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2008 Outlander 400 EFI
Can-Am 2008 Outlander 400 EFI User Manual
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2
Table of Contents
Default Chapter
3
Table of Contents
3
Safety Notice
10
General Information
11
Vehicle Identification
11
Vehicle Model Number
11
Vehicle Description Decal
11
Engine Emissions Information
12
Engine Serial Number
12
Vehicle Serial Number
12
Tightening Torque
13
Stud in Blind Holes
14
Uncovered Holes (Bolts and Nuts)
14
Self-Locking Fasteners Procedure
14
Loctite Application Procedure
14
Adjusting Screw
15
Pre-Assembled Parts
15
Standard Thread Repair
15
Stripped Thread Repair
15
Case-In Components/Metallic Gaskets
16
Gasket Compound
16
Mounting in Tandem
16
Mounting on Shaft
16
Manual Information
17
Typical Page of the Manual
18
Maintenance Chart
21
Vehicles Prepared as Per Storage Procedure
25
Vehicles Not Prepared as Per Storage Procedure
25
Preseason Preparation
25
Coolant Inspection
27
Engine Oil and Filter Replacement
27
Fuel System Protection
27
Storage Procedure
27
Battery Removal and Storage
28
Vehicle Cleaning
28
Vehicle Protection
28
ATV Immersion
29
Service Products
29
Special Procedures
29
Turn over
29
Troubleshooting
31
Cooling System Troubleshooting
31
High Engine Operating Temperature
31
Low or no Oil Pressure/High Oil Consumption
32
Lubrication System Troubleshooting
32
Cylinder and Head Troubleshooting
33
Oil Contamination (White Appearance)
33
Unusual Engine Noise And/Or Vibration at Idle Speed
33
Unusual Engine Noise And/Or Vibration While Operating
33
Crankshaft and Balancer Shaft Troubleshooting
34
Gear Indication Fails
34
Gear(S) Is (Are) Hard to Shift
34
Gearbox Troubleshooting
34
The ATV Accelerates Slowly, Especially When It Is Stopped
35
Rewing Starter Pawl Does Not Engage
35
Rewind Starter Troubleshooting
35
CVT Transmission Troubleshooting
35
Drive Pulley Noise at Idle Speed
36
Drive Pulley Noise When Accelerating/Decelerating
36
Engine Maximum RPM Is too High and Top Speed Is Not Reached
36
Belt Glazed Excessively or Having Baked Appearance
37
Pulleys Do Not Donwshift or Upshift Properly
37
Vibrations Originating from Drive Pulley
37
Vibrations Originating from Driven Pulley
37
Belt Desintegration
38
Belt Worn Excessively on Top Width
38
Electrical System Troubleshooting
38
Ignition System Troubleshooting/No Spark or Poor Spark
38
Starting System Troubleshooting
39
Charging System Troubleshooting
39
Starter Does Not Run/Keeps Running
39
Battery Not Charging or Charging Voltage Inadequate
39
Fuel System Diagnostic Flow Chart
41
Engine Removal/Installation
43
Engine View
44
Engine - General Information
45
Engine Removal
45
Engine Installation
49
Engine Mount Installation
49
Engine Mount Removal
49
Air Intake System
51
Air Intake System - General Information
52
Air Filter Cleaning
52
Air Filter Removal
52
Air Filter Installation
52
Air Filter Housing Draining
53
Air Filter Housing Installation
53
Air Filter Housing Removal
53
Exhaust System View
55
Exhaust System - General Information
56
Muffler Removal
56
Exhaust Pipe Inspection
57
Exhaust Pipe Removal
57
Muffler Installation
57
Exhaust Pipe Installation
58
Rewind Starter View
59
Rewind Starter - General Information
60
Rewind Starter Removal
60
Rewind Starter Assembly
61
Rewind Starter Disassembly
61
To Adjust Rope Tension (Rewind Starter)
62
Rewind Starter Installation
63
Starting Pulley Installation
64
Starting Pulley Removal
64
Lubrication System - Service Tools, Service Products
65
Lubrication System View
66
Oil Level Verification
67
Recommended Engine Oil
67
Lubrication System Maintenance
67
Lubrication System - General Information
67
Engine Oil Replacement
68
Engine Oil Pressure Test
69
Oil Filter Inspection
69
Oil Filter Installation
69
Oil Filter Removal
69
Oil Pressure Switch
70
Oil Pressure Switch Activation/Resistance Test
71
Oil Pressure Switch Removal
71
Oil Prressure Switch Installation
71
Oil Strainer Removal
71
Oil Strainer Installation
72
Oil Strainer Cleaning and Inspection
72
Engine Oil Pressure Regulator
73
Oil Pressure Regulator Inspection/Installation
73
Oil Pressure Regulator Removal
73
Oil Pump Removal
73
Oil Pump Inspection
75
Oil Pump Installation
76
Cooling System - Service Tools, Service Products
77
Radiator (2008) View
78
Radiator (2009) View
79
Water Pump View
80
Thermostat View
81
Refilling and Bleeding the Cooling System
82
Recommended Coolant
82
Draining the Cooling System
82
Cooling System - General Information
82
Cooling System Inspection
84
Cooling System Leak Test
84
Radiator Cap
85
Radiator Inspection
85
Thermostat Removal
85
Thermostat Test
85
Radiator Removal
86
Coolant Tank Removal
87
Radiator Installation
87
Coolant Tank Installation
88
Radiator Cooling Fan Test
88
Fan Relay Test
89
Fan Relay Control Circuit Test
89
Fan Relay Input Voltage Test
89
Fan Ground Circuit Continuity Test
90
Fan Input Voltage Test
90
Fan Power Circuit Continuity Test
91
Radiator Cooling Fan Removal
91
Coolant Temperature Sensor (CTS)
92
Radiator Cooling Fan Installation
92
Water Pump Cover Removal
92
Water Pump Cover Inspection
93
Water Pump Cover Installation
93
Water Pump Impeller Removal/Inspection/Installation
93
Water Pump Shaft and Seal Removal
93
Water Pump Shaft and Gear Inspection
95
Water Pump Shaft and Seal Installation
95
Magneto/Starter - Service Tools, Serivice Products
97
Magneto/Starter View
98
Magneto Cover Removal
99
Magneto/Starter - General Information
99
Magneto Cover Inspection and Cleaning
100
Magneto Cover Installation
100
Oil Seal Inspection
101
Oil Seal Installation
101
Oil Seal Removal
101
Stator Continuity Test
102
Stator Insulation Test
103
Stator Output Voltage Test
104
Stator Removal
105
Rotor Removal
105
Stator Installation
105
Stator Inspection
105
Crankshaft Position Sensor (CPS) Inspection
106
Crankshaft Position Sensor (CPS) Removal
106
Rotor Inspection
106
Rotor Installation
106
Crankshaft Position Sensor (CPS) Installation
107
Starter Voltage Test
107
Starter Cable Continuity Test
108
Starter Removal
108
Starter Installation
109
Continuously Variable Transmission (CVT) - Service Tools/Products
111
Continuously Variable Transmission (CVT) View
112
Continuously Variable Transmission (CVT) - General Information
113
Drive Belt Removal
113
Drive Belt Inspection
114
Drive Belt Installation
114
Drive Pulley Removal
115
Removal Procedure Continuation When Drive Pulley Is Blocked
116
Drive Pulley Disassembly
117
Governor Cup
117
Drive Pulley Cleaning
118
Fixed Sheave
118
Sliding Sheave
118
Drive Pulley Inspection
119
Centrifugal Lever Pivot Bolt
119
Centrifugal Lever
119
Spring
121
Drive Pulley Assembly
122
One-Way Clutch
122
Drive Pulley Installation
123
Driven Pulley Removal
124
Driven Pulley Disassembly
125
Driven Pulley Cleaning
126
Driven Pulley Inspection
126
Driven Pulley Installation
129
Cylinder Head/Cylinder - Service Tools, Service Products
131
Cylinder Head View
132
Cylinder and Piston View
133
Valve Adjustment
134
Cylinder Head/Cylinder Maintenance
134
Cylinder Head/Cylinder - General Information
134
Leak Test
135
Listen for Air Leaks
136
Decompressor Inspection
137
Decompressor Removal
137
Valve Cover Inspection/Installation
137
Valve Cover Removal
137
Decompressor Installation
138
Tensioner Inspection
139
Tensioner Installation
139
Tensioner Removal
139
Timing Chain Tensioner
139
Camshaft Timing Gear Removal
140
Camshaft Timing Gear Installation
140
Camshaft Timing Gear Inspection
140
Timing Chain Inspection
141
Guide Inspection/Installation
142
Rocker Arm Removal
142
Timing Chain Guide Removal
142
Timing Chain Removal/Installation
142
Rocker Arm Inspection
143
Camshaft Removal
144
Rocker Arm Installation
144
Rocker Arm Shaft
144
Camshaft Inspection
145
Cylinder Head Removal
146
Camshaft Installation
146
Cylinder Head Inspection
147
Cylinder Head Installation
147
Valve Spring Inspection
148
Valve Spring Removal
148
Valve Inspection
149
Valve Removal
149
Valve Spring Installation
149
Valve Stem Seal
149
Valve Face and Seat
150
Valve Stem and Valve Guide Clearance
150
Valve Installation
151
Valve Guide Installation
151
Valve Guide Removal
151
Valve Guide Inspection
151
Cylinder Removal
152
Cylinder Inspection
153
Cylinder Installation
153
Cylinder out of Round
153
Cylinder Taper
153
Piston Inspection
154
Piston Removal
154
Piston Pin
155
Piston/Cylinder Clearance
155
Piston Installation
156
Ring/Piston Groove Clearance
157
Piston Ring Installation
157
Piston Ring Removal
157
Piston Ring Inspection
157
Crankcase/Crankshaft - Service Tools, Service Products
159
Crankcase View
160
Crankshaft/Balancer Shaft View
161
Crankcase/Crankshaft - General Information
162
Starter Drive Inspection
162
Starter Drive Removal
162
Counter Shaft Oil Seal Installation
163
Counter Shaft Oil Seal Removal
163
Output Shaft Oil Seal Inspection/Installation
163
Output Shaft Oil Seal Removal
163
Shift Shaft Oil Seal Removal
164
Crankshaft Oil Seal Removal
164
Shift Shaft Oil Seal Installation
164
Crankshaft Oil Seal Installation
164
Crankcase Disassembly
165
Crankcase Cleaning
166
Crankcase Inspection
166
Balancer Shaft Oil Seal Replacement
167
Ball and Needle Bearings
167
Bearing Replacement
167
Crankshaft Oil Seal
167
Crankshaft Plain Bearing Installation
168
Bevel Gear Needle Bearing Removal
169
Counter Shaft Needle Bearing Removal
170
Bevel Gear Needle Bearing Installation
170
Counter Shaft Needle Bearing Installation
170
Balancer Shaft and Bevel Gear Ball Bearing Removal
171
Starter Drive Needle Bearing Installation
171
Starter Drive Needle Bearing Removal
171
Balancer Shaft (MAG Side) Ball Bearing Installation
172
Balancer Shaft Removal
172
Counter Shaft Ball Bearing Installation
172
Crankcase Assembly
172
Balancer Shaft Inspection
173
Balancer Shaft Installation
173
Crankshaft Locking Procedure
173
Crankshaft Inspection and Disassembly
174
Crankshaft Removal
174
Connecting Rod/Piston Pin Clearance
175
Connecting Rod Big End Axial Play
175
Connecting Rod Big End Radial Play
175
Crankshaft Radial Play MAG/PTO Side
176
Crankshaft Assembly
177
Crankshaft Installation
177
Gearbox/Output Shaft View
179
Gearbox/Output Shaft - General Information
180
Output Shaft Removal
180
Output Shaft Inspection
181
Output Shaft Installation
181
Gearbox Disassembly
182
Gearbox Inspection
184
Shift Forks
185
Thrust Washers
185
Gearbox Adjustment
185
Shift Drum
185
Bevel Gear Backlash Procedure
187
Gearbox Assembly
189
Gearbox Position Switch Test with BUDS
190
Gearbox Position Switches
190
Gearbox Position Switch Removal
191
Gearbox Position Switch Resistance Test
191
Gearbox Position Switch Installation
192
Shifter - Service Products
193
Shift Lever Removal
194
Shifter - General Information
194
Handle Removal
194
Handle Installation
194
Link Rod Inspection
195
Link Rod Installation
195
Link Rod Removal
195
Shift Lever Inspection/Shift Lever Installation
195
Shifting Plate Inspection
196
Shifting Plate Installation
196
Shifting Plate Removal
196
Engine Management System (EMS) Overview
199
Power Distribution Chart
200
ECM and VFB Interaction with the Electrical System
201
ECM Inputs/Outputs
201
Engine RPM Limiter
202
Engine Management System Description
202
Engine Control Module (ECM)
202
Controller Area Network (CAN)
202
Drowned Mode (Flooded Engine)
203
Monitoring System/Limp Home Mode
203
Power Distribution
203
Vehicle Speed Limiter
203
Communication Tools/Buds Software
205
Engine Management System
205
MPI-2 Power Supply
205
Multi-Purpose Interface-2 (MPI-2)
205
BUDS Software
206
Changes in ECM
207
Communication Problems
207
Monitoring System/Fault Codes
209
How to Read Fault Codes on the Multifunction Gauge
210
Specific Fault Codes
211
TPS "Out of Range" Fault
211
TPS (Throttle Position Sensor) Faults
211
Fault Code P0705 - Gearbox Position Sensor Fault
212
Fault Code P1513 - Incorrect Match of ECM and Mulfunction Gauge
212
TPS "Adaptation Failure" Fault
212
Fault Code Table
213
Air Induction
219
Electronic Fuel Injection
219
Fuel System
219
Throttle Body
219
Intake Manifold
220
Fuel System Recommendations
220
Electrical System Recommendations
220
Fuel Rail/Fuel Injector
220
Closed Throttle and Idle Actuator Reset
221
Electrical Connectors Recommendations
221
Fuel System Basic Adjustments
221
Idle Speed Adjustment
221
Throttle Cable Lubrication
222
Throttle Cable Adjustment
223
Throttle Cable Installation
223
Throttle Cable Removal
223
Fuel Injector Leakage Test
224
Injector Input Voltage Test
224
Injector Test with BUDS
224
Injector Control Circuit Test
225
Injector Resistance Test (at ECM Connector)
226
Injector Removal
226
Injector Resistance Test (at Component)
226
Fuel Rail Removal
227
Injector Installation
227
Fuel Rail Installation
228
Throttle Body Mechanical Inspection
228
Throttle Body Installation
229
Throttle Body Removal
229
Throttle Position Sensor (TPS) - General Information
230
TPS Resiatance Test
231
TPS Voltage Test
231
TPS Wear Test
231
TPS Removal
232
Idle Air Control Valve
232
TPS Installation
232
IACV Resistance Test
232
IACV Valve Circuit Resistance Test
233
CPS Voltage Test
234
Crankshaft Position Sensor (CPS)
234
IACV Visual Inspection
234
CPS Resistance Test
235
Manifold Absolute Pressure and Temperature Sensor (MAPTS)
236
MAPTS Input Voltage Test
236
MAPTS Test with BUDS
236
MAPTS Power and Ground Circuits Continuity Test
237
MAPTS Pressure Signal Continuity Test
237
Sensor Temperature Function
238
MAPTS Resistance Test
238
Coolant Temperature Sensor (CTS) View
239
CTS Resistance Test
239
MAPTS Installation
239
MAPTS Removal
239
CTS Installation
240
CTS Removal
240
ECM Connector Removal
240
Engine Control Module (ECM) View
240
ECM Connector Installation
241
ECM Connector Probing
242
Power Supply to ECM
242
ECM Ground Test
243
ECM Quick Troubleshooting Tips
243
ECM Power Circuit Test
244
ECM Wake up Circuit Test
245
Main Relay Circuit Test
245
ECM Automated Data Transfer
246
ECM Manual Data Entry
246
ECM Removal/Installation
246
ECM Replacement
246
Fuel Tank/Fuel Pump - Service Tools, Service Products
249
Fuel Tank/Fuel Pump View - 2008 Models
250
Fuel Tank/Fuel Pump View - 2009 Models
251
Fuel Tank Vent System Operation
252
Fuel Tank/Fuel Pump View - General Information
252
Fuel Tank Leak Test
253
Fuel Tank/Fuel Pump Inspection
253
Fuel Tank Check Valve and Pressure Relief Valve Test
255
Fuel Pump Pressure Test
256
Fuel Hose Replacement
257
Oetiker Clamp Replacement
257
Fuel Tank Check Valve and Pressure Relief Valve Installation
258
In-Line Fuel Filter (2008 Models) Removal/Inspection/Installation
258
Fuel Tank Draining
259
Fuel Tank Removal
259
Fuel Tank Inspection
262
Fuel Tank Protector Removal and Installation
262
Fuel Pump (2008) Activation in BUDS
263
Fuel Pump (2008) Quick Test
263
Fuel Tank Installation
263
Fuel Pump Input Voltage Test
264
Fuel Pump Relay Input Voltage Test
265
Fuel Pump Relay Continuity (Ground Circuit)
266
Fuel Pump Winding Continuity Test
266
Fuel Pump Installation
267
Fuel Pump Removal
267
Fuel Pump Strainer Replacement
267
Fuel Pump (2009) Activation in BUDS
268
Fuel Pump (2009) Input Voltage Test
268
Fuel Pump (2009) Quick Test
268
Fuel Pump (2009) Relay Input Voltage Test
269
Fuel Pump (2009) Relay Ground Control Circuit
270
Fuel Pump (2009) Removal
271
Fuel Pump (2009) Winding Resistance Test
271
Fuel Pump (2009) Installation
272
Fuel Pump (2009) Strainer Replacement
274
Fuel Level Sensor Resistance Test
275
Fuel Level Sensor Input Voltage Test
276
Ignition System - Service Tools, Service Products
277
Ignition System Operation
277
Ignition System Troubleshooting
277
Ignition Testing Sequence
277
Ignition Switch Operation
278
Ignition System - Safety Precautions
278
Intermittent Ignition Problems
278
Ignition Switch Continuity Test
279
Ignition Switch Input Voltage Test
279
Ignition Switch Removal
279
Ignition Switch Installation
280
Engine Stop Switch Continuity Test
280
Engine Stop Switch Operation
280
Ignition Coil Input Voltage Test
281
Ignition Coil Location
281
Ignition Coil Ground Circuit Continuity Test
282
Ignition Coil Resistance Tests
283
Secondary Winding Resistance Test/Spark Plug Cable Resistance Test
283
Spark Plug
283
Testing for Spark Occurence
283
Spark Plug Removal
284
Troubleshooting a Fouled Spark Plug
284
Spark Plug Analysis
285
Spark Plug Installation
285
Voltage Regulator
287
Electrical System
287
Magneto
287
Charging System Description
287
Battery
288
Voltage Regulator Continuity Test
288
Voltage Test Using BUDS
288
DC Current Test with an Inductive Ammeter
289
Voltage Test with a Multimeter
289
DC Current Test with a Multimeter
290
Battery Information
291
Battery Troubleshooting
291
Weak or Discharged Battery
291
Battery Voltage Test (no Load)
292
Battery Voltage Test (Load Applied)
292
Battery Removal
292
Battery Charging
293
Battery Cleaning
293
Battery Inspection
293
Battery Storage
293
Battery Cable Routing View
294
Battery Installation
294
Electrical System Main Ground
294
Start Button Continuity Test
297
Start Button Quick Test
297
Starter will Not Crank Engine
297
Starting System Operation
297
Power Signal to Solenoid Coil Test
299
Starter Solenoid
299
Solenoid Ground Control Circuit Test
300
Solenoid Diode Test
301
Solenoid Continuity Test
302
Solenoid Dynamic Test
303
Checking for Short Circuits between 2 Wires
305
Lights, Gauge and Accessories - General Information
305
Lights, Gauge and Accessories - Service Tools, Service Products
305
Lights, Gauge and Accessories Diagnostics
305
Electrical Connectors
306
Front Fuse Box
306
Fuses
306
Accessory Relay (R4)
307
Fear Fuse Holder (PF2)
307
Display 2 (Mode)
308
Multifunction Gauge
308
Display 1 (Speedometer)
308
Display 3 (Mode/Message)
309
Message Mode
309
Display Selector Button
310
Fuel Level Display
310
Tachometer
310
Transmission Position Display
310
Fault Codes Display
311
Indicator Lights
311
Cluster Unit Selection (MPH Vs Km/H)
311
Cluster Country Selection
311
Multifunction Gauge Pin-Out
312
Multifunction Gauge Testing
312
Speedometer Display
312
2/4WD Indicator Light
313
HI Beam Indicator Light
313
Transmission Position Display in the Multifunction Gauge
313
Fuel Level Indication and Low Fuel Level Indicator Light
314
Multifunction Gauge Input Voltage Test
314
Multifunction Gauge Removal
314
Multifunction Gauge Installation
315
New Multifunction Gauge Registration (Coding)
315
Vehicle Speed Sensor (VSS)
315
VSS Input Voltage Test
315
VSS Removal
316
VSS Signal Circuit Test
316
Headlight Switch Test
317
VSS Installation
317
12-Volt Auxiliary Power Connector
318
Override Switch Test
318
12-Volt Auxiliary Power Connector Test
319
12-Volt Power Outlet Test
319
12-Volt Power Outlet Installation
320
12-Volt Power Outlet Removal
320
Headlight Test
320
Headlight Bulb Replacement
321
Headlight Beam Aiming
322
Headlight Beam Adjustment
322
Front Position Lights
322
Front Position Light Bulb Replacement
322
Position Light Testing
323
Taillight/Brake Light Circuit Test
323
Taillight/Brake Light Operation
323
Only One Filament Functions
324
Taillight/Brake Light Bulb Replacement
324
Turn Signal Lights
325
Turn Signal Light Testing
326
Flasher Diodes Test
327
Turn Signal Switch Continuity Test
327
Hazard Warning Lights
328
Hazard Warning Switch Testing
329
Horn
331
Winch
332
Winch Control Switch Input Voltage Test
333
Winch Motor
333
Winch Relay Control Signal Voltage
333
Winch Test
333
D5 and D6 Diode Test
334
Winch Relay Voltage Drop
334
Winch Control Switch Continuity Test
336
Winch Installation
336
Winch Removal
336
Winch Control Switch Continuity Installation
337
Winch Control Switch Removal
337
Drive System
339
4X4 Coupling Unit - Service Tools, Service Products
339
4X4 Coupling Unit View
340
2WD/4WD Selector Test
341
4X4 Coupling Unit - General Information
341
2WD/4WD Selector Replacement
342
Actuator Installation
342
Actuator Removal
342
2WD/4WD Switch Removal
343
2WD/4WD Switch Test
343
2WD/4WD Switch Installation
344
Coupling Unit Disassembly
344
Coupling Unit Removal
344
Coupling Unit Inspection
346
Coupling Unit Assembly
347
Coupling Unit Installation
349
Front Drive - Service Tools, Service Products
351
Front Drive View
352
Front Drive - General Information
353
Front Drive Maintenance
353
Front Drive Oil Change
353
Front Drive Oil Level Verification
353
Drive Shaft Disassembly
354
Drive Shaft Inspection
354
Drive Shaft Removal
354
Drive Shaft Assembly
355
Drive Shaft Installation
355
Differential Removal
356
Differential Inspection
356
Differential Disassembly
356
Differential Adjustment
357
Backlash
358
Defferential Installation
359
Differential Assembly
359
Pinion Gear
359
Propeller Shaft Removal
359
Propeller Shaft Inspection
360
Propeller Shaft Installation
360
Rear Drive - Service Tools, Service Products
361
Rear Drive View
362
Rear Drive Maintenance
363
Rear Drive - Oil Replacement
363
Rear Drive - Oil Level Verification
363
Rear Drive - General Information
363
Differential Protector Installation
364
Differential Protector Removal
364
Drive Shaft Removal/Inspection/Disassembly
364
Drive Shaft Assembly (Rear)
365
To Install Drive Shaft (Rear)
366
To Remove Propeller Shaft (Rear)
366
Propeller Shaft Inspection (Rear)
367
Propeller Shaft Installation (Rear)
367
Rear Propeller Shaft U-Joint
367
U-Joint Removal
367
U-Joint Installation
368
Differential Removal (Rear)
368
Differential Inspection (Rear)
368
Differential Adjustment (Rear)
369
Differential Disassembly (Rear)
369
Differential Assembly (Rear)
371
Differential Installation (Rear)
371
Chassis
373
Wheels/Tires View
373
Tire Pressure
374
Wheel Removal/Installation
374
Wheels/Tires - General Information
374
Wheels/Tires Maintenance
374
Wheel Hub Removal
375
Tire Replacement
375
Tire Inspection
375
Wheel Hub Inspection
376
Wheel Hub Installation
376
Steering System - Service Tools, Service Products
377
Steering System View
378
Steering Alignment
379
Steering System - General Information
379
Steering System Adjustments
379
Handlebar Grip Installation
380
Handlebar Grip Removal
380
Multifunctional Switch Removal
381
Handlebar Covers Removal
381
Handlebar Covers Installation
381
Handlebar Covers Inspection
381
Throttle Lever Removal
382
Handlebar Removal
383
Throttle Lever Installation
383
Handlebar Inspection
384
Steering Column Removal
384
Steering Column Bearing Replacement
385
Steering Column Inspection
385
Steering Column Installation
386
Tie-Rod Inspection
386
Tie-Rod Installation
386
Tie-Rod Removal
386
Wheel Bearing Removal
387
Wheel Bearing Inspection
387
Knuckle Removal
387
Knuckle Inspection/Installation
387
Wheel Bearing Installation
388
Front Suspension - Service Tools, Service Products
389
Front Suspension View
390
Front Suspension - General Information
391
Strut Disassembly
391
Strut Removal
391
Strut Assembly/Installation
392
Strut Inspection
392
Suspension Arm Protector Inspection
392
Suspension Arm Protector Removal
392
Suspension Arm Removal
393
Suspension Arm Installation
393
Suspension Arm Protector Installation
393
Suspension Arm Inspection
393
Ball Joint Inspection
394
Ball Joint Installation
394
Ball Joint Removal
394
Rear Suspension - Service Tools, Service Products
395
Rear Suspension View
396
Rear Suspension - General Information
397
Rear Suspension Adjustment
397
Shock Absorber Removal
397
Spring Preload
397
Shock Absorber Inspection
398
Shock Absorber Disassembly
398
Shock Absorber Assembly and Installation
398
Torsion Bar Removal
399
Torsion Bar Inspection
400
Torsion Bar Installation
400
Trailing Arm Removal
400
Trailing Arm Bearing Replacement
402
Trailing Arm Inspection
402
Trailing Arm Installation
404
Brakes - Service Tools, Service Products
405
Front Brake Circuit (Except 2009 CE Models) View
406
Front Brake Circuit (2009 CE Models) View
407
Rear Brake Circuit View
408
Recommended Brake Fluid
409
Brakes - General Information
409
Brakes Maintenance
409
Brake Fluid Level Verification
409
Brake Bleeding - General Recommendations
410
Brake Bleeding Using a Vacuum Pump
410
Brake Fluid Draining
410
Brake Fluid Replacement
410
Brake Bleeding (Additiona Steps for CE Models)
411
Manual Bleeding Procedure
411
Brake Light Switch Installation
412
Brake Light Switch Removal
412
Brake Light Switch Test
412
Front Master Cylinder Removal
413
Parking Brake Mechanism Removal/Installation
413
Brake Lever Removal/Inspection
413
Brake Lever Installation
413
Front Master Cylinder Disassembly
414
Rear Master Cylinder Disassembly
414
Rear Master Cylinder Removal
414
Caliper Removal (Front and Rear)
415
Master Cylinder Inspection (Front and Rear)
415
Rear Master Cylinder Assembly
415
Rear Master Cylinder Installation
415
Brake Pad Removal
416
Caliper Inspection (Front and Rear)
416
Caliper Installation (Front and Rear)
416
Brake Pad Installation
417
Brake Pad Inspection
417
Brake Disc Inspection (Front and Rear)
417
Brake Pedal Removal
418
Front Brake Disc Removal/Installation
418
Rear Brake Disc Installation
418
Rear Brake Disc Removal
418
Brake Circuit Splitter Removal
419
Brake Pedal Inspection
419
Brake Pedal Installation
419
Brake Circuit Splitter Installation
420
Brake Hose Inspection
420
Brake Hose Installation
420
Brake Hose Removal
420
Body - Service Tools
423
Body Parts (Front) View
424
Body Parts (Rear) View
425
Body Parts (Side) View
426
Seat View
427
Bumpers View
428
Body - General Information
429
Decal Installation
429
Decal Removal
429
Reusable Plastic Rivets Removal
429
Seat Cleaning
430
Seat Installation
430
Seat Removal
430
Console Removal
431
Seat Cover Replacement
431
Console Installation
432
Vehicle Lock Removal
432
Side Panel Installation
433
Side Panel Removal
433
Vehicle Lock Installation
433
Footrest Installation
434
Footrest Removal
434
Bumper Removal
435
Inner Fender Installation
435
Inner Fender Removal
435
Front Fascia Removal
436
Front Fascia Installation
437
Front Skid Plate Removal
437
Lower Skid Plate Removal
438
Lower Skid Plate Installation
438
Front Skid Plate Installation
438
Front Bumper Installation
439
Front Bumper Removal
439
Fender Removal
440
Luggage Rack Installation
440
Luggage Rack Removal
440
Rear Fender
441
Fender Installation
442
Fender Support Removal
442
Fender Support Installation
443
Frame View (Outlander 400 EFI and Outlander 400 EFI XT Models)
445
Frame View (Outlander MAX 400 EFI and Outlander MAX 400 EFI XT Models)
446
Frame - General Information
447
Footrest Supports Removal/Inspection/Installation
447
Battery Support Removal
447
Battery Support Inspection/Installation
448
Frame Cleaning
448
Hitch Inspection/Installation
448
Hitch Removal
448
Frame Welding
449
Outlander 400 EFI Specifications - Engine
451
Technical Specifications
451
Outlander 400 EFI Specifications - Cooling System
453
Outlander 400 EFI Specifications - Gearbox
453
Outlander 400 EFI Specifications - Electrical System
454
Outlander 400 EFI Specifications - Fuel System
454
Outlander 400 EFI Specifications - Transmission
455
Outlander 400 EFI Specifications - Drive System
455
Outlander 400 EFI Specifications - Brakes
456
Outlander 400 EFI Specifications - Front Suspension
456
Outlander 400 EFI Specifications - Rear Suspension
456
Outlander 400 EFI Specifications - Steering
456
Outlander 400 EFI Specifications - Dimensions
457
Outlander 400 EFI Specifications - Material
457
Outlander 400 EFI Specifications - Tires and Wheels
457
Outlander 400 EFI Specifications - Weight and Loading Capacity
457
Outlander 400 EFI - Wiring Diagram Information
459
Outlander 400 EFI - General System Wiring Diagram
460
Radiator Expansion Bottle Vent Tube Routing (Outlander XT and LTD)
471
Throttle Plate Opening (All Models Except CE)
472
Throttle Lever Stopper Screw Setting
472
Accessory Shock Absorber / Spring Kits
473
Spring Applications Table
475
Spring Specifications Table
478
Table of Contents
483
Predelivery Inspection (Can-Am Outlander and Renegade)
483
Important Notice
484
Model Listing
485
Uncrating
486
Parts to be Installed
487
Battery - Installation
487
Battery Cable Routing
487
Front Bumper (Outlander XT Models)
488
Flag Holder (Renegade CE Models)
489
Mirrors (Outlander CE Models)
489
Winch Switch (Outlander XT and LTD Models)
489
Backrest - Outlander MAX Models
490
Locking Device - CE Models
490
Handlebar Guard - Outlander 400 XT Models
491
Accessories Installation
492
Mudguard - LTD Models
492
Vehicle Decals
492
Wind Deflector - X Models
492
Fluids
494
Central Skid Plate - X Models
494
General Guidelines
494
Recommended Fuel
494
Engine Oil
495
Coolant Level Verification
496
Engine Coolant
496
Gearbox Oil
496
Gearbox Oil Level Verification
496
Brake Fluid
497
Brake Pedal Fluid Level Verification
498
Front and Rear Differential Oil
498
Set-Up
499
Tires Pressure
499
Adjustments - General Guidelines
500
Brake Disk Cleanup
500
Protective Materials
500
Suspension Adjustment
500
Transmission Lever
500
Brake Pedal and Lever Adjustment
502
B.U.D.S. Programming
502
Entering Customer's Name (BUDS)
502
Resetting Trip Hours and Trip Distance (BUDS)
502
Resetting Last Service (BUDS)
503
Programing Keys with B.U.D.S.
503
Speedometer Reading Adjustment
503
Assembly Inspection
504
Final Inspection
504
Vehicle Test Run
504
Vehicle Cleaning
504
Delivery to Customer
504
Technical Data - Outlander 400 Series
505
High Altitude Use
517
High Altitude Specifications
518
Outlander 400 EFI Inappropriate D.E.S.S. Decal
523
CVT Drive Belt Guidelines
524
CAN-AM ATV B.U.D.S. Software and Communication Tools
525
MPI-1 Communication Tools
525
Multi-Purpose Interface (MPI-1)
525
MPI-1 Supply
526
Connections with Vehicle Using MPI-1
526
MPI-2 Communication Tools
527
Multi-Purpose Interface-2 (MPI-2) Info
527
MPI-2 Supply
527
Connections with Vehicle Using MPI-2
527
BUDS Software (Bombardier Utility and Diagnostic Software)
529
CAN-AM ATV Batteries Activation, Charging and Maintenance
532
Initial Charging
532
Battery Charging
532
Battery Activation
532
Battery Maintenance
533
Routine Charging
533
Charging for Voltage of 11.5 or Less
533
Battery Care Reminder
534
Battery Safety Warnings
534
Battery Storage
534
2008 ATV / VTT Table
538
Engine Table
539
Engine View - Outlander 400
544
Engine View - Renagade
546
Engine View - V500/650/800
549
Carburetor and Fuel System Table
556
Carburetor and Fuel System View - Outlander Renegade
558
Carburetor and Fuel System View - 400 EFI
559
Carburetor and Fuel System View - V500/650/800
562
Ignition Table
563
Ignition View - Outlander 400
564
Ignition View - V500/650/800
565
Starter Table
566
Starter View - Outlander
567
Transmission and Linkage Table
568
Transmission and Linkage View - Outlander 400
570
Transmission and Linkage View - V500/650/800
571
Brake System Table
573
Brake System View - Outlander/Renegade
574
Steering/Front Drive System and Suspension Table
575
Steering/Front Drive System and Suspension View - Outlander 400
577
Steering/Front Drive System and Suspension View - Outlander/Renegade
580
Rear Drive System and Suspension Table
583
Rear Drive System and Suspension View - Outlander/Renegade
585
Body and Accessories Table
587
Body and Accessories View - Outlander/Renegade
589
Rear Drive System and Suspension View - Outlander
590
Body and Accessories View - Outlander XT
591
Body and Accessories View - Renegade
592
Electrical System Table
593
Electrical System View - Outlander
595
4
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Can-Am 2008 Outlander 400 EFI Specifications
General
Brand
Can-Am
Model
2008 Outlander 400 EFI
Category
Offroad Vehicle
Language
English
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