8 IGNITION COIL (PTO) 11

BK-18 BK-20
A
BK-20
IGN_P
(-H-5)
(-H-5)
GND BK-12 JT WH/RD +55V
(-G-2)
WH/RD-18
3
55 VOLTS
19 2
OR/GN-18 IGNITION CONTROL JT BK 1 JT BK 1
1
CHASSIS BK-18 GROUND
(-H-2)
14
BK-18
20
BK-18
21 JT BK 3
BK-18
BK-16 BK-14
H H
BK-18
BK-18
BK-16
BK-16
BK-18
BK-18
BK-16
BK-18
BK-20
BK-16
BK-18
BK-18
BK-16
BK-18
(-G-6)
(-A-3)
(-F-7)
(-G-4)
(-G-6)
(-G-7)
(-D-3)
(-D-7)
(-C-6)
(-H-4)
(-C-8)
(-C-8)
(-F-7)
ACC 2-1
IGN_P-1
ACC-1
TL-1
COM-3
IGN_M-1
ACS-1
MG-11
SH2-A
HL-A
HL-E
SH1-A
SH1-B
REF: 515177987 REV: 1

1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
2017 TUNDRA 600 HO E-TEC LINE TYPES

55 / 60 VOLTS
12 VOLTS SWITCHED
12 VOLTS UNSWITCHED
A A
5 OR 3.3 VOLTS
J1A
DIGITAL SIGNAL
ACCESSORY Link
POWER CONTROL
15
ACC1 RD/OG-20
2
ANALOG SIGNAL
12 volts
1 RF IDENTIFICATION KEY COMMUNICATION
BK-18 Ground
RFID A-D GROUND
(-H-2)
D D
RD/OG-20 RD/OG-20 12 VOLTS POWER GROUND
11 C C
WH/GY-20 WH/GY-20 WH/GY-20 DATA AC VOLTAGE
JT BK 3 23 B B
BK/WH-20 BK/WH-20 BK/WH-20 CONTACT
5 A A
BK/GN-20 BK/GN-20 BK/GN-20 GROUND
30
WH-20
(-F-7) 9
RD/OG-16 S12V SH1-G BK/YE-20
(-G-7) 28
RD/OG-20 S12V SH2-H RD/GN-18
B CRANK POSITION SENSOR

B
JT RD/OG 1
CPS
7 2
WH/YE-18 GROUND
COMMUNICATION
6 1
BU/YE-18 SIGNAL CONNECTOR
(-E-6) HEADLAMP 1
RD/OG-18 S12V MG-8 COM
RD/OG-20
(-F-4)
JT RD/OG 2
(-C-3)
RD/OG-16
6
12 VOLTS
HL1
S12V ER-2 S12V
A
(-C-3)
GY/OG-16 HEADLAMP LOW
5
B
BK-16 GROUND
4
C
GY/WH-16 HEADLAMP HIGH
3
BK-16 GROUND
RD/OG-14
(-H-5)
13 JT WH/BK 2
WH/BK-20 WH/BK-20 CAN LO
14 JT WH/BG 1
WH/BG-20 WH/BG-20 CAN HI
JT BK 1
(-H-2)
JT RD/GN
KNOCK SENSOR HEADLAMP 2

J1B-9
KS HL2
33 2 A
YE/BU-20 SIGNAL JT BK 3 GY/OG-16 HEADLAMP LOW
CONTROL
12 VOLTS
C (-D-7) 34 1 B C
S12V TL-3 BG/BU-20 GROUND BK-16 GROUND
(-E-4)
(-C-6)
C
GY/WH-16 HEADLAMP HIGH
JT RD/OG 2
(-H-5)
THROTTLE POSITION SENSOR
TPS
RD/GN-18
OG/BK-18
1 3
WH/BN-20 SIGNAL JT BK 1
(-B-6) (-C-1)
STARTER RELAY
2
RD/OG-16 S12V COM-5 BK/OG-20 GROUND SD-A SOLENOID RD/GN-18
(-B-6) JT VT/BN
B
10 1
RD/OG-16 S12V COM-6 VT/BN-20 VT/BN-20 5 VOLTS
SD

CONTROL BY ECM
ERF
FA : 25A FB: 5A 3
VT/BN-20 5 VOLTS
BATTERY CHARGING
(START/RER CLOCK)
18 2
WH/BU-20 SIGNAL
1
BK/OG-20 GROUND
FA
FB
AIR TEMPERATURE SENSOR

A
TAIL LIGHT
D ATS D
RD/WH-14
RD/WH-14
TL
RD/VT-20
20 2
VT/WH-20 VT/WH-20 SIGNAL
RD-14
(-C-3) 3
JT BK/OG JT RD/OG 2 S12V RD/OG-16 12 VOLTS
27 1
2
WH-18 BRAKE
JT RD/VT
COOLANT TEMPERATURE SENSOR 1

BK-16 GROUND
CTS MULTIFUNCTION GAUGE MG
(-H-2)
2
BK/OG-18 GROUND
19 1 24
BG/OG-18 SIGNAL WH/BG-20
RD/VT-20
RD/VT-20
JT BK 3
23
WH/BK-20
EXHAUST TEMPERATURE SENSOR
(-E-7)
(-E-6)
EGTS
ENGINE 12 2
U12V
U12V
J2 BG/GY-20 BG/GY-20 SIGNAL (-B-3)

8
1
BK/OG-20 GROUND (-E-2)
15 9
RD/OG-18 RD/VT-20 U12V JT RD/VT BRAKE SWITCH
SH1-H
MG-9
RD/OG-18
16 OIL LEVEL SENSOR RD-20
4
GY
OLS 3
WH-20 BN
29 A LEFT GRIP WARMER
6 2
RD/WH-18 OG-20 OG
B
E JT RD/WH BK/OG-20 GROUND STEERING HARNESS CONNECTOR 1 E
14 1
RD/WH-18 BK-20 BK
SH1
16 JT GY/WH M
MAGNETO
CHASSIS MO BG/BK-18 WH-18 WH-20
BK-20
6 1 4 K RIGHT GRIP WARMER
MAGNETO YE-16 OG/BN-20 OG/RD-20
J1B JT OG
PC1
5 3 5 J
OG-16 OG-20 OG-20 OG-20
4 2 (-E-2) H 1
BN-16 JT RD/VT U12V RD/VT-20 RD/VT-20 OG-20 OG
9 (-C-1)
PC2
OG/BK-18 SOLENOID SD-B JT RD
3 10 OIL PUMP (-B-3) G 2
BN/WH-16 JT RD/OG 1 S12V RD/OG-16 RD-16 OG/RD-20 BN
2
OG/WH-16
11 OP JT GY/OG
GY/OG-16
F
GY/OG-16 BK-20
3
(-G-2) BK
B
JT WH/RD +55V WH/RD-18 55 VOLTS 4
1200W 1 9 E
YE/WH-16 BK/YE-20 BK/YE-20 BK-20 YE/BK
23 A
GN/YE-18 CONTROL 5
BK/BU-20 BK
JT RD/GN C 6
10
B JT BK/BU
FUEL PUMP 3D RAVE VALVE
A JT BK
FP ER 15 (-F-2)
BK-18 BK-20
(-H-5)
(-H-5)
BU-20 LEVEL + FP-B
F PUMP CONTROL A
BN/PK-18
4
JT RD/OG 1 S12V
(-B-3) 2
12 VOLTS DIMMER SWITCH
F
(-F-2)
BK/RD-20 LEVEL - FP-D
B (-F-7) 22 1
FUEL LEVEL SIGNAL BU-20 LEVEL + MG-15 BN/GN-20 CONTROL GY/WH-16
C VEHICULE SPEED SENSOR JT BK 1 JT BK 1
55 VOLTS WH/RD-18 GY/OG-16
INJECTOR (MAG)
FUEL LEVEL GROUND D (-F-7) VSS
BK/RD-20 LEVEL - JT BK/RD INJ_M 7 1
RD-16
RD/BK-20 12 VOLTS
8 2
BU-18 INJECTOR CONTROL JT BK/RD START / RER SWITCH
12 2
(-G-2) BK/RD-20 BK/RD-20 GROUND
12 1
WH/RD-18 JT WH/RD +55V WH/RD-18 55 VOLTS BK/BU-20
6 3
JT WH/RD GN/WH-20 SIGNAL
13
WH/RD-18 RD/VT-20 BACK LIGHT
INJECTOR (PTO)
INJ_P BG-20
1 2
WH/RD-12
GN-18 INJECTOR CONTROL

(-F-4) (-G-2) 1 STEERING HARNESS CONNECTOR 2
WH/RD-18 +55V OP-B JT WH/RD +55V WH/RD-18 55 VOLTS
(-F-4) SH2
WH/RD-18 +55V INJ_M-1
CAPACITOR IGNITION COIL (MAG) JT RD/OG 1 S12V
(-B-3) H
RD/OG-20
(-G-4)
WH/RD-18 +55V INJ_P-1 CAP+ BK-18
5
IGN_M 18 G
(-G-4) (-G-2) S YE/GN-20 YE/GN-20
7 3
WH/RD-18 +55V IGN_M-3 BK-18 JT WH/RD +55V WH/RD-18 55 VOLTS GRIP UP
{
19 F
(-G-4)
↑ OG/WH-20 OG/WH-20 BACK LIGHT
8 26 2
WH/RD-18 +55V IGN_P-3 BK-18 OG/BU-18 IGNITION CONTROL GRIP DOWN SET
21 E
BACK LIGHT
G 1
↓ OG/YE-20 OG/VT-20 G
BK-18 GROUND LEVER UP MODE
{
20 D
(-H-2)
↑ BN-20 BN-20
LEVER DOWN
22 C
3 B
JT BK 3 M YE/BN-20 YE/BN-20
BK-8
IGNITION COIL (PTO) 11
BK-18 BK-20
A
BK-20
IGN_P
(-H-5)
(-H-5)
GND BK-12 JT WH/RD +55V
(-G-2)
WH/RD-18
3
55 VOLTS
19 2
1
(-H-2)
14
BK-18
20
BK-18
21 JT BK 3
BK-18
BK-14 BK-14
H H
BK-18
BK-16
BK-16
BK-18
BK-18
BK-18
BK-20
BK-18
BK-18
(-G-4)
(-G-6)
(-G-7)
(-H-4)
(-D-7)
(-C-6)
(-C-8)
(-C-8)
(-A-3)
(-F-7)
(-F-7)
ACC1-1
IGN_P-1
TL-1
COM-3
IGN_M-1
MG-11
SH2-A
HL1-B
HL2-B
SH1-A
SH1-B
REF: 515177982 REV:

1 2 3 4 5 6 7 8 9 10
2017 Expedition LE 600 HO E-TEC
2017 Expedition SE 600 HO E-TEC
2017 Skandic SWT 600 HO E-TEC
2017 Skandic WT 600 HO E-TEC
219100863-010
1 2 3 4 5 6 7 8 9 10
2017 800R E-TEC LINE TYPES

55 / 60 VOLTS
12 VOLTS SWITCHED
12 VOLTS UNSWITCHED
A 5 OR 3.3 VOLTS A
J1A DIGITAL SIGNAL
POWER CONTROL
ACCESSORY
15
Link
ACC 1 RD/OG-20 ANALOG SIGNAL
2
RD/OG-18 12 volts COMMUNICATION
1 RF IDENTIFICATION KEY
BK-18 Ground A-D GROUND
RFID
POWER GROUND
(-H-2)
D
RD/OG-20 12 VOLTS
11 C
AC VOLTAGE
WH/GY-20 DATA
JT BK 3 23 B
BK/WH-20 CONTACT
5 A
BK/GN-20 GROUND
9
BK/YE-20
28
RD/GN-18
B B
CRANK POSITION SENSOR COMMUNICATION
RD/OG-18
(-C-8) CPS CONNECTOR
S12V HL-D
7 2
(-F-7)
WH/YE-18 GROUND COM
RD/OG-16 S12V SH1-G
6 1 (-E-3) 6
(-G-7)
BU/YE-18 SIGNAL JT RD/OG 2 S12V RD/OG-16 12 VOLTS
RD/OG-20 S12V SH2-H (-E-3) 5
4
JT RD/OG 1
3
BK-16 GROUND
HEADLAMP
13 JT WH/BK 2
WH/BK-20 WH/BK-20 CAN LO HL LAMP A
14 JT WH/BG 1 A
(-E-6)
WH/BG-20 WH/BG-20 CAN HI BK-16 BK-16 GROUND
RD/OG-18 S12V MG-8
B
(-H-2)
GY/OG-16 GY/OG-16 LOW BEAM
JT RD/GN
KNOCK SENSOR
C
J1B-9
KS GY/WH-16 GY/WH-16 HIGH BEAM

RD/OG-14
33 2 (-B-3) D
YE/BU-20 SIGNAL JT BK 3 JT RD/OG 1 S12V RD/OG-18 RD/OG-18 12 VOLTS
CONTROL
12 VOLTS
C 34 1 THERMOCOUPLE MODULE E LAMP B C

BG/BU-20 GROUND BK-16 BK-16 GROUND
THCM BK-16 GROUND
(-F-4)
(-D-7)
1 AUXILIARY
CAN HI
(-H-5)
(-H-5)
WH/BK-20 GY/OG-16 LOW BEAM
LIGHT
THROTTLE POSITION SENSOR WH/BK-20
2
CAN LO GY/WH-16 HIGH BEAM
TPS (-D-3) 3
JT RD/OG 2 S12V RD/OG-20 12 VOLTS JT BK 1 JT BK 1
1 3
WH/BN-20 SIGNAL
4
GROUND
RD/GN-18
OG/BK-18
BK-20
2
BK/OG-20 GROUND
JT VT/BN
STARTER RELAY
10 1
VT/BN-20 VT/BN-20 5 VOLTS (-C-1)
SD-A SOLENOID RD/GN-18
B

SD
(-H-2)
ACS ERF
CONTROL BY ECM
FA : 25A FB: 5A FC: 15 A 3

VT/BN-20 5 VOLTS
BATTERY CHARGING
START/RER CLOCK
18 2
JT BK 3
WH/BU-20 SIGNAL
1
BK/OG-20 GROUND
FC
FA
FB
(-F-4) AIR TEMPERATURE SENSOR

A
RD/OG-20 S12V ER-2

TAIL LIGHT
D (-D-8) ATS D
RD/WH-14
RD/WH-14
RD/OG-16 TL-3 TL
RD/VT-20
S12V
20 2
SIGNAL
RD/OG-16
VT/WH-20 VT/WH-20
RD/YE-16
RD-14
(-C-6) (-D-3) 3 B
RD/OG-20 S12V THCM-3 JT BK/OG JT RD/OG 2 S12V RD/OG-16 RD-18 12 VOLTS
27 1
2 C
WH-18 WH-18 BRAKE
JT RD/VT
1 A
BK-16 BK-18 GROUND
MULTIFUNCTION GAUGE
(-F-6)
COOLANT TEMPERATURE SENSOR

MG
JT RD/OG 2
S12V
CTS
(-H-2)
2 24
BK/OG-18 GROUND WH/BG-20
RD/VT-20
RD/VT-20
19 1 23 JT BK 3
BG/OG-18 SIGNAL WH/BK-20
ACS-3
ENGINE (-B-6)
(-E-7)
(-E-6)
RD/OG-16 S12V COM-5

(-B-6)
U12V
U12V
RD/OG-16 S12V COM-6 J2 8 (-C-3)

RD/OG-18
15 OIL LEVEL SENSOR 9
RD/VT-20
(-E-2)
U12V JT RD/VT BRAKE SWITCH
OLS
SH1-H
MG-9
16 4
RD/OG-18 RD-20 GY
29 A
3
WH-20 BN
B LEFT GRIP WARMER
BK/OG-20 GROUND
6 2
RD/WH-18 OG-20 OG
E JT RD/WH 14 STEERING HARNESS CONNECTOR 1 1 E
RD/WH-18 BK-20 BK
SH1
16 JT GY/WH M
MAGNETO
MO BG/BK-18 WH-18 WH-20
BK-20
CHASSIS 6
YE-16
1 4
OG/RD-20
K
MAGNETO
J1B JT OG
PC1
5 3 5 J
OG-16 OG-20 OG-20
4 2 3 (-G-2) (-E-2) H 1
BN-16 S12V JT WH/RD JT RD/VT U12V RD/VT-20 RD/VT-20 OG-20 OG
PC2
3 10 4 (-G-2) (-B-3) G JT RD 2
BN/WH-16 S12V JT WH/RD JT RD/OG 1 S12V RD/OG-16 RD-16 OG/RD-20 BN
2
OG/WH-16
11 OIL PUMP GY/OG-16
F
GY/OG-16 BK-20
3
BK
1200W 1
YE/WH-16
9 OP BK/YE-20
E
BK/YE-20 BK-20
4
YE/BK
9 (-C-1) (-G-2) B 15 (-F-2)
OG/BK-18 SOLENOID SD-B JT WH/RD +60V WH/RD-18 60 VOLTS BU-20 LEVEL + FP-B
5
BK/BU-20 BK
23 A (-F-2)
GN/YE-18 CONTROL BK/RD-20 LEVEL - FP-D JT RD/GN 6
C
10
RD/BU-18 JT BK/BU
B
FUEL PUMP 25 VEHICULE SPEED SENSOR
WH-20 JT BK
A
FP VSS BK-18 BK-20
ER
(-H-5)
(-H-5)
F A 4
3D RAVE VALVE 7 1 F
PUMP CONTROL BN/PK-18 (-D-3) RD/BK-20 12 VOLTS DIMMER SWITCH
2
(-F-7)
JT RD/OG 2 S12V 12 VOLTS JT BK/RD
B 12 2
FUEL LEVEL SIGNAL BU-20 LEVEL + MG-15 BK/RD-20 BK/RD-20 GROUND GY/WH-16
22 1
BN/GN-20 CONTROL JT BK 1 JT BK 1
C 6 3
60 VOLTS WH/RD-18 GN/WH-20 SIGNAL GY/OG-16
D (-F-7) INJECTOR (MAG)
FUEL LEVEL GROUND BK/RD-20 LEVEL - JT BK/RD RD-16
INJ_M
8 1 AIR CONTROLLED SUSPENSION START / RER SWITCH
WH/BU-18 INJECTOR CONTROL
12
WH/RD-18
1 2 ACS BK/BU-20
JT WH/RD BU-18 INJECTOR CONTROL (-D-2)
13 3
WH/RD-18 FC-B S12V RD/YE-16 12 VOLTS RD/VT-20 BACK LIGHT
INJECTOR (PTO) 14
WH/OG-20
2
DATA BG-20
INJ_P 1
WH/RD-12
GROUND
2 1
(-F-4) WH/GN-18 INJECTOR CONTROL STEERING HARNESS CONNECTOR 2
(-H-2)
WH/RD-18 +60V OP-B
7 2
(-E-4)
GN-18 INJECTOR CONTROL SH2
WH/RD-18 +60V J1B-3
CAPACITOR JT RD/OG 1 S12V
(-B-3) H
RD/OG-20
(-F-4) IGNITION COIL (MAG)
WH/RD-18 +60V J1B-4 CAP+ BK-18
5
18 JT BK 3 G
(-G-4) IGN_M S YE/GN-20 YE/GN-20
7
WH/RD-18 +60V IGN_M-3 BK-18 (-G-2) GRIP UP
{
3 19 F
(-G-4)
JT WH/RD +60V WH/RD-18 60 VOLTS ↑ OG/WH-20 OG/WH-20 BACK LIGHT
8
WH/RD-18 +60V IGN_P-3 BK-18 GRIP DOWN SET
26 2 21 E
BACK LIGHT
G OG/BU-18 IGNITION CONTROL ↓ OG/YE-20 OG/VT-20 G
LEVER UP MODE
1
{
20 D
BK-18 GROUND ↑ BN-20 BN-20
(-H-2)
LEVER DOWN
22 C
3 B
M YE/BN-20 YE/BN-20
BK-12 JT BK 3
IGNITION COIL (PTO) 11
BK-18 BK-20
A
BK-20
IGN_P
(-H-5)
(-H-5)
(-G-2) 3
BK-12 JT WH/RD +60V WH/RD-18 60 VOLTS
19 2
1
(-H-2)
14
BK-18
20
BK-18
21 JT BK 3
BK-18
BK-14 BK-14
H H
BK-18
BK-20
BK-16
BK-16
BK-18
BK-18
BK-18
BK-18
BK-20
BK-16
BK-18
BK-18
BK-16
BK-18
(-G-6)
(-D-6)
(-A-3)
(-F-7)
(-G-4)
(-G-6)
(-G-7)
(-D-7)
(-C-6)
(-H-4)
(-C-8)
(-C-8)
(-F-7)
THCM-4
IGN_P-1
ACC-1
TL-1
COM-3
ACS-1
MG-11
SH2-A
HL-A
HL-E
SH1-A
SH1-B
REF: 515177986 REV: 1

1 2 3 4 5 6 7 8 9 10
2017 Expedition Extreme 800R E-TEC
219100863-012
2017 Expedition LE 1200 4-TEC
2017 Expedition SE 1200 4-TEC
219100863-013
1 2 3 4 5 6 7 8 9 10
2017 SUMMIT 850 E-TEC RER

F1 : 5A
BATTERY
F3: 30A
ACCESSORY
F4 : 7.5A
LOADS
F2 : 25A
RD-12
LINE TYPES
55 / 60 VOLTS
12 VOLTS SWITCHED
BAT+ SD+ 12 VOLTS UNSWITCHED
FUSEBOX
RD-6
FB
ENGINE CONTROL MODULE 5 OR 3.3 VOLTS
A A
F
G
H
C
E
A
ECMB DIGITAL SIGNAL
RD/WH-12
RD/WH-12
POWER CONTROL
RD/OG-12
RD/GN-12
RD/GN-12
RD/YE-16
RD/VT-16
Link
RD-12
L1
ANALOG SIGNAL
BATTERY CHARGING RD/WH-16
L2 JT RD/WH COMMUNICATION
RD/WH-16 CHASSIS ENGINE
STARTER SOLENOID
L3
A-D GROUND
RD/WH-16 CHASSIS SD
A1 B
POWER GROUND
OG/BK-18 OG/BK-18 CONTROL
A
AC VOLTAGE
RD/OG-18 12 VOLTS
M1
VEHICULE LOADS RD/GN-16
M2 JT RD/GN
RD/GN-16
M4 JT RD/YE
RD/GN-16
JT RD/OG 2
RD/OG-12 JT RD/OG 1
B B
REVERSE BUTTON
RER
2
RD/VT-16 12 VOLTS
A3 1
RER CONTROL BG-20
RD/OG-16
(-G-7)
RFID
D
S12V
RD/OG-20 12 VOLTS
K3 C
DATA WH/GY-20 DATA
K2 B
CONTACT BK/WH-20 CONTACT
DIMMER-2
J3 A COMMUNICATION ACC 1
GROUND BK/GN-20 GROUND
2
CONNECTOR RD/YE-16 12 VOLTS
1
COM BK-16 GROUND
C 6 C
RD/YE-16 +12V
5
RD/WH-16 +12V
(-H-6)
A2 4
ECM POWER INPUT RD/BU-18 RD/BU-18 ECM POWER IN
3
BK-16 GROUND
JT BK 1
2
WH/BK-20 CAN LO
1
CAN HI
(-H-5)
(-E-8)
WH/BG-20
G3
ENGINE CUT OFF SIGNAL INPUT BK/YE-20 CONTROL STR 6P-6
G4 (-F-8)
BK/BU-20 GND STR 6P-3 TL
JT BK 2 4
RD/YE-16
FUEL PUMP RD/OG-18

3 B
RD/OG-18 RD/OG-18 12 VOLTS
FP 2 C
WH-18 WH-18 WH-18 BRAKE
M3 A
FUEL PUMP PWM CONTROL BN/PK-18 BN/PK-18 PWM CONTROL
1 A
BK-16 BK-16 BK-16 GROUND
B
FUEL LEVEL SIGNAL
(-H-5)
BU-20
55 V FOR FUEL PUMP L4

WH/RD-18 WH/RD-18
C
55 VOLTS
THCM
1
WH/BG-20 CAN HI
D
BK-20 FUEL LEVEL GROUND JT BK 2
D 2
CAN LO D
(-H-6)
WH/BK-20
3
RD/OG-20 S12V
4
JT BK 1 BK-20 GND
(-H-7)
JT BK 1
BRAKE SWITCH
STR 4P
4
RD/OG-18 GY-20
3
OG-20 OG-20
LEFT GRIP WARMER
H3 JT WH 2
BRAKE SIGNAL INPUT WH-20 WH-18 BN-20
1
BK-20 OG-20
(-H-5)
E GAUGE SUMMIT GAUGE SUMMIT
E
MG MG JT BK 2
STR 6P
(-C-3) 6
ECMB-G3 CONTROL BK/YE-20 BK-20
2 7 5
RD/OG-18 12 VOLTS HEATED LEVER OUTPUT BN-20 BN-20 BN-20
4 1 JT OG 4
BU-20 FUEL LEVEL SIGNAL HEATED GRIPS OUTPUT OG-20 OG-20 OG-20
C2 JT WH/BK 10 (-D-3) 3
CAN LO WH/BK-20 WH/BK-20 CAN LO ECMB-G4 GND BK/BU-20 BK-20
RIGHT GRIP WARMER
C1 JT WH/BG 9 2
CAN HI WH/BG-20 WH/BG-20 CAN HI GRIP BK-20 BN-20
1
BK-20 OG-20
5 8
HEATER UP OG/WH-20
(-H-5)
(-H-5)
MUFFLER TEMP. SENSOR 6
BK-20
F F
EGTS
JT BK 2
JT BK 2
6 5
HEATER DOWN OG/VT-20
C3 2
EGTS SIGNAL BG/GY-20 SIGNAL
(-H-6)
D3 1
GROUND BK/BU-20 GROUND
8
BK-18 GROUND
GRIP AND LEVER HEATER
(-H-6)
JT BK 1 CONTROL SWITCH
3
HIGH BEAM GY/WH-20
JT BK 1 UP
VEHICLE SPEED SENSOR DOWN
VSS DIMMER
D2 3
5 VOLTS RD/BK-20 5 VOLTS
4
GY/WH-16
F2 2
GROUND BK/BU-20 GROUND
E2 1 HEADLAMP
SPEED SIGNAL INPUT GN/WH-20 SPEED SIGNAL (-C-7) 2 DIMMER SWITCH
JT RD/OG 1 S12V RD/OG-16
1
GY/OG-16
G HI
G
LO
MANIFOLD AIR PRESSURE TEMP SENSOR
JT GY/WH
JT GY/OG
MAPTS
F3 4
INTAKE MANIFOLD PRESSURE SIGNAL WH/BU-20 PRESSURE SIGNAL
HEADLAMP 1
E4 3
5 VOLTS PK/BU-20 5 VOLTS HL1
B2 2 C
INTAKE MANIFOLD TEMP. SIGNAL WH/OG-20 TEMPERATURE SIGNAL GY/WH-18 HIGH BEAM
F4 1 B
GROUND BK/BU-20 GROUND BK-18 GROUND
A
GY/OG-18 LOW BEAM
(-H-7)
GND JT BK 1
HEADLAMP 2
JT BK 2 JT BK 1
BK-12 BK-12 HL2
C
GY/WH-18 HIGH BEAM
BK-16
BK-20
BK-20
BK-16
BK-20
BK-16
BK-16
BK-20
BK-18
BK-20
BK-18
BK-18
BK-20
H CHASSIS B H
BK-18 GROUND
A
LOW BEAM
(-H-6)
(-C-6)
(-D-8)
(-D-3)
(-H-7)
(-H-7)
(-D-6) GY/OG-18
(-E-8)
(-F-7)
(-F-8)
(-F-8)
(-F-6)
(-C-8)
GRIP-6
FP-D
COM-3
STR 6P-2
STR 6P-1
STR 4P-1
TL-1
ACC 1-1
MG-8
THCM-4
HL2-B
HL1-B
JT BK 1
REF: 515178206 REV: 1

1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
2017 MXZ, RENEGADE 850 E-TEC

START
RER
CLOCK BATTERY ACCESSORY LOADS
RD-12
F1 : 5A F3 : 30A F4 : 7.5A F2 : 25A
LINE TYPES
55 / 60 VOLTS
BAT+ SD+
FUSEBOX
RD-6 12 VOLTS SWITCHED
FB
12 VOLTS UNSWITCHED
F
G
H
C
E
A
A 5 OR 3.3 VOLTS A
ECMB DIGITAL SIGNAL
RD/WH-12
RD/WH-12
RD/OG-12
RD/GN-12
RD/GN-12
RD/YE-16
RD/VT-16
Link
RD-12
POWER CONTROL
L1
BATTERY CHARGING RD/WH-16
ENGINE
ANALOG SIGNAL
L2 JT RD/WH CHASSIS
RD/WH-16
STARTER SOLENOID COMMUNICATION
L3 CHASSIS
RD/WH-16 SD A-D GROUND
A1 B
STARTER SOLENOID OG/BK-18 OG/BK-18 CONTROL
POWER GROUND
A
RD/OG-18 12 VOLTS
JT RD/GN
AC VOLTAGE
M1
VEHICULE LOADS RD/GN-16 ACC 1
M2 JT RD/YE 2
RD/GN-16 RD/YE-16 12 VOLTS
M4 JT RD/OG 2 1
RD/GN-16 BK-16 GROUND
RD/OG-12 JT RD/OG 1
(-H-6)
JT RD/VT
JT BK 1
B B
RD/OG-20
RD/OG-18
RD/OG-20
RD/OG-16
RD/OG-18
RD/VT-20
RD/VT-20
(-G-7)
(-G-7)
(-D-5)
(-D-8)
(-F-5)
(-F-5)
(-D-3)
S12V
U12V
S12V
S12V
U12V
S12V
S12V
MG-8
THCM-3
SH-7
SH-8
STR 4P-4
MG-9
RFID-D
COMMUNICATION
C CONNECTOR C
ACC2
COM 2
6
RD/YE-16 12 VOLTS
RD/YE-16 12 VOLTS
1
5
BK-16 GROUND
RD/WH-16 12 VOLTS
A2 4
DIAGNOSTIC POWER RD/BU-18 RD/BU-18 ECM POWER IN TL
3 4
BK-16 GROUND RD/YE-16 RD/YE-16 TAIL LIGHT
2 3 B
WH/BK-20 CAN LO RD/OG-18 RD/OG-18 RD/OG-18 12 VOLTS
1 2 C
WH/BG-20 CAN HI WH-18 WH-18 WH-18 BRAKE
1 JT BK A
(-H-4)
BK-16 BK-16 BK-16 GROUND
(-H-5)
JT BK 2
JT BK 2
RFID
(-B-3) D
K3 C
DATA WH/GY-20 DATA THCM
D CONTACT K2
BK/WH-20
B
CONTACT WH/BG-20
1
CAN HI D
J3 A 2
GROUND BK/GN-20 GROUND WH/BK-20 CAN LO
(-B-5) 3
JT RD/OG 1 S12V RD/OG-20 12 VOLTS BRAKE SWITCH
4
BK-20 GROUND STR 4P
(-B-8) 4
JT RD/OG 1 S12V RD/OG-18 GY-20
(-H-6)
3
OG-20 OG-20
LEFT GRIP WARMER
JT WH
BRAKE SIGNAL INPUT H3
WH-20
(-D-7)
BRAKE JT WH FUEL PUMP ECMB-H3 BRAKE
(-D-3)
WH-20 WH-18
2
BN-20
FP JT BK 1 1
BK-20 OG-20
M3 A
FUEL PUMP PWM CONTROL BN/PK-18 BN/PK-18 PWM CONTROL
(-H-5)
B
BU-18 FUEL LEVEL SIGNAL
L4 C
55 V FOR FUEL PUMP WH/RD-18 WH/RD-18 55 VOLTS GAUGE
GAUGE
D JT BK 2
BK/BU-20 FUEL LEVEL GROUND MG MG EMERGENCY ENGINE CUT OFF SWITCH
E E
STR 6P
G3 (-E-8) (-E-3) 6
ENGINE CUT OFF CONTROL INPUT BK/YE-20 CONTROL STR 6P-6 ECMB-G3 CONTROL BK/YE-20 BK-20
4 5
HEATED LEVER OUTPUT BN-20 BN-20 BN-20
5 JT OG 4
HEATED GRIPS OUTPUT OG-20 OG-20 OG-20
G4 (-E-8) (-E-3) 3
ENGINE CUT OFF CONTROL GROUND BK/BU-20 GND STR 6P-3 ECMB-G4 GND BK/BU-20 BK-20
RIGHT GRIP WARMER
2
BK-20 BN-20
1
BK-20 OG-20
(-H-5)
(-H-5)
JT BK 2 JT BK 2
START / RER SWITCH
12
BK/BU-20 FUEL LEVEL GROUND BK-20
15
FUEL LEVEL SIGNAL RD/VT-20 BACK LIGHT
C2 JT WH/BK 23
CAN LO WH/BK-20 WH/BK-20 CAN LO RD/VT-20
F JT WH/BG
F
C1 24
CAN HI WH/BG-20 WH/BG-20 CAN HI SH
1 JT BK
BK-20 BK-20
A3 (-F-7) (-F-3) 2
START/RER CONTROL BG-20 START/RER SH-2 ECMB-A3 START/RER BG-20 RD/GN-20
22 3
(-B-4) LEVER DOWN BN/YE-20 BN/YE-22 LEVER DOWN
8
JT RD/OG 1 S12V RD/OG-18 S12V
21 4
GRIP DOWN OG/VT-20 OG/YE-22 GRIP DOWN
SET
18 5
(-B-5) 9 6
CLOCK (U12V)
(-H-6)
JT RD/VT U12V RD/VT-20 GY/OG-16 GY/OG-17 BACK LIGHT BACK LIGHT
(-B-7) 7 JT RD
JT RD/OG 1 S12V RD/OG-16 RD-17
(-B-7) 8
JT BK 1 JT RD/VT U12V RD/VT-20 RD/VT-20
VEHICLE SPEED SENSOR
20 9
VSS LEVER UP BN-20 BN-22 LEVER UP
D2 3 19 10
5 VOLTS RD/BK-20 5 VOLTS GRIP UP OG/WH-20 OG/WH-22 GRIP UP
MODE
F2 2 3 11
GROUND BK/BU-20 GROUND MODE YE/BN-20 YE/BN-22
E2 1 16 12
SPEED SIGNAL INPUT GN/WH-20 SPEED SIGNAL HIGH BEAM GY/WH-20 GY/WH-16 GY/WH-17
11
G BK-18 GROUND G
DIMMER SWITCH
GY/OG-17
GY/WH-17
(-H-6)
RD-17
MANIFOLD AIR PRESSURE TEMP SENSOR
MAPTS JT BK 1
HEADLAMP 1
F3 4
INTAKE MANIFOLD PRESSURE SIGNAL WH/BU-20 PRESSURE SIGNAL HL1
E4 3 C
5 VOLTS PK/BU-20 5 VOLTS GY/WH-18 HIGH BEAM
B2 2 B
INTAKE MANIFOLD TEMP. SIGNAL WH/OG-20 TEMPERATURE SIGNAL BK-18 GROUND
F4 1 A
GROUND GROUND LOW BEAM
(-H-6)
BK/BU-20 GY/OG-18
JT BK 1
JT GY/WH
JT GY/OG
GND JT BK 2 JT BK 1
HEADLAMP 2
BK-12 BK-12 HL2
C
GY/WH-18 HIGH BEAM
H H
BK-20
BK-20
BK-20
BK-16
BK-16
BK-20
BK-18
BK-18
BK-18
BK-20
BK-16
CHASSIS B
BK-18 GROUND
A
LOW BEAM
(-H-6)
(-G-7)
(-G-5)
(-D-5)
(-D-7)
(-H-7)
(-H-7)
(-D-5)
GY/OG-18
(-E-8)
(-F-8)
(-F-8)
(-B-8)
COM-3
TL-1
STR 6P-2
STR 4P-1
STR 6P-1
ACC 1-1
SH-1
MG-11
THCM-4
HL1-B
HL2-B
JT BK 1
REF: 515178205 REV:

1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
2017 ENGINE HARNESS 600 ACE iTC

A ECMA ECMA CAMSHAFT POSITION SENSOR A
CAPS
D4 1
BK/GN-18 GROUND
E2 2
YE/GN-18 SIGNAL
ELECTRONIC THROTTLE CONTROL OR/GN-18 3
12 VOLTS
ETC
6 K4
3.3 VOLTS BG/YE-18
5 L1
MOTOR (+) BG/RD-18
B B
4 K3
SIGNAL 2 BG/GN-18
HARNESS INTER CONNECTOR
MOTOR (-) 3
BG/BK-18 L2
HIC
2 A2 4
GROUND BG/GY-18 OR/GN-18 12 VOLTS
1 F3 C1 3
SIGNAL 1 BG/WH-18 OG/BU-18 REVERSE ENABLE
2
VT/GN-16 12 VOLTS
1
VT/BU-16 12 VOLTS
C C
MANIFOLD ABSOLUTE PRESSURE

AND TEMPERATURE SENSOR INJECTOR CYLINDER 1
MAPTS INJ_1
4 G4 1
PRESSURE SIGNAL WH/BU-18 VT/BU-18 12 VOLTS
3 B4 J1 2
5 VOLTS PK/BU-18 BN/RD-18 CONTROL
2 H3
TEMP. SIGNAL WH/GY-18
D GROUND 1
BK/BU-18 H2 D
JT VT/BU
IGNITION COIL
CYLINDER 1
COIL_1
1
VT/BU-16 12 VOLTS
CTS
1 J2 M1 3
SIGNAL BK/OG-18 BN/BK-16 CONTROL
E 2 A1 E
GROUND BG/OG-18
INJECTOR CYLINDER 2
CRANKSHAFT POSITION SENSOR INJ_2

1
F CPS VT/GN-18 12 VOLTS
F
1 H1 K1 2
SIGNAL BU/YE-18 BN/BU-18 CONTROL LINE TYPES
2 K2
SIGNAL YE/WH-18 55 / 60 VOLTS
12 VOLTS SWITCHED
JT VT/GN
IGNITION COIL
CYLINDER 2 12 VOLTS UNSWITCHED
COIL_2 5 OR 3.3 VOLTS
1
VT/GN-16 12 VOLTS DIGITAL SIGNAL
Link
G OIL PRESSURE SWITCH POWER CONTROL G
OPS M2 3
BN/OG-16 CONTROL ANALOG SIGNAL
E3
SIGNAL LT BU-18 COMMUNICATION
A-D GROUND
POWER GROUND
AC VOLTAGE
H H
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2017 ENGINE HARNESS 900 ACE iTC

CAMSHAFT POSITION SENSOR
A ECMA ECMA A
CAPS
D4 BK/GN-18 1 GROUND
E2 YE/GN-18 2 SIGNAL
OR/GN-18 3 12 VOLTS
ELECTRONIC THROTTLE CONTROL
ETC HARNESS INTER CONNECTOR
6 K4
3.3 VOLTS BG/YE-18
HIC
B MOTOR (+) 5
BG/RD-18
L1
OR/GN-18 4 12 VOLTS B
4 K3 C1 3
SIGNAL 2 BG/GN-18 OG/BU-18 REVERSE ENABLE
3 L2 2
MOTOR (-) BG/BK-18 VT/GN-16 12 VOLTS
2 A2 1
GROUND BG/GY-18 VT/BU-16 12 VOLTS
1 F3
SIGNAL 1 BG/WH-18
INJECTOR CYLINDER 1
INJ_1
1 12 VOLTS
C VT/BU-18 C
B3 BN/RD-18 2 CONTROL

AND TEMPERATURE SENSOR
JT VT/BU
IGNITION COIL
MAPTS CYLINDER 1
4 G4
PRESSURE SIGNAL WH/BU-18 COIL_1
3 B4 1
5 VOLTS PK/BU-18 VT/GN-16 12 VOLTS
2 H3
D D
1 H2 M4 3
GROUND BK/BU-18 BN/BK-16 CONTROL
JT VT/GN
INJECTOR CYLINDER 2
COOLANT TEMPERATURE SENSOR INJ_2

1
CTS VT/BU-18 12 VOLTS
1 J2 K1 2
E SIGNAL BK/OG-18 BN/BU-18 CONTROL E
2 A1
GROUND BG/OG-18
IGNITION COIL
CYLINDER 2
COIL_2
1
VT/GN-16 12 VOLTS
CRANKSHAFT POSITION SENSOR M2

BN/OG-16
3
CONTROL
F F
CPS
1 H1
SIGNAL BU/YE-18 LINE TYPES
2 K2
SIGNAL YE/WH-18 55 / 60 VOLTS
INJECTOR CYLINDER 3 12 VOLTS SWITCHED
INJ_3 12 VOLTS UNSWITCHED
1
VT/BU-18 12 VOLTS 5 OR 3.3 VOLTS
J1 2
BN/GY-18 CONTROL DIGITAL SIGNAL
Link
G G
OIL PRESSURE SWITCH POWER CONTROL
OPS IGNITION COIL 3
ANALOG SIGNAL
E3 COIL_3
SIGNAL LT BU-18
1
COMMUNICATION
VT/GN-16 12 VOLTS
A-D GROUND
M1 3
POWER GROUND
BN/YE-16 CONTROL
AC VOLTAGE
H H
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1 2 3 4 5 6 7 8 9 10
2017 ENGINE HARNESS 1200 iTC

CAMSHAFT POSITION SENSOR
A ECMA ECMA A
CAPS
D4 1
BK/GN-18 GROUND
E2 2
YE/GN-18 SIGNAL
3
OR/GN-18 12 VOLTS
ELECTRONIC THROTTLE CONTROL
ETC HARNESS INTER CONNECTOR
6 K4
3.3 VOLTS BG/YE-18 HIC
B MOTOR (+) 5
BG/RD-18
L1
OR/GN-18
4
12 VOLTS B
4 K3 C1 3
SIGNAL 2 BG/GN-18 VT/OG-18 REVERSE ENABLE
3 L2 2
MOTOR (-) BG/BK-18 VT/GN-16 12 VOLTS
2 A2 1
GROUND BG/GY-18 VT/BU-16 12 VOLTS
1 F3
SIGNAL 1 BG/WH-18
INJECTOR CYLINDER 1
INJ_1
2
C VT/BU-18 12 VOLTS C
B3 1
BN/RD-18 CONTROL

AND TEMPERATURE SENSOR
JT VT/BU
IGNITION COIL
MAPTS CYLINDER 1
4 G4
PRESSURE SIGNAL WH/BU-18 COIL_1
3 B4 1
5 VOLTS PK/BU-18 VT/GN-16 12 VOLTS
2 H3
D D
1 H2 M4 3
GROUND BK/BU-18 BN/BK-16 CONTROL
JT VT/GN
INJECTOR CYLINDER 2
COOLANT TEMPERATURE SENSOR INJ_2

2
CTS VT/BU-18 12 VOLTS
1 J2 K1 1
E SIGNAL BK/OG-18 BN/BU-18 CONTROL E
2 A1
GROUND BG/OG-18
IGNITION COIL
CYLINDER 2
COIL_2
1
VT/GN-16 12 VOLTS
CRANKSHAFT POSITION SENSOR M2

BN/OG-16
3
CONTROL
F F
CPS
1 H1
SIGNAL BU/YE-18
2 K2
SIGNAL YE/WH-18 LINE TYPES
INJECTOR CYLINDER 3 55 / 60 VOLTS
INJ_3 12 VOLTS SWITCHED
2
VT/BU-18 12 VOLTS 12 VOLTS UNSWITCHED
J1 1
BN/GY-18 CONTROL 5 OR 3.3 VOLTS
G G
OIL PRESSURE SWITCH DIGITAL SIGNAL
OPS
Link
IGNITION COIL 3
POWER CONTROL
E3 COIL_3
SIGNAL LT BU-18
1 ANALOG SIGNAL
VT/GN-16 12 VOLTS
COMMUNICATION
M1 3 A-D GROUND
BN/YE-16 CONTROL
POWER GROUND
H AC VOLTAGE H
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2017 ENGINE HARNESS 850 E-TEC

A RAVE POSITION SENSOR RAVE ACTUATOR A
ECMA ECMA
ERF E-RAVE
3 F3 E4 1
5 VOLTS PK/VT-18 PK/BG-18 SENSOR 5 VOLTS
2 E3 F4 2
SIGNAL WH/VT-18 BK/BG-18 SENSOR GROUND
1 E2 D4 3
GROUND BK/VT-18 WH/BG-18 SENSOR SIGNAL
G4 JT BG/RD 4
BG/RD-18 BG/RD-18 ACTUATOR (+/-)
JT BG/BN
THROTTLE POSITION SENSOR H4
BG/RD-18 BG/BN-18
5
ACTUATOR (-/+)
B TPS J4
BG/BN-18 B
3 D2
5 VOLTS PK/BR-18
K4
BG/BN-18
GROUND 2
BK/BN-18
C2 THROTTLE BODY INJECTOR MAG
1 D3 INJ TB MAG
SIGNAL WH/BN-18
A3 1
BN/BU-18 CONTROL
A4 2
VT/BU-18 12 VOLTS
KNOCK SENSOR
KS THROTTLE BODY INJECTOR PTO
2 G1
SIGNAL YE/BU-18 INJ TB PTO
C 1 H1 A2 1 C
GROUND BG/BU-18 BN/GN-18 CONTROL
A1 2
VT/GN-18 12 VOLTS
CTS
2 B1
SIGNAL BK/OG-18
1 C1
GROUND BG/OG-18 OIL PUMP FEEDBACK SWITCH
E1
BK/WH-18 PC1
D CRANKSHAFT POSITION SENSOR F1
BG/BK-18 PC2 D
CPS
SIGNAL 1
BU/YE-18
K2 OIL PUMP
2 K1 OP
GROUND WH/YE-18
B4 1
GN/YE-18 CONTROL
2
WH/RD-18 55 VOLTS
OIL LEVEL SENSOR
OLS
SIGNAL 1
LT BU-18
F2 DIRECT INJECTOR MAG.
L1 JT WH/RD
E 2 G3
WH/RD-14 INJ DI MAG E
GROUND BK/BU-18
M1 2
BU-16 CONTROL
1
WH/RD-16 55 VOLTS
DIRECT INJECTOR PTO

INJ DI PTO
M2 2
GN-16 CONTROL
1
MAGNETO WH/RD-16 55 VOLTS
F F
MAG LINE TYPES
IGNITION COILS 55 / 60 VOLTS
YE-12
COILS 12 VOLTS SWITCHED
YE-12 L3 JT B K 1 1
BK-16 BK-16 GROUND 12 VOLTS UNSWITCHED
YE-12 J3 2
OG/BU-18 CONTROL MAG 5 OR 3.3 VOLTS
3
WH/RD-16 55 VOLTS DIGITAL SIGNAL
Link
M3 JR BK 2 4
BK-16 BK-16 GROUND POWER CONTROL
G K3 5
G
OR/GN-18 CONTROL PTO ANALOG SIGNAL
6
CAPACITOR WH/RD-16 55 VOLTS COMMUNICATION
(+) A-D GROUND
BK-16
BK-16
WH/RD-12 POWER GROUND

(-) GROUND
AC VOLTAGE
BK-12
L4
BK-16
H M4
BK-16 ENGINE H
219100863-019 REF 864 440 REV 1

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2017 SECONDARY HARNESSES

H H
G G
F F
E E
D D
C C
B B
A A
219100863-020 REF: REV:

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SAFETY NOTICE

CAUTION Indicates a hazardous situation

1. Reinforced holes in footrest

NOTICE Do not use footrest opening or steer-

ENGINE EMISSIONS procedures in this manual may lead a vehicle to

This manual uses technical terms which may be

Section 06 ENGINE Page heading

Subsection title MAGNETO

Loctite 243 Drop represents a

Bold face number

Document number for 55 Page number

NOTICE Pay attention to torque specifications.

Remove starting pulley no. 2. TYPICAL Italic bold face type-

Bold face number following part

4.8 8.8 9.8 10.9 12.9

FASTENER FASTENER GRADE/TORQUE

FASTENER INFORMATION Threadlocker Application for

1. Clean threads (bolt and nut) with solvent.

1. Clean threads (bolt and hole) with solvent.

Threadlocker Application for Stud

1. Adjust screw to proper setting.

NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application

Application for Stripped Thread Repair 1 2

3. Apply a strip of proper strength Loctite on lead-

Threadlocker Application for Case-In

1. Clean inner housing diameter and outer gasket

PERIODIC MAINTENANCE SCHEDULE

M ou ntain Serie s O nly

M ou ntain Serie s O nly

EVERY 2 YEAR OR 6 000KM (4,000 MI) (WHICHEVER COMES FIRST)

EVERY 3 YEARS OR 10 000KM (6,000 MI) (WHICHEVER COMES FIRST)

GENERAL – Tuned pipe

Inspecting the Rubber Mount

Adjusting the Engine Stopper

Replacing the Engine Coolant

specifically recommended for aluminum en- TYPICAL VIEW

Remove RH side panel and hood. Refer to BODY

Refilling and Bleeding the Cooling System

8. Lift rear of vehicle and support it safely.

3. With engine cold, slowly fill coolant tank up to

Replacing the In-Line Fuel Filter

14. Add coolant up to 15 mm (1/2 in) above the

Removing the In-line Fuel Filter

1. Release fuel pressure in the system. Refer to

15. When engine has completely cooled down,

When installation is complete, carry out a fuel sys-

for leaks. Failure to carry out a fuel system

Removing the Spark Plugs

Inspecting and Cleaning the Throttle

Inspecting the Throttle Cable

5. Remove lock securing spark plug wire to spark

2. Using a wire gauge, confirm electrode gap is

Installing the Spark Plugs (Non-OEM)

8. Remove spark plugs by hand.

Use the PULLEY FLANGE CLEANER (P/N 413 711

NOTICE Use only the recommended type oil

Verifying the Chaincase Oil Level

If the plug indexing angle is not within specifica-

Replacing the Drive Pulley Wear Parts