2010-2011 CanAm UNLOCKED Spyder RT-RTS-Service & Parts PDF

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can-am |
Z010-Z011
EIT-
2010 - 201 1
Shop Manual
SPYDERTM RT
can-am |
TABLE OF CONTENTS
SAFETY NOTICE ............................................................... .. .................................... .. XII
INTRODUCTION ..................................................................................................... .. XIII

GENERAL INFORMATION .................................................. .. ................................... .. XIII
VEHICLE INFORMATION .................................................... .. ................................... .. XIV
MANUAL INFORMATION ................................................... .. ................................... .. XV
FASTENER INFORMATION ................................................. .. ................................... .. XIX
01 MAINTENANCE
01 - MAINTENANCE SCHEDULE .................................... .. ...................................... .. 7
02 - STORAGE PROCEDURE ......................................... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
GENERAL ...................................................... .. .................................... .. 11
PROCEDURES ....................................................... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 11
CLUTCH SYSTEM ISM5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 12
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................... .. 12
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12
VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12
03 — PRESEASON PREPARATION ................................... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13
PROCEDURES ....................................................... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13
VEHICLE PREPARED AS PER STORAGE PROCEDURE . . . . .. .................................... .. 13
VEHICLE NOT PREPARED AS PER STORAGE PROCEDURE . . . . .. .................................... .. 13
O2 ENGINE
01 - ENGINE REMOVAL AND INSTALLATION .......................... .. .................................... .. 15
GENERAL ...................................................... .. .................................... .. 16
PROCEDURES ....................................................... .. .................................... .. 16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 16
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 23
02 — AIR INTAKE SYSTEM .................................................. .. .................................... .. 27
GENERAL ............................................................ .. .................................... .. 28
PROCEDURES ................................................. .. .................................... .. 28
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 28
RESONATOR ................................................ .. .................................... .. 29
AIR FILTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 30
U3 — EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 33
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 35
EXHAUST SYSTEM INSTALLATION SEQUENCE . . . . . . . . . . . . . . . . . .. .................................... .. 35
MAINTENANCE ............................................... .. .................................... .. 36
CATALYTIC CONVERTER FRONT GASKET REPLACEMENT . . . . . .. .................................... .. 36
INSPECTION ................................................... .. .................................... .. 38
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 38
MUFFLER HEAT SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 38
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 38
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 39
HEAD PIPE (FRONT CYLINDER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 41
HEAD PIPE (REAR CYLINDER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 42
04 — LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 45
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 50
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 50
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .................................... .. 50
TABLE OF CONTENTS
O2 ENGINE (C0nt'CI)
04 - LUBRICATION SYSTEM (COn’['d)
MAINTENANCE (cont'd)
ENGINE OIL FILTER ................................................................. ..
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
OIL PRESSURE SWITCH (OPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
OIL TANK STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
OIL HOSE CONNECTOR TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
OIL JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
OIL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
ENGINE OIL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
OIL DUCT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
OIL TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
05 — COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
ENGINE COOLANT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
COOLING SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
COOLANT TANK CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
COOLANT TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
COOLANT TEMPERATURE SENSOR (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
WATER PUMP HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
WATER PUMP IMPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
WATER PUMP SHAFT AND SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
06 - MAGNETO AND STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
MAGNETO COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
SPRAG CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
SPRAG CLUTCH GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
STARTER DRIVE GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
ELECTRIC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
O7 - CYLINDER HEAD AND CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
CYLINDER LEAK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
BALANCE SHAFT DRIVE GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
CAMSHAFT TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
TABLE OF CONTENTS
I r
ENGINE (cont‘d)
07 — CYLINDER HEAD AND CYLINDER (c0nt'd)
PROCEDURES (confd)
BALANCE SHAFT ...................................................................................... .. 113
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 115
VALVE LIFTER BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 118
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 121
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 122
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 124
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 127
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 127
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 130
PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 131
08 — CRANKCASE AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 133
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 136
ENGINE REASSEMBLY SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 136
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 137
DRIVE GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 137
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 140
CRAN KCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 144
CRAN KSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 150
CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 153
BALANCE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 155
09 — CLUTCH (SM5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 157
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 162
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 162
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 163
CLUTCH FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 163
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 168
CLUTCH OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 168
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 171
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 171
CLUTCH LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 171
MASTER-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 171
CLUTCH SOLENOID VALVE (CSV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 171
CHECK VALVE (CLUTCH SOLENOID VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 173
HYDRAULIC PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 174
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 175
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 177
CLUTCH DIAPHRAGM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 178
PRESSURE PLATE AND CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 181
CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 182
CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 183
CLUTCH HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 187
CLUTCH DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 189
10 - CLUTCH (SE5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 195
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 198
TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 199
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 199
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 201
PRESSURE RETAINING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 202
TABLE OF CONTENTS
02 ENGINE (cont’d)
10 - CLUTCH (SE5) (C0nt'd)
PROCEDURES (cont'd)
PRESSURE PLATE ..................................................................................... .. 203
CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 205
CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 207
CLUTCH HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 212
CENTRIFUGAL CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 213
CLUTCH DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 216
11 — HYDRAULIC CONTROL MODULE (SE5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 223
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 225
SYSTEM DESCRIPTION (COMPONENTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 225
SYSTEM DESCRIPTION (PRINCIPLE OF OPERATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 228
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 232
HCM OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 232
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 232
HCM OIL PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 232
PROCEDURES ............................................................................................ .. 234
SHIFT AND CLUTCH SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 234
OIL HOSE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 237
HCM OIL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 237
HYDRAULIC CONTROL MODULE (HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 238
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 240
INTERMEDIATE OIL PUMP GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 243
SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 246
12 — GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 249
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 253
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 253
REVERSE BUTTON TEST WITH B.U.D.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 253
GEARBOX POSITION SENSOR (GBPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 253
OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 255
REVERSE ACTUATOR (SM5 MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 257
SHIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 260
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 261
03 ELECTRONIC MANAGEMENT SYSTEMS

O1 - OVERVIEW ................................................................................................... . . 269
GENERAL ................................................................................................. .. 269
ENGINE MANAGEMENT SYSTEM (EMS) ............................................................. .. 270
VEHICLE STABILITY SYSTEM (VSS) ................................................................... .. 272
DYNAMIC POWER STEERING (DPS) .................................................................. .. 272
ELECTRONIC SHIFT SYSTEM (SE5) ................................................................... .. 272
02 - CONTROLLER AREA NETWORK (CAN) ................................................................. .. 273
GENERAL ................................................................................................. .. 273
SYSTEM DESCRIPTION ............................................................................... .. 273
03 - COMMUNICATION TOOLS AND B.U.D.S ............................................................... .. 275
GENERAL ................................................................................................. .. 275
TROUBLESHOOTING ................................................................................... .. 275
DIAGNOSTIC TIPS ..................................................................................... .. 275
PROCEDURES ............................................................................................ .. 276
MULTI-PURPOSE INTERFACE-2 (MPI-2) ............................................................... .. 276
B.U.D.S. ............................................................................................... .. 277
IV
TABLE OF CONTENTS
03 ELECTRONIC MANAGEMENT SYSTEMS (cont‘d)

04 - DIAGNOSTIC AND FAULT CODES ....................................................................... .. 281
GENERAL ................................................................................................. .. 281
MONITORING SYSTEM ............................................................................... .. 281
FAULT CODES ......................................................................................... .. 284
FAULT CODE DIAGNOTIC ............................................................................. .. 287
SPECIFIC FAULT CODES .............................................................................. .. 291
FAULT CODE TABLE ................................................................................... .. 292
O4 FUEL SYSTEM
01 — ELECTRONIC FUEL INJECTION IEFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 343
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 343
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 346
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 346
THROTTLE POSITION SENSOR RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 346
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 346
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 348
FUEL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 348
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 350
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 354
THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 357
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 361
CAMSHAFT POSITION SENSOR (CAPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 362
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 364
AMBIENT AIR PRESSURE AND TEMPERATURE SENSOR IAAPTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 367
COOLANT TEMPERATURE SENSOR (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 370
HEATED OXYGEN SENSOR IHOZS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 372
KNOCK SENSOR (KS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 377
THROTTLE ACCELERATOR SENSOR (TAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 378
ELECTRIC THROTTLE ACTUATOR (ETA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 379
ENGINE CONTROL MODULE (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 380
02 — FUEL TANK AND FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 389
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 391
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 392
FUEL SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 392
FUEL SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 393
TROUBLESHOOTING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 396
DIAGNOSTIC FLOW CHART (FUEL PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 396
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 396
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 396
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 398
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 401
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 404
FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 406 ‘
EVAP PURGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 407
05 ELECTRICAL SYSTEM
01 - POWER DISTRIBUTION AND GROUNDS ............................................................... .. 413
GENERAL ................................................................................................. .. 413
POWER DISTRIBUTION DIAGRAM ................................................................... .. 413
REAR FUSE BOX ...................................................................................... .. 414
V
TABLE OF CONTENTS
O5 ELECTRICAL SYSTEM (COI'It'd)

01 - POWER DISTRIBUTION AND GROUNDS (cont'd)
GENERAL (cont'd)
VOLTAGE REGULATOR/RECTIFIER FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 414
FRONT FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 415
RELAYS ................................................................................................ .. 416
GROUNDS ............................................................................................. .. 418
O2 - WIRING HARNESS AND CONNECTORS ................................................................ .. 419
GENERAL ................................................................................................. .. 420
CONNECTOR ABBREVIATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 420
WIRING HARNESS ROUTING ......................................................................... .. 421
WIRING HARNESS SPLICE LOCATION ............................................................... .. 431
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 438
WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 438
DEUTSCH CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 439
MOLEX CONNECTOR (ECM) .......................................................................... .. 440
PACKARD CONNECTOR (TCM AND GAUGE) ......................................................... .. 443
DELPHI CONNECTORS (DPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 444
AMP MULTILOCK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 444
AMP CONNECTOR (8-CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 446
BOSCH CONNECTOR (VCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 446
BATTERY CABLE TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 448
03 - IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 451
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 451
SYSTEM DESCRIPTION ............................................................................... .. 451
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 452
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 452
IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 455
SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 457
SPARK PLUGS ......................................................................................... .. 457
04 — CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 459
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 459
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 460
CHARGING SYSTEM OUTPUT ........................................................................ .. 460
PROCEDURES ............................................................................................ .. 462
VOLTAGE REGULATOR/RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 462
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 463
05 - STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 467
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 467
STARTING SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 467
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 468
ELECTRIC STARTER ................................................................................... .. 468
D2 DIODE (STARTER SOLENOID) ..................................................................... .. 469
ENGINE STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 471
START BUTTON . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 471
PRE-STARTING RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 472
STARTER SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 472
VI
TABLE OF CONTENTS
05 ELECTRICAL SYSTEM (cont'd)

05 - STARTING SYSTEM (cont’d)
PROCEDURES (COnt'd)
CLUTCH SWITCH ...................................................................................... .. 474
06 — DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 475
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 475
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 475
PARTS REPLACEMENT GUIDELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 476
D.E.S.S. MODULE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 476
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 476
KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 476
D.E.S.S. MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 479
07 — LIGHTS, GAUGE AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 481
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 481
SYSTEM DESCRIPTION (LIGHTING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 481
SYSTEM DESCRIPTION (MULTIFUNCTION GAUGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 483
SYSTEM DESCRIPTION (REAR STORAGE COMPARTMENTS - 2010 MODELS) . . . . . . . . . . . . . . . . . . . . . .. 493
SYSTEM DESCRIPTION (REAR STORAGE COMPARTMENT - 2011 MODELS) . . . . . . . . . . . . . . . . . . . . . . .. 493
SYSTEM DESCRIPTION (LEFT MULTIFUNCTION SWITCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 493
SYSTEM DESCRIPTION (CRUISE CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 494
SYSTEM DESCRIPTION (AUDIO AND COMMUNICATION SYSTEMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 494
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 495
MULTIFUNCTION GAUGE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 495
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 495
HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 495
FOG LIGHTS (OPTION PACKAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 502
LICENSE PLATE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 505
TURN SIGNAL LIGHTS/HAZARD WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 506
TURN SIGNAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 508
HAZARD WARNING LIGHTS SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 508
TAILLIGHT/BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 509
POSITION LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 511
BACK UP LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 512
MULTIFUNCTION GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 513
ANALOG COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 517 I
ANALOG COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 517
LEFT MULTIFUNCTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 517
FRONT HEATED GRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 519
PASSENGER HEATED GRIP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 520
RADIO MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 522
PASSENGER RADIO CONTROL SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 525
SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 527
AUXILIARY AUDIO IN JACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 531
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 532
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 534
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 536
REAR STORAGE COMPARTMENT SWITCHES (2010 MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 536
REAR STORAGE COMPARTMENT SWITCHES (2011 MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 537
FRONT STORAGE COMPARTMENT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 537
HOOD ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 538
PBS SWITCH (HOOD ACTUATOR FUNCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 538
FRONT CASE SWITCH (FCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 539
VII
TABLE OF CONTENTS
O5 ELECTRICAL SYSTEM (COnt'd)

07 - LIGHTS, GAUGE AND ACCESSORIES (COr1t'd)
PROCEDURES (cont'd)
CRUISE CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 540
CENTRAL PANEL SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 541
08 — ELECTRONIC SHIFT SYSTEM (SE5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 543
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 543
TROUBLESHOOTING WITH B.U.D.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 545
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 547
GEAR SHIFTING SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 547
REVERSE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 547
TRANSMISSION CONTROL MODULE (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 548
O6 DRIVE SYSTEM
01 - DRIVE BELT AND REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 551
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 553
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 553
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 553
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 558
REAR SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 561
FRONT SPROCKET (WITHOUT FLYWHEEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 562
FRONT SPROCKET (WITH FLYWHEEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 563
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 565
REAR TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 566
REAR WHEEL TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 567
07 CHASSIS
01 - VEHICLE STABILITY SYSTEM IVSSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 569
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 569
SYSTEM DESCRIPTION (FEATURES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 569
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 574
YAW RATE SENSOR (YRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 574
PILLION RIDER (PASSENGER) SWITCH (PRSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 576
WHEEL SPEED SENSOR (VSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 579
VEHICLE CONTROL MODULE (VCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 580
02 — STEERING (DPS) AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 587
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 589
SYSTEM DESCRIPTION (FEATURES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 589
SENSOR RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 590
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 591
STEERING ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 591
SAS RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 595
TORQUE SENSOR RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 596
DPS STRATEGY ACCORDING TO FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 596
FAULT CODE C0051 AFTER DPS REPLACEMENT OR SAS RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 596
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 597
FRONT WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 597 ‘
VIII
TABLE OF CONTENTS
07 CHASSIS (confd)
02 - STEERING (DPS) AND WHEELS (cOnt'd)
PROCEDURES (Cont'd)
FRONT TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 597
HANDLEBAR GRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 598
MULTIFUNCTION SWITCH (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 602
MULTIFUNCTION SWITCH (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 604
THROTTLE HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 606
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 609
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 610
STEERING COLUMN BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 611
STEERING ANGLE SENSOR (SAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 612
DPS UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 614
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 618
TIE-ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 621
KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 622
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 623
WHEEL BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 624
03 - FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 627
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 629
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 629
SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 629
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 629
SUSPENSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 629
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 630
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 630
AIR DEFLECTOR (UPPER ARM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 631
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 631
UPPER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 633
AIR DEFLECTOR (LOWER ARM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 634
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 634
LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 635
PIVOT BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 636
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 637
LINK ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 637
04 — REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 639
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 641
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 642
ACS SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 642
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 644
TROUBLESHOOTING WITH B.U.D.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 645
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 645
ACS POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 645
ACS SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 649
ACS RELAY (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 651
ACS COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 652
ACS SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 654
ACS AIR SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 655
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 657
SWING ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 659
IX
TABLE OF CONTENTS
07 CHASSIS (Cont'd)
05 - BRAKES ....................................................................................................... .. 665
GENERAL ................................................................................................. .. 668
FAULT CODES ......................................................................................... .. 668
ADJUSTMENT ........................................................................................... .. 668
PARKING BRAKE CABLE ADJUSTMENT .............................................................. .. 668
MAINTENANCE .......................................................................................... .. 669
BRAKE FLUID .......................................................................................... .. 669
INSPECTION .............................................................................................. .. 677
BRAKE SYSTEM PRESSURE VALIDATION ............................................................ .. 677
TROUBLESHOOTING GUIDELINES (PARKING BRAKE) ............................................... .. 678
PROCEDURES ............................................................................................ .. 678
CALIPER ............................................................................................... .. 678
BRAKE PAD ............................................................................................ .. 681
BRAKE DISC ........................................................................................... .. 683
ENCODER WHEEL .................................................................................... .. 685
BRAKE PEDAL ......................................................................................... .. 686
BRAKE FLUID RESERVOIR ............................................................................ .. 688
DUAL MASTER CYLINDER ............................................................................ .. 688
MASTER CYLINDER ROD ............................................................................. .. 689
PARKING BRAKE FRONT PULLEY .................................................................... .. 690
PARKING BRAKE REAR PULLEY ...................................................................... .. 692
PARKING BRAKE CABLE .............................................................................. .. 694
PARKING BRAKE MOTOR ............................................................................. .. 695
PARKING BRAKE MODULE (WPM) ................................................................... .. 696
PARKING BRAKE SWITCH (PBS) ...................................................................... .. 697
PARKING BRAKE LIGHT SWITCH (HBS) .............................................................. .. 698
BRAKE LIGHT SWITCH (BLSI ......................................................................... .. 699
LOW PRESSURE SWITCH (LPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 700
06 — BODY .......................................................................................................... .. 703
GENERAL ................................................................................................. .. 715
VEHICLE CARE ........................................................................................ .. 715
TROUBLESHOOTING GUIDELINES IWINDSHIELDI .................................................. .. 715
PROCEDURES ............................................................................................ .. 715
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 715
MIRRORS .............................................................................................. .. 716
SERVICE COVERS ..................................................................................... .. 716
FRONT FASCIA ........................................................................................ .. 716
MIDDLE SIDE PANELS ................................................................................ .. 717
TOP SIDE PANELS ..................................................................................... .. 718
REAR SIDE PANELS ................................................................................... .. 719
GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 720
CENTRAL PANEL ...................................................................................... .. 721
BOTTOM FRONT SIDE PANELS ....................................................................... .. 722
BOTTOM REAR SIDE PANELS ........................................................................ .. 722
ACOUSTIC PANELS .................................................................................... .. 723
FRONT CARGO MODULE ............................................................................. .. 723
FRONT STORAGE COMPARTMENT LATCH .......................................................... .. 725
CONSOLE MODULE ................................................................................... .. 726
REAR CARGO MODULE ............................................................................... .. 728
WINDSHIELD .......................................................................................... .. 730
WINDSHIELD SUPPORT............................................................................... .. 732
WINDSHIELD MOTOR ................................................................................ .. 732
X
TABLE OF CONTENTS
O7 CHASSIS (c0nt'd)
06 - BODY (c0nt'd)
PROCEDURES (cont'd)
WINDSHIELD MODULE (WPM) ....................................................................... .. 736
07—FRAME ........................................................................................................ .. 739
GENERAL ................................................................................................. .. 740
PROCEDURES ............................................................................................ .. 740
LATERAL SUPPORTS .................................................................................. .. 740
FRAME ................................................................................................. .. 742
O8 TECHNICAL SPECIFICATIONS
01 — SPYDER RT (SM5/SE5) .................................................................................... .. 745
O9 WIRING DIAGRAM
01 - WIRING DIAGRAM INFORMATION ...................................................................... .. 753
GENERAL ................................................................................................. .. 753
WIRING DIAGRAM LOCATION ........................................................................ .. 753
WIRING DIAGRAM cones............................................................................ .. 753
DIAGNOSTIC TIPS ..................................................................................... .. 754
XI I
SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to cor- NOTICE Indicates an instruction which, if not
rectly service and repair 2010 - 2011 Can-AmT'“ followed, could result in severe damage to ve-
roadsters described in the list in the /N7'/?0DUC- hicle components or other property.
T/ON.
This edition was primarily published to be used by NOTE: Indicates supplementary information re-
technicians who are already familiar with service quired to fully complete an instruction.
procedures relating to Bombardier Recreational Although the mere reading of such information
Products Inc. (BRP) products. Mechanical tech- does not eliminate the hazard, your understand-
nicians should attend continuous training courses ing of the information will promote its correct
given by B.R.P.T.|. use. Always use common shop safety practice.
Please note that the instructions will apply only It is understood that this manual may be trans-
if proper hand tools and special service tools are lated into another language. In the event of any
used. discrepancy, the English version shall prevail.
The content depicts parts and procedures appli- BRP disclaims liability for all damages and/or in-
cable to the particular product at time of writing. juries resulting from the improper use of the con-
SEHV/CE and WARRANTY BULLET/N5 may be tents. We strongly recommend that any services
published to update the content of this manual. be carried out and/or verified by a highly skilled
Make sure to read and understand them. Dealer professional mechanic.
modifications that were carried out after manufac-
turing of the product, whether or not authorized
by BRP, are not included.
In addition, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or ex-
act replicas of the parts.
The use of BRP parts is most strongly recom-
mended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt.
The engines and the corresponding components
identified in this document should not be utilized
on productlsl other than those mentioned in this
document.
lt is understood that certain modifications may
render use of the vehicle illegal under existing
federal, provincial and state regulations.
This manual emphasizes particular information de-
noted by the wording and symbols:
A WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.
A CAUTION Indicates a hazardous situation

which, if not avoided, could result in minor or
moderate injury.
XII
rmr2011-051
INTRODUCTION
INTRODUCTION
GENERAL INFORMATION
This Shop Manual covers the following BRP made 2010 - 2011 Can-Am Roadsters.
YEAR MODEL COLOR MODEL NUMBER
RT SM5 Full Moon ASAA, A3AB, ASAC
Timeless Black B5AA, B5AB, B5AF, B5AG
SM5
Orbital Blue B5AC
RT—S
TTmeless Black A4AA, A4AB, A4AD, A4AF A4AG
SE5
Orbital Blue A4AE
Full Moon A7AA
SM5
201° RT Audio & Orbital Blue A7AD
Convenience Full Moon A9AA
SE5
Orbital Blue A9AD
Full Moon A7AC
SM5
Orbital Blue A7AF
RT Techno
Full Moon A9AC
SE5
Orbital Blue A9AF
Magnesium ASBA, ABBB, A7BA
SM5
Orbital Blue A7BC, A7BD
RT
Magnesium A9BA, A9BB
SE5
Orbital Blue A9BC
TTmeless Black BBBA
Orbital Blue B5BC
SM5
2011 Magnesium BSBD
Viper Red B5BE
RT-S
Timeless Black A4BA, A4BB
Orbital Blue A4BC, A4BD
SE5
Magnesium A4BE, A4BF
Viper Red A4BG, A4Bl-l
RT Limited SE5 White Pearl B9BA, BSBB
The information and component/system descriptions contained in this manual are correct at time of writ-
ing. 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 differences between the manufactured product and the de-
scription and/or specifications in this document.
BRP reserves the right at any time to discontinue or change specifications, designs, features, models or
equipment without incurring obligation.
imizoi 1-051 Xlll

INTRODUCTION
VEHICLE INFORMATION
VEHICLE IDENTIFICATION
NUMBER (V.I.N.)
‘I I
1 2 rrnc2008-O01-11 ‘l__a
_rmo2008-0O14)91_a 1. Engine Identification Number (E. LN.) location

TYPICAL — VEHICLE SERIAL NUMBER LABEL
1. I/I.N. (Vehicle Identification Number) E MP EL
2. Model number
mfl£. _
scuumtn nzoturmu r-nuwcismg E“l9"fDI$9Ilmrlve|vI Kiflwee
TI§VENflifl)NFOlMSTDu$EPAMOCAufOR>&lAfl£GJLAfi0N$N¢IJCA!I.E Ea“ “mi, mm M mm
to MG>EI.YEAIIN£WMflfDKYClF$ANDISCEfl\F!DTOANH(+MOlI
Penal)FM}
mi§N,%%M E"-MAM - M, Famllleuewmmusa
Uh-run new mi lmedaznwltflk
,5 M; Cumrol iiyslzm lvrilubiu
iziimuxssrcwromewx |:<w-imrsunrm nu mane ll cuxonure Wesma hkifili IIWNUI
uuis-umquuur wxmomcvusrru mm IJf.L'MN€‘l muons rrixznm H
Aunoniiizrrimsunnsnouo-a awnmermnunias. Fwd "'*'
vmgiiaauwmumuivmnkssuuknbauonvmwuiima """“'
rrno200&00 1 054
rm0ZDIO'O01-D99_h
LOCATION OF I/./.N.
7. Swing arm (W.N. label)
2. Lower frame (Ill. N. stamped on left side)
ENGINE IDENTIFICATION
NUMBER (E.l.N.)
The engine identification number is located near
the left rear engine mount, under exhaust pipe.
rm02ClOBDO1-044_h
7. EPA exhaust emission label located under seat
XIV
rmr201H)51
INTRODUCTION
MANUAL INFORMATION parts used in a particular model vehicle. However,

they represent parts which have the same or a
MAN UAL PROCEDURES similar function.
Many of the procedures in this manual are inter-

related. Before undertaking any task, you should
read and thoroughly understand the entire section
or subsection in which the procedure is contained.
A WARNING
Unless otherwise specified, the engine
should be turned OFF and cold for all main-
tenance and repair procedures.
A number of procedures throughout the book re-

quire the use of special tools. Before starting any
procedure, be sure that you have on hand all re-
quired tools, or their approved equivalents.
The use of RIGHT and LEFT indications in the text
are always referenced to the driving position (sit-
ting on the vehicle).
V ‘Q
‘.\
1->’i‘_'] » 4-2
II'I'I!2008'001"OO4_8
TYPICAL
1. Left
2. Flight
This manual uses technical terms which may be

different from the ones of the PAHTS CAZAILOGS.
When ordering parts always refer to the specific
model PARTS CATALOG.
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
l
rmr20T 1-051
xv
INTRODUCTION
TYPICAL PAGE
Section 06 ENGINE A Page

_ heading‘
Subsection oi iMAGI\iEToi<i indicates section
and subsection.
Subsection title —i—> ETD
Indicates applicable {Models
models.
Loctite 243 Drop represents a

a< service product
Exploded view assists to be applied.
you in identifying parts _ Modal
_ _
and their related
Dotted box contains
positions.
- .4‘? parts applicable to a
specific model.
Bold face number

is used to identify
a part referred to
NEW indicates that the the text.
part must be replaced >
with a new one.
R AU’! is
>g?
Illustration number
for publishing process. A ‘“°‘"°
Document number for

publishing process. | P mimlwaoui 55-(i Page number
Specific torque applicable to this installation.

NOTICE Pay attentio n t0 torque specifications.
Some of these are 'in lbf-in instead of lbf'ft.
Use appropriate torque wrench.
Typical_iso_200G_en
XVI
rrr\r2011-051
INTRODUCTION
TYPICAL PAGE
Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEM)
Tittle in bold
indicates category A GENERAL
of information to be
carried out NOTE: The following procedures can be done
without removing the engine.
During assemblyfinstallation, use the torque val- pt
ues and service products as in the exploded A _
Reference to a
views
Clean threads before applying a threadlocker. Re-
- 1
specific section -—i;-..——>sELF-ioc/c/A/G FAS7FNER5and L00
or subsection. TITEHAPPL/CATION sections at the beginning of
this manual for complete procedure.
A WARNING
Torque wrench tightening
must be strictly adhered to.
specifications ¢.,__V
I-IIt
"-. __‘_
.
I < Iflflliit
flan: _" q
'4 .'
/§’w'¢"\
‘C’: "TYPICAL"
indicates a general
view which may
not represent exact
details.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners. etc.) must n-teen
be replaced with new ones. l
l
PROCEDURES NOTE: To remove starting pulley bolts, hold mag- Call-outs pertaining
Indicates component ___>MAGNETo FLYWHEEL
neto flywheel with a socket as shown. to above illustration.
I. I
procedures apply to.
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 i>Magneto Flywheel Removal - follows text to which
it applies.
C3Tl'|€d CUP Remove muffler, refer IO the EXHAUSTSYSTEM
section.
Remove acoustic panel.
Remove rewind starter.
Remove starting pulley no. 2. ltalicbold face type-
Models(
setting indicates a
Remove the connecting flange retaining the
procedure applicable
rewind starter to the engine housing. to a specific
rnodellsl.
mmddflflnflt 57
Bold face number followingpart

name refers to exploded view
at beginning of subsection.
typicaI_txt_2008,en
rmr201 H151 XV
INTRODUCTION
TIGHTENING TORQUES
1'ighten 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.
A 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. 11ghten fastener to the recommended torque value.
NUTICE 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 8 V A \ A \ I ‘ t
class and _ k U l O
head V F
_, \
I r\
_ \>
,
_ " Z Z Z @ T.
8 10 ‘I2
Property A - ~ A - ~ ~ A
classand r war \ r wr w r xr \
“"7 t - 1 V- t - 1 \ - ; -
‘_ \ - 1 t - 1 —
" \ - 1
markings - \‘
GET" -r‘ - \4
ADUABBS
FASTENER FASTENER GRADE/TORQUE
5'25 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade

M4 1.5—2N-nn 2.5—3N~m 3.5—4N'rn 4—5N-m
(13 — 18 lbfvinl (22 — 27 lbf~in) (31 — 35 Ibfvftl (35 - 44 lbfvftl
M5 3—3.5l\l~m 4.5—5.5N~m 7-8.5 Nvm 8—1ON'm
(27 — 31 lbfeftl (40 — 47 lbfvftl (62 — 75 Ibf~ftl (71 — 89 lbf~ft)
6.5—8.5N'm 8—12N'm 10.5—15N¢rn .
M6 <58 - 75 lbfvftl <71 - 106lbf¢ft) (93 - 133 lbf-in) 16 N'm (142 'bf°'“)
M8 15 Nirn (133 |bf'in) 25 Nvm (18 lbf'ft) 32 N'rn (24 lbf'ft) 40 N'm (30 lbfeftl
M10 29 N'm (21 lbf'ft) 48 N'm (35 lbf'ft) 61 Nvm (45 lbf'ft) 73 N°rTi (54 lbf'ftl
M12 52 N°m (38 lbf'ft) 85 Nvm (63 lbfeftl 105 N°m (77 |bf°ft) 128 N°l'T1 (94lbf'ft)
M14 85 N'm (63 lbfvftl 135 Nim (1 OO lbf'ft) 170 N'rTl (125lbf'f’£) 200 N'm (148 lbfeftl
XVIII rmr2011-051
INTRODUCTION
FASTENER INFORMATION Threadlocker Application for

Uncovered Holes (Bolts and Nuts)
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
could cause damage to the vehicle or possible
personal injury.
SELF-LOCKING FASTENERS lllll 555‘

PROCEDURE
A
.\_ 1. Apply here
2. Do not apply
oq uq%q1_!vl5_lglq¢!lwlrlr(.%
1. Clean threads (bolt and nut) with solvent.
‘uh k"K§'\
2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
AUUAELA threads and allow to dry.
TYP/CAL — SELF-LOCK/NG 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
LOCTlTE® 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. I/////J 7//////I
r2007-O-40 D04 s
1. On fastener threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.

2. Apply LOCTITE PRIMER N (P/N 293 800 O41) on
threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
rmr2011-O51 XIX
I 1 I i L 1 I -
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. 'l'ighten as required.
Threadlocker Application for Stud
nstallation in Blind Holes 1
/
<22
/
NT
iiigii "
av
lfT)l'ZOClT'U4D'OO5 8
1. On stud threads
ss
\-
2. On threads and in the hole
Q/% 2/
%l,;'?%/,. AODAEOA
1. Apply here
2. Do not apply
3. On retaining nut threads

1. Clean bolts and nuts with solvent.
2. Assemble components.
1. Clean threads (stud and hole) with solvent.
3. Tighten nuts.
2. Apply LOCTITE PRIMER N (P/N 293 800 O41) On
threads and allow to dry. 4. Apply a few drops of proper strength Loctite on
bolt/nut contact surfaces.
3. Put 2 or 3 drops of proper strength Loctite
threadlocker on female threads and in hole. 5. Avoid touching metal with tip of flask.
NOTE: To avoid a hydro lock situation, do not ap- NOTE: For preventive maintenance on exist-
ply too much Loctite. ing equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces.
4. Apply several drops of proper strength Loctite
on stud threads. Threadlocker Application for an
pegs
5. Install stud. Adjustment Screw
6. Install cover, part, etc.
7. Apply a few drops of proper strength Loctite on
uncovered stud threads.
8. install and tighten retaining nut(s) as required.
AODASPA
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.
XX rmr2011 051
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
.
.
.
.
AO0A3QA
Release agent
Stripped threads
Form-A-Thread
Tapes
<—m
-<l_$i\ \ \ \iIg ///:
lmr20U 7-04fl—OOB_a
a@a\
. Cleaned bolt 1. Proper strength Loctite
. Plate 2. Loctite Primer N (P/N 293 800 D41) and Gasket Eliminator 518
New threads (P/N 293 800 O38) on b0 th si'des Of gasket
mymmeums Threadlocker 3. Loctite Prlrrier N only
Standard Thread Repair 1. Remove old gasket and other contaminants us-
Follow instructions on Loctite FORM-A-THREAD ing LOCTITE CHISEL (GASKET REMOVERl (P/N 413
81668 package. 708 500). Use a mechanical means only if nec-
essary.
lf 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 O38) 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
$71-4NDAl?D THREAD HEPA/H 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) ‘Fghten 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
rmr201l-O51 XXI l
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
strength and gap are required.
.4.
I‘:'
¢,'0,0
4. Install according to standard procedure.
'O'Q‘0‘v o%°v‘¢‘>'
.v,o‘4,o.>
4~': :':‘:"~‘:‘§oO.'Q.”
‘-0§‘:’ 3'0‘ :°¢¢‘°’ o'1
‘o0'1o''§o‘:'‘§‘\‘
o°§" ‘0‘v'¢‘0'0'o' 5. Wipe off excess product.
6. Allow 30 minutes for product to cure.
AOOASUA NOTE: Normally used on worn-out housings to
1. Bearing prevent leaking or sliding.
2. Proper strength Loctite lt 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)
AOOABVA
\
ii N 1
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with LOCTITE PRIMER
N (P/N 293 800 O41).
XXII rmr201 1-051

SERVICE TOOLS INDEX
ADAPTER HOSE BEARING PUSHER/REMOVER CLUTCH ASSEMBLY HOLDER

(P/N 529 035 652) (P/N 529 O36 095) (P/N 529 O36 133)
a,
#3; Page: 186, 211, 624

Page: 212
Page: 53 BEARING PUSHER
(P/N 529 036 O96) CLUTCH PACK COMPRESSION TOOL
BALANCE SHAFT PLAIN BEARING (P/N 529 036 144)
REM/INST
T’ 77 t
(P/N 529 036 O94)
Page: 186, 211
Page: 148 BELT TENSION METER Page: 207

(P/N 529 036 115)
BALL JOINT EXTRACTOR CRANKCASE SEAL PUSHER
(P/N 529 035 827) (P/N 529 036 O92)
Page: 554 Page: 257
BLIND HOLE BEARING PULLER SET CRANKSHAFT PLAIN BEARING TOOL

(P/N 529 O36 117) (P/N 529 O36 O93)
Page: 633
i l
BALL JOINT INSTALLER
(P/N 529 035 975)
Page: 148
Page: 25, 115, 147, 185, 210, 560, CRIMPING TOOL (HEAVY GAUGE
WIRE)
562, 565, 661, 687
(P/N 529 085 730)
Page: 624, 633, 636 CLUTCH ASSEMBLY HOLDER
(P/N 529 O35 618)
BALL JOINT REMOVER SUPPORT
(P/N 529 036 121)
W Page: 448
CRIMPING TOOL (KOSTAL)

(P/N 529 O35 909)
Page: 633, 636
.\_H/-I-""“‘__:..."-3
Page: 187
Page: 445
1
SERVICE TOOLS INDEX
ECM ADAPTER TOOL ENGINE LIFTING TOOL KOSTAL DIE

(P/N 529 036 166) (P/N 529 036 181) (P/N 529 035 906)
I‘Q
' ‘E
Page: 55, 173, 254, 351, 353, 359,

Page: 21, 23-24
$09
Page: 445
362, 366, 369, 372, 374, 377, 379, FLUKE 115 MULTIMETER
382-383, 403, 410, 442, 452, 457 (P/N 529 035 868) LARGE HOSE PINCHER
ECM TERMINAL REMOVER 2.25 (P/N 529 032 500)
(P/N 529 036 175)
Page: 81
Page: 54, 91-92, 172-173, 234, 258,
351-352, 359, 363, 365-366, 371, MAGNET SOCKET
Page: 442 404, 409, 460, 474, 499, 502, 506-507. (P/N 529 O36 178)
509, 511, 513-515, 518-521, 523-526,
ECM TERMINAL REMOVER 3.36 548-549, 575, 577-579, 582, 613, 646.
(P/N 529 036 174) 651, 654, 697, 736-737
FUEL HOSE ADAPTER

(P/N 529 036 O23)
"‘;_ Im
Page: 614, 618, 621
s
MAGNETO PULLER
(P/N 529 036 097)
Page: 442
ENGINE LEAK DOWN TEST KIT

(P/N 529 035 661) Page: 394
Page: 94
HANDLE
(P/N 420 877 650) MAIN SHAFT PROTECTOR
(P/N 529 O36 123)
Page: 84, 256-257
Page: 106 Page: 256, 268
2
SERVICE TOOLS INDEX
MAIN SHAFT SEAL INSTALLER MPI-2 INTERFACE CARD OIL SEAL PUSHER
(P/N 529 O36 088) (P/N 529 O36 018) (P/N 529 035 757)
.1"/3'-§\ g
fi E. .
Page: 84
.~:,:___j,.>
PISTON CIRCLIP INSTALLER 991

Page: 256
Page: 277 (P/N 529 036 072)
MAIN SHAFT SEAL PUSHER
OETIKER PLIERS
(P/N 529 036 124)
(P/N 295 000 070)
.-..._-. ,»f~*""~*-*-w._i. Page: 129
PITMAN ARM ..IlG

*3 I (P/N 529 036 225)
Page: 257
MASTER CYLINDER ROD ADJUSTER Page: 57-59, 79-81, 392, 397, 399,
I
(P/N 529 036 119) 410 i
I
OIL PRESSURE GAUGE
(P/N 529 036 142)
_..;_, - _
... A-I Page: 618, 620
‘_ _: ._ Q.‘
-_ ‘
PITMAN ARM LOCKING TOOL
Page: 689 I .'I \\)\
(P/N 529 036 228)
MASTER KEY
(P/N 529 036 106)
Page: 233
OIL SEAL INSTALLER

(P/N 529 036 069) Page: 591, 593
Page: 476, 478
PITMAN ARM PULLER
MPI-2 DIAGNOSTIC CABLE (P/N 529 036 227)
(P/N 710 000 851) I
i. Page: 115
OIL SEAL INSTALLER

(P/N 529 O36 070)
Page: 276
Page: 618
Page: 256-257
SERVICE TOOLS INDEX
PITMAN ARM PUSHER SOCKET SPANNER TEST CAP

(P/N 529 036 226) (P/N 529 O36 113) (P/N 529 035 991)
a._.e.~
‘ . -J V» f
Page: 560 I‘?
SPANNER TOOL
(P/N 529 036 223) Page: 76
Page: 620
VACUUM/PRESSURE PUMP
PRESSURE GAUGE (P/N 529 O21 800)
(P/N 529 O35 709)
.
30 4,; \
.' : -.
Page: 464, 532
SPRING INSTALLER/REMOVER
_¢'
illll
Page: 76, 165-166, 169, 173, 393
-;_._‘
T
Page: 53, 394

(P/N 529 035 983) 408, 411
PROTECTION SLEEVE
VALVE GUIDE INSTALLER (6 MM)
(P/N 529 036 071)
(P/N 529 036 075)
~\K . Page: 37, 40
SPRING REMOVER
§~
(P/N 529 036 O07)
Page: 256-257 Page: 126
PULLER/LOCKING TOOL VALVE GUIDE REMOVER (6 MM)

(P/N 529 O36 O98) (P/N 529 036 074)
Page: 630, 657
lam
SUCTION PUMP
(P/N 529 O35 880) Page: 125
Page: 94, 136-137, 152
SEAL PUSHER VALVE SPRING COMPRESSOR CUP

,1
(P/N 529 035 766) (P/N 529 O36 O73)
\-. ,_. _ .1
¢;;; ;
-
‘I.
um ~. y--¢\\
|
Page: 81 Page: 121
Page: 84
4
SERVICE TOOLS INDEX
VALVE SPRING COMPRESSOR

(P/N 529 035 724)
Page: 121
5
SectionO1 MAINTENANCE
Subsecti0n01 (MAINTENANCE SCHEDULE)
MAINTENANCE SCHEDULE
SERVICE PRODUCTS
Description Part Number Page
CABLE LUBRICANT .................................................................... .. 293 600 041 ........................................... .. 9
The chart gives an equivalence between mileage and year. Perform the maintenance operation to what-
ever time comes first.
Maintenance is very important for keeping the vehicle in safe operating condition. Proper maintenance
is the owner's responsibility. Perform periodic checks and follow the maintenance schedule.
A WARNING
Failure to properly maintain the vehicle according to the maintenance schedule and procedures
can make it unsafe to operate.
NOTICE The initial maintenance is very important and must not be neglected.
INITIAL INSPECTION I 0001(0) (000011)
A2 ADJUST _
I: INSPECT EVERY 10 000km (6,000 mi) or 1 year

L’R: '-"B'*'°ATE
REPLACE
EVERY 20 non km i1z.ooo mi) or 2 YEARS
NOTE
ENGINE
Engine oil and oil filter Fl R Check oil level every 500 km (300 mi)
Oil tank strainer I, C I, C Inspect and clean if necessary
HCM oil filter (SE5 model) H R
Valve clearance A Inspect first at I0 000 km (6,000 mi)
Air filter 7 H
Air filter housing C Wipe off any oil in housing
Clutch fluid (SM5 model) I H
Engine coolant I I Fl
Radiator, hoses and water pump I” Check condition, leak and cleanliness
Radiator cap/cooling system pressure test I
Exhaust pipes joints/gaskets H
Reverse mechanism (SM5 model) A
ELECTRONIC MANAGEMENT SYSTEMS
Fault codes I I
Hear wheel speed sensor I Adjust every time rear wheel is loosened
Passenger switch I
rmr2011-052 7
Section 01 MAINTENANCE
Subsection01 (MAINTENANCE SCHEDULE)
INITIAL INSPECTION I 000 km (000 mi)
A: ADJUST
C, CLEAN EVERY 5 000km (3,000mi)
I: INSPECT EVERY 10 000km (6,0IJOmi) or 1 year
L‘R: L"B"'°'“E
REPLACE
EVERY 20 000 km (12,000 mi) 0|’ z YEARS
NOTE
FUEL SYSTEM
Throttle body l,C
Throttle twist grip I
Fuel hoses I
Replace every
Fuel filter 5 years or 30 000 km
(19,000 mi)
ELECTRICAL SYSTEM
Spark plugs I I R
Battery connections l,C
Lighting system (brake light, hazard warning lights,
tum signal lights, position lights, license plate
light)
Electric windshield
Control switches
DRIVE SYSTEM
Drive belt l,A I,A Inspect wear, alignment and tension
Flear sprocket bearing Replace every 50 000 km (31,000 mi)
Hear axle bearings
Bearing seals, 0-rings and wear sleeves of rear
axle
WHEELS
Carry out rotation when tread depth reaches 4 mm (5/32 in).
Front tires Rotate Iires must be removed from the wheels in order to respect
rotation direction
Wheel bearings
Front wheel nuts
Hear wheel nut
STEERING
Steering play
Tie rod
Front wheel alignment I
SUSPENSION
Shock absorbers
Front suspension arms
Ball joints
ACS rear shock absorber hoses and fittings
8 rmr2011-052
Subsection O1 (MAINTENANCE SCHEDULE)
INITIAL INSPECTION 1 000km (600mi)
A: ADJUST
I: INSPECT EVERY 10 000km (6,000 mil or 1 year

L‘ LUBIIICATE EVERY 20 000 km (12,000 mi) or 2 YEARS
R: REPLACE
NOTE
BRAKES
Brake fluid I R
Brake pads and discs I
Brake hoses I
Parking brake I I
BDDY/FRAME
Passenger handholds I Check solidness
Footpegs L Use multi-purpose lubricant
Plastic parts fasteners I Check solidness
SW98 °°"‘pa""‘e"I ""“°heS' key ba”e'S' 8"‘)

hinges
l I L Use CABLE LUBRICANT (P/N 293 000 041) or an equivalent
rmr201 I-052 9 I
SubsectionO2 (STORAGE PROCEDURE)
STORAGE PROCEDURE
SERVICE PRODUCTS
BRP FUEL STABILIZER ............................................................... .. 413 408 600 ......................................... .. 11
XPS ROADSTER WASH .............................................................. .. 219 701 703 ......................................... .. 12
XPS STORAGE OIL (EXCEPT U.S. COUNTRY) ........................... .. 413 711 600 ......................................... .. 11
XPS STORAGE OIL (U.S. COUNTRY ONLY) ............................... .. 413 711 900 ......................................... .. 11
GENERAL 2. Spray XPS STORAGE OIL (EXCEPT U.S. COUN-

TRY) (P/N 413 711 600) or XPS STORAGE OIL (U.S.
If the vehicle is not ridden for at least 4 months, COUNTRY ONLY) (P/N 413 711 900) into throttle
such as during the winter, proper storage is nec- body (5 seconds in each openings) while crank-
essary to keep the vehicle in good condition. ing in drowned mode (throttle wide open and
depress start button).
PROCEDURES 3. Reinstall air filter housing cover.
FUEL SYSTEM NOTE: Do not run engine during storage period.
Fuel System Protection CLUTCH SYSTEM (SM5)

With the new fuel additives, it is critical to use the
BRP FUEL STABILIZER (P/N 413 408 600) Or an equiv-
Clutch Fluid Level Inspection
alent to prevent fuel deterioration and fuel system Check clutch fluid level. Refill if necessary.
gumming. Follow the manufacturer's instructions
for proper use. COOLING SYSTEM
Pour fuel stabilizer in fuel tank. Fill up fuel tank. Coolant Inspection
NOTICE Engine should be run after fuel sta- Check coolant level.
bilizer is added to ensure fuel system compo- Test coolant density using an antifreeze hydrome—
nents protection against varnish deposits. ter.
Do not drain fuel system. NOTE: Follow manufacturer's instructions for
proper use.
ENGINE A 50/50 mixture of antifreeze and distilled water
Engine Oil and Filter Replacement will provide the optimum cooling, corrosion pro-
tection and antifreeze protection.
Change engine oil and filter. Refer to LUBH/CA-
7'/ON SYSTEM subsection. Do not use tap water, straight an-
tifreeze or straight water in the system. Tap
HCM Oil Filter Replacement (SE5) water contains minerals and impurities which
Change HCl\/I oil filter. Refer to HYDRAUL/C CON- build up in the system. Straight water will
TROL MODULE (SE5) subsection. cause the system to freeze while straight an-
tifreeze will cause system temperature prob-
Engine Internal Lubrication lems.
Engine internal parts should be lubricated to pro- Change coolant if necessary. Refer to COOL//\/G
tect them from rust formation during the storage S)/STEM subsection.
penod.
Proceed as follows: ELECTRICAL SYSTEM
1. Remove air filter housing cover. Refer to A/H’ Battery Charging
/NM/(E SYSTEM subsection.
Slow charge the battery once a month at the rec-
ommended charging rate of 2 A. It is not neces-
sary to remove the battery.
rmr2011-D53 11
Subsection02 (STORAGE PROCEDURE)
WHEELS AND TIRES NOTICE Do not polish windshield with any

plastic cleaner/polisher.
Tire Pressure
lnflate all tires to their recommended pressure. A WARNING
Do not apply a vinyl or plastic protector on
BRAKE SYSTEM the seat as the surface will become slippery
and the operator or the passenger may slip
Brake Fluid Level Inspection off the vehicle.
Check brake fluid level. Refill if necessary.
Vehicle Protection
Brake System Lubrication Touch up all metal spots where paint has been
Clean and lubricate mechanism of parking brake. scratched off.
Lubricate parking brake cable. Install a plastic bag over muffler outlet to prevent
Lubricate pivoting point of brake pedal. moisture from entering it.
Cover the vehicle with a permeable material.
SUSPENSION Avoid using plastic or similar non-breathing,
coated materials that restrict air flow and allow
Suspension Lubrication heat and moisture to accumulate.
Lubricate front suspension arms. Refer to FRO/I/7' Store vehicle in a dry unheated area, away from
SUSPENSION subsection. sunlight, with a small amount of daily temperature
variation.
VEHICLE
Vehicle Cleaning
To clean the vehicle, do not use high pressure
washers (like the ones found in car washes) as it
may damage certain parts of the vehicle.
NOTICE Do not clean the windshield with al-
kaline or acid cleaner, gasoline or solvent to
avoid windshield damage.
To clean the vehicle, proceed as follows:
1. Rinse the vehicle thoroughly with water to re-
move loose dirt.
2. Using a soft clean cloth, wash the vehicle with
water mixed with a mild detergent, such as
soap specially formulated for motorcycles or
automobiles.
3. While washing the vehicle, check for grease
or oil. If necessary, use XPS ROADSTER WASH
(P/N 219 701 703) or a mild automotive de-
greaser. Follow thoroughly the manufacturer's
instructions.
4. Dry the vehicle with a chamois or a soft towel.
Vehicle Waxing
SURFACE PRODUCT/PRECAUTION
. . Apply only non-abrasive wax,
Glossy hmshes safe for clear coat paints
Mat surfaces Avoid applying wax
12 rmr20l l-O53
Section O1 MAINTENANCE
Subsection 03 (PRESEASON PREPARATION)
PRESEASON PREPARATION
Prior to use the vehicle, proper preparation is re- 5. Check that the engine stop button is working
quired after the storage period. properly.
Any worn, broken or damaged parts found during 6. Start engine, release parking brake and ensure
the storage procedure should have been replaced. parking brake indicator is off on the multifunc-
If not, proceed with the replacement. tion gauge cluster.
7. Drive forward slowly a few feet then apply
PROCEDURES brake to test.
VEHICLE PREPARED AS PER VEHICLE NOT PREPARED AS PER

STORAGE PROCEDURE STORAGE PROCEDURE
Remove vehicle protective cover, muffler protec- Proceed with the same steps as specified in VE-
tive bag and clean the vehicle. H/CLES PREPARED AS PER STORAGE PROCE-
Charge battery as required. Refer to CHARG/NG DURE above.
SYSTEM Carry out these additional steps:
Check the following items: — Check the level of engine coolant. Refer to
— "Fires: Look for damage, incorrect inflation and COOL//\/G SYSTEM subsection.
excessive tread wear. — Check the brake fluid level. Refer to BRAKES
— Wheels and lug nuts: Look for damage. subsecflon.
Check front wheel lug nuts if they are properly — Lubricate the front suspension arms. Refer to
tighten. Be sure the rear wheel axle nut and FRONT SUSPENS/ON subsection.
cotter pin are in place. — Replace engine oil and filter. Refer to LUBR/CA-
— Drive belt: Look for fraying, cuts, punctures T/ON SYSTEM subsection.
and missing teeth. Verify alignment. For addi- — Replace HCl\/I oil filter (SE5 model). Refer to
tional information, refer to DR/I/E BELT AND HYDRAUL/C CONTROL MODULE (SE5) sub-
REAR WHEEL subsection. section.
— Leaks: Look under the vehicle for any leaks.
— Brake pedal: Press and make sure you feel
firm resistance. Pedal must fully return when
released.
- Throttle handle: Twist a few times. Be sure
it operates freely and returns to idle position
when released.
— Clutch lever (SM5 model): Squeeze to be
sure it operates easily and fully returns when
released. Adjust if needed. Refer to CLUTCH
(SM5 subsection.
— Clutch oil level (SM5 model): Check clutch
fluid level. Refer to CLUTCH (SM5}subsection.
— Gearshift selector (SE5 model): Be sure
gearshift selector operates normally in both di-
rections and returns to center when released.
Turn ignition key ON:
l. Check the gauges, indicator lamps, and mes-
sages on the multifunction gauge cluster.
2. Ensure headlights, taillight, brake light, turn sig-
nals, and hazards are working properly.
3. Ensure horn is working properly.
4. Start engine and verify steering operates freely.
rmr2011-054 13 '
Section 02 ENGINE
Subsection O1 (ENGINE REMOVAL AND INSTALLATION)
ENGINE REMOVAL AND INSTALLATION

SERVICE TOOLS
BLIND HOLE BEARING PULLER SET ......................................... .. 529 O36 117 ......................................... .. 25
ENGINE LIFTING TOOL .............................................................. .. 529 036181 ............................. .. 21, 23-24
/‘""f~| I:
L~_'= F‘I 8
.-.4’31'. 'Is~'1¥
J. j—
4 /'=”
(as lbf- rt) Q,2 - "'.42
'ii.‘.~f"~.~~ *‘~ r»;>\.
48 N- <1 ' .;iI=‘-':<'f.~,-f-:1""- "
0
(35lbf‘-Tit) v_~(“.'
- O , _
T 24 N,m )=:'é£L%’€\D1 >. ,. "
i-I
.\ ‘
17 lbf-ft) q-us‘
~.s;»=_-,,=,
/A P1 .~~;-
, "3
{<7
0',
'O\T:3
I
‘P
t _\
it
‘ 2» ,_ .> -
/Q . r ~ _/.1 i
at ’ Q\A
1
\ Ii.» . , ‘ \-Li.“
/>2<. \
, ‘I-\ \ Z \‘“. + * “C. 1-. ‘F
'Q’\i.\
jjégc
" .a__[_
24 NJ .@ m /‘ I §f{,_:-;~*‘_';"‘ 1.‘ . V"
(‘l7lbf-ft) » %J:."/'i=
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is tr-J
J. \_
ix
5.
\
/\
‘>-
‘\—- ,_‘g.1.i _»¢-_. =:'i" .\
35é
43 N. 48 N-m
(35 |bfS=‘t) (35 Ibf'ft) ‘'@/Y
isA\.
as Q3
48 N-m
E \A
Issibl/2
' \ “Z I‘ “
,l./»:
48 N-m
(35 lbf-ft)
m = Component must be replaced when removed.

rmf20l0-006-DO1_b
rmr201 H155 15
Section 02 ENGINE
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)
GENERAL Remove muffler and catalytic converter. Refer to

EXHAUST SYSTEM subsection.
A CAUTION To avoid potential burns, let en- Remove both lateral supports. Refer to FRAME
gine and exhaust system cool down. subsection.
During assembly/installation, use the torque val- Remove the air filter housing and the resonator.
ues and service products as in the exploded view. Refer to A/R /N734/(E SYSTEM subsection.
Clean threads before applying a threadlocker. Re- Release drive belt tension. Refer to DR/I/EBELT
fer to SELF-LOCK/NG FASTENERS and LOCT/ TE AND REAR WHEEL subsection.
APPL/CAT/ONat the beginning of this manual for
complete procedure. On Right Side of Vehicle:
1. Disconnect the coolant hoses from cylinder
A WARNING heads.
Torque wrench tightening specifications
Locking devices when removed must be re-
placed (e.g.: locking tabs, elastic stop nuts,
cotter pins, etc.).
NOTICE Hoses, cables or locking ties re-

moved during the procedure must be rein-
stalled as per factory standard.
PROCEDURES
ENGINE rm120'l 0-O06-I] O2_a
1. Coolant hoses
Preparation for Engine Removal
2. Remove screws retaining water pump cover.
Place vehicle on a workstation that will have ac-
cess to an engine-lifting hoist.
Disconnect the BLACK (-) cable from battery, then
the RED (+) cable.
A WARNING
Always disconnect battery cables exactly in
the specified order, the BLACK (-) cable first.
It is recommended to disconnect electrical
connections prior to disconnecting fuel lines.
Refer to L-?ODYsubsection to remove the follow- rmr2008-DUE-01 1 _a
ing: 3. Unplug the clutch actuation valve connector.

— Both middle side panels
— Both top side panels 4. Remove the starter cable from the starter.
— Both rear panels
— Both bottom side panels (rear and front)
— Front storage compartment
— Glove box
— Acoustic panels.
Drain oil (engine and oil tank). Refer to LU5’R/CA-
T/ON SYSTEM subsection.
Drain engine coolant. Refer to COOL/NG SYS-
TEM subsection.
16 rmr201 I-O55
Section 02 ENGINE
rrnr201 0006-006_a
rrnr20l U-006-D03_a 1. Cut this locking tie
7. Clutch actuation valve connector 2- C/UICIT ECTIVBTIO/1 Valve /7058
2. Starter cable 3- Spark plug cable
5. Unplug spark plug cable from the front cylinder 8. Disconnect the clutch actuation valve hose
head. from throttle body.
rrnr20l U-006-U04_a
rrr\r20l 0-00&007_a
7. Spark plug cable
1. Cut this Oetiker clamp
6. Unplug the electric throttle actuator (ETA) con-
nector. 9. Unplug the oil pressure switch
rmi’201 0-ODS-0OB_a
rmr201lH)06-005_a
7. Oil pressure switch
1. ETA connector 10. Remove ground wire from engine.
7. Cut locking tie attaching spark plug cable and
clutch actuation valve hose.
rmr20l1-D55 17
Section O2 ENGINE
rmr201(>O06-O12_a
1. Retaining clamps
rmrZO'l0-00601131
1- Ground Wire screw 14. Lift throttle body and attach it against the top
11. On SM5 models, disconnect clutch hose and frame member‘ ' _ _
discard seanng Washers NOTE: Place clean rags inside intake adapters to
NOTE: Place a container under clutch hose to re- avoid debris in engine’
cover the clutch fluid. On Left Side of Vehicle:
1. On SE5 models, detach the clutch servo hose
from the bottom of oil tank.
>§“\.-
_: --~ -. -4
.-'_a= 22:.»-1
.\.:_\_-_ _ ' _ .. »-\/-
‘ I‘
r. I
; " "- --
I r 1 - 1:-.1 - = ‘J .
17?:
, fl I "~ °;
5
Q._ f
If‘-v.s-_~.~
- 0
rn-ir20iCHl0E'>OD9_a ~ gs»; LL-_,r;>n_ ~-
4.A. ‘\-L_
~
-<\.¢__~m§
1T-T *"'ct~
.- ."I
. _ -F54.
C VT0‘ |~_‘_
,-_~ * r
F ~ (*1Y'\T"» _ J‘
SM5 MODEL SHOWN *~ ._ ' _.

-at . I 1'3
1. Clutch hose ‘\.. “ ‘ T” 1 —~-. _‘-Z
‘\ ~... -A ..~-i 0
- - - ri'rir20OB4)46-0O3_a
12. Remove screws retaining the EVAP canisterto SE5 MODEL SHOWN
CYllnder- 1. Clutch sen/o hose
2. Oil tank
2. Cut locking tie retaining ignition coil wire and

unplug ignition coil connector.
I
I
-~i~.- .
ri-M2010-006-OI U_a
1. EVAP canister support screws
13. Loosen clamps securing throttle body to in- ,...,0,.,.,.,,;..,,3_. '

take adapters. 1. Cut this locking tie
2. Ignition coil connector
18 rrnr2011-055
Section O2 ENGINE
3. Unplug spark plug cable from the rear cylinder .\,_ '" . I /,
head. \'“-F-i_:;,/31'
rrnr201U-O05-U16_a
1. Oil hoses
7. Remove the oil tank and oil cooler with the ig-
rmr2010-005-0143 nition coil.
1' Spark plug came 8 Remove the LH footrest.
4. Disconnect the oil tank vent from crankcase. 8.1 Remove bolt retaining shifting link to shift-
5. Remove the front sprocket and move drive belt ing block.
rearward. Refer to GEARBOX subsection for
procedure.
: - 5
.»i\-
rmr2D104)U6JJ17_a
TYPICAL — SM5 ENGINE SHOWN
1. Shifting b lo ck
2. Shifting /ink
rmr201(>0084115_a 8.2 Remove screw securing the middle of the

TYPICAL footrest to frame.
1. Oil ta n l< ve nt
2. Front sprocket screw
6. Remove both oil hose connectors from

crankcase.
1f‘l1l‘2U'lD~UQ5-Q1 H_a
1. Retaining screw
8.3 Remove both screws securing the rear of

footrest to footrest support.
rmrZ011-055 19
Section O2 ENGINE
Subsection 01 (ENGINE REMOVAL AND NSTALLATION)
— -
i3 /I runs’
.5’ ~
-? .
rmr2Dl D006-fl21_a
tm1ZO'lI-O55-OO1_a 1. Reverse actuator screws
VIEW FROM THE REAR or VEHICLE _
1- Flearrerain/no screws 12. Unplug the following sensors.
9. Remove screws retaining reverse cable sup- _. _ _ .. ._...
port to engine and detach the end of the cable 7'“
from the reverse lever. _- ._
I .'
,_
71.40?
Ti
rrrii20'lO-005022_a
7. Gearbox position sensor (GBPS)
rmr2010-006-02 (La
7. Reverse cable support

2. Retaining screws
3. Reverse lever
10. Unplug the reverse actuator.
L1 rn-ir20l O-OD$D23_B
l 1. Camshaft position sensor (CAPS)
rmr201 (J-O06-028_a
I. RBVETSG BCTIJHTOI COI')!76Cl'OI'
11. Remove screws retaining the reverse actuator

to frame.
rrnr20l0-D06-024_a
7. Both knock sensors (KS)
20 rmr2Cl1 1-055
Section 02 ENGINE
529035181
moiwoeizsj 2. On RH side of the vehicle, remove the front

1. Coo/ant temperature sensor (CTS) |Q\/\/er engine bQI’[_
rn'ifl0‘ll)-O06~02E_a
7. Crankshaft position sensor (CPS) '""1°‘°°°°°3°-“

1. Right lower engine bolt
13. Detach clamp retaining knock sensor wires to
engine. 3. Remove engine support bolts.
rmr201lH]O&027_a
_ , rrnrZD1C|-0O5lJ31_a
Cl
1' amp retaining screw 7. Upper engine support bolt
2. Lower engine support bolt
Lifting Engine
1. Install the lifting tool. 4. On the LH side of engine, remove both front
engine bolts.
1.1 Turn the handlebar fully LH to avoid dam
aging it with lifting tool.
1.2 Install the hook of the ENGINE LIFTING
TOOL (P/N 529 036 181) between cylinde T
heads.
rmr201 1-055 21
Section O2 ENGINE
_ .c.~-.._ .,.... _ -..-...v..,»_e.......~e.......... ~ M... l~ .. MM, __.s,.......e...s-.1-Lr.__,..,...

ll
.iI I
; .. _ r"‘A I I dip.
.1 - ,.
’_- I»?-.. ;. L4 Li‘ >2-:
. ‘ ‘£’-‘—'=-
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.
,- BGI?
- —T. sew... -. - .. _ I M E .1...
rmr2008-I708-026_a
ALIGNMENT PIN — HOMEMADE TOOL
A. Approximately 400mm (16in)
B. 19mm (3/4 in)
rmr201 (1-00641293
7. Left front engine bolts
5. Remove the rear upper engine bolt.
I ._
rrl'\QOlJ8-008-Cl25_3
TYPICAL
1. Engine mounts shield
2. Alignment pin
Lean engine against alignment pin.

rrrir20l U005-D32_a Install all mounting bolts and mounting nuts.
1. Rear upper engine bolt
Torque mounting bolts and mounting nuts to
6. Remove the rear engine support on the RH side 48 Nem (35 lbf~ft).
of vehicle. Remove alignment pin.
7. Lift engine slowly and remove it from vehicle. Install all other removed parts.
Engine Installation Final Assembly
The installation is the reverse of the removal pro- Make sure coolant and oil drain plugs are rein-
cedure. However, pay attention to the following. stalled and tight.
NOTE: Prior to install engine, inspect condition of Fill cooling system. Refer to COOL/NG SYSTEM
engine mounts. subsection.
Position engine in chassis. Fill engine with the recommended oil and re-
Install the engine mounts shield. quired quantity. Refer to LUBR/CAT/ON SYSTEM
Install an alignment pin (homemade tool) through subsection.
engine supports and chassis to align the engine. Reconnect battery.
A WARNING
Connect RED (+) cable then BLACK (-) cable.
Always connect RED (+) cable in first.
Start engine and let it reach its operating temper-

ature.
Stop engine and check coolant and oil levels. Re-
fill as necessary.
22 rmr201 1-O55
Section OZ ENGINE
Align and adjust tension of drive belt. Refer to

DR/VE BELTAND REAR WHEEL subsection.
Test drive vehicle to confirm proper operation.
ENGINE MOUNTS
Engine Mounts Removal
Front Rubber Mounts
Refer to BODYsubsection to remove the follow-
ing parts:
— Both top side panels rmr2010-DOG-O31 _a
— BOLT) middle SICIG DEIHGIS 1. Upper engine support bolt

— Both bottom side panels (rear and front)
— Glove box On the LH side of engine, remove the rear upper
— Central panel. engine bolt-
Release drive belt tension. Refer to DR/VE BELT
AND REAR WHEEL subsection.
Move oil tank and oil cooler (for LH side) or radiator
(for RH side) aside to make room.
Remove the air filter housing cover.
On left side, remove retaining bolt securing res-
onator.
nnr201 D-O06-0323!
7. Rear upper engine bolt
Loosen both jam nuts of engine longitudinal stabi-

lizer rod. ‘
Remove bolt securing the engine longitudinal sta-
bilizer rod from the front engine support.
imr2010-007~002_a
1. Resonator
2. Resonator retaining bolt
Install the ENGINE LIFTING TOOL IF’/N 529 036181).
5290361 B1
irrir2U10-O05-O33_a
On RH side of the vehicle, remove engine support 7. Front jam nut I

bolts.
rrnr2011-O55 23
I
Section O2 ENGINE
Subsection 01 (ENGINE REMOVAL AND NSTALLATION)
3' 3
if ' \'- I.
_.. -.2
.
I
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7‘'\,1 ‘
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9.4, ‘i/" 1 rmr2ODB-D08 04 E _8
7. Front rubber mount

IMQDII-O06-1(I1_3
2. Remove these nuts
TYPICAL
1. Rearjam nut Rear Rubber Mounts
2. Stabilizer rod retaining bolt
Refer to BODYsubsection to remove the follow-
Remove nuts securing the front engine support. ing parts:
?c — Both top side panels
— Both middle side panels
- Both bottom side panels
l — Glove box
— Central panel.
Release drive belt tension. Refer to DR/I/E BELT
Install the ENGINE LIFTING TOOL (P/N 529 036181).
Z
II'T\l’2DO8-OOB-(]39_a
RH SIDE OF VEHICLE
528036181
,~.
Remove engine support bolts.
rn'ir2010-005-035_a
TYPICAL
1. Left front engine support bolt
Lift the engine just enough to free the front of en-

gine.
Unscrew nuts retaining front rubber mount on
frame.
rmr201 0006-O31_a
1. Upper engine support bolt
24 rmr201 1 -055
Section 02 ENGINE
rrrir200B-0084]25_a
TYPICAL
rr'rir20OB-O46-DU 5_a 1. Engine mounts shield
2. Alignment pin
TYPICAL — LH REAR ENGINE SUPPORT
7. Engine support nuts
2. Engine support bolts Tighten rubber mount nuts to specification.
Using the BLIND HOLE BEARING PULLER SET RUBBER MOUNT NUT TORQUE
(P/N 529 036 117), remove rear rubber mounts. 48 N-m (35lbf°ft)
‘lighten all engine bolts.

Fingertight the engine longitudinal stabilizer rod
until any play is removed, Hold engine stabilizer
rod and torque both jam nuts.
Remove the alignment pin.
Adjust drive belt tension. Refer to DRIVE BELT
Rear Rubber Mounts
52903611 7
Insert rubber mount into tube and align the tab
with the recess on tube.
Using a plastic hammer, insert rubber mount into
tube.
lighten nuts to specification.
RUBBER MOUNT NUT TORQUE
48 N'm (35 lbfeftl
Adjust drive belt tension. Refer to DR/VE BELT

rmi200B-D46-D07
TYPICAL
Engine Mounts Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Front Rubber Mounts
Install rubber mount.
Install the alignment pin.
rmr2011-055
25
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Section 02 ENGINE
Subsection 02 (AIR INTAKE SYSTEM)
GENERAL
During assembly/installation, use the torque val- /
ues and service products as specified in the ex-

ploded views. -‘

fer to SELF-LOCK/NG FASTENERS and LOCTITE
complete procedure.
A WARNING M G‘.

must strictly be adhered to.
Locking devices when removed must be re- €\\ Q“;
"M—r- _§P_
placed with new ones (e.g.: locking tabs, “I
elastic stop nuts, cotter pin, etc.). rriio2(]'l0-001-l04_a
RIGHT SIDE si_-ioWN

7 . Retaining clips
2. Air filter cover
NOTICE Hoses, cables and locking ties re-
moved during procedures must be reinstalled 3. Push air filter cover forward to expose air filter.
as per factory standards. 4. Pull out filter.
PROCEDURES
AMFMIER
Air Filter Removal
Never remove or modify any com-
ponent in the air intake system. Always use
genuine parts or suitable equivalent when
replacing air filter. The engine management
is calibrated to operate specifically with these
components. Otherwise, engine performance
degradation or damage can occur.
1. Refer to BODYsubsection and remove the fol-
lowing parts: imu2010-I101-1U5_a
— Right middle side panel RIGHT SIDE SHOWN

1. Air filter
— Right top side panel
— Right acoustic panel. NOTE: A small amount of oil in the air filter area
2. Release the 3 retaining clips from the air filter is normal. Clean as necessary.
cover Air Filter Inspection
Inspect air filter for cleanliness and damage.
It is NOT recommended to blow
compressed air on the paper filter. This could
damage the paper fibers and reduce its filtra-
tion ability when used in dusty environments.
NOTICE Do not wash the paper filter with any
cleaning solution.
Replace air filter as necessary.
28
rmr2011-056
Section O2 ENGINE
Air Filter Installation 5. Remove the n_ut that retains the headlight ad-
C f H instan air filter in its cove,’ juster cable (high beam on CE models) to the
are U V .. . . . LH side panel support and move the cable
Properly position air filter cover then secure with aSide_
both clips.
Reinstall parts in the reverse order of their re- 1""'“ "
moval.
RESONATOR
Resonator Removal
1. Remove the front cargo module, refer to BODY -
subsection.
2. Remove LH lateral support, refer to FRAME
subsection.
3. From the right side of vehicle, loosen clamp
securing resonator hose to air filter cover and
push the hose off of the filter cover.
rrrir2011~079-O02_b
1. Headlightadjuster
2. Side panel support
6. Remove the resonator retaining bolt.
rmi’20‘l 0-007-DO3_a
1. Resonator hose
2. Air filter cover
4. On left side of vehicle, disconnect the wire har- ,;,,,,,,,,_,,,,,_,,,,k,.,

ness connectors (3) to the console module and 1_ )qes,,,,,.,-,0,
move them aside 2. Resonator retainlrig bolt
7. Pull the resonator up off it's front mounting

ii
' i, .W_~<~;-W-‘:4-Qipfivll 7 \ bracket, then out to the side of the vehicle.
_ / Resonator Inspection
“'-”'/"';)-7'*‘z-."- " ~ I‘ - - -
, @® /g Inspect resonator and hose condition paying at-
“Q, ._ P /' tention for deformation, cracks or other damage.
fi
_;i.Pf§, I’ [f“,,f?]: 7 pg g_ My/A X Replace any defective part.
I),
U. I
\> ‘LCD -‘ -\ .
/I
V \'\._
-”T.",‘~:T_:*-——*',_ _ .
ff" Cb IX i!-l."
\" f '-
g_.
-1.~< Resonator Installation
,--/ Q __, Installation IS the reverse of the removal proce-
,/;j/ 1 E
. :1. / \T;c >.
/
rrnrZ01U-038-O29_a
... :1 mpQ. ET“
1"*».459.»
-1 \‘*‘i"i . dure however, pay attention to the following.
Ensure the 2 rubber cushions are installed in the
SOME PARTS REMOVED FOR CLARITY
resonator mounting bracket.
1. Console module harness connectors
rmr2011-O56 29
Section 02 ENGINE
in
rmr20i0-D07-O04_b
1. Cut these locking ties
3. Unplug the breather hose from the bottom

= ._.. ---a.-‘AL -I 4. of the air filter housing. Discard the Oetiker
rmr201 1 -056-001_a
clamp.
1. Rubber cushions
2. Resonator mounting bracket
3. Steering column
Ensure the resonator mounting pins on the inlet

tube properly engage in the rubber cushions when
installed.
.12».WL
r
imi’201 0-0O7£i05_a
1 Air filter housing
2. Breather hose
4. Release the 4 clips retaining the the LH side of

the air filter housing cover.
rmr201 1-056-O02_a
7 . Resonator mounting pins
AIR FILTER HOUSING P-

In 1n'7>~_T,
._.~:.\i,'V'_'_i
I
Air Filter Housing Removal it Te-'18‘

lowing parts on each side of vehicle:
— Front cargo module
— LH and RH acoustic panels.
‘ski _
2. On left side of vehicle, cut locking ties securing rmr201 O-D07-0053
wiring harness to air filter housing. 1. Locking clips
5. Remove the RH lateral support, refer to FRAME

subsection.
6. On right side of vehicle, loosen clamp securing
resonator hose to air filter cover and push hose
off of air filter cover.
30
rmr2011-056
Section 02 ENGINE
rmr2010-0070U3_a
rrm’Z0‘| 0-O07-009_a
1‘ Resonator hose
- - FROM RH OF VEHICLE
2' A” filter Cover 1. Retaining screws
7. Release the 4 clips retaining the RH side of the 10 Pu" air filter housing out of Vehide
air filter housing cover. ' '
Air Filter Housing Installation
For installation, reverse the removal procedure
however, pay attention to the following.
Install and tighten screws to specified torque us-
ing the following sequence.
HOUSING RETAINING SCREWS TORQUE
6N'm (53|bf°in)
W4‘ l l‘
;i2010-0(i7~007_a- H ‘_y’:_1 - E‘.

J“ if /
1. LOCkl!7Q C/IDS f-.
1:‘ ‘L
8. Remove air filter housing cover. g1

9. Remove air filter housing retaining screws. V /
1 ‘l ' “j-Z’ A __ _ l—_€l‘_l ‘ '/
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rmr201 0-O07-G10_a
l
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l
rrnr2U10-007-UOEl_a
FROM LH OF VEHICLE
7, Retaining screws
rmr201 1-056 31
Section 02 ENGINE
Subsection 03 (EXHAUST SYSTEM)
EXHAUST SYSTEM
SERVICE TOOLS
SPRING INSTALLER/REMOVER ................................................. .. 529 O35 983 ................................... ..37, 40
SERVICE PRODUCTS
LOCTITE 243 (BLUE) ........................................................... .. 293 800 O60 ......................................... .. 38
rr'nr201i 057 33
Sect|on 02 ENGINE
See ELECTRON/C‘ FUEL

INJECTION (EFI) E
=e*:“S-r’
.0,
V, 43 N-m
sq‘;
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/
S (38 lbf-ft)
‘\See ELECTRONIC FUEL
INJECTION (EF!)
V
av
(115 Ibf-In) (E
@‘ 18 N-m
(159 |bf'Il'I) 7 N m (‘I59 lbf-in)
$—m
/® /
20 N-m \
I6; iilafwnl "5 ‘bf F‘)
11 N'm
(97 lbf-|n) ’
NEW
//
$23‘ \c\£ 2o N m 5Nm

(159 lbf In)
@
Loctite
243
,
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(97 lbf~|n)
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when removed
(49 lbfqn 1»
Section 02 ENGINE
Subsection O3 (EXHAUST SYSTEM)
GENERAL EXHAUST SYSTEM TORQUE SEQUENCE
A WARNING 1. Rear head pipe (RH) to cylinder head

To avoid potential burns, never touch ex- 2. Front head pipe (LH) to cylinder head
haust system components immediately after 3. Catalytic converter support bracket to frame
the engine has been run as these compo- mount
nents are very hot. Let engine and exhaust
system cool down before performing any 4. Rear head pipe to catalytic converter (clamp)
servicing. 5. Front head pipe to catalytic converter (clamp)
6. Muffler mounting bolt
During assembly/installation, use the torque val-
ues and service products as specified in the ex- 7. Muffler to catalytic converter flange bolts
ploded view.
3. Check exhaust system clearance gaps as com-
Clean threads before applying a threadlocker. Re- ponent fasteners are torqued:
APPL/CAT/ON at the beginning of this manual for 3.1 Ensure clearance between the LH for-
complete procedure. ward head pipe and the drive belt ls at
least 8mm (5/16in).
A WARNING
Torque wrench tightening specifications \_ ___,,_
must be strictly adhered to. Locking de- _.._._._i—
vices must be replaced when removed (e.g.: I.
locking tabs, elastic stop nuts, self-locking
fasteners, cotter pins, etc.).
Hoses, cables or locking ties removed during a

procedure must be reinstalled as per factory stan-
dards.
EXHAUST SYSTEM
INSTALLATION SEQUENCE - 'i:i<:.'fi>?"‘
NOTE: When installing exhaust system compo- rrnfZ0‘l D-IJ08—002_a
nents, use new gaskets and new hardware as TYPICAL

1. Head pipe to drive be/t clearance
applicable. Apply specified torques. Refer to the
exploded view. 3.2 Ensure clearance between the LH inlet
1. Install all exhaust system components loosely pipe on the catalytic converter and drive
to ease adjustment of components. belt is at least 8mm (5/16in).
2. Torque exhaust system components in the fol-
lowing order. Adjust sequence as required ac-
cording to parts removal and installation to en-
__%%l§_*s1\ __#
-r W T‘ *7’-‘ ;‘)'7‘-:’_)‘-IIl
sure proper clearances are obtained.

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rrnr20i0-DOE-003,a
TYPICAL
7. Catalytic converter Inlet pipe to drive be/t clearance
rmr201 1-O57 35
Section 02 ENGINE
3.3 Ensure clearance between the LH inlet

pipe on the catalytic converter and the
l
frame is at least 3 mm (1/8 in).
\
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. _, -_._.-, ,_ _ _ __ ._
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7. Catalytic converter inlet pipe to frame clearance

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rmr2010-O08-008_a
TYPICAL
__ ._._n
7. Park brake pulley nut/bolt to muffler clearance
4. Recheck clearances when all components are

l
torqued. Adjust as required.
3.4 Ensure clearance between the flange on
the catalytic converter outlet pipe and the MAINTENANCE
swing arm is at least 4mm (5/32 ft).
NOTE: This measurement is taken at a slight CATALYTIC CONVERTER FRONT
angle with the suspension fully extended. GASKET REPLACEMENT
NOTE: When replacing the front catalytic con-
iii?
__-_4,-‘T-
0- verter gasket, the catalytic converter and muffler
can be removed as a unit.
1. Open the seat and both side rear cargo com-
partments.
2. Remove both mirrors, refer to BODYsubsec-
'IlOI'I.
3. Remove the following body panels, refer to
. 1" BODYsubsection:
— LH and RH middle side panels
— LH and RH wind deflectors
- LH and RH top side panels
rmr2010-O08-OO7_a
— LH and RH acoustic panels
TYPICAL I — LH and RH rear side panels.
7. Converter flange to swing arm clearance
4. Remove clamp retaining catalytic converter
3.5 Ensure clearance between the park brake pipe to front head pipe.
pulley nut/bolt on the rear wheel and the
muffler is at least 10 mm (13/32 in).
36 rmr201 1-057
Section O2 ENGINE
II K‘ .. ‘. “ Y‘ ' r4)/ > >3.
,.> ‘VT’ Yr ‘-1 x }
A V ~x .
\~
rmr201 1-O57-O01_a rrnr2011~057-003_a

‘ \. //_
ckg/
U
FRONT HEAD PIPE TO CATALYTIC CONVERTER 1. Frame
1. Exhaust clamp to remove 2. Catalytic converter
3. Fon/vard support bracket
5. Remove spring and clamp retaining catalytic 4. Screws to remove (2) LH side
5. Screw to remove (1) RH side
converter to rear head pipe.
REQUIRED TOOL
7. With the assistance of a coworker, support the
muffler and remove the muffler retaining bolt.
SPRING INSTALLER/REMOVER (P/N 529 O35 983)
rrnr2011-O57-0U4_a
1. Muffler
2. Muffler retaining bolt to remove
NOTICE Insert padding between muffler and

park brake pulley on rear wheel axel to prevent
contact between parts and damage to the muf-
rmr2011-O57-0O2_a
fler.
REAR HEAD PIPE TO CATALYTIC CONVERTER
1. Exhaust spring to remove 8. As you support the catalytic converter, unhook
2. Exhaust clamp to remove the aft rubber support from the catalytic con-
verter.
6. Remove the screws that secure to the frame
the forward support bracket for the catalytic
converter.
rmr201]-057 37
Section 02 ENGINE
| 1 I
PROCEDURES
MUFFLER HEAT SHIELD
Heat Shield Removal
Remove the three screws mounting the heat
shield to the forward end of the muffler.
/WI
rmr2011~057-0D5_a
1. Aft rubber support to remove (catalytic converter)
9. Carefully pull the catalytic converter off both

head pipes.
Do not let the muffler contact any
part of the vehicle to avoid damaging the fin-
ish on the muffler or any part it may contact. LAG
Wrap the muffler with a thick cloth or blanket rmr201 1-057-004_b
1. Muffler
to protect it during removal, installation. 2. Muff/er shield
10. Remove exhaust gasket from each head pipe.
Heat Shield Installation
11. Install a NEW exhaust gasket on each pipe.
1. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) to
12. Install the muffler and catalytic converter in the threads of the mounting screws.
the reverse order of the removal however, pay 2. Position heat shield on muffler, install and
attention to the following: torque the three mounting screws.
— Clean muffler retaining bolt threads and ap-
ply LOCTITE 243 (BLUE) (P/N 293 800 O60), or MUFFLER SHIELD SCREW TORQUE
install a new bolt. 5.5 N'm (49 Ibfsftl
- Apply torques as specified.
MUFFLER RETAINING
BOLT
CONVERTER SUPPORT
BRACKET
MUFFLER
18 Nsm (159Ibf'in) 7 Nsm (62 lbf'in) Muffler Removal
1. Position vehicle for ease of access to muffler
retaining bolt and muffler flange screws under
INSPECTION the vehicle.
Always inspect exhaust system parts for the fol- 2. Remove the nuts and springs that secure the
lowing defects or damages: muffler flange to the catalytic converter flange.
— Cracks NOTE: The socket head screws may be left in the
- Tearing flanges at this time.
— Bending
- Dents
— Corrosion
— Leaks
— And any other damage or defect which could
affect system performance.
Replace as required.
as rI'nr20'|‘I-O57
Section 02 ENGINE
2. Insert muffler pipe over catalytic converter pipe

and insert the two socket head screws through
the flanges.
3. Install muffler retaining bolt on muffler support
and tighten nut until it bottoms out loosely.
4. Install springs and retaining nuts on the muffler
flange screws and tighten nuts slightly. Do not
torque them at this time.
5. Torque the muffler retaining nut first, then
torque the flange nuts as specified in the fol-
lowing table.
MUFFLER TORQUE SEQUENCE
rmr201 1 -057006_a
1. Muffler flange
18 Nvm
STEP 1 Muffler retaining nut (159|bf.in)
2. Catalytic converter flange
3. Nuts and springs to remove
STEP 2 Inner muffler flange nut 11N,m
3. While supporting muffler, remove the muffler STEP 3 Outer muffler flange nut (97 lbfsinl
mounting hexagonal screw from the muffler
support. NOTE: Ensure clearance between the flange on
the catalytic converter exit pipe and the swing
arm is as specified with full swing arm extension.
Refer to EXHAUST SYSTEM /NS TAL LA T/ON SE-
QUENCE for illustration.
CATALYTIC CONVERTER FLANGE TO
SWING ARM CLEARANCE
At least 4mm (5/32in)
(with full swing arm extension)
When compressing the rear suspen-

sion, ensure the muffler clears the park brake
pulley on the rear caliper by at least 10 mm
(.394in). If clearance is not obtained, loosen
rrn120'I I -D57-D04_a then re-torque the flange nuts until proper
1. Muffler clearance is obtained. Refer to EXHAUST
2. Muffler retaining bolt to remove
SYSTEM INSTALLATION SEQUENCE for iIIus- ,
NOTICE Insert padding between muffler and tration.
park brake pulley on rear wheel axel to prevent 6. Start engine and ensure the muffler gasket ring
contact between parts and damage to the muf- is not leaking.
fler.
4. Remove the two socket head screws from the CATALYTIC CONVERTER
muffler flange and carefully remove the muffler
from the catalytic converter. Catalytic Converter Removal
5. Discard old muffler gasket. 1. Open the seat and both rear side cargo com-
partments.
Muffler Installation 2. Remove both mirrors, refer to BODY subsec-
1. Install a NEW muffler gasket on the muffler end tion.
of the catalytic converter exhaust pipe. 3. Remove the following body panels, refer to
BODYsubsection:
NOTICE Insert padding between muffler and
park brake pulley on rear wheel axel to prevent — LH and RH middle side panels
contact between parts and damage to the muf- - LH and RH wind deflectors
fler. - LH and RH top side panels
rmr201 1-057 39
Section 02 ENGINE
— LH and RH acoustic panels 7. Remove the screws that secure the forward
— LH and RH rear side panels. support bracket for the catalytic converter to
4. Remove the MUFFLER, see procedure in this the frame.
subsection.
5. Remove the spring retaining the catalytic con-
verter to the rear head pipe (RH side). g f.-.\ l ' .
REQUIRED TOOL '7 -_‘:
9‘ J|;v
'
I.
. 7"“ ,
‘\’
\ L t
2- I \ ' \
SPRING INSTALLER/REMOVER (P/N 529 035 983) :._ ' T}: ‘I’ /J
1
“~
Q_ \
-» '1 *1. /\
6. Loosen the exhaust clamps securing the cat-

alytic converter to both head pipes sufficiently
to slide the clamps down the pipes.
NOTE: Note the position of each clamp for instal-
lation.
5?’/”
..
rml’ZO1 I -O57-0[I3_a
1.
2.
Frame
Catalytic converter
2
i;;§//
ff. 4/ r T5; '1 ‘-1
3. Fon/vard support bracket

4. Screws to remove I2) LH side
5. Screw to remove (1) RH side
8. As you support the catalytic converter, unhook

the rubber support above the converter.
,Qn
mam -v ..._..M__
rrnr20I1-O57-0DI_a
FRONT HEAD PIPE TO CATALYTIC CONVERTER

1. Exhaust clamp to remove
‘U¢I\
rmr201 1415741053
1. Aft rubber support to remove (catalytic converter)
9. Carefully pull down on catalytic converter ex-

haust pipes to disconnect them from the head
pipes.
Catalytic Converter Installation
1. Install NEW gaskets on the head pipes.
_ 1 2. Assure both exhaust clamps are positioned
loosely on catalytic converter pipes prior to
insertion on front head pipes.
. 2
rn\r20l1-U57-lJOZ_a 3. Insert the catalytic converter support bracket
REAR HEAD PIPE TO CATALYTIC CONVERTER onto the converter support hooks. Ensure the
1. Exhaust spring to remove grommets are in good condition.
2. Exhaust clamp to remove
40 rmi'2O I 1-O57
Section 02 ENGINE
Subsection O3 (EXHAUST SYSTEM)
4. Insert the catalytic converter pipes over the 4. Remove LH lateral support, refer to FRAME
head pipes. subsection.
5. Insert the support hook above the catalytic con- 5. Remove air intake system resonator, refer to
verter into its rubber support. A/R /NIAKE SYSTEM subsection.
6. Slide exhaust clamps over each converter to 6. Remove the muffler. Refer to MUFFLER RE-
head pipe joint and tighten them just enough for MOVAL in this subsection.
them to remain in position. 7. Remove the catalytic converter. Refer to CA7?
7. Install the RH head pipe spring using same tool AL YT/C CONVERTER REMOVAL in this subsec-
as removal. tion.
NOTE: Make sure pipe joints are bottomed out to 8. Remove the oxygen sensor from the head pipe,
prevent leakage which could affect system effi- refer to HEATED OXYGEN SENSOR (H023) in
ciency. the ELECTRON/C FUEL /N./ECT/ON /EF/) sub-
8. Install screws that secure the forward con- section.
verter support bracket and torque as specified.
F-""' . "r... ,M-1'5.»
9. Properly position exhaust clamps at converter
to head pipe joints and torque as specified. ‘E _ fi_1.i.‘~,_.a;iri§‘-7,."
I :1. ) "Q/-"1
Iv. ' Ti‘
"
_. "' ,1"? T‘ ‘.9
»~.-.1. _______
CONVERTER TORQUE SEQUENCE
Forward converter 7 N'm \
',
I
iriIE§‘ifi'@~='1)
‘"i"~--,_
':- I:
-- -ME
. -'
~1-
G‘-QQ‘ .
“.-
> _ ~ - -{L.' !$...-.||i...., --- T"
.- . .; es,
STEP 1
support bracket (62 Ibf-in)
/7 2.-..,~_%T~.—
I.
\
-L
‘iv .» i r I - ‘ \.
_
STEP 2
Rear head pipe to
converter 18 N,m . 1/,
Front head pipe to l159'bf'i"l
-'1'“
\ llll 7'1
JI.-, \'~<(§"‘
I-If.‘- 1g
STEP 3 rmr2U1D-0Cl5—005_a
COHVBTIGT 7. Front oxygen sensor (LH side)
2. Front head pipe
10. Ensure proper exhaust system clearance gaps
are obtained. Refer to EXHA US T5 Y5‘TEM /N- 9. Remove and discard the four nuts retaining
S7I4LLA77QN SEQUENCE at the beginning of head pipe to front cylinder head.
this subsection.
11. Install muffler, refer to MUFFLER INSTALLA-
T/ON
1," ,
12. Install all remaining removed parts and panels.
HEAD PIPE (FRONT CYLINDER)

Head Pipe Removal (Front Cylinder)
1. Open the seat and both rear side cargo com-
partments.
tion.
rmr100B-O10-U143
BODYsubsection:
TYPICAL
— LH and RH middle side panels 1. Front cylinder head
2. Nut locations (one is not visible)
— LH and RH wind deflectors 3. Gasket, head pipe to cylinder head
- LH and RH top side panels
— LH and RH rear side panels 10. Remove head pipe by carefully moving the
pipe forward off the mounting studs, rotating
— LH middle side panel it so that it can be pulled out on the LH side
— LH bottom front side panel of the vehicle.
— Oil cooler duct.
rmr2011-O57 41
Section 02 ENGINE
Head Pipe Installation (Front Cylinder)

1. Install NEW head pipe gaskets.
2. Install head pipe loosely on cylinder head using
four NEW retaining nuts.
3. Install oxygen sensor, refer to HEATED OXY-
GEN SENSOR (HO257 in the ELECTRON/C
FUEL /N./ECT/ON (EF/I subsection.
4. Install remaining exhaust system components
loosely.
5. Torque exhaust system fasteners and ensure
proper exhaust system clearance gaps are ob-
tained. Refer to EXHAUSTSYSTEM/NS771lLLA-
T/ON SEQUENCEin the beginning of this sub- rm r2 D10-ODS-DO6_a
section. 1. Rear oxygen sensor (RH side)

2. Rear head pipe
6. Install air intake system resonator, refer to A/R
/N771/(E SYSTEM subsection. 6. Remove and discard the four nuts retaining
7. Install LH lateral support, refer to FRAMEsub-
head pipe to rear cylinder head.
section.
Install all remaining removed parts and panels in-
cluding oil cooler duct. Referto BOD Ysubsection.
HEAD PIPE (REAR CYLINDER)

Head Pipe Removal (Rear Cylinder)
1. Open the seat and both rear side cargo com-
partments.
tion.
BODYsubsection:
- LH and RH middle side panels rmr20DS-O10-fl15_a
— LH and RH wind deflectors TYPICAL

1. Rear cylinder head
— LH and RH top side panels 2. Nut locations (two are not visible)
3. Gasket, head pipe to cylinder head
— LH and RH acoustic panels
— LH and RH rear side panels. 7. Pull head pipe from mounting studs and rotate
4. Remove the muffler and catalytic converter, it so that it can be pulled out on the RH side of
refer to MUFFLER REMOIAAIL and CAIALYT/C the vehicle.
CONVERTER REMOVAL procedures in this
subsection. Head Pipe Installation (Rear Cylinder)
5. Remove the oxygen sensor from the head pipe, 1. Install NEW head pipe gaskets.
refer to HEATED OXYGEN SENSOR (H0257 in 2. Install head pipe loosely on cylinder head using
the ELECTRON/C FUEL /N./ECT/ON (EF// sub- four NEW retaining nuts.
section. 3. Install oxygen sensor, refer to HEATED OXY
GEN SENSOR (HOZS) in the ELECTRON/C
FUEL /N./ECT/ON (EF/) subsection.
4. Install remaining exhaust system loosely.
42 rmr201l-057
Section 02 ENGINE
5. Torque exhaust system fasteners and ensure

proper exhaust system clearance gaps are ob-
tained. Refer to EXHA US TS YSTEM /NS 7ALLA-
T/ON SEQUENCEin the beginning of this sub-
section.
Install all removed panels, refer to BODYsubsec-
tion.
rmr2011-057 43
Section02 ENGINE
Subsection 04 (LUBRICATION SYSTEM)
LUBRICATION SYSTEM
SERVICE TOOLS
ADAPTER HOSE ......................................................................... .. 529 035 652 ......................................... .. 53
ECM ADAPTER TOOL ................................................................. .. 529 O36 166 ......................................... .. 55
FLUKE 115 MULTIMETER .......................................................... .. 529 O35 868 ......................................... .. 54
OETIKER PLIERS ......................................................................... .. 295 OOO O76 ................................... .. 57-59
PRESSURE GAUGE ..................................................................... .. 529 O35 709 ......................................... .. 53
SERVICE PRODUCTS
LOCTITE 243 (BLUE) ................................................................... .. Z93 BOO O60 ................................... .. 55, 61
LOCTITE 515 ............................................................................... .. 413 702 700 ......................................... .. 64
LOCTITE 648 (GREEN) ................................................................ .. 413 711 400 ................................... ..67, 69
LOCTITE CHISEL (GASKET REMOVER) ..................................... .. 413 708 500 ......................................... .. 64
PULLEY FLANGE CLEANER ....................................................... .. 413 711 809 ............................. .. 57, 60-61
SUPER LUBE GREASE ................................................................ .. 293 550 O30 ......................................... ..68
XPS SYNTHETIC BLEND OIL (SUMMER GRADE) ..................... .. 293 600121 ......................................... .. 50
rrnr2011-(J58 45
Section OZ ENGINE
L 1
A’-‘ 7 I ‘- 7
7..
, -.
Eng_ine
0') See installation
procedure
Loctlte _. ~ . J-¢~l/
1 C L OCIIIB
'
648 “Super Lube
2 43 / . O‘ Qrease _ _
13 I|\l- I1 N ' '31 - 5 N-m 0
(159 lbfI-IiIn) (97 ">*""l Engine
0 /\ __/ 1 <44 Ibr-rm I I
ax. x
1 ' ‘r
.
I I _,\
I .
0" Loctite 1 I
515 1 ; _
6 ’ 1 ’
Engine .
l lit.-if1..
Loctite
\\7I;I
648 6
. -;-~=
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1
. . (II
‘ av‘ I
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aI
r -
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st“
-4,, l|'- IT’! ' rI
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.
J l ’fl=S-;;."-
l)?{1€$:<11?\i£_1/)1’7"1.‘- r
-1,‘____,5'
1
.:_
L’_
\v< at I
/
Finger tight
NEW
Loctite
5910
X _ .
14 N m 6Engrne oil
(124 II)f'lII)
Engini 6Loctite 243
oil A 01%
' ‘*’\ 11 N-m
% (97 lbf-in)
20 N-m (5 -
(15 |bf.fl) Engine > <6Loct|te 243
oil
11 N-m 11 N.
(97Ibf-in) I r97|b1=.'§:,1
= Component must be replaced when removed.
rmr2DO8-011-Oo‘|_c
46 rm r201 1-058
Sect|onO2 ENGINE
Subsect|0n04 (LUBRICATION SYSTEM)
SE5 engine
/ 10 N-m Q 49 |bf.
(89 lbfqn) ( ";)L0ct a te 243
If
“ii
% , h
\ \ mfffr
I
/
/7|\|.m
~
SM5engme / (62|bf_m) _, /L,
/
1~/*2
/
’>
\
Q
Mm
WT”;
1| m
\
1| ‘.
1‘;/\
\#@ Y‘<@-
// 55Nm W \‘\\1|f'
\ M} MW ~
\,
Loctlte 243 \\\((~
9
7 N-m
20 m (62 Ibf-in)
(15 Ibf~ft)
*9 NEW
NEW = Component must be replaced when removed
47
Section 02 ENGINE
ENGINE LUBRICATION CIRCUIT (RH VIEW)
"¢iI'§*
rm|20!1-Q09-100_a
Magnetic drain plug 9. Balance shaft support plain bearing (clutch housing)
Engine oil strainer 70. Oil tube (piston cooling and lubrication)
Oil scavenge pump 17. Clutch shaft (free pinion and clutch drum)
Oil pressure pump 12. Oil duct cover
Oil pressure regulator 13. Timing chain rensioner (rear cylinder)
U"-“lr'=$~>!\1.\‘ Oil pressure switch 14. Upper balance shaft
7. Engine oil filter 15. intake camshaft (rear cylinder)
8. Crankshaft support plain bearing (clutch housing) 16‘ Exhaust camshaft (rear cylinder)
48 rrnr2011-058
Section02 ENGINE
Subsection04 (LUBRICATION SYSTEM)
ENGINE LUBRICATION CIRCUIT (LH VIEW)
\_‘
-11
..
..-10
—9
K ;~@§:_/5
rmr201 1-009-101_a
1. Balance shaft plain bearing (clutch side) 8. Oil jet and clutch shaft
2. Balance shaft plain bearing (MAG side) 9. Oil nozzle (generator cooling)
3. Crankshaft plain bearing (clutch side) 10‘ Main shaft (free pinion)
4. Crankshaft plain bearing (MAG side) T 1. Wining chain tensioner (front cylinder)
5 Connecting rod plain bearings 12. Intake camshaft (front cylinder)
6. Oil hose connector (to oil cooler then oil tank) 13. Exhaust camshaft (front cylinder)
7. Oil hose connector (from oil tank)
rmr201 1-058 49
i Z i
Section O2 ENGINE
GENERAL 3. With the engine already at normal operating

temperature, start engine and let it run at idle
During assembly/installation, use the torque val- for at least 30 seconds.
ploded views. NOTE: Running engine for at least 30 seconds al-
lows the scavenge oil pump to drain the oil from
Clean threads before applying a threadlocker. Re- the engine crankcase back into the oil tank. Not
fer to SELF-L OCKING FASTENERS and LOCT/TE carrying out this step could result in overfilling the
APPL/CAT/0Nat the beginning of this manual for engine oil.
complete procedure.
4. Stop engine.
A WARNING 5. Unscrew and remove the oil dipstick.
must be strictly adhered to. _
Locking devices must be replaced with new

ones when removed (e.g.: locking tabs, elas-
tic stop nuts, cotter pins, etc.).

moved during a procedure must be reinstalled
as per factory standards.
MAINTENANCE lg
rmr200B-O11 -100_a
ENGINE OIL TYPICAL

1. Oil dipstick
2. Oil tank
Recommended Engine Oil
US6 XPS SYNTHETIC BLEND OIL (SUMMER GRADE) 6. Wipe off the dipstick.
(P/N 293 600 121). 7. Reinsert and completely screw in the dipstick
NOTE: The XPS oil is specially formulated and to assure an accurate reading.
tested for the severe requirements of this engine. 8. Unscrew and remove the dipstick.
If not available, use a 5W 40 semi-synthetic (min- 9. Check the oil level on the dipstick; it should be
imum) or synthetic motorcycle oil meeting the re- near or equal to the upper mark.
quirements for API service SL, SJ, SH or SG clas-
sification. Always check the API service label on
the oil container.
The same oil is used for the engine, gearbox,
clutch and hydraulic control module (HCM) in the
SE5 models.
To avoid damaging the clutch, do
not use a motor oil meeting the API service SM A 3
or ILSAC GF-4 classification. Clutch slippage
will occur. 2 I‘iL|'.‘L-1,4‘!
Engine Oil Level Verification

To obtain a precise reading of the rmr20DB4J1 1-102_a
engine oil level, follow this procedure and 1. Full

make sure engine is at normal operating tem- 2. Add
3. Operating range
perature.
Oil Level is at or Near Upper Mark
1. Park the vehicle on a level surface.
1. Properly insert and tighten dipstick.
2. Remove the LH middle side panel. Refer to
BODYsubsection. 2. Install the LH middle side panel, refer to BODY
subsection.
50 rmr201 1-O58
Section 02 ENGINE
Oil Level Under Operating Range

1. Add a small amount of recommended oil.
NOTE: The oil quantity between ADD mark and
"F" mark is 0.5 L (.5 qt (U.S. liq.)).
2. Recheck oil level.
3. Repeat the above steps until oil level reaches
the dipsticks upper (F) mark. Do not overfill.
4. Properly insert and tighten dipstick.
5. Install the LH middle side panel, refer to BOD)’
rmr200B-OI 1-1033
subsection. TYPICAL
1. Drain plug
Engine Oil Change 2. Oil tank
1. Prior to changing the oil, ensure vehicle is on a 7. Remove the dipstick.
level surface.
8. Allow sufficient time for oil to completely drain.
The engine oil filter and the hy- 9. Clean area around engine drain plug.
draulic control module (HCM) oil filter (SE5)
must be replaced at the same time. The oil 10. Place an appropriate drain pan under the en-
change should be carried out with a warm gine.
engine. 11. Remove the engine oil drain plug and discard
the sealing washer.
A CAUTION Engine oil can be very hot.
2. Remove the following LH body panels, refer to
BODYsubsection:
— Middle side panel
- Top side panel
— Rear side panel
— Bottom front side panel
- Bottom rear side panel.
3. Remove the bottom plate under oil tank.
rmr2DDB-O1 1-1lJ4_a
TYPICAL
1. Engine oil drain plug
2. Oil filter cover
12. Allow sufficient time for oil to completely drain

from crankcase.
13. Clean the magnet on the engine drain plug.
14. Using NEW sealing washers, install engine
and oil tank drain plugs.
rmr2DO8-011-101_a
TYPICAL
NUTICE Never reuse the drain plug sealing
1. Bottom plate washer. Always replace it with a new one.
2. Oil tank
15. Tighten drain plugs (engine and oil tank) as
4. Clean area around drain plug under oil tank. specified.
5. Place an appropriate drain pan under oil tank. DRAIN PLUGS TORQUE (ENGINE AND OIL TANK)
6. Remove the drain plug and discard the sealing 20 Nem (15 lbfvft)
washer.
16. Replace engine oil filter. Refer to ENG/NE 0lL
F/L7'EF?further in this subsection.
rmr2011-O58 51
Section 02 ENGINE
SE5 Model 28. Reinstall all removed body panels.

17. Replace the HCM oil filter. Refer to H)’- 29. Dispose of used oil as per your local environ-
DFrA U./.lC CON7'/‘POL MODULE (SE5) subsec- mental regulations.
tion.
All Models ENGINE OIL FILTER
18. Pour 3 L (3.2 qt (U.S. liq.)) of the recom- Engine Oil Filter Removal
mended oil into the oil tank. NOTE: Refer to O/L CHANGE for the list of re-
19. Start engine and let idle for two minutes. quired body panels to be removed.
IMPORTANT NOTICE 1. Remove oil filter cover screws.
Do not rev up engine during idling period as this
may cause permanent engine damage.
Ensure oil pressure warning lamp

goes out within 5 seconds from engine start. If
oil pressure warning lamp stays ON for more
than 5 seconds, STOP ENGINE and recheck oil
level.
20. Ensure engine oil filter cover, engine and oil
tank drain plugs, and HCM filer cover (SE5
models) are not leaking.
rmr20084)11-105_a
21. Stop engine. TYPICAL
NOTE: The oil level dipstick is accurate when the 1. Oil filter cover
2. Cover screws
oil temperature is at 80°C (176°F). If the oil level
is checked when the oil is at room temperature 2. Remove oil filter cover with O-ring. Discard
(20°C (68°F)), the proper oil level indication is O-ring.
half way between the lower (ADD) and upper (F) 3. Remove oil filter.
marks on the dipstick. This must be considered
to prevent overfilling the oil tank. 4. Dispose of filter as per your local environmental
regulations.
SM5 Model
22. Add 0.9 L I1 qt (U.S. liq.)) Of the RECOM- Engine Oil Filter Installation
MENDED ENG/NE O/L in the oil tank. Installation is the reverse of the removal proce-
NOTE: The total quantity is 3.9L dure. However, pay attention to the following.
(4.1 qt (U.S. liq.)). 1. Check and clean oil inlet and outlet orifices in
23. Check oil level immediately and adjust if re- crankcase for dirt and contaminants.
quired. - - ,_-,,,...
24. Reinstall all removed body panels.
25. Dispose of used oil as per your local environ-
mental regulations.
SE5 Model
26. Add 1.2 L (1 .3 qt (U.S. liq.)) of the HECOM-
MENDED ENG/NE O/L in the oil tank.
NOTE: The total
(4.4qt (U.S. liq.)).
quantity is
27. Check oil level immediately and adjust if re-

4.2 L
. .
rmr2008-O11-0043
-,-(1 . ‘Q3’-
.I Q
quired. TYPICAL
NOTE: When the engine oil filter and the HCM oil 1. Oil inlet orifice from oil pressure pump
2. Oil outlet orifice to engine lubrication system
filter are replaced, the total oil quantity to add will
be 4.3 L (4.5 qt (U.S. liq.)). 2. Install a NEW O-ring on the oil filter cover.
52 rmr2011-058
Section02 ENGINE
3. To ease assembly and prevent displacement of

the O-ring during installation, apply a light coat
of oil on the oil filter and oil filter cover O-ring. ’ -
Refer to following illustration. '-’-.1!

._ ,‘1Il_ '_ _—
1 \ "V
.»_-g
__ .
529035709
O/L PRESSURE GAUGE
A
--»1
rmr20DB—01 1005;:
1. App/y oil here
INSPECTION
ENGINE OIL PRESSURE TEST
NOTE: The engine oil pressure test should be car- 52903 5652
ried out with a warm engine (80°C (176°F) engine HOSEADAPTER

oil temperature) and with the RECOMMENDED 3. Remove the 0/L PRESSURE SW/TCH, see the
E/\/G/NE 0/L at the appropriate level. procedure in this subsection.
1. Remove the bottom plate aft of the radiator. NOTE: Place a container to retrieve engine oil that
Refer to BODYsubsection. may flow out of engine.
4. Install the hose adapter into the oil pressure
switch port.
rmr2OOE-O1 1-1 fl6_a
TYPICAL
1. Bottom plate
Z. Connect the ADAPTER HOSE (P/N 5'29 O35 652) IO

rmr200EO1 1»1D'I_a
the PRESSURE GAUGE (P/N 529 O35 709).
TYPICAL
7. Oil pressure gauge
2‘ Hose adapter
5. Start engine and measure the engine oil pres-

sure.
NOTE: Measured engine oil pressure should be
within the following specifications.
rmr201 1 058
53l
Section O2 ENGINE
OIL PRESSURE 1400 RPM 5000 RPM Oil Pressure Switch Inspection
MINIMUM 70kPa (IOPSI) 350kPa (51 PSI) Ensure engine oil pressure is within specifica-
NOMINAL 150 l<Pa (22 PSI) 420 KPH (61 PSI) tions. Refer to ENG/NE O/L PRESSURE TESTin
MAXIMUM 300 kPa (44 PSI) 550 kPa (80 PSI) this subsection.
If the engine oil pressure is good, carry out an O/L
6. After engine oil pressure test, reinstall oil pres- PRESSURE SW/ TCH RES/SE4/VCE TEST
sure switch, see procedure in this subsection.
7. Reinstall body panels. Oil Pressure Switch Resistance Test
NOTE: The engine must be warm to test the oil
PROCEDURES pressure switch properly.
l. Disconnect the oil pressure switch connector.
OIL PRESSURE SWITCH (OPS)
Oil Pressure Switch Location
The oil pressure switch is located on the RH side
of vehicle on clutch housing.
‘Iv '
~.--/
->
Li in 1*». V‘ ,_
ya rrnr2008-011~lO8_b
7. Oil pressure switch connector
2. Set a FLUKE 115 l\/IULTIMETER (P/N 529 035 868)

to Q selection.
rrnr2008-01 1~1 0B_a 3. Test the resistance of the OPS switch as fol-
TYPICAL lows.
2. Clutch housing OPS RESISTANCE TEST (Q)
ENGINE NOT RUNNING
Oil Pressure Switch Access OPS Engine Close to O Q
Remove the following RH body panels, refer to switch pin ground (normally closed switch)
BODYsubsection:
— Middle side panel If resistance is incorrect, replace the oil pressure
switch.
- Top side panel
— Rear side panel If the resistance is correct, retest the OPS switch
with engine running. Read result and compare to
— Bottom front side panel table.
— Bottom rear side panel.
ops RESISTANCE TEST in)
Oil Pressure Switch Activation ENGINE RUNNING
The engine oil pressure switch activates if engine OPS switch pin] Engine ground | Infinite (OL)
the oil pressure is in the following specified pres-
sure range. If resistance is incorrect, replace the oil pressure
switch.
OIL PRESSURE SWITCH ACTIVATION POINT ‘
If the resistance is correct, test the oil pressure
30 kPa to 60 kPa (4.4 PSI to 8.7 PSI) switch wiring circuit.
54 rmr201 I -058
Section 02 ENGINE
Oil Pressure Switch Circuit Test

OPS Circuit Dynamic Test
‘I. First, ensure an engine oil pressure test has
been performed and that engine oil pressure is
within specifications.
2. Start the engine.
3. Disconnect the OPS connector.
4. Ground the OPS connector. The low oil pres-
sure pilot lamp should turn on.
5. Unground the OPS connector. Oil pilot lamp 5rhQO09-OZ3~102_b
should turn off.
lf the test succeeded and the low oil pressure pilot If circuit continuity is not within specification, re-
lamp stays ON when engine is running, try a new peat test at the engine disconnect (HICI connec-
OPS. tor. Repair wiring/connectors as required.
If the low oil pressure pilot lamp does not come on If circuit continuity is within specification, carry out
with the circuit grounded, test continuity of OPS a multifunction gauge WOW test in B.U.D.S., re-
circuit wiring. fer to LIGHTS, GAUGE A/\/D ACCESSOR/ES sub-
section.
OPS Circuit Continuity Test NOTE: If the engine oil pressure is within spec-
1. Disconnect connector "A" from the ECM. Re- ification, OPS tests and the OPS wiring circuit
fer to ELECTRON/C FUEL /N./ECT/ON (EF/) tested good, check multifunction gauge and ECM.
subsection.
2. Install the ECM ADAPTER TOOL (P/N 529 036166) Oil Pressure Switch Removal
on ECM-A connector. l. Start vehicle and let engine run approximately 5
minutes.
NOTE: This is recommended to avoid oil drainage
from engine when removing switch.
2. Disconnect the oil pressure switch connector.
3. Unscrew and remove the oil pressure switch.
529038166
3. Test for continuity of OPS circuit as per follow-

ing table.
TEST PROBES RESISTANCE
ECM adapter Close to O Q
OPS connector pin E3 (continuity)
vrriY2D03-OII -I 08_a
TYPICAL
2. Clutch housing
Oil Pressure Switch Installation

Apply LOCTITE 242 (BLUE) (P/N 293 aoo 060) on
threads of oil pressure switch.
rmr201 I -O58 55
SectionO2 ENGINE
NOTICE Do not apply Loctite 243 to the first

thread. If Loctite seeps into pressure switch, oil
pressure switch may malfunction.
Tighten oil pressure switch as specified.
OIL PRESSURE SWITCH TORQUE
15 N'm (133 lbfvinl
OIL TANK
Oil Tank Access
Remove the following LH body panels, refer to
BODY subsection: 2 Remove these screws
— Upper side panel
4 Remove bolt above ignition coil securing oil
- Middle side panel tank to lateral support
- Bottom front side panel.
Oil Tank Removal
1. Drain oil tank. Follow the procedure in ENG/NE
0/L CHANGE in the beginning of this subsec-
tion.
2. Disconnect vent hose from top of oil tank.
1 Ignition coil
2 Remove this bolt
5 Remove ignition coil retaining bolt
rmr2008-O11-111_a
TYPICAL
1. Vent hose
2. Oil tank
3. Remove screws retaining oil cooler to oil tank.
Ignition coil bolt
6 At the bottom of oil tank disconnect the oil tank

return hose
56
Section 02 ENGINE
j-
1/
/
Q)
rmr200E-01 ‘I-1 17_a
rmr200B-01 1-1 1 5_a TYPICAL

1. Oil cooler out/er hose
TYPICAL 2. Remove this Oetiker clamp
1. Return hose
2. Oil tank
SE5 Model
REQUIRED TOOL 9. Remove the HCM clutch servo hose in the front
OETIKER PLIERS (P/N 295 000 O70) of the oil tank.
\
Q. Q l...
7. Behind oil tank, remove the screw securin oil o
irrm
,..- /\
tank to oil cooler support bracket. _r::\ ‘I
rm r2 O08-O46-003_a
TYPICAL
1. Clutch servo hose
2. Oil tank
AII Models
10. Remove oil tank.
Oil Tank Installation
1. Ensure the rubber cushions are properly in-
stalled in the oil tank support.
"T112008-01 I-1l6_a
TYPICAL 2. Clean oil residue on oil tank fittings and oil

1. Oil cooler support bracket
2. Remove this crew
hoses using PULLEY FLANGE CLEANER (P/N 413
711 809).
8. Disconnect the oil cooler outlet hose. 3. Install NEW Oetiker clamps.
4. Using a NEW sealing washer, install oil tank
drain plug.
NOTICE Never reuse a sealing washer a sec-
ond time. Always replace it with a new one.
5. Tighten drain plug to specification.
rmr2011-058
51
i i
Section 02 ENGINE
DRAIN PLUG TORQUE ‘

2ON'm (l5lbf'ft)
6. Refill oil tank with recommended oil. Refer to

ENGINE OIL in this subsection.
OIL TANK STRAINER

Oil Tank Strainer Access
BOD)/subsection:
- Middle side panel rmr2008-011-110_fl
TYPICAL
— Bottom front side panel. 1. Oil tank strainer
2. O-ring
Oil Tank Strainer Removal
1. Drain oil tank. See ENGINE 0/L CHANGEpro- Oil Tank Strainer Cleaning
cedure in this subsection. Clean oil tank strainer with a parts cleaner, then
2. Remove Oetiker clamp and disconnect oil tank use air pressure to dry it.
return hose. Oil Tank Strainer Inspection
REQUIRED TOOL Check condition of strainer mesh. Replace
OETIKER PLIERS (P/N 295 000 O70) strainer as required.
\ Oil Tank Strainer Installation

For installation, reverse the removal procedure.
is \\ However, pay attention to the following.
1. Wipe off any oil spillage on oil tank.
5».K 2. Install a new O-ring on the oil strainer.
3. Apply engine oil on O-ring.
.--"““'j 4. Install strainer in oil tank and tighten to specifi-
cation.
I oii. STRAINER TORQUE ‘
20 N'm (15 lbf¢ft)
NOTICE Take care not to damage O-ring

while inserting strainer into oil tank. Apply oil
on O-ring to ease installation.
5. Install a NEW Oetiker clamp on oil return hose.
REQUIRED TOOL
OETIKER PLIERS (P/N 295 O00 O70)
rmr2fl08-011-109_a
TYPICAL
1. Strainer end
2. Oil tank return hose
3. Oil rank
3. Unscrew and remove oil tank strainer with its

O-ring. Discard the O-ring. ss-K
58
rm r201 1-058
M l M
Section 02 ENGINE
6. Refill oil tank with recommended oil. Refer to

ENGINE OIL at the beginning of this subsec-
tion.
7. Install all other removed parts.
OIL COOLER
Oil Cooler Access
Remove the following LH body panels, refer to ,
BODYsubsection: ,
- Middle side panel ,",;;;.,,,.,,,_,
— Bottom front side panel. TYPICAL
1. Oil cooler inlet hose
2. Engine outlet connector tube
Oil Cooler Removal
1. Drain oil tank. See ENGINE OIL CHANGE pro- REQUIRED T00‘-
cedure in this $l1b$@<=1i0n- OETIKER PLIERS (P/N 295 000 070)
2. Remove screws retaining oil cooler to oil tank.
Qv~\Q
=.
//%\\
5. Behind oil tank, remove screw securing oil

cooler to support.
rmQ008-011-112_a
1. Oil cooler
2. Remove these screws
3. Remove bolt above ignition coil securing oil

tank to frame.
1
rmr2008-011-1 'l9_a
TYPICAL
1. Oil cooler
2. Support
3. Remove this screw
6. Remove and discard Oetiker clamp securing oil

inriwwi-ii=i_=i cooler outlet hose.
TYPICAL
1 . Ignition
' ' coil
2. Remove this bolt
4. Disconnect oil cooler inlet hose from engine

outlet connector tube.
rmr2011-058 59
M M i
Section02 ENGINE
-.____\_
OIL HOSE CONNECTOR TUBES
Oil Hose Connector Tube Location
The oil hose connector tubes are located on the
crankcase, magneto side.
rrr\r20D8-O1 1-120_a
1. Oil cooler
2. Oil cooler outlet hose
7. Disconnect oil cooler outlet hose.

NOTICE Be careful to avoid breaking oil
cooler outlet tube.
SE5 Model
8. Remove the HCM clutch servo hose from the rmr2008-O1 ‘I-OD7_a
TYPICAL
front of the tank. 1. Oil hose connector tube "IN"
2. Oil hose connector tube "OUT"
"\l Oil Hose Connector Tubes Access

BODYsubsection:
_ -. " — Middle side panel
— Top side panel
- Rear side panel
-40% Oil Hose Connector Tube Removal

rmr2DD8-O45-IJ03_a
TYPICAL 1. Drain engine oil, refer to ENG/NEOIL CHANGE
1. Clutch servo hose in this subsection.
2. Oil tank
2. Remove oil hoses from connectors tubes.
AII Models 3. Loosen connector tube retaining screws.
9. Move oil tank rearward to remove oil cooler 4. Remove connector tubes and O-rings. Discard
from vehicle. O-rings.
Oil Cooler Installation
however, pay attention to the following.
Clean oil residue on oil coolerfittings and oil hoses
using PULLEY FLANGE CLEANER (PIN 413 711 809).
Refill oil tank with recommended oil and check en-
gine oil level. Refer to ENG/NE OIL at the begin-
ning of this subsection.
60
rmr201 1-D58
Section 02 ENGINE
LIZ’
OK4
3 *9 ‘I O<~4
2 1
rmr200B—D1 ‘|-0O7_b
rmr2DG‘B-0‘l1~0OE_a
TYPICAL
TYPICAL 1. From oil tank
1. Screws 2. To oil cooler
2. Oil hose connector tube "IN"
3. Oil hose connector tube "OUT" 6. Refill oil tank with recommended oil and check
4. O-rings
engine oil level. Refer to ENGINE OIL in this
Oil Hose Connector Tube Inspection subsection.
Clean oil hose connector tubes with a parts
cleaner, then use air pressure to dry the parts. OIL JET
A WARNING Oil Jet Location
The oil jet is located on the magneto side,
Always wear skin and eye protection. Chem- screwed into the crankcase. lt supplies oil to
icals can cause skin rash, skin burns and se- the clutch.
vere eye injury.
Check connector tubes for cracks or other dam- Q), W

ages. Replace if necessary.
/ \
Oil Hose Connector Tube Installation
However, pay attention to the following details.
1. Clean oil residue on hose fittings using PULLEY
FLANGE CLEANER (P/N 413 711 809).
2. Always replace connector tube O-rings with ' ‘ 1
NEW ones. rmr20ClB-O11-D31_a
3. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on TYPICAL

1. Oil jet
connector tube retaining screws.
4. Tighten connector tube retaining screws to Oil Jet Access
specification. Remove the following LH body panels, refer to
} CONNECTOR TUBE SCREW TORQUE W BODYsubsection:
11N'rTi (97 Ibf'in)
— Top side panel
5. install hoses as illustrated. — Rear side panel
Oil Jet Removal
1. Remove screw plug.
2. Remove and discard gasket ring.
3. Unscrew oil jet from crankcase.
rmr20'l'l-058 61
— j
Section 02 ENGINE
Z l Z I i 1 i — Z I l
ta, Oil Pump Module Removal

1. Remove clutch. Refer to CLUTCH (SM5) or
CLUTCH (SEQ subsection.
2. Remove parts listed in the following illustration.
I'IT\ I1 U08-01 I~D32_a
TYPICAL
1. Plug screw (‘N
2. Gasket ring
\.: .\-/
3. Oil jet
Oil Jet Cleaning -I=~. (O

Clean oil jet with a parts cleaner, then use air pres-
sure to dry it. I rmr2008-D11-O11_b
Snap ring
. Oil pump gear
A WARNING . Needle pin
Oil pump module screws
Always wear skin and eye protection. Chem- meow» Oil pump module cover
icals can cause skin rash, skin burns and se-
vere eye injury. 3. Using a rag, block the oil passages to prevent
the needle pin from falling into the crankcase.
Oil Jet Installation
however, pay attention to the following details.
1. Fasten oil jet finger tight. ecf‘
2. Install a new gasket ring on the screw plug.
3. Wipe off any oil spillage.
OIL PUMP MODULE

The engine is equipped with two oil pumps, an oil
pressure pump and an oil scavenge pump. Both
pumps are integrated into one oil pump module. imrzoosmwia ‘RI -
BLOCK HOLES IN CRANKCASE WITH A RAG
Oil Pump Module Location
The oil pump module is located behind the clutch 4. Remove the remaining oil pump module parts:
on the crankcase.
3| I I I I‘ ) ‘lb -> :»{ _-Q11’! V
7:‘ " '
II '
. 5;‘; ‘ _ J /l
_ r ‘Ag.’ ;o -' I
fr?» __ 7 r“
2I
.-- i'l\1 Iii»
-f
M12008-Oi H31 0_I:i
[kl-_
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‘:1-_ _.,.i 4‘
Kw
0%‘ “?;~\~
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k.i ‘%"i>>..~§.
1. Oil pump module
62 rmr2011-058
Section 02 ENGINE
. . ,w -_
.
1.31:.‘ I
I ‘<
I , wk”
,
/"'11 ,
Radial Clearance
"11
J Y4
" ‘
.-J . N1.
’
'
J
-1
I
'
A-.\. Using a feeler gauge, measure the radial clear-
ance as illustrated. Refer to table following
illustration for service limits.
5 4
’6 i-’:‘- ‘J.’ g-, 32 1
rrnr2008-01 1-019_a
. Inner rotor (pressure pump)
. Outer rotor (pressure pump)
EON“. Needle pins
4. Oil pump housing
5. Oil pump shaft
6. Inner rotor (scavenge pump)
7. Outer rotor (scavenge pump)
8. Dowel pin
Oil Pump Module Inspection

NOTE: The inspection procedure is the same for
both oil pumps.
1. Check oil pump module housing and crankcase vmr20OE0‘l2-(l14_,a
surface (where the oil pump module housing TYPICAL

1. Outer rotor
fits) for flatness with a straight edge. 2. Inner rotor
2. Inspect oil pumps and oil pump bores for wear I OUTER AND INNER ROTOR CLEARANCE
marks, scratches, cracks or other damages.
Replace damaged parts. SERVICE LIMIT
A
3. Check inner rotorfor corrosion pin holes, pitting
or other damages. If defects or damages are B 0.25 mm (.0098 in)
found, replace oil pump inner and outer rotor. C
If clearance between inner and outer rotors ex-

ceeds the tolerance, replace the respective oil
pump.
If clearance between outer rotor and its bore in
crankcase or if oil pump module housing exceeds
the tolerance, replace the oil pump module and
the crankcase if required.
Axial Clearance
1. Measure outer rotor thickness with a microme-
ter.
vrnr200B-D ‘l 2411 6_a
TYPICAL
7. Pitting on the teeth
rmr201 1-05B 63
Section 02 ENGINE
NOTE: When the axial clearance of the oil pump

assembly increases, the oil pressure decreases.
... gt. Oil Pump Module Installation

1. Clean all metal components in a solvent.
2. Flemove old sealant from mating surfaces of
crankcase, oil pump module housing and oil
pump module cover, using LOCTITE CHISEL
rmr2D08-G11-020
(GASKET REMOVER) (P/N 413 708 500) and
OUTER ROTOR THICKNESS scotch-bride (if necessary).
3.Apply a thin film of LOCTITE 515 (P/N 413 702
2. Using a depth gauge, measure the depth of the 700) on crankcase and oil pump module housing
corresponding oil pump bore as illustrated. surface using a small sponge.
IMPORTANT: When beginning the application
of sealant, the assembly and the first torquing
should be carried out within 10 minutes. It is
suggested to have all required parts, tools and
products on hand to save time.
NOTICE Remove excessive Loctite from the
oil pump bores.
rmr20OB~D1‘l-U21
OIL PUMP BORE DEPTH (O/L PUMP HOUSING)
iv-
l
>-7
'-.‘$1?
L, ris 1rl'\|’2 O1 1 -O09-OO3_fl
E
.‘ -.
' t.
—>
gr
~ §
7/ P
CRANKCASE
1. Apply Loctite here
rrr\r2008-01 ‘I-022
OIL PUMP BORE DEPTH (CRANKCASE)
Calculate the difference between measurements

of the outer rotor and corresponding oil pump
bore; it should not exceed the following specifi-
cation.
MAXIMUM AXIAL CLEARANCE
0.15 mm (.0059 in)
lf the oil pump axial clearance is out of tolerance,
replace the complete oil pump assembly.
64
rmr201 1-058
Section OZ ENGINE
-__
___,
,..“'\~.I
m1r2(l1‘l-DD947O4_a
OIL PUMP MODULE HOUSING

rmr201 1-0O9»O06_a
1. Apply Loctite here
1. Oil pump module housing
4. Coat inner and outer rotors with oil. 2. Dowel pin
5. Install oil suction pump rotor into the crankcase. 10. Install needle pin in the middle bore of the oil
6. Preassemble needle pin (into the lower bore) pump shaft.
and inner rotor on oil pump shaft. l1.Assemble inner rotor on oil pump shaft.
7.lnsta|| pre~assembled oil pump shaft in 12. Install outer rotor into oil pump module hous-
crankcase. mg.
NOTE: Markings on inner and outer rotors must NOTE: Markings on inner and outer rotor must be
face towards the inner side of the crankcase. visible.
3.--'
rrnr2U1'l-D09-005_a
1. Outer rotor, suction pump rmr201 1—0D9—OO7_a
2. Oil pump shaft 7. Needle pin
3. Groove for oil pump gear snap ring 2. Inner rotor, pressure pump
4. Needle pin g 3. Outer rotor, pressure pump
5. Inner rotor, suction pump 4. Markings on inner and outer rotor
6. Marks on inner and outer rotor
8. Install oil pump module housing on crankcase. 13. Install complete oil pump module cover.
9. Install the dowel pin in the oil pump module
housing and crankcase.
rmr201 1-058 65
Section O2 ENGINE
Oil Pressure Regulator Removal

1. Remove clutch. Refer to CLUTCH (SM5) or
CLUTCH /SE5) subsection.
2. Remove oil pump module cover. Refer to O/L
PUMP MODULE in this subsection.
rmr201 1 -009-OClE_a
O/L PUMP MODULE COVER

7. Retaining screws
to >;§;=
14. Tighten oil pump module retaining screws in a 1./7' S
criss-cross pattern to specification.
rmfZOO&O11-O1l_a
I OIL PUMP RETAINING scmzws TORQUE Q 1. Oil pump gear
2. Oil pump module cover
11 N~m (97lbf¢inl
NOTE: Check the pressure regulator piston for
15. After installation, check for smooth operation freedom of movement. If piston moves freely
of the oil pump assembly. and oil pressure is within specification, there is
16. Install all other removed parts. no need to remove the plug screw.
Final Test 3. Using a vise with aluminium jaws, lightly clamp
oil pump module cover.
After engine is completely reassembled, start en-
gine and make sure oil pressure is within specifi- 4. Unscrew the screw plug.
cations (refer to ENG/NE OIL PRESSURE 7'ESTin 5. Remove the regulator spring.
this subsection). 6. Remove the regulator piston.
ENGINE OIL PRESSURE
REGULATOR
Engine Oil Pressure Regulator
Location
The engine oil pressure regulator is located inside
the oil pump module cover.
rmr2008-O1 1-O12_a
Screw plug
Regulator spring
Regulator piston
§wNfi Oil pump module cover
Oil Pressure Regulator Inspection

rmr2OOB-01 1-010_a
1. Inspect the regulator piston for scoring or other
1. Engine oil pressure regulator damages. Check also the bore of the oil pump
module cover.
66 rmr201 I-D58
Section 02 ENGINE
2. Check if piston moves easily in oil pump module

cover
3. Check compression spring for any deformation.
-2
4. Check compression spring free length. -2
-2
rm r2008-01 1-300_a
1. Plug screw
2. Punch marks
rl'T\YZCIO8-O1 1-013
OIL DUCT COVER
NOTE: The oil duct cover supplies additional oil to
SPRING FREE LENGTH the main shaft in the gearbox.
NEW NOMINAL 37.6mm (1.48 in)
SERVICE LIMIT 36.6 mm (1.441 in) Oil Duct Cover Location
The oil duct cover is located on the crankcase be-
5. Replace worn or damaged components. hind the clutch.
6. Clean bore and screw threads in the oil pump .2-r -_ '*'"‘%
module cover of metal shavings and other con-
taminants.
Oil Pressure Regulator Installation
1. Apply LOCTITE 648 (GREEN) (P/N 413 711 400) On
the screw plug threads.
2. Install and turn in the screw plug until it is
2.3 mm ¢ 0.1 mm (.091 in i .004in) deeper rmr20OB-O1 1-Cl27_a
than the outer edge of the bore in the oil pump 7. Oil duct cover
module cover, see following illustration.
Oil Duct Cover Removal
1. Remove clutch. Refer to CLUTCH (S/I/I5) or
CLUTCH (SE5) subsection.
2. Remove two (2) retaining screws and pull oil
duct cover from the crankcase.
_ -P
2“ \' ,-
1 —)-; _
rml’lOO8-O1 1-OI 4_a

X I; 4Q Q‘)
1. Screw plug v I 1‘ 6',
2. Outer bore edge in pump module cover
' "Q,_
0.
,_‘
_~_
A. 2.3mm 1 0.1mm (.091 in 1 .004 in)
3. Check if oil pressure regulator functions prop-

erly by pushing on regulator piston. V are
t,.“I~ .-
.._ _
‘A
f
-._.0
P:E":
‘ 24.-')“:
,I.~ I''L'1”.r
“-'-o.-
rmr2OCI5-O1 I-Cl28_a
4. Secure plug screw with four (4) center punch Retaining screws
marks. Oil duct cover
O-ring (discard)
#wN# Oil seal
rmr201 1-058 67
Section O2 ENGINE
Oil Duct Cover Inspection “ ‘I _ .>5I§'*\ _\~. Lu’

Inspect oil duct cover for cracks or other damages.
Replace if necessary.
F
Clean oil passage in cover with a parts cleaner,
then use an air gun to dry it.
A WARNING
Always wear skin and eye protection. Chem-
icals can cause skin rash, skin burns and se-
t 1/Y
vere eye injury.
rrr\r2DD8—Ol 1-025_a
7. Engine oil strainer
Oil Strainer Removal

1.Separate both crankcase halves. Refer to
CRANKCASE AND CRAN/(SHAFTsubsection.
2. Pull oil strainer from its location.
\_-_ I
Oil Strainer Inspection
‘tr I‘
\'.
Clean oil strainer with a parts cleaner then use air
l‘> pressure to dry it.
rrnr2008-01 1-O29_a Check oil strainer for damage, replace it if neces-
7. Clean oil passage sary.
Oil Duct Cover Installation Oil Strainer Installation
For installation, reverse the removal procedure. Refer to CRANKCASE in CRANKCASE AND
However, pay attention to the following details. CRAN/<$HAFTsubsection.
1. Install a NEW O-ring.
2. Apply SUPER LUBE GREASE (P/N 293 550 030) on OIL TUBE
O-ring and oil seal, as shown. Oi Tube Access
The oil tube is located inside crankcase, between
both crankcase halves.
_ P
. 0 __ _ \~’
"P it <1
AQ ._ Q \ _
m\r200B-011-030_a
7. Apply Super Lube grease here
3. Install remaining parts, refer to the appropriate

subsections.
I H
rmr2008-I111-033_a
OIL STRAINER 7. Oil tube

2. Crankcase halve - magneto side
Oil Strainer Location NOTE: If the engine has to be dismantled within
The oil strainer (sieve) is located between both the scope of repair work, take this opportunity to
crankcase halves. clean the oil tube.
68 rmr2011-O58
Section 02 ENGINE
Oil Tube Removal

Separate both crankcase halves, refer to
Oil Tube Inspection
Clean oil tube with a parts cleaner, then use air
pressure to dry the parts.
Oil Tube Installation
NOTE: If the oil tube is damaged or bent during
work in the crankcase, it must be replaced.
rmr2UOB-O40-O01 _n
1. Oi! tube
2. Loctite 648 (GREEN) (P/N 413 717 400)
3. Needle pin
NOTE: Make sure not to apply too much LOCTITE

648 (GREEN) (P/N 413 711 400) On Oil tube, other-
wise oil passage may be clogged.
At assembly, ensure the needle
pin in the oil tube is correctly fitted in the
crankcase. If this is not done, the oil spray di-
rection will change potentially causing engine
damage.
rmr2011-058 69
Section 02 ENGINE
Subsection 05 (COOLING SYSTEM)
COOLING SYSTEM
SERVICE TOOLS
HANDLE .................................................................... .. 420 877 650 ......................................... .. 84
LARGE HOSE PINCHER ............................................ .. 529 O32 500 ......................................... .. 81
OETIKER PLIERS ....................................................... .. 295 OOO O70 ................................... .. 79-81
OIL SEAL PUSHER .................................................... .. 529 O35 757 ......................................... .. 84
SEAL PUSHER .......................................................... .. 529 O35 766 ......................................... .. 84
SUCTION PUMP ....................................................... .. 529 O35 880 ......................................... .. 81
TEST CAP .................................................................. .. 529 O35 991 ......................................... .. 76
VACUUM/PRESSURE PUMP .................................... .. 529 O21 800 ......................................... ..76
SERVICE PRODUCTS
BRP PREMIXED COOLANT ...................................... .. 219700362 ......................................... ..75
DOW CORNING 111 ................................................. .. 413 707 O00 ......................................... .. 84
LOCTITE 243 (BLUE) ................................................. .. 293 800 O60 ......................................... .. 82
rmr201 1-059 71
Section 02 ENGINE
COOLANT TEMPERATURE SENSOR (CTS)
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72 rmr201 1 059
Section 02 ENGINE
Subsection05 (COOLING SYSTEM)
WATER PUMP
11 N-m
(97 Ibf-in)
Loctite 243
'~>
Hand tighten
6
Dow
Corning
111
(T/.
rm\’l0U6-O12-OO'l_b
rmr201 1-059 73
Section 02 ENGINE
RADIATOR, COOLING FAN, THERMOSTAT AND COOLANT TANK
2.5 N-m __§ “L

(22 Ibf-in) NEW
~ Ii? ' \ \. l
III
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rmr201 1-059-001,8
74 rmr201l 059
Section02 ENGINE
GENERAL Draining the Cooling System

During assembly/installation, use the torque val- 1. Open the front storage compartment cover.
ues and service products as in the exploded 2. Refer to BOD)/subsection and remove on the
VIGWS. RH side of vehicle:
Clean threads before applying a threadlocker. Re- — Service cover
fer to SELF-LOCK/NG FASTENERS and LOC77TE — Middle side panel
APPLICATION at the beginning of this manual for — Bottom front side panel.
complete procedure. 3. Place a drain pan under radiator drain plug.
A WARNING 4. Remove the drain plug from radiator.
Locking devices must be replaced with new
ones when removed(e.g.: locking tabs, elas-
tic stop nuts, cotter pin, etc.).

MAINTENANCE
ENGINE COOLANT
REPLACEMENT
A WARNING rmrZOflB-O12-101_a
To avoid potential burns, do not remove the TYPICAL — RADIATOR DRAIN PLUG LOCATION
coolant tank cap or loosen the cooling drain
plug if the engine is hot.
Recommended Coolant
Use BRP PREMIXED COOLANT (P/N 219 700 362) or
a blend of 50% antifreeze with 50% distilled wa-
ter.
To prevent antifreeze deterioration, always use
the same brand. Never mix different brands un-
less cooling system is completely flushed and
refilled.
rrnrZO0B-O1 2~024_&
To prevent rust formation or freez- 1. Radiator drain plug

ing condition, always replenish the system
with the BRP premixed coolant or with 50% 5. Discard the O-ring on drain plug.
antifreeze and 50% distilled water. Do not use 6. Remove coolant tank pressure cap.
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 and does not have the same effi-
ciency. Always use ethylene glycol antifreeze
containing corrosion inhibitors specifically
recommended for aluminum engines.
rmfZO1 1-059 75
Section 02 ENGINE
5. Run engine until thermostat opens, then stop

engine.
NOTE: Use B.U.D.S. to monitor engine tempera-
ture.
THERMOSTAT OPENING TEMPERATURE
75°C (167°F)
6. Let engine cool down.

7. Recheck coolant level and top up if necessary.
8. Test the density of the coolant using an an-
tifreeze hydrometer. Follow the hydrometer's
manufacturer instruction for proper use.
rrnr20OB-O12-1DU_A
NOTICE Ensure the coolant density is ade-
TYPICAL - COOLANT TANK PRESSURE CAP
quate to avoid any damage from freezing.
Refilling the Cooling System 9. Reinstall pressure cap.
1. Ensure vehicle is on a flat surface and engine is 10. Reinstall removed parts.
cold.
2. Install a NEW O-ring on drain plug. INSPECTION
3. Tighten drain plug to specification.
DRAIN PLUG TORQUE I
COOLING SYSTEM LEAK TEST
25 NWT) (18Ibf'f’£) A WARNING
In order to avoid getting burned, do not re-
4. Using a long reach funnel, fill cooling sys- move the coolant tank cap or loosen the en-
tem until coolant reaches upper level mark of gine drain plug if the engine is hot.
coolant tank.
APPROXIMATE COOLANT CAPACITY 1. Open the front storage compartment cover.
3.2 L (.8 U.S. gal.)
2. Remove the service cover on the RH side. Re-
fer to BOD)/subsection.
3. Remove coolant tank pressure cap.
4. Install the TEST CAP (P/N 529 O35 991) on filler
neck of coolant tank.
\ 52903 5991
rrno2 O08-D01-O39_b 5. Pressurize the cooling system through the

TYPICAL coolant tank using the pump included in the
1. Upper level mark
VACUUM/PRESSURE PUMP (P/N 529 O21 800).
NOTE: Do not install coolant tank pressure cap at
this time.
76 rmr2011-059
Section 02 ENGINE
NOTE: Leaking coolant from the engine leak indi-

cator hole indicates a damaged rotary seal on wa-
ter pump side. Leaking oil indicates a damaged oil
seal on oil pump side. If either seal is leaking, both
seals must be replaced at the same time with the
water pump shaft. Referto WATER PUMPSHAFT
AND SEALS in this subsection.
7. If a coolant leak is not visible and the pressure
drops, spray a soap/water solution and look for
air bubbles.
52902 1 BOD
PROCEDURES
COOLING FAN
Cooling Fan Operating Condition
RADIATOR coo|.||\|c FAN
ENGINE COOLING FAN COOLING FAN
TEMPERATURE RELAY OPERATION
> 101°C (214°F) Close Starts
< 97°C (207°F) Open Stops
rmrl008
Cooling Fan Test using B.U.D.S.
TYPICAL
1. Connect vehicle to latest applicable B.U.D.S.
LEAK TEST PRESSURE version, refer to COMMUNICATION TOOLS
90 kPa I13 PSI)
AND B.U.D.S.
2. In B.U.D.S., select:
If pressure drops, check the following compo- — Activation page tab
nents for coolant leaks. — ECM page.
— All hoses 3. Click on the cooling fan to activate it.
Cylinder/base vm» ) 5‘-1 I Qhudcg In-vw I um ) now )
Coolant tank M“
Q
rpm»
. _. |
Engine leak indicator hole. \
'_ um i
Q
. l.\~. é'.».-. =.-J 1 is ~
» Iv
’-"I
'
7 r W I
l s_' \_, 2;, _ um.“-=
I , V 1 '
\._!t
9 > \- ' '
.15}
. ._i- ,
I-
‘I ~ if-fad
rrr\r200B-015081_b
1. Activate fan here
1
If cooling fan works;
— Check coolant temperature sensor (CTS).
If the cooling fan does not work;
rmr2008-O12-U22_e - Check the 10 A fuse.
TYPICAL
1 Leak indicator hole If fuse is good;
2 Water pump housing — Check the cooling fan relay.
3 Starter
rmr201 1-059 77
Section 02 ENGINE
Cooling Fan Relay Test

1. Remove the cooling fan relay (R4). Refer to
POWER D/STR/BUT/ON AND GROUNDS sub-
section.
2. Install a jumper wire end between pins D8 and
C7.
If the fan works correctly by jumping the relay;
— Replace the relay.
If the fan does not work;
- Check the wiring harness and connectors be-
tween fuse box and cooling fan.
If the fan does not work after all tests;
- Replace it. 1mQO'I 1-0594‘lO2_a
1. Fan air deflector duct

2. Thermostat
Cooling Fan Removal 3. Cooling fan connector
1. Refer to BODYsubsection and remove the fol- 5. Remove thermostat from the fan air deflector
lowing RH side panels: duct
— Middle Side Panel
6. Remove screws securing air deflector duct and
— Top Side Panel cooling fan to radiator.
— Bottom Rear Side Panel
- Bottom Front Side Panel
— Rear Side Panel.
2. Remove headlight adjustment cable from RH
side panel support.
3. Remove RH side panel support.
. .. . -1 4-., . ‘Y -
‘ , ,. _.-- . it
1%“ -‘Q JV. .., i . _
ifitiv-7‘b“.*'\T 1, ' I 7 T *
. ).¢I1I,' ?_ -‘T \ ‘wow ‘-

e TI
"rm
rmr201 1-O5 9-003,5
W.1 7. Top cooling fan screws (2)
'qr,
2-3,,1
1;:‘-1\-;'_= L‘ 73.
Q3?
..r1%»\\§Y
A 3,-._‘4_\F‘
' *i_'
I I‘| YA
-ll-)1
.9‘! I5
e
-» =
rfl'\l'20'lO-011-OO1_e
I +5.
~— waeik
,__ ,"n ‘D I,
' . .v U
- » ..—.:.
_ "i
“S.
.i
TYPICAL
7. RH side panel support
4. Disconnect cooling fan connector.

NOTE: The cooling fan connector is attached to
the engine side of the fan air deflector duct, next
to the thermostat. rrnr2011—059-OD4_a
TYPICAL
1. Bottom cooling fan screws (2)
2. Fan deflector duct
78 rmr2011-059
Section 02 ENGINE
Cooling Fan Installation

For the installation, reverse the removal proce-
dure however, pay attention to the following.
Be sure to:
— Reconnect fan connector
— Mount thermostat on fan air deflector duct.
FAN MOUNTING SCREW TORQUE
7 N'm (62 lbf¢in)
RADIATOR
Radiator Removal rmr201 I-059~DU2_a
NOTE: For access, refer to COOLING FAN RE- 7. Fan air deflector duct
MOl44L in this subsection. 2. Thermostat
3. Cooling fan connector
1. Drain engine coolant. Refer to ENG/NE
COOLANT REPLACEMENT in this subsec- 5. Cut Oetiker clamps securing radiator hoses.
tion. REQUIRED TOOL
2. Remove radiator mounting bolt on top of radia- OETIKER PLIERS (P/N 295 000 070)
tor.
F‘ \\
£-K
./ A
6. Disconnect radiator hoses.
7. Lift radiator and remove it from vehicle.
8. If replacing radiator, remove cooling fan from
radiator.
rmr201 1 0590055
TYPICAL
1 . Radiator bolt Radiator Inspection
1. Check radiator fins for clogging or damage.
3. Disconnect cooling fan connector.
2. Check for any coolant leakage.
4. Remove thermostat from fan air deflector duct.
3. Remove insects, mud or other obstructions us-
ing low pressure water.
Radiator Installation
However, pay attention to the following.
Make sure the rubber mounts between bottom of
radiator and frame are not missing.
rmr201 1-059 79
Section O2 ENGINE
~-'1.» .71 »/ l 4-Jr 1'“ ;- T"

I
I ~»e%Qili
/
I _ ;.
Y1.-:_»-. ' ,,
.
C‘ _l_} %> l
.15 I
I ‘I
, I .
II»
I
I
REQUIRED TOOL
.317); ‘qr, -TS’~/1))-<=-_
-f"‘-1 or -"_'W
';I<.¢{
II’
. , >- I OETIKER PLIERS (P/N 295 O00 O70)
5’ 3&§\*~UIww"
J! __-~ (E ' * _ 4.-—
2:
C
TII
I.
-._ F—7' it II—

-4 '_ ,. . i ""~ r. U
i -. »m-i
1
~\‘
, 2.-:4
iv \ ct.-=_.>
GI is
Y
- /
‘1~
‘______.__\h> ox
a\_ 1 ‘r
6l:_-S
1:-L
*ss__ee;e»ae-/. ' K is
rmr200B-050001 _a / A
TYPICAL
1. Radiator rubber mounts
4. Pull out thermostat housing. Catch spilled
Install a NEW radiator drain plug O-ring. coolant.
Refill and bleed engine cooling system. Refer to
ENG/NE COOLANTin this subsection. Thermostat Test
To test thermostat, put thermostat in water, then
THERMOSTAT heat the water. Thermostat should begin to open
as per following specification.
Thermostat Location
THERMOSTAT OPENING TEMPERATURE
The thermostat is a single action type mounted
externally on the RH side the engine. It is Starts to open I 75°C (167°F)
mounted on the engine side of the cooling fan air
deflector duct. Thermostat Installation
However, attention to the following.
1.Thermostat must be installed with its wider
section toward the bottom.
2. Install NEW clamps using Oetiker pliers.
3. Refill and bleed cooling system. Refer to MAIN-
TENANCE in this subsection.
COOLANT TANK CAP

Coolant Tank Cap Inspection
1. Ensure cap seal is in good condition.
2. Using a pressure cap tester, check cap opening
rmr201 1-059-0O2_a pressure.
7. Fan air deflector duct
2. Thermostat CAP OPENING PRESSURE
3. Cooling fan connector
90 kPa 1 7kPa (13 PSI i 1 PSI)
Thermostat Removal
1. For access, refer to COOLING FAN REMOWIL COOLANT TANK
in this subsection.
2. Drain engine coolant. Refer to ENG/NE Coolant Tank Removal
COOLANT REPLACEMENT in this subsec- 1. Remove the front fascia. Refer to BODYsub-
tion. section.
3. Remove hose clamps. 2. Remove the RH side headlight. Refer to
LIGHTS GAUGE AND ACCESSORIES sub-
secfion.
3. Remove coolant tank pressure cap.
80 rmr2011-059
Section 02 ENGINE
4. Drain coolant tank.

REQUIRED TOOL
SUCTION PUMP (P/N 529 O35 880)
'3'!
‘l
rrr\r200B-012 -O33__a
TYPICAL
1. Oetiker clamp
2. Coolant hose
5. Disconnect the overflow hose from top of REQUIRED TOOL

coolant tank. OETIKER PLIERS (P/N 295 O00 O70)
Z
_.I_g — _
\\
/
rmr20l18—Ol 2-032_a
TYPICAL 9. Remove hose from coolant tank.
1. Overflow hose
6. Unlatch coolant tank and lift it. Coolant Tank Installation

7. Pinch coolant tank hose. The installation is the reverse of the removal pro-
cedure.
REQUIRED TOOL
LARGE HOSE PINCHER (P/N 529 O32 500) COOLANT TEMPERATURE
SENSOR (CTS)
Refer to ELECTRON/C FUEL //V./ECT/ON /EF//
subsection for testing and replacement proce-
dures of the coolant temperature sensor (CTS).
WATER PUMP HOUSING

Water Pump Housing Access
8. Remove Oetiker clamp securing coolant tank For access, refer to COOL/NG FAN RE/l//0|/54L in
hose. this subsection.
Water Pump Housing Removal
A WARNING
To avoid potential burns, do not remove the
coolant tank cap or loosen the cooling drain
plug if the engine is hot.
rmr20l1 069 81
i I
Section 02 ENGINE
Drain cooling system. Refer to ENG/NE U ,. 1. ' / I =/ ’

COOL/IN7'in this subsection. <- -J‘§.g‘Iti'l1\.\A‘*.' \.sin». " .
#'\\t\_\§.~>’ma\I-l
Remove water hoses from water pump housing. »- -,,{¢\\.i=e.*' (£992:-*=?"i2@!g /.¢\¢
" ‘$4
Remove screws retaining water pump housing.
.2.
~»\‘-5‘:-/§¢;’ <:3=;~<:\,.-r:*’.*'.‘§"i‘-"-.€'\
4.0‘-:<,>|1 ,
i ‘
‘w_
,
_,<§§ \) g-,~.'..;,
eta
~ Q..
cf'
-_ »:~t»*=:»§>
an i‘ .» I
gs» l ,
‘sf -- O
rbs2D10-DDS-D0l_a
'l?».f_/ylgj‘
‘ -r.f;¢ Alf’ um‘? _v ‘“./'
7. Water pump cover

2. Apply Loctite on this screw
Install a new sealing washer on drain screw.

r|'l'|fZOOB-O12-DU3_6
Tighten screws of water pump housing to specifi-
1. Cooling system drain plug cation in a crisscross sequence.
2. Sealing washer
3. Retaining screws WATER PUMP HOUSING SCREWS
4. Water pump cover
11 Nim (97lbf'in)
Water Pump Housing Inspection
lnspect water pump housing gasket . If gasket is WATER PUMP IMPELLER
brittle, hard or damaged, replace as necessary.
Water Pump Impeller Removal
1. Remove water pump housing. See procedure
in this subsection.
2. Use proper snap ring pliers to unscrew water
pump impeller.
NOTE: Water pump shaft and impeller have right-
hand threads. Remove by turning counterclock-
wise and install by turning clockwise.
rmr200&O12-D0-La
1. Gasket
Water Pump Housing Installation

Installation is the reverse of the removal proce-
gzi
To avoid coolant leakage: rm r2DO84II1 2-O05_a
— Ensure gasket is properly inserted in water TYPICAL

1. Snap ring pliers
pump housing groove. 2. Water pump impeller
To avoid oil leakage:
3. Remove impeller from water pump shaft.
— Apply LOCTITE 243 (BLUE) (P/N 293 800 060) On
the screw indicated in the following illustration. Water Pump Impeller Inspection
Check impeller for cracks or other damage. Re-
place impeller if damaged.
82 rmr2011-059
Section 02 ENGINE
Water Pump Impeller Installation 7. Tap out oil seal and rotary seal together from
The installation is the opposite of the removal pro- inside towards the outside.
cedure. However, pay attention to the following. REQUIRED TOOL
"lighten water pump impeller by hand. Do not PUNCH 4 mm (.157 in)
overtighten.
WATER PUMP SHAFT AND 1
SEALS
Water Pump Shaft/Seal Removal 1-.
1. Remove clutch cover. Refer to the appropriate
clutch subsection.
2. Remove water pump housing and impeller, see
procedures in this subsection.
3. Pull out on water pump gear to remove it.
4. Remove needle pin.
rmK20OH-O12-n0s_a
5. Remove thrust washer. 7. Clutch cover
2. Punch
Water Pump Shaft/Seal Inspection

Clean leak indicator hole in clutch cover of all con-
tamination.
cow\"’N_-:3 1*-an
rrnr200B-012-OO6_a
TX‘ .
1. Water pump gear
2. Needle pln
3. Thrust washer
6. Sharply strike the water pump shaft from the

outside towards the inside to remove it.
REQUIRED TOOL n'nr2OCl8-OI 2-0O9_a
1. Clutch cover
PLASTIC HAMMER 2. Leak indicator hole
Water Pump Shaft/Seal Installation

NOTICE Always replace rotary seal and wa-
ter pump shaft together. Also, install a NEW oil
seal (behind rotary seal) at the same time.
NOTE: Never use oil in the press fit area of the oil
seal.
5; 0
A ..
1. Install oil seal using the following tools.
rrniQ008—012-O07_a
7. Water pump shaft
rmr201 1-059 as
Section 02 ENGINE
REQUIRED TOOLS _.f\'. '1
OIL SEAL PUSHER (P/N 529 O35 757) 1' ‘ "'%
HANDLE (P/N 420 877 650)
rmr200&Cl12-OI 1_a
1. Proper installed oil seal
3. Carefully press-in water pump shaft assembly

into clutch cover.
REQUIRED TOOL
SEAL PUSHER (P/N 529 035 766)
Vr\1fZOO8-O1 3-OI S_a
1. Handle
2. Oil seal pusher
2. Apply specified product on sealing lip and push

oil seal in place.
REQUIRED PRODUCT ON OIL SEAL
DOW CORNING III (P/N 413 707 000) I
NOTE: Sealing lip must face towards the inside of

clutch cover. 529035765
1mr2OOB-01 2-OI l)_a

rmr20flB-012-D12_a
1. Oil seal
2. Installer handle with oil seal pusher 1. Clutch cover
2. Water pump shaft assembly
3. Rotary seal installer
NOTICE Never use a hammer for water

pump shaft assembly installation. Use press
only.
4. Reinstall thrust washer, needle pin and water
pump gear.
84 rmr201 I-059
Section 02 ENGINE
- qgg
1.“. wt
s;
rrnr2008-012-D06_a
1. Water pump gear
2. Needle pin
3. Thrust washer
5. Reinstall water pump impeller and check if wa-

ter pump turns smooth after installation.
6. Properly reinstall remaining parts. Refer to ap-
propriate subsections.
rmr201 I-O59 85
Section 02 ENGINE
Subsection 06 (MAGNETO AND STARTER)
MAGNETO AND STARTER

SERVICE TOOLS
FLUKE ‘I15 MULTIMETER .......................................................... .. 529 O35 868 ................................... .. 9I—92
MAGNETO PULLER .................................................................... .. 529 O36 O97 ......................................... .. 94
PULLER/LOCKING TOOL ............................................................ .. 529 O36 O98 ......................................... .. 94
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................. .. 293 550 O04 ......................................... .. 99
DOW CORNING 111 ................................................................... .. 413 707 OOO ................................... ..9I, 99
DREI BOND SEALING COMPOUND .......................................... .. 420 297 906 ................................... ..90, 94
LOCTITE 243 (BLUE) ................................................................... .. 293 800 O60 ................................... .. 91, 93
LOCTITE 648 (GREEN) ................................................................ .. 413 711 400 ................................... .. 95-96
PETAMO GREASE GHY133N .................................................... .. 420 899 271 ................................... ..97, 99
PULLEY FLANGE CLEANER ....................................................... .. 413 711 809 ......................................... .. 95
rmr201 mac 87
Section 02 ENGINE
5N- TTI
(44 lbf~in)
Loctite 243 (6; :\,L'f'§‘i‘n)
Us
Drei Bond N,
7 N")?
|bf,m) sealing
Compound 11 ,'-n
(97Ibfll1)
6 Loctite
Z 243
CPS, see
Loctite 0 ‘J33 ELECTRONIC FUEL
648 _ INJECTION
(EFIl
so N-m 2
<22 Ibf-ft) L6 Dow
Corning 111
I30 N IT’! 243 \
(97 lbf-ft) \
\
11 N-m
(97 lbf-in)
Drei Bond \
" ' ‘\
sealing compound 0
Z
\
\
\
\
Q J
Ir
I
I
/—-.
\
\
\
\
\
\
O)
"
\
l"|'I\
11 N m 3 N'm
(97 lbf in) (27 Ibf-in) I
.1
l_ _
_____ _ 751]/175Tnnodels
-— — - _/
jSE5 models
11 N-m
(97 lbf-in)— \ \§:"\1 1 N-m ,
J a -192 lPt'i_"t /’
a ' 4' 6Engine oil
/7
\
3,,
?~
Jr)
Y
1'
§
1; ‘
1 0, I
P ..
6Engine oil
Dow
Corning O
1 ‘I 1 0 \\
6
_ Petamo grease Loctiteo
"El"-£i;:i;'z:si1*t2:.“s:s....
rmr200B-O51 -00 I _(:
Ghv133n 648
88 rmr201 1-060
Section 02 ENGINE
GENERAL PROCEDURES
NOTE: It is good practice to check for fault MAG N ETO COVER
codes using the B.U.D.S. software as a first trou-
bleshooting step. Refer to the D/A GNOSTICAND Magneto Cover Removal
FAULT CODES subsection.
Procedure with Engine in Vehicle
NOTE: To carry out the following instructions, it is
not necessary to remove the engine from the ve- Remove the following LH body panels, refer to the
hicle. For a better understanding, many of the fol- BOD)/subsection:
lowing illustrations are produced with the engine - Middle Side Panel
removed from the vehicle. — Top Side Panel
Always disconnect the negative wire from the bat- - Bottom Rear Side Panel
tery before working on the engine. — Bottom Front Side Panel
— Rear Side Panel.
A WARNING Drain engine oil, refer to the LUBH/CAT/ON SYS-
Always disconnect the BLACK (-) cable first TEM subsection.
and reconnect last.
On SE5 model, remove the hydraulic control mod-
A WARNING ule. Refer to the HYDRAULIC CONTFIOL MOD-
ULE KSE5) subsection.
Before carrying out any inspection or main-
tenance procedure on the vehicle, wait until Remove crankshaft position sensor (CPS).
the engine and exhaust system have cooled Remove screw and washer securing magneto ca-
down to avoid potential burns. ble clamp to engine.
Always carry out electrical tests on components

before removing or installing them to ensure their
state of operation.
ploded view.
Clean threads before applying threadlocker. Re-
fer to SELF-LOCK/NG FASTENERS and LOCT/TE
APPL/CA7’/ONat the beginning of this manual for
complete procedure.
A WARNING
Torque wrench tightening specifications rmr200E-013-002_a
must be strictly adhered to. TYPICAL
Locking devices when removed (e.g.: locking 1. Crankshaft position sensor (CPS)
tabs, elastic stop nuts, self-locking fasteners, 2. Retaining screw
3. Washer
cotter pins, etc.) must be replaced with new 4. Cable clamp
ones.
Disconnect magneto connector from voltage reg-
ulator and cut locking tie (gray connector with
NOTICE Hoses, cables and locking ties re- YELLOW wires).
89
rm|’Z011-OEO
Section O2 ENGINE
— ' 4/
. _// ‘g
.1 P-:~\~
. . ' .-'7 ._ -~
__ ___,>' _‘
vfrl’ 11‘
. I .
. %.¢...L ‘-
rmr2010-(127-001 _fl
UNDEFINEATH LH LATERAL SUPPORT

1. Voltage regulator/rectifier ‘ rmr200B-U13-O03_a
2. Magneto connector
SM5 MODEL
1. Magneto cover
Remove headlight adjustment cable from LH mid- 2. Retaining screws
dle side panel support.
Remove LH middle side panel support.
.‘-4.1
. "._\
:1 )
rmr200EH)514302_a
SE5 MODEL
1. Magneto cover
2. Retaining screws
_./’
rmr20104J11-O02_a Magneto Cover Inspection
1. Middle side panel support Clean magneto cover and check for cracks or
Procedure with Engine Removed from Vehicle other damages. Replace if necessary.
Remove magneto cover retaining screws and pull Magneto Cover Installation
magneto cover from engine.
Install a NEW magneto cover gasket.
Apply DREI BOND SEALING COMPOUND (P/N 420
297 906) on stator cable grommet as shown in fol-
lowing illustration.
90
rmr2011-060
Section 02 ENGINE
— LH Middle side panel

— LH top side panel.
Disconnect the magneto wiring harness connec-
tor on the voltage regulator/rectifier.
/
_/mm
T)‘..» ‘1*‘_ .. ,
c_!4’
2:4»
_ .2
D4‘ _‘IT'.
. .‘:;7:'._\
vmr2OD6-O41 -003_a
‘e . 1 at .
\
TYPICAL 1
1. Apply Drei Bond sealing compound
Apply DOW CORNING 111 (P/N 413 707 000) to the

O-ring on the crankshaft position sensor (CPS). rmr2010-D2 7-CID I _d
UNDERNEATH LH LATERAL SUPPORT

Apply LOCTITE 243 (BLUE) (P/N 293 800 060) to the 1. Voltage regulator/rectifier
mounting screws retaining the CPS and it's har- 2. Magneto connector
ness Ieta'“'“9 damp‘ _ _ _ Set the FLUKE 115 MULTIMETER (P/N 529 025 ass)
Iighten magneto C0)/91 FBTHIIIIRQ 5¢l'9W9 T0 513901‘ to Q and compensate resistance of the multimeter
fication as per the following sequence. probes.
MAGNETO COVER RETAINING SCREWS Connect multimeter between YELLOW wires as
TORQUE per table below.
11 N'm (97 lbf'in)
rrnI200B-024-O09_a
Read resistance.
rmr201)-011-OD2_a
TYPICAL — TIGHTENING SEQUENCE
Refill engine with recommended oil.
STATOR
Stator Continuity Test
Remove the following body panels to access volt-
age regulator/rectifier, refer to the BODYsubsec-
tion:
— LH Mirror
— LH Wind deflector
rmr2011-060
Section 02 ENGINE
STATOR CONTINUITY TEST

N... . ........
RESISTANCE @ /"I 1
'_'.L ..
TERMWAL 20=c (68°F) V ' _

ur,5,\_T‘
1and2
k v4
T I _.g
1and3 0.1-19
. .
;. _ tat‘;
_/
2and3
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P . is Read resistance.
STATOR INSULATION TEST
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\\*5»? T YL
TEST PROBES RESISTANCE @
20°C (68°F)
Any YELLOW wire and
VIl7GD5A engine ground Infinity (open circuit)
TYPICAL
If there is any resistance or continuity, the stator
If any reading is out of specification, replace sta- coils and/or the wiring is grounded and needs to
tor. be repaired or replaced.
Reconnect the magneto harness connector to the Reconnect the magneto harness connector to the
voltage regulator/rectifier. voltage regulator/rectifier.
Stator Insulation Test Stator Output AC Voltage Test
Disconnect the magneto harness connector as Disconnect the magneto harness connector on
per the previous continuity test. the voltage regulator/rectifier unit.
. . /___
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rrnr20l 0-027-001_d
l‘l7'l1ZO'lU-O27—UOI_d
UNDERNEATH LH LATERAL SUPPORT UNDERNEATH LH LATERAL SUPPORT
1. Voltage regulator/rectifier 1. Voltage regulator/rectifier
2. Magneto connector 2. Magneto connector
Set the FLUKE 115 MULTIMETER (P/N 529 O35 868) Secure the connector over the lateral frame sup-
to Q. port with a locking tie so that the pins are facing
Connect multimeter between any YELLOW wire outwards towards you.
and engine ground. Install a set of thin. insulated, "clip-on" type
probes on the multimeter.
92
rmr201 1-060
Section 02 ENGINE
Set multimeter to Vac scale.

Start engine.
Connect multimeter alternately between the ter-
minals as indicated in the following chart.
rmr20fJ8-013-O05_a
1. Stator
2. Stator retaining screws
3. Harness holding plate
4. Holding plate screw
rmr20DB-D24»009_a Stator Inspection

Read voltage. Check stator condition for signs of rubbing, over-
heating, insulator breakdown and any other dam-
STATOR OUTPUT AC VOLTAGE TEST ages which may render it unserviceable. If dam-
TEST ENGINE aged, replace it.
SPEED TERMINAL VOLTAGE
For electrical tests, refer to the CHARGING SYS-
O 1 and 2 TEM subsection.
60 Vac
400° RPM minimum Stator Installation
2and3 For installation, reverse the removal procedure.
If voltage is lowerthan specification, replace mag- NOTE: Stator position is determined by a key tab
neto stator. on the stator which aligns with a notch in the case.
Cut the locking tie and reconnect the magneto har-
ness connector to the voltage regulator/rectifier
unit.
Stator Removal
Remove MAGNETO COVER, see procedure in
this subsection.
Remove screw securing stator cable holding
plate.
Remove stator retaining screws, then pull the sta-
tor and it's cable from the cover.
rrnr20IJ8-013-006,6
TYPICAL - STATOR ALIGNMENT NOTCH
Apply LOCTITE 243 (BLUE) (P/N 293 800 O60) to

the stator mounting screws, the stator harness
retainer screw (inside the cover) and the harness
clamp screw.
rmr2011-O60 93
Section 02 ENGINE
Apply 8 bead 01°DREl BOND SEALING COMPOUND Remove MAGNETO COVER, see procedure in
(P/N 420 297 906) on the stator cable grommet as this subsection.
shown in next illustration.
Remove screw and washer securing rotor to
crankshaft.
I
-(3
\_
rrnr2ODS-013-007 a
DREI BOND SEALING COMPOUND APPLICATION
When installing the stator, align the

cable in the case, insert the grommet, then in
stall the cable holding plate to secure the cable rmr2008-01 3-0ClE_a
in its proper position. TYPICAL
1. Screw M16
-> 2. Washer
3. Rotor
Remove rotor.
NOTE: It may be necessary to heat the rotor cone
for approximately five minutes with a common
heat gun to break the Loctite bond between the
parts.
REQUIRED TOOL A
MAGNETO PULLER (P/N 529 036 097)
rrnrZOCl8-O13-iOI_a
7. Stator cable holding plate

2. Stator cable grommet 529036097
MA GNETO PULLER
ROTOR
Rotor Removal
Lock crankshaft. Refer to CRANKSHAFT AND
CRANKCASE subsection.
REQUIRED TOOL
PULLER/LOCKING TOOL (P/N 529 O36 O98)
szaoasoss
94
rmr201 I -060
Section 02 ENGINE
Clean the crankshaft taper and the inside surface

of the rotor cone with PULLEY FLANGE CLEANER
(P/N 413 711 809).
NOTICE Taper on crankshaft and in rotor
cone must be free of grease.
Apply LOCTITE 648 (GREEN) (P/N 413 711 400) as Tol-
lows:
— On the inside surface of the rotor cone
— On the rotor mounting screw.
NOTICE Take care not to apply Loctite 648
_iLl
(GREEN) into the bearing bushing of the sprag
rrnr2008-013-010_a clutch gear.
TYPICAL
1. Rotor Oil sprag clutch in sprag clutch housing and install
2. Magneto puller installed sprag clutch gear.
For rotor disassembly, see SPRAG CLUTCHin this
subsection.
Rotor Inspection
Check inner surface of the rotor for scratches,
cracks or other damages.
Check the rotor keyway for wear or damages.
Check if trigger wheel teeth are bent or otherwise
damaged. 3.-I
rmr2008-013-011_a
1. Sprag clutch
2. Sprag clutch housing
3. Sprag clutch gear
4. Apply engine oil here
Slide rotor onto crankshaft. The woodruff key and

the keyway must be aligned.
Rotate the starter double gear clockwise to align
the intermediate gear teeth with the sprag clutch
L2,; x1 gean
._\
vmr200B-04101 l_a
TYPICAL
1. Rotor with trigger wheel
Check the woodruff key and keyway on the crank-

shaft for wear or damages.
Replace parts as necessary.
Rotor Installation
rrnr2011-060 95
Section O2 ENGINE
Subsection O6 (MAGNETO AND STARTER)
Check sprag clutch operation by rotating sprag

clutch gear as follows:
— Must lock in the clockwise direction
— Must release in the counterclockwise direction.
rmr2DOB-013-D12_a
TYPICAL
1. Starter double gear
2. Intermediate gear rmr2008-01 3-01 4_a
SPRAG CLUTCH FUNCTIONAL TEST

‘lighten rotor retaining screw to specification. 1. Must lock in the clockwise direction
ROTOR RETAINING SCREW NOTE: If defective replace the following parts: as

LOCTITE 648 (GREEN) a unit.
THREAD LOCKER
(P/N 413 711 400) - Sprag clutch
TORQUE I30 N'm (96 Ibf¢ft) — Sprag clutch housing
— Sprag clutch gear.
SPRAG CLUTCH Sprag Clutch Installation
Sprag Clutch Removal For installation, reverse the removal procedure.
Pay attention to the following details.
Before removing the rotor, loosen sprag clutch
housing screws located inside rotor. Apply LOCTITE 648 (GREEN) (P/N 413 711 400) as fol-
lows:
Proceed with ROTOR REMOVAL, see procedure
in this subsection. — Between the rotor and the sprag clutch housing
surface
Remove sprag clutch gear. - On the threads of the sprag clutch housing
Remove sprag clutch housing screws and sprag screws.
clutch housing. Install screws but do not torque at this time.
Apply engine oil on the sprag clutch and on the
inside surface of the sprag clutch gear.
rrnr2 008-01 3-OI 3_a
1. Sprag clutch housing screws

2. Rotor
3. Sprag clutch 34
4. Sprag clutch housing
Sprag Clutch Inspection rmr20OB-013-01 1_a
lnspect sprag clutch and sprag clutch housing for . Sprag clutch
Sprag clutch housing
wear and other damages. Sprag clutch gear
:I*~P°l\1*‘ Apply engine oil here
Check the collar of the sprag clutch gear.
96 rrnr201‘l-060
Section 02 ENGINE
Install rotor on crankshaft, refer to ROTOR /N- Sprag Clutch Gear Installation
STALLAT/ONin this subsection. The installation is the reverse of the removal pro-
‘lighten sprag clutch housing screws to specifica- cedure. However, pay attention to the following.
tion. Apply engine oil on the bushing and collar of the
SPRAG CLUTCH HOUSING SCREWS TORQUE ‘ sprag clutch gear.
30 Nvm (22 Ibf'ft)
STARTER DRIVE GEARS
SPRAG CLUTCH GEAR Starter Drive Gear Location
The starter drive gears are located on the engine
Sprag Clutch Gear Removal MAG side behind the magneto cover.
Remove the ROTOR, see procedure in this sub-
section.
Pull sprag clutch gear from the rotor.
hi " _'."‘ ‘I
15?? 1
.-Y. ,-.
rmr2 DOE-O13-O15_a
rm|200B-O13-OI I_l:i STARTER DRIVE GEARS

1. Rotor 1. Intermediate gear
2. Sprag clutch gear 2. Starter double gear
3. Starter gear
4. Location pins
Sprag Clutch Gear Inspection
Inspect gear, especially teeth and sprag clutch col- Starter Drive Gear Removal
lar, for wear and other damages. Remove ROTOR, see procedure in this subsec-
Check bushing for scoring, wear and other dam- tion.
ages. Replace sprag clutch gear if necessary. Remove the intermediate gear.
Remove the starter double gear.
Starter Drive Gear Inspection
Inspect the gears for wear, pitting, cracks,
chipped or broken teeth, and any other dam-
ages.
Replace parts as necessary.
T11
I7,
I {—-F;
Starter Drive Gear Installation

;-\ _.
4"'\. ~' \ .
“twists” cedure. Pay attention to the following details.
Apply PETAMO GREASE GHY133N(P/N 420 899 271)
on the starter gear before installing the starter
double gear.
vmt2005-041-01B_a Apply engine oil on the location pins before in-
INSPECT stalling the starter double and intermediate gears.
1. Teeth
2. Collar
3. Bushing
rmr201 1-060 97
Section 02 ENGINE
ELECTRIC STARTER
Starter Test
Refer to the STARTING SYSTEM subsection to
validate starter operation.
Starter Troubleshooting Tips
If starter is noisy, check the condition of the
starter and the starter gears.
If starter is noisy and skipping, check the sprag
clutch.
rmi’ZO0B-013-102_a
Starter Removal TYPICAL

Remove the following RH body panels, refer to Pull radiator off its mounting plate and move
BODYsubsection: it back on the lower plate to enable access to
- Middle side panel starter.
- Top side panel
Radiator core is very fragile and eas-
— Bottom rear side panel ily damaged. Special care should be taken to
— Bottom front side panel avoid damaging the cooling fins when working
- Rear side panel. around the radiator. Bent or torn fins reduce
Remove headlight adjustment cable from LH mid- the radiator's efficiency and could lead to radi-
dle side panel support. ator leaks or higher engine operating tempera-
tures.
Remove RH middle side panel support.
Remove the RED rubber protector from the
starter terminal and disconnect the (+) cable from
the starter terminal.
NOTE: Starter is case grounded.
Remove the two starter retaining screws.
‘K-
Pm.
r1'nr20'IO—O'l‘I-0D‘(_8
1. Middle side panel support
Disconnect the battery.

rrnr2008-O13-O17_a
NOTICE Always disconnect BLACK (-) cable 1. Starter (+) terminal

2. Retaining screws
first and reconnect last.
Remove screw retaining top of engine coolant ra- Starter Installation
diator (do not disconnect radiator hoses). Installation is the reverse of the removal proce-
dure. However, pay particular attention to the fol-
lowing.
Make sure that starter and engine mating surfaces
are free of debris.
98 rmr201 ‘I-060
Section 02 ENGINE
NOTICE Premature wear may arise if the

starter is not properly aligned.
Apply PETAMO GREASE GHY133N (P/N 420 899 271)
on the starter output drive gear.
Apply DOW CORNING 111 (P/N 413 707 000) on the
starter boss and O-ring seal.
Secure starter to engine.
STARTER RETAINING SCREWS TORQUE
ll N'rn (97 lbf'in)
Connect the RED (+) cable to the starter and

torque nut to specification.
STARTER CABLE NUT TORQUE
6N'm (53 lbf'in)
Apply DIELECTRIC GREASE (P/N 293 550 004) On ter-

minal and nut.
Reconnect the battery.
A WARNING
Whenever connecting the RED (+) cable to
the starter motor, make sure the battery ca-
bles are disconnected to prevent electrical
shock. Always connect RED (+) battery cable
first then BLACK (-) cable last.
Test starter operation.
rmr201 1-060 99
Section 02 ENGINE
Subsection 07 (CYLINDER HEAD AND CYLINDER)
CYLINDER HEAD AND CYLINDER

SERVICE TOOLS
BLIND HOLE BEARING PULLER SET ......................................... .. 529 O36 117 .................. .. 115
ENGINE LEAK DOWN TEST KIT ................................................. .. 529 O35 661 .................. .. 106
OIL SEAL INSTALLER ................................................................. .. 529 036 O69 .................. .. I15
PISTON CIRCLIP INSTALLER 991 .............................................. .. 529 036 072 .................. .. 129
VALVE GUIDE INSTALLER (6 MM) ............................................. .. 529 O36 O75 .................. .. 126
VALVE GUIDE REMOVER (6 MM) .............................................. .. 529 O36 074 .................. .. 125
VALVE SPRING COMPRESSOR CUP .......................................... .. 529 O36 073 .................. .. 121
VALVE SPRING COMPRESSOR .................................................. .. 529 O35 724 .................. .. 121
SERVICE TOOLS — OTHER SUPPLIER

SNAP-ON PISTON RING COMPRESSOR TOOL ........................ .. RC—98O .................. .. 120
SNAP-ON PLIERS ........................................................................ .. YA 8230 .................. .. 122
SERVICE PRODUCTS
LOCTITE 518 ............................................................................... .. 293 800 O38 .................. .. 109
LOCTITE 5910 ............................................................................. .. 293 800 O81 .................. .. 120
MOLYKOTE G-N .......................................................................... .. 420 297 433 .................. .. 126
rmr2011-O61 101 ‘
Section 02 ENGINE
FRONT CYLINDER (NO. 1)
9 N-m 11 N-m
(80 Ibf-in) Q‘ (97 lbf-in)
/ \ K6 Dow Corning111
Q \
Petamo grease
Ghy0133n
¥
\ C
11 N-m i, . -
(97 Ibf-in) \ f?‘ ‘ E"§i'|"°
See ‘#1
.9 ‘M’ 3, 3 19 N-m
tightening . Q (168 lbf-in)
sequence _ Q
Petamo greaseb
Ghy 13311
18 N m
(159 (bf-in)_\
_ ° ‘Q
_
fr Q
‘Q I 3
ss (\1-
(43 “£911 ‘79,~"~~/
\ 1
*1»;-ow» 6 Loctite 243
L:-4.1 " . 1 11 N-m
\ - " . \ I‘ f ,-. \
(97|bf~in)
M J 6 L octlte
_ 243
. 4 L‘?_
Loctite e4so\ " ,

1": '
7Nm
u Sb" '¥ '1 " .;' ' '; .'_‘
(62 'b“'i") / 1 ” N .-‘:1 11 N-m

58 N-m 1 \ (97 lbf-in)
See
tightening
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(43|bf-ft) ‘— ' -“
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Engine V. _
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sequence 12 N-nj on »;-__' ’ » , (18|bf-ft)
Dow Corn|ng1110 j .
'4,
Loctite 4?/°
m = Component must be replaced when removed. (97 |bf'ifl)§/
rr'm’ZO10~D12—UO'|_b
102 rmr2011»061
Section 02 ENGINE
Su bsection 07 (CYLINDER HEAD AND CYLINDER)
REAR CYLINDER (NO. 2)
9 N-m
(80 Ibf-in)
11 N-m
(97 lbf~in)
Loctite
243
~
g Dow
C°"'li"9
111
;'/ -L_
}rw€_/
0 p. O
50 |\|.m 'I'I
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(37 |bf.fi) (97 Ibf-in
‘ vs? Ibf-in)
l . §
0-0 3.. .-53 19 NW‘, 0 , Petamo

Loctite243 0 g
/’\~—‘Z5ZZ Iwslbf--n> ~_ Ggygggn
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14 1*
$4
0 Petamo grease _ 3"
25 N-m t Ghy133n 12 N "J
(1s Ibf-ft) (106 lbf-In) i
Q-== Engine
o|I 6
”58 N-m
(43 Ibf-ft)
k #
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- 18 N-m
Petamo grease .
Q. I . Q (159Ibf-in)
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fie _ <11
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Loctite 2436?
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Co r (%gW111
9 - -_ A ‘~/— (627N".T-1
lbf In)
40 N-m
(29 Ibf~ft)
A \
x O Engine oil
rmr2(110—OI 2-OO2_a
rmr201 1-061 ‘I03

Section 02 ENGINE
CYLINDERS/PISTONS
30 N-m
(22 Ibf~fi)
Engine oil _
20 N-m 6 ' L ft 243
/
(15 lbfim
%
1» Y
O~_
1
Engine oil QC be
30 N'm 19 N-m
(22 Ibvfi) (14lbf'fi)
0
Loctite 243
19 N-m
(14 Ibf-ft)
30 N-m _,. I
(22 Ibf'fI£) ' i.' Engme oil 20 N_m
__ (15 Ibf-ft)
En9ine Ono / } -.)

Petamo greaseé
Ghy 133n
6 Petamo grease
Ghy 133n

fTT\I'20iD—[)12-QQQJ.)
104 rmr2011»061
Section 02 ENGINE
Subsection O7 (CYLINDER HEAD AND CYLINDER)
GENERAL 1‘
NOTE: When diagnosing an engine problem, al-

ways perform the cylinder leak test. This will help
41*as .‘
3,‘
1
‘- tr;-"Iva: , ",1.
';
pinpoint a problem. Refer to LEAK TES7'in this
subsection for procedures.
Always place the vehicle on a level surface.
2
NOTE: For a better understanding, some illustra-
tions are taken with engine out of vehicle. To per-
form some instructions, it is not necessary to re- K‘ _- ,-
move engine from vehicle. I1'__.'
\v>n
-\:_"._
Always disconnect battery cable before working _
\\
11.-._‘
H
' ‘P’
I 4ii
_. I‘;
‘ .3313?’
on the engine.
NOTICE Always disconnect BLACK (-) cable rmr201fl-O12-(‘JO4_a
first and reconnect last. 1. Front cylinder (no. 1)

2. Rear cylinder (no. 2)
ues and service products as in the exploded MAINTENANCE
VIEWS.
Clean threads before applying a threadlocker. Re- VALVE CLEARANCE

fer to SELF-LOCK/NG FASTENERS and LOCTITE NOTE: Check and adjust valve clearance only on
APPL/CA7‘/0Nat the beginning of this manual for
complete procedure. a cold engine.
A WARNING Valve Clearance Inspection

NOTE: Procedure is the same for both cylinders.
must be strictly adhered to. Remove WILI/E COVER See procedure in this
Locking devices when removed (e.g.: locking subsecfion.
tabs, elastic stop nuts, cotter pin, etc.) must Bring crankshaft to ignition TDC of the cylinder
be replaced with new ones. to be verified. Refer to CRANKSHAFTLOCK/NG
PROCEDURE in the CRANKCASE AND CRANK-
SHAF7'subsection.
IVUTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled Use a feeler gauge and check valve clearance.
as per factory standards. NOTE:lntake and exhaust valves must be
checked with cylinder at ignition TDC.
Even if the removal of many parts is not neces-
sary to reach another part, it is recommended to
remove these parts in order to check them.
When disassembling parts that are duplicated
in the engine, (e.g.: valves, springs, etc.), it is
strongly recommended to note their position
and to keep the parts of the same assembly as a
"group". If you find a defective component, it will
be much easier to find the cause of the failure.
Since parts were break-in together during the
engine operation, they will keep their matched fit
when parts are reassemble together within their
"group".
NOTE: The cylinders are referenced as front
(no. 1) and rear (no. 2).
rmr2011-061 105
Section 02 ENGINE
INSPECTION
CYLINDER LEAK TEST
1 General
Before performing the cylinder leak test, verify the
following:
— Clamp(s) tightness
I — Radiator and hoses condition.
NOTE: For best accuracy, the leak test should be
done with the engine at normal operating temper-
ature.
Q
'- ease; A WARNING
rmr2008-014-005_a
Prevent burning yourself due to handling on
7. Camshaft
2. Feeler gauge the hot engine.
3. Va/ve lift bucket
VALVE CLEARANCE Preparation

0.22 mm to 0.29 mm Remove spark plugs. Refer to /GN/T/ONSYSTEM
EXHAUST (.0087 in to .01 14in) subsection.
0.11 mm to 0.18mm Remove WILVE COVER See procedure in this
INTAKE (.0043 in to .0071 in) subsection.
Bring the piston of tested cylinder to ignition TDC.
Adjust valve clearance if out of specification. Refer to CRANKSHAFT LOCK/NG PROCEDURE
NOTE: To ease valve adjustment procedure, note in the CRANKCASE AND CRANK$HAFTsubsec-
each valve clearance prior to proceed. IIIOD.
Valve Clearance Adjustment Leak Test

Adjust valve clearance by replacing the adjust- Install the tool on engine, and then to an adequate
ment shim of the required valve. air supply.
NOTE: When replacing the adjustment shims, REQUIRED TOOL
crankshaft must be locked at ignition TDC.
ENGINE LEAK DOWN TEST KIT (P/N 529 O35 661)
Refer to appropriate procedures in this subsection
to remove the following parts:
— liming chain tensioner
— Balance shaft drive gears (rear cylinder)
— Camshaft timing gears
— Camshaft
- Valve lifter bucket.
Remove adjustment shim and check its thickness
with a micrometer.
Choose the proper adjustment shim thickness to
reach the specified valve clearance.
New shim thickness = 529035661
1*
Recorded valve clearance — Adjustment
specification + Old shim thickness Set needle of measuring gauge to zero.
NOTE: All testers have specific instructions on
After parts reassembly, recheck valve clearance. gauge operation and required pressure. Refer to
manufacturer's instructions.
Supply combustion chamber with air pressure.
106 rmr2011-061
Section 02 ENGINE
PROCEDURES
VALVE COVER
Valve Cover Removal
E (Engine in Vehicle)
Remove RH lateral support, refer to the FRAME
subsection.
Remove air filter housing and resonator. Refer to
the A/R /N7I4/(E SYSTEM subsection.
rmr2008-014~1 I2_a
Remove fuel tank protectors. Refer to the FUEL
1. Leak tester 7I4N/<' AND FUEL PUMP subsection.
2. Air supply hose Loosen throttle body clamps and lift throttle body
Note the amount or percentage of leakage (de- in order to make room.
pending on tester). Support throttle body using locking ties.
LEAKAGE ENGINE
PERCENTAGE CONDITION
0% to 15% Excellent condition
16% to 25% Good condition
26% to 4°% FZ‘Q.§l?.Zdl§L‘?r'$rl.3§L’§§d

- Poor condition, diagnose
41% and hlgher and repair engine
Diagnosis
Listen for air leaks.
- Air escaping on intake port/throttle body means
leaking intake valvels).
- Air escaping on exhaust port means leaking ex-
haust valvelsi.
— Air bubbles out of radiator means leaking cylin- rmr2DOB-014-1D1_a
der head gasket. TYPICAL
— Air/coolant escaping from cylinder/head means
damaged gasketls) and/or loosened screws (re- Rear Cylinder
fer to C)/L/NDER HEAD further in this subsec- Remove its retaining screws then pull EVAP can-
tion). ister away.
— Air escaping into crankcase area means exces-
sively worn cylinder and/or broken piston rings
(refer to CYL/NDER and P/STON R/NGS further
in this subsection).
NOTE: For all the checkpoints mentioned above,
see the appropriate engine subsection to diag-
nose and repair the engine.
Assembly
Reverse the preparation procedure. Ensure to
respect torque values and use of appropriate
products/lubricants. Refer to exploded views of
this and other sections of this manual as required.
rrnr2011-061 107
Sectlon 02 ENGINE
rm r2008-01 A-1 04_a
Front Cylinder
Disconnect the camshaft position sensor (CAPS)
Completely remove valve cover screws

rmr2ODB-014-1 u8_a
J Extra? Completely remove valve cover screws.
\$1 a)q\§;39-
1:’ ‘ \‘,
.*-E ‘I \
Q\~.>1»'-
Pull out valve cover towards RH side of vehicle
TICE Be careful not to damage gasket
rmr201 D-01 2-006__a
rmr201 1-061
Section 02 ENGINE
Pull out valve cover ha
1*
TICE Be careful not to damage gasket
-1
41¢’
rmr2008~01 4-006_a
FRONT CYLINDER
1. Retaining screws
2. Valve cover
3. Valve cover gasket
4. Camshaft position sensor (CAPS)
Valve Cover Inspection

Valve Cover Removal Check the valve cover for cracks or other dam-
(Engine Removed) ages.
Disconnect camshaft position sensor (CAPS) Check if the gasket is brittle, hard or otherwise
(front cylinder) damaged.
Unscrew cover retaining screws Replace all defective parts.
Remove the cover with the gasket Valve Cover Installation
For installation reverse the removal procedure.
,6
Take care that the gasket is located properly into
the groove in the cover.
Position the valve cover with the camshaft posi-
tion sensor on front cylinder.
NOTE: When installing valve cover while engine
is on vehicle, it may be easier to first install gasket
GI .- 3% in cover using LOCTITE 518 (P/N 293 800 038).
-..,\
.
/iv-~'i$'£'7"_:a,
§.
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Q
REAR CYLINDER
Retaining screws
2 Valve cover
3 Valve cover gasket
109
Section 02 ENGINE
4/
2-/" rmr200B-01 4-008_a

,,,,,2,,1,H,,M,,8_., 1. Balance shaft
1. Camshaft position sensor fifijrtewdriver
2. Front cylinder
Remove nut, balance weight and balance shaft
BALANCE SHAFT DRIVE GEARS drive gears.
Balance Shaft Drive Gears Location NOTE: Take care not to loose woodruff key when
removing balance shaft gear.
The balance shaft drive gears are located in the
rear cylinder head.
Balance Shaft Drive Gears Removal
Remove I/4LVE COVER, see procedure in this
subsection.
Lock crankshaft at ignition TDC (rear cylinder). Re-
fer to CRANKSHAFT LOCK/NG PROCEDURE in
the CRANKCASEAND CRAN/(SHAFTsubsection.
NOTE: Always place a rag into timing chain area
to avoid parts falling inside the engine during re-
moval.
NOTICE To avoid stretching the timing chain
when loosening the nut, use a screwdriver to
hold balance shaft. rrr\r2008-014-009_a
Nut
Balance weight
Balance shaft gear
¥@Nfi Woodruff key
Remove timing gear screws on exhaust side and

remove balance shaft drive gear.
110 rmr201 1-061

Section 02 ENGINE
‘aj I.‘
rmr2008-O14-010_a
1. iimlng gear screws

2. Balance shaft drive gear
Balance Shaft Drive Gears Inspection rrnr200B-01 M11 1 _a
lnspect gear teeth for wear or other damage. 1. Marks

If gears are pitted, scored, rounded, cracked or
chipped, they should be replaced. TIMING CHAIN TENSIONER
NOTE: Balance shaft drive gears are paired. Re- ‘liming Chain Tensioner Removal
place balance shaft drive gears as a set.
NOTE: Make sure that the crankshaft is set to
Balance Shaft Drive Gears Installation ignition TDC of the respective cylinder. Refer
For installation reverse the removal procedure. to CRANKSHAFTLOCK/NG PROCEDURE in the
However, pay attention to following.
Remove plug screw and gasket ring.
Install the longer screws (M6 x 14) on balance
shaft drive gear. Pull out chain tensioner.
" 1 "
-s_.'\“§(.1JInP
_ ® (I V‘ '\ \\,, \
1-,,
I ..-
..
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1.
4
J
=3
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_ ' 1:) Q’:r I T :_;;,. I
rmr200G-014-n10_a
1. Longer M6 x 14 screws here
1. @_'- J .\-I".‘aAI"‘
rrnr2008-014-D07_a
. __'
‘hk'A~ ))"\,.. I "f ‘-. ,,.. I ..._I >II
1. Plug screw
2. Gasket ring
Ensure to install longer screws 3. Chain tensioner
M6 x 14 to balance shaft drive gear on exhaust
camshaft (rear cylinder). If the longer screws Timing Chain Tensioner Inspection
were installed on the other gear, the camshaft Check chain tensioner for free movement in bore
would be blocked. and/or for scoring.
Align mark on balance shaft gear with mark on Compress chain tensioner and check if it works
camshaft timing gear. properly.
rmr201‘l~O61 111
Section 02 ENGINE
‘liming Chain Tensioner Installation

Apply engine oil on chain tensioner.
11ghten chain tensioner plug screw to specifica-
tion.
CHAIN TENSIONER PLUG SCREW TORQUE
30 Nam (22 lbf'ft)
CAMSHAFT TIMING GEAR

Camshaft Timing Gear Removal rmr200H-01 4-01 3_,a
Remove V4LVE COVER. See procedure in this TYPICAL - FRONT CYLINDER

1. Distance screws
subsection. 2. Upper chain guide
Lock crankshaft at ignition TDC of the respective Remove timing chain guide.
cylinder. Refer to CRANKSHAFT LOCKING PRO-
CEDURE in the CRANKCASEAND CRANKSHAFT
subsection.
For rear cylinder, proceed with BALANCE SHAFT
DRIVE GEARS REMOWIL. See procedure in this
subsection.
Loosen camshaft timing gear screws.
/R-\
rmr2008-01 4-01 4_8
1. Timing chain guide
Remove camshaft timing gear screws.
O
*3
rrnr2008{)‘I4-012_a
TYPICAL - FRONT CYLINDER SHOWN
‘Ii
1. Timing gear screws
2. Trming
' gear (intakeI
3. iirning gear (exhaust)
Remove CHAIN TENSIONER See procedure in

this subsection. \_. ‘S Q
' \
For front cylinder, remove upper chain guide.
rr1vr2008-(J1 4-O1 5
Secure timing chain with a retaining wire.

Remove camshaft timing gears.
112
rmr201 I 061
Section 02 ENGINE
Camshaft ‘liming Gear and Upper

Chain Guide Inspection
Check camshaft timing gears for wear or deterio-
ration.
If a gear is worn or damaged, replace it as a set
(both camshaft timing gears, intermediate gear
and timing chain).
NOTE: For intermediate gear replacement refer
to CRANKCASE AND CRAN/<SHAFTsubsection. _ _ ‘13.
Check upper chain guide for wear, replace if nec-

essary.
Camshaft ‘liming Gear Installation
The installation is the reverse of the removal pro- vmi’ZOO8-(J15-004_a
cedure. However, pay attention to the following. TYPICAL

1. Marks on timing gears
NOTE: If timing gears of both cylinders have
been removed, refer to ENG/NE REASSEMBLY Install the TIMING CHAIN TENSIONER. See pro-
SEOUENCE in the CRANKCASE AND CRANK- cedure in this subsection.
.S‘HAFTsubsection. Install the BALANCE SHAFT DRIVE GEARS (rear
cylinder). See procedure in this subsection.
NOTICE Improper valve timing will damage
engine components.
BALANCE SHAFT
l\/lake sure that crankshaft is locked at TDC of the
respective cylinder. Balance Shaft Location
Camshaft timing gear with trigger pin has to be The balance shaft is located in cylinder head of
installed at intake camshaft (front cylinder). rear cylinder.
Balance Shaft Removal
Remove camshaft timing gears from rear cylinder.
Refer to CAMSHAFT TIMING GEAR in this sub-
section.
Remove bearing flange retaining screws and with-
draw bearing flange and balance shaft from cylin-
der head.
I ,.\ - ._I
rrnr2008-014~012_b
TYPICAL - FRONT CYLINDER SHOWN

1. Intake camshaft
2. liming gear
..e\..~
3. Trigger pin
'
4. Front cylinder head
Install timing gears on camshafts so that marks 1rnI'2CI03-D14-O1G_a
"IN" on intake and “EX" on exhaust camshaft are . Retaining screw

. Washer
aligned. . Upper chain guide
Bearing flange
9‘I:P~‘~)'\>~‘ Balance shaft
rmr201 I-061 113

Section 02 ENGINE
Balance Shaft and Bearing Flange

Inspection K
l
§
Balance Shaft ‘I; T\_ I
Check oil seal running surface of balance shaft for

grooves.
Measure diameter of balance shaft bearing jour-
(‘I
.i
j. I A
Iil
' I
.
I
8
nals. \ I “ -V ‘ .‘, If
Replace if necessary.
Clean ventilation orifice in balance shaft using an \
0~I
air gun. ,5‘ ' '\‘.‘ ) ' - '\ . I
\1
NOTICE Always wear eye protection. rrnr201D-012-00B_a
BEARING FLANGE
1. Oil orifice
2 ‘I A. Beari'ng flange inside diameter
Substract the balance shaft bearing journal from

the plain bearing inside diameter to obtain radial
h......... clearance.
PLAIN BEARING RADIAL CLEARANCE
SERVICE LIMIT I 0.07 mm (.O028in)
Balance Shaft Ball Bearing Inspection

Check ball bearing of balance shaft for excessive
play and smooth operation.
rrr\l'Z0l ‘I-O12-I103_a
BALANCE SHAFT
1. Identification groove
2. Ventilation orifice
A. Plain bearing journal
B. Ba/lbearing journal
PLAIN BEARING JOURNAL "A"

84.973 mm to 34.989 mm
NEW (1 .8769 in to 1.3778 in)
SERVICE LIMIT 34.953 mm (1 .376In)
BALL BEARING JOURNAL "B” .._ Abe

14.981 mm to 14.992 mm imrzoosoinaizoj
NEW (.5898 in to .5902in) 1. Ball bearing
SERVICE LIMIT 14.970 mm (.5894in) Balance Shaft Oil Seal Inspection

Check if oil seal behind ball bearing is brittle hard
Bearing Flange or damaged.
Check plain bearing for scoring or other damages.
Measure plain bearing inside diameter. Balance Shaft Ball Bearing
Replacement
Balance Shaft Ball Bearing Removal
Remove camshaft holder from cylinder head.
Heat camshaft holder up to 100°C (212°F) before
removing the ball bearing.
114 rmr2011-061
Section 02 ENGINE
NOTICE Clean camshaft holder from oil be-

fore heating.
Remove ball bearing from camshaft holder.
REQUIRED TOOL
BLIND HOLE BEARING PULLER SET
(P/N 529 036 117)
NOTE: Take care not to damage cylinder head dur-

ing removal.
Balance Shaft Ball Bearing Installation
Heat camshaft holder up to 100°C (212°F) before
installing the ball bearing.
Use a suitable pusher to install ball bearing. rrrir2008-014-022_a
1. Oil seal
To properly install camshaft holder, refer to 2. Oil seal installer
CAMSHAFTin this subsection. 3. Camshaft holder
Balance Shaft Oil Seal Replacement Balance Shaft Installation

Balance Shaft Oil Seal Removal cedure. However, pay attention to following.
Proceed with BALANCE SHAFT BALL BEARING To properly install camshaft timing gear, refer to
REMOVAL. CAMSHAFT TIMING GEAR
Use a screwdriver to remove oil seal from
camshaft holder. NOTICE Improper valve timing will damage
engine components.
NOTICE Take care not to damage oil seal
area. To properly install balance shaft drive gears, refer
to BALANCE SHAFT DRIVE GEARS in this sub-
Balance Shaft Oil Seal Installation section.
Install oil seal with sealing lip facing towards ball
beanng. CAMSHAFT
REQUIRED TOOL Camshaft Removal
OIL SEAL INSTALLER (P/N 529 036 O69) Proceed with CAMSHAFT T/MING GEAR RE-
MOVAL. See procedure in this subsection.
Remove camshaft holder.
529036069
rmr2011-D61 115
Section 02 ENGINE
5.
/1\
.;_(
‘.1
‘kg
N/-'
Ci
3\\>
i n'nr2008-O‘l4~U27_a
1. Lobes
A. Camshaft journal
CAMSHAFT JOURNAL DIAMETER

rmr2ClD3-01 4-023_a 23.967 mm to 23.980 mm
1. Retaining screws NEW l-9436in to .9441 ifll
2. Washers
3. Camshaft holder SERVICE LIMIT 23.950 mm (.9429in)
Remove exhaust and intake camshafts. Measure clearance between camshaft and
camshaft holder, using a plastic feeler gauge.
NOTE: The plastic feeler gauge is available at au-
tomotive parts retailer.
Place the camshaft in the cylinder head and apply
a plastic-gauge on the camshaft bearing journal.
1 r Di 2
‘I
'11"
2:-_€' . <
I
1-J‘? J7
rmr2OOB-U14-O24_a . I. J"
7. Exhaust camshaft ., .1‘
2. Intake camshaft
Camshaft Inspection
Check each lobe and bearing journal for scoring,
scuffing, cracks, or other signs of wear.
Measure camshaft bearing journal diameter, using vrnr2006-016065_a
a micrometer. 1. Plastic gauge
2. Camshaft bearing journal
Install camshaft holder in the proper position and

tighten bearing cover screws to specified torque.
Unfasten camshaft holder.
Measure the maximum width of the pressed plas-
tic gauge with the corresponding graduated scale.
116 rmr2011-061
Section 02 ENGINE
1 .3 - 1 -
'" 0.0; 2 _‘i;_/ _
“ls
.. Q.‘ ‘
,_
.1
,_-
rmr200E~O‘|4»D26_a
rnr200B-D16~066_b
V 1. Smaller washers
7. Praised plastic gauge
2' G” “med 5°“ Lubricate camshaft holders with engine oil before
CLEARANCE BETWEEN CAMSHAFT AND placing them W0 Cvlinder head-
CAMSHAFT Ho‘-DER Fit camshaft holder and tighten screws to specifi-
SERVICE LIMIT | 0.06 mm (.OO24in) ¢atiOn as Per following sequenw
_ CAMSHAFT HOLDER SCREWS TORQUE
Camshaft Installation H N_m (gmbmn)
cedure. However, pay attention to the following. _
Take care not to interchange intake and exhaust '-E- ' _ _ __
camshafts. R‘ 1*’ It i .
_ _ __1l
_ <* E A
aw,’ 1’ E-*1 I1 _
. ,"".
,., 1,
56 ~:é‘§/
(G 11/ “'“i“+"’“LJ ;ff* . ;,...f.. 1*‘
> F 2 3 .-
’_| ____ 5») 1 WitsiiB)‘;
.7? ..._<.
" " vmr2DO8-O1 5-O20_a

\ (® I I TIGHTENING SEQUENCE
(‘ "» Y‘ J I NOTE: After bearing cover installation check if
‘M’ ‘w camshafts turn easily.
7' Check l44LVE CLEARANCE See procedure in this
4 subsection.
.T""‘Z;Z§Z§.°Z.m.1.f.
2. 2 mar s
VALVE LIFTER BUCKET
jj ;’;{;1g;;;§;";a¢;“eP@'"*ma’k Valve Lifter Bucket Removal
5; mow” Dame pa,»mma,k Remove the following parts, see procedures in
this subsection:
Install smaller washers where shown. _ \/awe Cover
rmr201 1-061 117
Section O2 ENGINE
— Balance shaft drive gears (rear cylinder)

— Chain tensioner
— Camshafts.
Use a magnet and lift valve lifter bucket.
cl)
-‘>1
Adjustment shim could be stuck in
valve lifter bucket. Take care not to loose ad-
justment shim.
.. I 1
‘ ._
~14," , . A‘. J ‘ ‘ '_-_' /
> “ __,_< A‘ "5 ; . f:-\\
Q
J
-0
' " ‘ 4 ‘l 'iI
. vrnr2008-UI6022_a
I In .“"}.\<.'.l 1. Adjustment shim
2. Valve spring retainer
ll
f
CYLINDER HEAD
j j '*\ 4
.3 Cylinder Head Removal
Remove engine from vehicle. Refer to ENG/NE
in- ti 6-1“-
'1‘ .Q'i.'l, '11‘. '..9 HE/I//0l44L AND /N.S‘77lLLA 7'/ONsubsection.
'..'
"GU".‘-1
|-‘K. K,
J "I Remove support between cylinder heads.
.1
vrnr2008-O'| 6—D2‘|_a
1. Valve lifter bucket

2. Adjustment shim
Valve Lifter Bucket Inspection

Check surface of valve lifter bucket for scoring or
other damages.
- , 1‘
Measure diameter of valve lifter bucket. If diam- H 1‘
j I‘r 7; ‘ ‘-2
»
eter is out of specification replace it. . 4 1'

_
VALVE LIFTER BUCKET DIAMETER
QI
33.459 mm to 33.475 mm A?“
NEW 113173111 to 1.3179 in) ~‘~’./'1‘)-t I ) / '1 '1 h
1mr20Cl8-O14-03O_a
SERVICE LIMIT 33.440 mm (1.3165inI
1. Support
‘ VALVE LIFTER BUCKET RADIAL CLEARANCE ‘ Unscrew spark plug.
SERVICE LIMIT 0.08 mm (.0031 in) Remove I/ALVE COI/EH’. See the procedure in this
subsection.
Valve Lifter Bucket Installation Remove CAMSHAFT 7'/M/NG GEAR See proce-
NOTICE Place adjustment shim properly in dure in this subsection.
place before installing valve lifter bucket. Remove cylinder head screws.
Remove cylinder head nuts.
118 rmr201 1-O61

Section 02 ENGINE
J. .
, _ .-'__
i§4-“'2
‘K 4"of.» ‘_ V-
-'; 4
I. -V >
»:11~1 ~
':~' V ¢'__ :~,_'.-I
.I>-<—2
‘,- _ -.1-; . ' .
rmr2DOB-D14-031_a
rmr2008-O14-U33_a
1. Cylinder head screws
2. Cylinder head nuts 1. Cylinder head
2. Cylinder head gasket
3. Cylinder
Pull cylinder with cylinder head from bottom end.
NOTICE Take care not to damage piston and Remove cylinder base gasket and discard it.
rings during cylinder removal.
Remove cylinder screws.
NOTE: If the cylinder head does not have to be
disassembled, do not separate cylinder head from
cylinder.
rmr200B-O14»034_a
1. Cylinder base gasket
Cylinder Head Inspection

Check for cracks between valve seats or other
damages, if so, replace cylinder head.
rmr2OOB»(114»O32_p Blow out oil support through cylinder head to
1. Cylinder screws check if they are not clogged.
Separate cylinder head from cylinder.
Remove cylinder head gasket and discard it.
1'< 1
J T I .
L
. ,1‘),
:11]
.5‘? '1' P‘
J nu
~ J
,7‘ cw.‘
. 0' .
rmVZO08-014-0353
1. Oil orifices to lubricate camshaft bearings

2. Oil orifices
3. Oil orifice (front cylinder only)
rrr\r2011-061 119
M
Section 02 ENGINE
Check valve lifter bucket bore for wear or scoring. NOTICE Always replace cylinder base gasket
Measure valve lifter bucket radial clearance, refer by a NEW one before installing the cylinder
to l44Ll/E L/FTE/-? BUCKET If clearance exceeds with cylinder head.
specified tolerance, replace valve lifter bucket and Apply LOCTITE 5910 (P/N 293 800 081) on crankcase
measure radial clearance again. sealing surface where crankcase halves are
If radial clearance is still out of specification re- jointed, as shown in the illustration below.
place cylinder head.
Check camshaft bearing for wear or scoring.
To measure the camshaft bearing, install camshaft
holder according to the specified torque in the ex-
ploded views and measure diameter with a bore
gauge.
CAMSHAFT BEARING
(CAMSHAFT HOLDER INSTALLED)
24.007 mm to 24.020 mm
NEW (.9452 in to .9457 in)
SERVICE LIMIT 24.040 mm (.9465 in)
rm V2008-III 4-036_a
Measure camshaft radial clearance, refer to 1. Apply Loctite 5910 here

CAMSHAFT If clearance exceeds specified tol- Apply engine oil in the bottom area of the cylinder
erance, replace camshaft and measure radial bore and on piston rings.
clearance again.
NOTE: Make sure piston rings are properly
If radial clearance is still out of specification re- spaced, refer to Pl5TON R/NG5 in this sub-
place cylinder head. section.
Cylinder Head Installation Compress piston rings.
For installation, reverse the removal procedure. Apply engine oil on the band of the tool.
However, pay attention to the following. REQUIRED TOOL
Fit cylinder on cylinder head.
SNAP-ON PISTON RING COMPRESSOR
Install cylinder screws and tighten to specification TOOL (P/N RC-980)
as per following sequence.
CYLINDER HEAD M8 SCREWS TORQUE
30 NIIT1 (22 Ibf'f’t)
@-T-tv
1
I1
0
rmr200B-014-037_a
1. Piston ring compressor tool
2. Cylinder with cylinder head assembly
Slide timing chain through chain passage, then

rrnr200&G14-O3 Z_b
slide cylinder with cylinder head over piston.
TIGHTENING SEQUENCE
First tighten M1 O nuts by hand, then tighten them
according to the following sequence.
120 rmr2011-061
Section O2 ENGINE
CYLINDER HEAD M10 NUTS TORQUE

58 N'rT| (43 lbf'ft)
- - 5290357 24
#161;:-._,j '11‘A. -.
J’ I f C‘
I"Q‘
I5;
‘.
‘H K :— '- ‘
.... "'r ..., ‘ .

IFTIQOOB-U14-D3 Bj
.- 529036073
TIGHTENING SEQUENCE
Remove valve cotters.
Tighten Allen socket screws in cylinder head.
CYLINDER HEAD M6 SCREWS TORQUE
12 N'm (106lbf'in)
,
‘AI).‘. Q1 rmr20DB-(J14-12U_a
1. Valve spring compressor clamp

2. Valve spring compressor cup
3. Valve cotters
rrr\r2008-014-041_a
1. Cylinder head screws Remove valve spring retainer, then outer and inner
valve spring.
Install all other removed parts.
VALVE SPRING
Valve Spring Removal
NOTE: Whenever valves are removed, it is rec-
ommended to replace valve stem seal at the same
time.
Remove the following parts, see procedures in
this subsection:
- Cylinder head
— Camshafts
- Valve lifter bucket and adjustment shim. vmr20OB-DI 6-03l_a
Compress valve spring. 1. Spring retainer

2. Outer valve spring
REQUIRED TOOLS 3. Inner valve spring
VALVE SPRING COMPRESSOR (P/N 529 O35 724) Valve Spring Inspection
VALVE SPRING COMPRESSOR CUP Check valve spring for rust or corrosion and free
(P/N 529 036 073) length.
rmr201 1-061 121
M m
Section 02 ENGINE
VALVE SPRING FREE LENGTH After springs are installed, ensure it is properly
INNER VALVE SPRING
locked by tapping on valve stem end with a soft
hammer so that valve opens and closes a few
NEW 39.24 mm (1.5449in) times.
SERVICE LIMIT 38.00 mm (1.4961 in)
OUTER VALVE SPRING
VALVE
NEW 41.97 mm (1.6524in) Valve Removal
SERVICE LIMIT 40.50 mm (1 .5945in) Remove l44LVE SPF?/NG, see procedure in this
subsection.
Valve Spring Installation Push the valve stem, then pull intake and exhaust
valves out of cylinder head.
cedure. However, pay attention to the following. __. __‘—q_ 1 -_
Colored area of the valve springs must be placed _r»-'

' " ‘*-5' ‘
on top.
_
er
111112006-OM-O42_i
1. Intake valves 38mm (1.5 in)

2. Exhaust valves 37 mm l1.2in)
Valve Stem Seal Removal

vmr2C|O8-016-03I_b
Remove valve stem seal and discard it.
1. Colored area of the valve spring
REQUIRED TOOL
To ease installation of cotters apply some oil or
grease on them, so that they remain in place while SNAP-ON PLIERS (P/N YA 8230)
releasing the spring.
NOTE: Valve cotters must be properly engaged in
valve stem grooves.
NOTICE Improperly locked valve springs will
cause engine damage.
. vmI'2006-O43-O22
Remove valve spring shim.
@&_ .__..».\. we-t.._......_..-.
vrnr20OB016032 _a
1. Valve cotters
122
r|'nr2011-O61
Section 02 ENGINE
VALVE STEM DIAMETER

INTAKE VALVE
i’ 1 I 5.961 mm to 5.975 mm
NEW 1.2347111 to .2352 in)
SERVICE LIMIT 5.950 mm (-2343 in)
Ex:-must VALVE
5.946 mm to 5.960 mm
NEW (.2341 in to .2346 in)
bi-.. Replace valve if valve stem is out of specification

rmr2010-D1 2-O1 1_
or has other damages such as wear or friction sur-
1. Valve spring shim
2. Valve stem seal face.
Measure VALVE GU/DE. See procedure in this
Valve Inspection subsecflon.
Valve Stem Seal Valve Face and Seat
Always install NEW valve stem seals whenever
valves are removed.
Valve
lnspect valve surface, check for abnormal stem
wear and bending. If out of specification, replace
by a new one. -2
VALVE STEM RUNOUT 3t
IINTAKEIEXHAUST)
NOMINAL NEW 0.005 mrn (.0002inl
SERVICE LIMIT 0.05 mm (.002inI \1
Valve Stem
R40Dmo1r84A
Measure valve stem in three places using a mi-
crometer. 1. Valve seat
2. Exhaust valve contaminated area
3. Valve face (contact surface to valve seat)
Check valve face and seat for burning, pitting and

other signs of damage. Replace valve or cylinder
head if necessary.
Apply some lapping compound to valve face and
work valve on its seat with a lapping tool.
Ea A
R4D0rn1:m83A
A. Valves stem diameter
rmr2011-061 123
I i I i 1 I I
Section 02 ENGINE
3 A NOTICE Be careful when valve stem is

passed through sealing lips of valve stem
1 . -;"';'_“‘~
Q) seal.
,£
§'qn I;_,/
1|’,
rrn Q 008-OI 4-O43_a
1. Valve seat rmr20‘II')-O12-01I_a

2. Valve face (contact sun‘ace to valve seat)
3. Turn valve while pushing against cylinder head 7. Valve spring shim
2. Sealing lips of valve stem seal
A. Valve seat angle 45°
NOTE: Ensure to seat valves properly. Apply To ease installation of cotters, apply oil or grease
marking paste to ease checking contact pattern. on them so that they remain in place while relea-
sing the spring.
Repeat procedure until valve seat/valve face fits
together. After springs are installed, ensure it is properly
locked by tapping on valve stem end with a soft
Measure valve face contact width. hammer so that valve opens and closes a few
NOTE: The location of contact area should be in times.
center of valve face.
NOTICE Improperly locked valve springs will
Measure valve seat width, using a caliper. cause engine damage.
VALVE SEAT CONTACT WITH
INTAKE VALVE VALVE GUIDE
1.00 mm to 1.40 mm Valve Guide Inspection
NEW 1.039415 to .0551 in) NOTE: Clean valve guide to remove carbon de-
SERVICE LIMIT 1.60 mm (.063in) posits before measuring.
EXHAUST VALVE Measure valve guide in three places using a small
bore gauge.
1.25 mm to 1.55 mm
NEW 1.0492111 to .061 in)
If valve seat contact width is too wide, too narrow

K . .
or has dark spots, replace the cylinder head.
Valve Installation ~' /, a
C / . 4
1.». .-.
/ . :* ’7.‘/.
‘L
'/j
.- j ,‘
'7
V»
I V’
.'
/
,. :1 'j‘/,.~.-’./ -,7
,- >,/.1». HI K
' //‘
. . »:r;4- -1’
NOTE: Make sure the valve spring shim is in- ,’_/.
/..' ,1,
.)
"/,
-,./,
.. ,
Iv.
I
V‘ 1
-,
stalled before installing valve stem seal.

Apply engine oil on valve stem and install it. vn1|2D08-016042J:
A. Valve guide diameter
124
rmr2011-061
Section 02 ENGINE
VALVE GUIDE DIAMETER

(INTAKE AND EXHAUST VALVES) 1‘ )\ 1
6.006 mm to 6.018 mm l .‘K
\
.X
.
NEW 1.236515 to .2359 ml
If valve guide is out of specification or has other

damages such as wear or friction surface, replace l*J
it.
Valve Guide Replacement ‘N
'1///[I
\\\\\\\t\\\\\w §\|\\\\1\\*~E
I2 In
NOTE: Do not heat up cylinder head for valve

guide replacement. E‘ .~\§ I‘!N‘a»
\\\-
s"\\\\§
Remove the followings parts, see procedures in \\§\
this subsection:
— Cylinder head
— Valve springs vmr2OClB-O1&C|37_a
1. Reamer
- Valves. 2. Valve guide, sharp edge
Remove valve stem seal and valve spring shim.
Remove valve guide.
REQUIRED TOOL
VALVE GUIDE REMOVER (6 MM) (P/N 529 036 074)
Hammer
*--/~ r " 1
Q, I
I 1
1
52 9036074
1 1
rmr2010-D12-O1‘I_a
1. Valve spring shim

2. Sealing lips of valve stem seal
NOTE: Clean valve guide area from contamination S

before removal.
!\1'\\§\\\\\\\\-
/\ ~S\\*I
Use a special reamer and machine valve guide top
until sharp edge is removed. '$11 ///1
wg-\"‘
:\
I
The sharp edge near the top of the
valve guide must be machined away. Other-
wise it will foul the valve guide hole in the head
and destroy the head when removing the valve »'/ /= ’///1/
1'\$‘
I ///\\~
guide. vmr200B-O16-D3E_a
1. Valve guide remover
Check the valve guide bore in the head for scoring

or other damage.
NOTICE If any signs of galling are visible in
the bore, the cylinder head must be replaced.
rmr2011-051 125
Section 02 ENGINE
Valve Guide Installation

Clean the valve guide bore before reinstalling the 4-"T//1
valve guide into cylinder head.
NOTE: Intake and exhaust valve guides are differ-
ent. Intake valve guide has a longer chamfer.
A In
’//\\\\\\\\\\ WI
\\\\\\‘l
‘S//M
‘
'2
iota)“ ; -/ ‘O .\\\§\\-\~
Q-‘
C10
\*'
~\\\._
._.§§‘
‘“\\“"
‘\
<fx\\'\
<\‘i.‘° 1. Valve guide installer
2. Valve guide
.. 3. Thrust surface of cylinder head
._.
'.\‘§\\\\
\.
-.3.:\;{Q77??-.\\_ ;.\ \_..\‘\1.‘.- .\>_-\
§v;_‘_\‘\.
- . \~.>: A. Measurement from thrust surface to valve guide top
VMFZOCIB-016-O42_a VALVE GUIDE MEASUREMENT A

1. Longer chamfer on intake valve guide MINIMUM NEW 13.10 mm (.5157in)
Apply MOLYKOTE G-N (P/N 420 297 433) on valve MAXIMUM NEW 13.50 mm (.5315in)
guide and in valve guide bore, prior to install it into
the cylinder head. Valve has guide to be adjusted in diameter by us-
ing a reamer.
Install valve guide.
REQUIRED TOOL
VALVE GUIDE INSTALLER (6 MM) (P/N 529 036 075)
,V I W
. 1/. <1 /, . I
. **x ‘ (.1 ‘f ’:._;.;_
}'.‘ "I\. . . gt . . \
529036075
,2’/ff‘ RI: . " ,4
Push valve guide in the cold cylinder head as per 1.»-ii)‘ P .<;
following illustration. vmr2()0B-0'I5~C)42_D
A. Valve guide diameter
VALVE GUIDE DIAMETER

IINTAKEIEXHAUSTI
6.006 mm to 6.018 mm
NEW I (.2365in to .2369inl
NOTE: Ensure to turn reamer in the right direc-
tion. Use cutting oil and clean often reamer/valve
guide from metal shavings.
NOTE: After valve guide installation, ensure
valve seats properly against cylinder head. Refer
to VALVE /NSPECT/ON in this subsection.
126 rmr201 ‘I-061

Section 02 ENGINE
CYLINDER
Cylinder Removal
For cylinder removal refer to C)/L/NDER HEAD
REMOVAL in this subsection.
./2
Cylinder Inspection
Cyfinder
Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder. rmr2DDB-014-D45_a
Piston/Cylinder Clearance 1. Piston circlip

2. Piston pin
Check piston/cylinder clearance, refer to PlSTON 3. Piston
in this subsection. Detach piston from connecting rod.
Chain Tensioner Hole
Piston Inspection
Ensure that chain tensioner and hole in the cylin-
der are in perfect condition. Piston
lnspect piston for scoring, cracking or other dam-
Cylinder Installation ages. Replace piston and piston rings if neces-
For cylinder installation refer to CYLINDER HEAD sary.
/N$i'I4LLA7'/0Nin this subsection. Using a micrometer, measure piston at 10mm
l.394in) perpendicularly (90°) to piston pin.
PISTON
Piston Removal
Remove cylinder head with cylinder, see CYLIN-
DER HEAD in this subsection.
Place a rag under piston in the area of timing chain
passage.
Remove one piston circlip and discard it.
vmr200B-D16-049_e
1. Measuring perpendicularly l90°) to piston pin

A. 10mm (.394in)
The measured dimension should be as described

in the following table. If not, replace piston.
PISTON MEASUREMENT
SIZE A
-
96.940 mm to 96.950 mm
rmfZ0O8-01 4-044,! NEW (3.8165 in to 3.8169 in)
1. Piston circlip
2. Small screwdriver SERVICE LIMIT 96.920 mm (38157 in)
NOTE: The removal of both piston circlips are not SIZE B

necessary to remove piston pin. 96.950 mm to 96.960 mm
Push piston pin out of piston. NEW (3.8169 in to 3.8173 in)
SERVICE LIMIT 96.930 mm (38161 In)
rmr2011-061 127
Section 02 ENGINE
\\.
\ I "
1‘ ‘l
‘ m'\120‘I0-012-012,3 F00 BOEA
1. Red or green paint mark lsize code) of piston

7. Micrometer set to the piston dimension
NOTE: If the wear limit is exceeded, a new pis- With the micrometer set to the dimension, adjust
ton must be used or the cylinder replaced, com- a cylinder bore gauge to the micrometer dimen-
plete with piston. When replacing the piston al- sion and set the indicator to 0 (zero).
ways use new circlips securing the piston pin.
Take special care when matching the piston with
cylinder:
Piston with red paint mark = size “A” — Cylinder
size "A"
Piston with green paint mark = size "B" — Cylin-
der size "B" 1
The cylinder size code "A" or "B" is stamped on
the lower side of the cylinder.
{.
FOOBOBA
7. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge
1/K O
vrnr200B-O16-D51_a
7. Size code "A" or "B" of cylinder
Piston/Cylinder Clearance °o. 31*

~T-°‘ '
Adjust and lock a micrometer to the piston dimen- -' U’
sion. 5.»: 1?? E

.,,.. \
FODBDAA
TYPICAL
7. Indicator set to 0 (zero)
Position the dial bore gauge 20 mm (.787 in) above

cylinder base, measuring perpendicularly (90°) to
piston pin axis.
128
rmr2011-061
Section 02 ENGINE
Read the measurement on the cylinder bore

gauge. The result is the exact piston/cylinder wall
clearance.
PISTONICYLINDER CLEARANCE 52903 E072
0.050 mm to 0.075 mm
NEW (.002 in to .003 in) NOTICE Always replace disassembled piston
SERVICE LIMIT 0.090 mm (.OO35in) circlip(s) by NEW ones. Place a rag on cylinder
base to avoid dropping the circlip inside the en-
NOTE: Make sure used piston is not worn. See gine.
PISTON MEASURE/l/IE/\/7T
Place circlip in sleeve as per following illustration.
If clearance exceeds specified tolerance, replace
piston by a new one and measure piston/cylinder
clearance again. 3%
lf piston/cylinder clearance is still out of specifica-
tion replace cylinder also.
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false. 1 A
2\
Piston Installation
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod. R4DUmo(r1DOA
NOT!(7E Take care that both pistons will be 1. Circlip

installed with the marks (size code of piston) 2. Sleeve
3. Piston circlip installer handle
showing to the rear of the engine.
Push piston circlip installer handle until circlip
reaches middle of sleeve.
Insert the end of the handle into piston pin.
Hold piston and push handle to engage the circlip
into piston groove.
l -0.~
rmi?0OB-O14-U47_a
fl
7. Size code ofpiston
2. Main shaft
3. Clutch shaft
rmr2008-O14-048_a
Assemble the NEW piston circlip as per following 7. Sleeve

procedure: 2. Piston circlip installer handle
REQUIRED TOOL NOTE: Take care that the hook of the piston circlip
is positioned properly.
PISTON CIRCLIP INSTALLER 991 (P/N 529 036 O72)
rmr2011-061 129
Section O2 ENGINE
Ring End Gap

To measure the ring end gap place the ring
in the cylinder in the area of 8mm to 16mm
(.315 in to .63 in) from top of cylinder.
NOTE: In order to correctly position the ring in the
cylinder, use piston as a pusher.
Using a feeler gauge, check ring end gap. Replace
ring if gap exceeds above described specified tol-
i i-1- ...__ erance.
vrnr200E~0‘I 6-054
RING END GAP
CORRECT POSITION OF THE PISTON CIRCLIP
APPLICABLE TO ALL RINGS
PISTON RINGS 0.15 mm to 0.35 mm
NEW (.0059 in to .0138inI
Piston Rings Removal SERVICE LIMIT 1 mm (.0394inl
Remove cylinder head with cylinder, refer to
CYL//VDEFI’ HEAD in this subsection. Piston Rings Installation
Remove PISTON See procedure in this subsec- Install the oil scraper ring first with marking "O"
tion. on top, then the lower compression ring with the
stamping ”E" and "TOP “ facing up.
Piston Rings Inspection
Ring/Piston Groove Clearance
Using a feeler gauge measure each ring/piston
groove clearance. If the clearance is too large, the
piston and the piston rings should be replaced. iiies-"-I
RING/PISTON GROOVE CLEARANCE
UPPER COMPRESSION RING
0.025 mm to 0.070 mm
i”iIllIll<—2
SERVICE LIMIT
NEW 1.001 in to .0028in)
0.120 mm (.0047inI
LOWER COMPRESSION RING
EH
0.025 mm to 0.070 mm 7. Upper compression ring
2. Lower compression ring
NEW (.001 in to .0028 in) 3. Oil scraper ring
OIL SCRAPER RING
NOTE: First install spring and then the ring of oil
scraper ring. The oil scraper ring must be installed
0.015 mm to 0.060 mm by hand.
NEW (.0006 in to .0024 inl
SERVICE LIMIT 0.100 mm (.0039in) Install other rings using a ring expander to prevent
breakage.
__,-a
Check that rings rotate smoothly after installation.
‘,1- Space the piston ring end gaps 120° apart and do
4-/I not align the gaps with the piston pin bore or the
thrust side axis.
Jg If
vmr2008-016-055_a l
1. Piston
2. Feeler gauge
130 rmr201 1-061

Section O2 ENGINE
_/‘TX’ Connecting Rod Small End Bushing

Measure inside diameter of connecting rod small
end bushing.
Z5‘-'3?/*"'T’1
"L:-xi)
WQ Q
y/_\__/"L"/Q/2/\<—"2 2
/
A31C2OA
R‘l0fl4motr1 1A
1. DO NOT align ring gap with piston thrust side axis
2. DO NOT align ring gap with piston pin bore ax/s 1. Bore gauge
2. Connecting rod
A. 720°
CONNECTING ROD SMALL END DIAMETER
PISTON PIN 22.010mm to 22.020 mm
NEW (.8665in to 8669(0)
Piston Pin Removal SERVICE LIMIT 22.030 mm (.8673 in)
For piston pin removal, see P/.S‘7'0Nin this sub-
section. Compare measurements to obtain the connecting
rod/piston pin clearance.
Piston Pin Inspection
PISTON PIN RADIAL PLAY
Using synthetic abrasive woven, clean piston pin
from deposits. I SERVICE LIMIT I 0.040|"nm(.0016inI I
Inspect piston pin for scoring, cracking or other
damages. Piston Pin Installation
Measure piston pin. See the following illustration Refer to P/5TONin this subsection.
for the proper measurement positions.
_, I..
R4ODmotr30A A
A. Piston pin diameter
PISTON PIN DIAMETER

21.997 mm to 22.000 mm
NEW (.866 in to .8661 ml
SERVICE LIMIT 21.990 mm (.8657inI
Replace piston pin if diameter is out of specifica-

tions.
rmr2011-061 131
Section 02 ENGINE
Subsection 08 (CRANKCASE AND CRANKSHAFT)
CRANKCASE AND CRANKSHAFT

SERVICE TOOLS
BALANCE SHAFT PLAIN BEARING REM/INST .......................... .. 529 036 094 ....................................... ..1-48
BLIND HOLE BEARING PULLER SET ......................................... .. 529 036117 ....................................... .. 147
CRANKSHAFT PLAIN BEARING TOOL ....................................... .. 529 036 093 ....................................... .. 148
PULLER/LOCKING TOOL ............................................................ .. 529 036 098 ....................... .. 136-137, 152
SERVICE PRODUCTS
LOCTITE 243 (BLUE) ................................................................... .. 293 800 O60 ....................................... .. 147
LOCTITE 5910 ............................................................................. .. 293 800 081 ....................................... .. 149
PETAMO GREASE GHY133N .................................................... .. 420 899 271 ....................................... .. 149
rmr2011 062 133

Section O2 ENGINE
CRANKCASE
8 N-m
(71 lbf-in)
Loctite
243
Loctite _
L O ct I te
5%)” 243
O
t§_ 11 N-m
' (97 Ibf-in)
Engine
6 oil
E
ta.
Loctite 59106 ‘ g
'1 ~11 N~m I 8 N-m
O 6 (97 |bf.in) (71 Ibf-in)
‘ grease 24
Ghy 1330
Engine
0" Loctite
243 6% K '%
Petamo greaseo
G hy 133n I
NEW
/6 11 N-m
Loctite
243
/’.___
= Component must be replaced when removed. 7 Ibf'il1)

rm Q0084] 53-00d_I:|
134 rmr201 1 -062

Section 02 ENGINE
CRANKSHAFT AND BALANCE SHAFT

Petamo
ffi grease
Ghy (133n
25 N-m
Hyatt) II
240 N-m
(177 lbf-ft)
bit’ Engine
Peta mo
grease
I
2 l"l'I
./()0, $4..
6’
oil
G hy 6133n
(i'[1
.
»
0 Petamo
Loctite grease
“J-1%
243 Gh y 1 33n
Petamo
grease
Ghy 133n See tightening procedure
6
Petamo
9 rease Z -—’ 6 Petamo grease
150 |\|.m Ghy133n
/ Ghy 133n
(111 Ibf'ft) Petamo
grease
Ghy 1336
- r I
. » cg) Loctite
O
Q, \ , 243
Pe*62"°.%sa*
y n "1' "" s.~ p
~' '
6
/-
~..-, U
O
2N
5 -m
I 1 8 Ibf' ft)
‘ . r - \.
Petamo
grease ._ 0
Ghv133n so N-m fi*4 11 N-m
= Component must be replaced when removed. (37 IIDf'fIZ) CLOCTIIB 648 i0_(97 II3f'I|'l)
rmrZ00&015-0024:
rmr201 1-062 135

Section 02 ENGINE
GENERAL
NOTICE Always disconnect battery before
working on the engine.
O
52903 E098
Even though many parts do not need to be re-
moved to reach other parts, it is recommended Install timing chain and timing chain drive gears of
to remove these parts anyway in order to inspect rear cylinder, refer to T//I///NG C/-/A/Nin this sub-
them. section.
When disassembling parts that are duplicated NOTE: Ensure to align mark on timing chain inter-
in the engine, (e.g.: timing chain, drive gears), mediate gear with mark on crankcase, then install
it is strongly recommended to note their posi- mating gear on crankshaft.
tion (front/rear cylinder ) and to store them as a
"group". F97

ploded views.
Clean threads before applying a threadlocker. Re- .-
fer to SELF-LOCK/NG FASTENERS and LOCT/TE 7
APP./_/CAT/ONat the beginning of this manual for

procedure.
A WARNING
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pin, etc.) must
be replaced with new ones. rrnr2008-O1 54J76_a
7. Align marks
NOTICE Hoses, cables and locking ties re- Install water pump drive gears, then balance shaft
moved during a procedure must be reinstalled drive gears.
as per factory standards. NOTE: Ensure to align both dots on balance shaft
drive gears.
ENGINE REASSEMBLY
SEQUENCE
NOTE: This procedure describes only the re-
assembly sequence of critical components, which
are important to achieve the proper camshaft tim-
ing for both cylinders. Refer to appropriate topic
in this manual for complete instructions.
After a complete engine tear down,
in order to achieve proper camshaft timing,
the following engine reassembly sequence
must be strictly followed.
Rear Cylinder Reassembly
,
_ Q I inLU)’
Lock crankshaft when connecting rod of rear cylin-

der is at TDC.
REQUIRED TOOL
rmr2008-015-016:6,’ TL‘;
"
‘T W “I
PULLER/LOCKING TOOL (P/N 529 036 098)
1. Align dots of balance shaft drive gears
136 rrnr2011-062
Section 02 ENGINE
Install and torque locking nuts of crankshaft and

balance shaft.
Refer to CYLINDER HEAD AND CYLINDER to re- IQ
install the following components of rear cylinder:
— Piston
— Cylinder
— Cylinder head
— Timing chain guide and chain tensioner
- Balance shaft drive gears of upper balance
shaft.
Reinstall remaining parts of rear cylinder.
D
Front Cylinder Reassembly
NOTICE Rear cylinder reassembly must be rmr200S-015-D26_a
completed FIRST as explained above. 1. Align marks

2. liming chain drive gear
Unscrew the PULLER/LOCKING TOOL (P/N 529 036
098). Refer to CYLINDER HEAD AND CYLINDER sub-
section to reinstall the following components of
Turn crankshaft on clutch side 300° counterclock- front cylinder:
wise. - Piston
Lock crankshaft when connecting rod of front — Cylinder
cylinder is at TDC. — Cylinder head
— Timing chain guide and chain tensioner.
Reinstall remaining parts of front cylinder.
PROCEDURES
DRIVE GEARS
Drive Gear Location
The drive gears are located on the engine clutch
side behind the clutch housing.
rr'nr2008-O15-079_a
TYPICAL - TURN CRANKSHAFT 300° COUNTERCLOCKWISE
NOTICE Keep connecting rod of front cylin-

der in central position when turning the crank-
shaft, to avoid it getting tilted in crankcase.
Install timing chain and timing chain drive gears
of front cylinder, refer to T/M/NG CHAIN in this
subsecnon.
NOTE: Ensure to align mark on timing chain in-
termediate gear with mark on the bearing flange,
then install mating gear on balance shaft.
rmr201 ‘l-O62 137

Section 02 ENGINE
1 6->Q°‘“
1. Crankshaft locking nut
2. Crankshaft spring washer
3. Balance shaft locking nut
rmr2DD8-015-010_,a 4. Balance shaft spring washer
TYPICAL 5. Balancing mass
1. Primary drive gear
2. Balance shaft drive gears Remove primary drive gear.
Remove balance shaft drive gears.
Remove thrust washer.
Remove water pump drive gear.
Remove water pump intermediate gear.
Scribe a mark on timing chain intermediate gear
aligned with the crankcase molded mark, prior to
removing timing chain drive gear.
rmr2008-O15-O1 1_a
1. Water pump gear

2. Water pump intermediate gear
3. Timing chain drive gears, rear cylinder
4. 17ming chain intermediate gear, rear cylinder
Drive Gear Removal

Lock crankshaft at ignition TDC of rear cylinder,
refer to CRAN/(SHAFTin this subsection. rrnrZDCl8-01 5-01 4_a
Remove chain tensioner of rear cylinder. 1. Scribe a mark on timing chain intermediate gear
2. Molded crankcase mark
Remove clutch housing and clutch drum assem-
bly. Refer to CLUTCH (S/I//5) or CLUTCH (SE5) Remove timing chain drive gear.
subsection.
Unscrew crankshaft locking nut.
Remove spring washer.
Unscrew balancer shaft locking nut.
Remove spring washer and balancing mass.
138 rmr201 1-062

Section 02 ENGINE
>1“. \ .r -. . .—
_.). ' T\
F-.1) 1
"7
-‘ "-S ..» I3 ‘i ~ A. ' Balance Shaft Drive Gears
- SKI
‘I; - ug ’~» , _ '1)»
.U;.."‘ 1'-\'“§v7..\&_" ' T:""
The following instruction is only
ts valid if camshaft timing gears of front cylinder
have not been removed before. In this case,
the camshaft of front cylinder is spring loaded
and will turn the balance shaft counterclock-
Ulw-, 2 1 (‘*0 '"-C»-*. wise.
I _.
I‘.
I N'¢1§\\\:§ 2
4 3 Temporarily install balance shaft drive gears in any
position.
Install balancing mass, spring washer and tighten
rmr200B-01 5-O13_a
locking nut to specification.
1. Primary drive gear BALANCE SHAFT GEAR LOCKING NUT TORQUE
2. Balance shaft drive gears
3. Thrust washers 150N'm (111lbf'ft)
4. Water pump drive gear
5. Water pump intermediate gear
6. 17ming chain drive gear Temporary pull up drive gear from crankshaft.
Drive Gear Inspection Turn balance shaft clockwise until marks of drive
gears can be aligned.
lnspect gear tooth for wear or other damage.
If gears are pitted, scored, rounded, cracked or Reinstall balance drive gear on crankshaft to its
chipped, they should be replaced. final position.
NOTE: Balance shaft drive gears and timing chain .1..-
drive gears are paired. Replace balance shaft drive
gears and timing chain drive gears as a set.
‘I -:1»: '41 r)
Drive Gear Installation
cedure, However, pay attention to the following.
NOTE: Crankshaft must still be locked at ignition
TDC of rear cylinder. 1:... _
P
Ensure mark (scribed during removal) of timing
chain intermediate gear (rear cylinder) matches P, T’ ‘T .-an
with the molded mark on crankcase. '5'/T
rmr2D08-015-O15__a
1. Balancing mass
2*-""T-I 2. Balance shaft gear
__ 2 If --
I _1
4‘Q:~#-.-v~-=
rmfZ008-OI5~0‘l4_a
I _ 2.!-"'_._.,._ .7 _ _
1. Mark on timing chain intermediate gear
2. Crankcase molded mark TT
rmr200$015-100_a
NOTICE Wrong position oftiming chain drive 1. Align marks
gears will lead to wrong camshaft timing and 2. Balance shaft driven gear
cause severe engine damage.
rmr201 1-062 139

Section 02 ENGINE
Wrong position of balance shaft

drive gears will lead to wrong camshaft tim-
ing of front cylinder and cause severe engine
damage.
Reinstall remaining parts, use service products
and torque values as described in the exploded
view. ei-
NOTICE To achieve proper camshaft timing,
See the ENG/NE REASSEMBLYSEOUENCE in
this subsection. FFHIZOOB-O15-IO3_3
1. Chain tensioner guide

TIMING CHAIN
Remove timing chain intermediate gear and nee-
"liming Chain Location dle bearings.
The front cylinder timing chain is located on the Remove thrust washer.
engine MAG side behind the magneto cover.
The rear cylinder timing chain is located on the en-
gine clutch side behind the clutch housing.
‘firming Chain Removal (Front Cylinder)
Remove CAMSHAFT T/M/NG GEARS from front
cylinder. Refer to CYL/NDER HEAD AND CYL/N-
DER subsection. m
Refer to MAGNETO AND .S‘7ZlRTER subsection

and remove:
- Magneto cover
— Rotor FIYVZOOB-U1 5-104_a
— Starter drive gears. TYPICAL
1. Timing chain intermediate gear
Remove screws and spring washers securing the 2. Needle bearings
bearing flange. 3. Thrust washer
Remove the bearing flange. Remove timing chain.
Remove distance sleeve.
Q - ' ' _
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rmr2D08-O15-102_a
1. iiming chain
TYPICAL NOTE: Mark the operating direction of the timing
1. Retaining screws
2. Spring washers chain before removal.
. Bearing flange
-ISO.. ) Distance sleeve
Remove chain tensioner guide.
140 rmr2011-062
Section 02 ENGINE
‘liming Chain Removal (Rear Cylinder)

(_.: )
I I I <
Remove CAMSHAFT T/M/NG GEARS from rear
cylinder. Refer to CYL/NDER HEAD AND CYL/N- _~ A i __
DER subsection. \
Refer to CLUTCH (5/1//5)0r CLUTCH (SE5) Subsec-
ll ,_ at ,-,~ ~
tion and remove: Mfg,:3“_ ' \ M", . .; @-
- Clutch housing I3 J~:ii'.-‘nit’; , I
-?1";li'!~- 1 y
— Clutch drum assembly. ~. I‘, ,i¢'Ip\'...
‘,___ .._j ;:;1l‘
m
1 * \. 1. 1
.
Remove primary drive gear and balance shaft "9'-S. "T

--. Lv.'7T"_“ w
‘a
gear. See DR/VE GEARS in this subsection. _.. YT’
@-.1I».(£"-
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Remove screws and spring washers securing the rmr‘2I}08-D1 5-1DB_a
bearing flange. 1. Needle bearings
Remove the bearing flange. 2. iiming chain intermediate gear
3. Thrust washer
Remove distance sleeve.
Remove timing chain.
Ff _’
~ 4 I\_)é
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~. .-u
-
rmr2008-O15-1D6_a ' ?_¥_:F,'>;;';'lT;-.- ‘Lb:-I‘. I
Retaining screws TITIIQOIJB-O15-IO9_5

Spring washers 1. Timing chain
Bearing flange
.4=$~>!\1.~‘ Distance sleeve
NOTE: Mark the operating direction of the timing
Remove chain tensioner guide. chain before removal.
"liming Chain and Drive Gear
Inspection
Inspection is the same for both timing chains and
timing chain drive gears.
NOTE: Always keep the parts of each cylinder as
a group.
Timing Chain
NOTE: Check timing chain on camshaft timing
'1“ it gear for excessive radial play.
Check chain links condition for wear or other dam-
age.
Measure timing chain length. Mark 21 pins on
chain and measure the distance at the outer di-
Remove timing chain intermediate gear and nee- ameter of pins.
dle bearings. NOTE: Ensure to eliminate play in chain while
Remove thrust washer. measuring.
rmr2011-D62 141
Section 02 ENGINE
Q
rmr2008-O15—O2I_a
A. iiming chain length
TIMING CHAIN LENGTH

(DISTANCE OF 21 PINS)
SERVICE LIMIT I 165.2 mm (6.504in)
If chain is excessively worn or damaged, replace it
as a set (camshaft timing gears and timing chain). 1mr2l)0B-015-023
Bearing Flange
INTERMEDIATE GEAR INSIDE DIAMETER
lnspect bearing flange pin for scoring, pitting or
other damages. SERVICE LIMIT I 22.015mrn 1.866716)
Measure pin diameter at the running surface of Replace timing chain intermediate gear if out of
the needle bearings. specification.
NOTE: Timing chain intermediate gear and timing
chain drive gear are paired. Replace as a set.
‘liming Chain Guide and Chain Tensioner
Guide
k
1mr2008—015-Cl22_a
A. Pin diameter
BEARING FLANGE PIN DIAMETER 2

rmrZO0B-O1 5-024_a
SERVICE LIMIT I 15.980 mm (.6291 in) 1. ‘liming chain guide
Replace bearing flange if pin is out of specifica-
tion. Check timing chain guide and chain tensioner
guide for wear, cracks, deforming or grooves
Needle Bearings caused by timing chain.
Check needles for wear or pitting. Replace timing chain guide and/or chain tensioner
Check needle cage for cracks or other damage. guide if groove depth is out of specification.
Replace if necessary. cnoova DEPTH I
1'|ming Chain Intermediate Gear SERVICE LIMIT 1.2mm (.0472 in)
lnspect gear teeth for wear or other damage.
If gear is pitted, scored, rounded, cracked or ‘liming Chain Installation
chipped, it should be replaced. (Front Cylinder)
Measure inside diameter of intermediate gear. The installation is the reverse of the removal pro-
cedure, However, pay attention to the following.
NOTE: Crankshaft must be locked at ignition TDC
of front cylinder, prior to installing timing chain and
timing chain drive.
142 rmr201 1-062

Section 02 ENGINE
To achieve proper camshaft timing, "liming Chain Installation

See the ENG/NE HEASSEMBLYSEOUENCE in (Rear Cylinder)
this subsection. The installation is the reverse of the removal pro-
Fit thrust washer with grease onto timing chain cedure, However, pay attention to the following.
intermediate gear, to avoid dropping it into NOTE: Crankshaft must be locked at ignition TDC
crankcase. of rear cylinder, prior to installing timing chain and
timing chain drive.
"4 I
Y‘! To achieve proper camshaft timing,

See the ENG/NE HEASSEMBLYSEOUENCE in
this subsection.
w‘<‘Q;
’-1 Q~ Fit thrust washer with grease onto timing chain
1"’: 1‘~i intermediate gear, to avoid dropping it into
crankcase.
Q’; ?“§:)."§_<;
\w
Es
‘2"'~'~T‘
\_ ‘‘.‘3;rn\‘
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\‘I‘.
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r,’ \\
. ‘I
'‘Y
“Q‘
Q.
‘
rmr200&D1 5-025_a
3'§
Q
Q,,
Q4 \QA
1. Timing chain intermediate gear fin
2. Thrust washer 1 i 1'fl ’ "*7
’ ‘
1 .- -it.-, /5=1.’ r r
Ensure to align mark on timing chain intermediate I~Q
RX‘
N
gear with mark on bearing flange during installa- —\
9*.3- -{Aw v
Q,
t V
5.’. 'v!
tion. _l T1’
l,!'1'
rmr2ODB-O15-025_8
1. Timing chain intermediate gear

-Q _ 2. Thrust washer
\. Ensure to align mark on timing chain intermediate

gear with mark on crankcase.
rrnr2008-015025,;
7. Align marks
2. Timing chain drive gear
NOTICE Wrong position of timing chain drive rmr20UB-015-0143
gears will lead to wrong camshaft timing and 7. Align mark on timing chain intermediate gear
2. Crankcase mark
cause severe engine damage.
Properly reinstall camshaft timing gears, refer to NOTICE Wrong position of timing chain drive
gears will lead to wrong camshaft timing and
CAMSHAFT 7'/M/NG GEAR in CYL/NDEH HEAD cause severe engine damage.
AND CYL/NDEH subsection.
Properly reinstall camshaft timing gears, refer to
CAMSHAFT T//l///NG GEAR in CYLINDER HEAD
AND CYL/NDE/5’ subsection.
rrn r201 1-062 143
Section 02 ENGINE
CRAN KCASE Remove the oil filter cover and the oil filter.
Remove engine from vehicle, referto ENG/NERE Refer to MAGNETO AND SMRTEH Subsectmn
MOMAL AND /N5‘fi4LLA7'/ON subsection. and remove:
— Magneto cover
Crankcase Disassembly — Rotor
Lock crankshaft at ignition TDC of front cylinder, — Starter drive gears.
refer to CHAN/(SHAF7'in this subsection. Refer to 7'/M/NG CHAIN in this subsection and re-
Remove electric starter from engine. move:
Refer to CYL/NDEH HEAD AND CYL/NDE/5’ sub- — Timing chains
section and remove: — Timing chain drive gears.
— Front cylinder head Refer to DH/l/E BELTAND HEAR WHEELS sub-
— Cylinder section and remove:
- Piston. — Front sprocket.
Unscrew crankshaft locking bolt. Refer to GEARBOX subsection and remove:
Use a 14 mm Allen wrench and turn crankshaft on — Gearbox position sensor (GBPS)
magneto side 300° counterclockwise, then lock it - Shifting mechanism.
at ignition TDC of rear cylinder. Remove the oil duct cover. Discard O-ring.
Remove the snap ring.
Remove the thrust washer.
2'\*
rmr2 O08-D1 5-O27_a
TURN CRANKSHAFT 300° COUNTERCLOCKWISE
Refer to CYL/NDEH HEAD AND CYL/NDER sub-

rmr200S-015-n28_a
section and remove: . O
Oi/duct cover
.
— Rear cylinder head . -ring
Snap ring
— Cylinder s@m~. Thrust washer
— Piston.
NOTE: Before splitting the crankcase, measure
Refer to CLUTCH /.5‘/V/5)or CLUTCH (.S'E5)subsec— crankshaft axial play. Refer to CHAN/(5‘HAFTin
tion and remove: this subsection.
— Clutch housing Remove crankcase screws.
— Clutch plates
— Clutch hub
— Clutch drum.
Remove DH/I/E GEARS, see procedure in this
subsection.
NOTE: Oil pump removal from crankcase is not
necessary, but recommended to see condition of
oil pump (refer to LL/BR/CA 7'/ON S Y8TEM subsec-
tion).
144 rmr2011-062
Section 02 ENGINE
vi} \’__d,1 R
1 ._ . E A. K NOTE: For oil strainer inspection, refer to LUBRI-
Q1‘ - . - .2, CA 7'/ON SYSTEM subsection.
\
,\ Crankcase Inspection and Cleaning
1 < “.41. \r_ I ll ‘. Clean crankcase using a part cleaner.
"?; ,.~_-,'
-._-., .
zen»
_. . 1
l,-'- ’1 ' ' H
. I. Dry crankcase using compressed air.
is Blow out the oil supply orifices and check if they

'\ C 0- ‘I ‘ .--J" ‘ ’ '~ "/72"
i :"1_ 4'" i \"~9/).
' ___ (.20 vrgwir 7 _. _'¢\‘
\?i?_; ~i"+# are not clogged.
A WARNING
O
"‘' N Always wear skin and eye protection. Chem-

rmr2DD8-O‘l5»{132_e icals can cause skin rash, skin burns and se-
1. Screws M6x 65 (qty 13) vere eye injury.
2. Screws M6 x 45 (qty 5)
3. Screw M6 x 30 (qty 1)
4. Screw M6 x 80 (qty 1)
Carefully split crankcase halves by using a soft "‘<~..¢».,1_ _ 4:~.l

~ _ ,.
hammer. ».- - M »- _ .I Ii'*'_' ‘
_, _. ‘I q ‘ -9, 4 ‘
IVUTICE During disassembly, be careful -,_~» _'_

. .- '-f .
A _
. r 1
. ,
not to damage the sealing surfaces of the
crankcase halves.
1‘. .,
' '
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- I in.
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rmr2OCl80‘l 50373
CRANKCASE HALVE -— CLUTCH SIDE
1. Check oil supply orifices
rmr20(JS-O15-U33
Pull crankshaft and balance shaft out of crankcase.

Refer to GEARBOX and remove:
- Gearbox C . -l
- Reverse intermediate gear.
Remove engine oil strainer from crankcase halve 1 "‘f
(clutch side).
l'.”-?-at
"-*‘ . 5%?‘
\ "Q. . ,
rmY2 D08-D1 5-O38_a

'1
"_
fit;*‘@1<.“JO
*>;~
-
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‘.
CRANKCASE HALVE - CLUTCH SIDE

1. Check oil supply orifices
rrn(ZOOB-Oi 503S_B
7. Engine oil strainer
rmr201 1-O62 145

Section 02 ENGINE
. A -* ~. ' _ I I
.:* ' _--— ' -7
.-1rJ-
.'
.5»-‘“
‘es-:.;+.~ . \
‘ .. “-_ ‘i ~
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rI 0
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_.; _-» —-
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9
.1" ’""‘"%'- ‘_ , all» -1

I - 5‘ ,“\. ,‘,_ _ . I
-/i
. ‘- i ' X 7,1 '1 '
g
rrnr2008-O15-039 a
CRANKCASE HALVE — CLUTCH SIDE
grU
‘ -
H
l" i . .
L
‘
l
J
H
_
».
I
:
.
.
rmr2008-O1 5—042_a
CRANKCASE HALVE — MA GNETO SIDE
T. Check oil supply hole 1. Check oil supply hole
Check crankcase halves for cracks or other dam-

age. Replace if damaged.
‘ - u.\ i if
.0" ‘N l 1 Check if oil hose connectors are bent or otherwise
damaged. Refer to OIL HOSE CONNECTORS in
C /1,": I .-“ LL/BF’/CAT/ON SYSTEM subsection if replace-
ment is necessary.
,.<‘i“| i 4'“ Q1 '§_ t
Lubricate ball bearings and check for smooth oper-
/6;‘
ation. Checkfor excessive play and/or pitting. Re-
place if necessary.
Check plain bearings for scoring or other dam-
ages.
rrnr2l]0B-015-U40_a
Measure plain bearing inside diameter and com-
CRANKCASE HALVE —- MAGNETO SIDE
pare with crankshaft/balance shaft bearing journal
1. Check oil supply orifices diameters (refer to CI?ANKSHAFTand BALANCE
SHAF7l. Replace if the measurements are out of
specification.
g_ C
, ‘ . (1
' 2) . . ‘*9 .‘ .
i I ‘
H" » ‘
‘;;‘-
; Q9 I, _
%
" I...'
nn(ZOOB-O15-U413
R
i i-"i@%;a'i-:~
CRANKCASE HALVE — MAGNETO SIDE
~ t”*§_.,i@,..P,. (<7 .,v
‘ 9)!
o
A'ft
o._, I ,'i'=.\._
rmr200B-01 5-O43_a
-if
-__—A
J-—
7. Check oil supply orifices TYPICAL — CRANKCASE HALVE

7. Crankshaft plain bearing
2. Balance shaft plain bearing
A. Measure plain bearing inside diameter — crankshaft
B. Measure plain bearing inside diameter — balance shaft
PLAIN BEARING INSIDE DIAMETER

(SERVICE LIMIT)
CRANKSHAFT 46.035 mm (1 .8124in)
BALANCE SHAFT 32.060 mm (1.2622iI'il
146 rmr201 1-062

Section 02 ENGINE
Crankcase Bearing Replacement NOTE: Sealing ring of clutch shaft ball bearing (on
Always heat crankcase halves up to 140°C (284°F) magneto side) must face outside the crankcase
for removal and installation of bearings. (bearing balls visible from inside).
Always support crankcase halves

properly when ball bearings and/or plain bear-
ings are removed and installed. Damages to
crankcase halves may occur if this procedure
is not performed correctly.
Ball Bearing Removal
Remove screws securing bearings.
rrnr2DDB-O15-047_a
A. Sealing ring
Reinstall bearing screws, apply LOCTITE 243

(BLUE) (P/N 293 800 O60) and tighten to specifica-
tion.
BEARING SCREWS TORQUE
11 Nvm (97|bf-in)
Plain Bearing Removal

rmr200B-015-045_a
7. Bearing screws Mark the partition of the plain bearings on
crankcase halves, prior to removing the plain
NOTE: Prior to removing, take note of the assem- bearings.
bly direction of the ball bearings.
Remove clutch shaft ball bearing from magneto T "Til
side crankcase half. “Fr .l
~*‘_“‘“. ‘I§"*=’_ I 1-cl.
REQUIRED TOOL 1
" - J,‘
‘~u‘i
(P/N 529 036 117)
Press out remaining ball bearings with suitable

N _| ‘J F.
punch.
‘ i
Ball Bearing Installation |
’- *i’_9~ '
'*—_ _,/
1
NOTE: Disassembled ball bearings must be re- . _ 4 0
placed by new ones. "-’*-_._-.:;.. $0lit -"1 '

rmr2008-0150 57_a
NOT/C'E Unless otherwise instructed, never TYPICAL
use hammer to install ball bearings. Use press 1. Partition of crankshaft plain bearings
2. Partition of balance shaft plain bearings
only. 3. Marks
Install NEW ball bearings using a punch. Remove plain bearings with the proper plain bear-
NOTE: install ball bearings in the same assembly ing remover/installer.
direction as previously noted
Slightly oil ball bearings at the outer race to ease
installation.
rmr201‘l-062 147
Section 02 ENGINE
. ’ (‘"7 ‘\ ., I , ‘
REQUIRED TOOL .-.3 .LJ ."¢ -.i- , F;
/.'\__‘l!! ;;. .. " <-_:,' A 1 l
\~ _.. '-. ’ '
CRANKSHAFT PLAIN 4. -_." '1, _, W ' ~'_‘__0‘ . |
CRANKSHAFT BEARING TOOL
(P/N 529 O36 093) __‘___ ‘ -,
_.
.
_ ___..
._=q»
>_
_ _ ,
BALANCE SHAFT PLAIN I’)~
BALANCE SHAFT BEARING REM/INST

3
i-
. |_
(P/N 529 O36 094) _
if
'5-.
‘ -P
PM '
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.__.‘_~
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rmr2008-D15052_a W I C7-‘ ‘F’, I I -A T TH fly‘ T
7. Crankcase half
2. Marking of tolerance group
529035093
CRANKSHAFT PLAIN BEARING REMOVER/INSTALLER
If marking is not visible anymore, measure inside
diameter of crankcase where plain bearing fits.
I
via;
529035094
BALANCE SHAFT PLAIN BEARING REMOVER/INSTALLER
,1 gr ,.__ —\ -L__
, , -_ u ..__.a
_
_
__
Place suitable support sleeve underneath the In

proper bearing seat before removing plain bear- l,_ _.,v, ‘__ _‘ __ A P
ings.
Using a press, carefully push the plain bearings ¢'
7 “'1':
out from the crankcase half inside towards the rmr200E-O15-D53
outside. MEASURE INSIDE DIAMETER OF CRANKCASE
NOTE: During disassembly, make sure not to Use the following table to find proper tolerance
damage the sealing surfaces of the crankcase group of plain bearing.
halves.
CRAN KCASE PLAIN BEARING
Plain Bearing Installation INSIDE DIAMETER TOLERANCE
NOTE: Plain bearings are available in 3 tolerance (CRAN KSHAFT) GROUP
groups (red, blue and yellow). 49.899 mm to 49.908 mm
RED
The proper tolerance group is marked with paint (1.9645in to 1.9649inl
on the crankcase. 49.908 mm to 49.918 mm
BLUE
(1 .9649in to 1.9653 in)
49.918 mm to 49.929 mm
(1 .9653 in to 1.9657 in) YELLOW
CRANKCASE PLAIN BEARING

INSIDE DIAMETER TOLERANCE
(BALANCE SHAFT) GROUP
35.909 mm to 35.918mm
RED
(1.413? in to 1.4141 in)
35.918 mm to 35.928 mm
BLUE
(1 .4141 in to 1.4145 in)
35.928 mm to 35.939 mm
YELLOW
l1.4145in to 1.4149 in)
148 rmr201 1-062

Section 02 ENGINE
NOTICE Unless otherwise instructed, never Carefully press-in the plain bearings in the same
use hammer to install plain bearings. Use direction as during disassembly.
press only. Position plain bearings as illustrated:
Install plain bearings with the same tools as per — Balance shaft plain bearing 1.5 mm (.059 in) be-
removal. low crankcase reference surface.
Fit the plain bearings with PETAMO GREASE GHY — Crankshaft plain bearing 2mm (.O79in) below
133N (P/N 420 899 271). crankcase reference surface.
Use O-ring to hold the plain bearings in place dur-
ing installation.
Place suitable support sleeve underneath the
proper bearing seat before installing plain bear-
ings.
NOTICE The partition of the plain bearings
must be positioned in the same direction as
marked on crankcase halves during removal.
. ....... ,,.,..c ,,.,._M,:..,......Y i;
-3
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,
.
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1
,
.
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'. rmr2011-013-0O7_a
.‘3\.1\.
rs.--,
PLAIN BEARINGS POSITIONING
7. Crankcase reference surface
: ,1 1 _. A. 1.5mm I.059inI
B. 2mm (.O79in)
-, - /
0 ' ‘ , . /
L.‘ . 9 '--
|-_- » I\ .' ' - NOTE: Remove O-ring before completely press-in
. _. ’ ll‘ plain bearings.
\ I.
.;.,__ __ -, Make sure not to damage the sealing surfaces of
‘
. I ls. .97.. -.....m
U -
the crankcase halves.
rmr2008-01 5os7_a
TYPICAL
7. Partition of crankshaft plain bearings
Crankcase Assembly
2. Partition of balance shaft plain bearings
3. Marks
The assembly of crankcase is essentially the re-
verse of removal procedure. However, pay atten-
Mark position of oil orifice on crankcase half tion to the following details.
(magneto side) and on plain bearing installer. Install a new crankcase gasket.
Align mark on plain bearing installer with mark on Coat the plain bearings with PETAMO GREASE GHY
crankcase half.
133N (P/N 420 899 271) before mounting crankshaft
and balance shaft.
‘Q H“ NOTE: Correctly reinstall crankshaft (refer to
CRANKSHAFT).
i I . 5, l'v_,/ .
Q For reinstallation of gearbox and oil seals, refer to
GEARBOX subsection.
r“_\ . _
Apply a seam of LOCTITE 5910 (P/N 293 800 O81) on
the oil strainer to fit into crankcase.
mr 1?’-
rm|20DE|-D15-O58_a
1. Oil orifice position marked on crankcase‘ _
2. Oil orifice position marked on plain bearing installer
NOTICE Wrong oil orifice position will stop

oil supply to plain bearings and will cause en-
gine damage.
rmr201 1 -062 149

Section 02 ENGINE
- ' l‘, On SM5 model, remove magneto cover plug

screw.
\"*&—-4 x
5‘ 4Q .
1
4-P
. ' 1Z
Q 1
l‘|'fll’lDD8‘U'l1-D25_D
7. Apply Loctite 5970 here
lighten crankcase screws as per the following se-

quence.
rmr20UB»015-lJO4_a
SM5 MODEL
‘i’-A . "R “"4- ’\> r= T‘-
1. Plug screw
2. O-ring
M», to t. On SE5 model, remove plug screw on the hy-

draulic control module (HCl\/l) housing.
' El
.\ a
p
.E
E
H-Ygfifitél ‘*‘te
r g.t=>*
rmr2UCl8015-D32_b
TIGHTENING SEQUENCE

NOT/CE To achieve proper camshaft timing,
See the ENG/NE REASSEMBLYSEOUENCE in
this subsection.
CRANKSHAFT rmr2ODB-U53-0O1_a
SE5 MODEL
Crankshaft Locking Procedure 1. Plug screw
2. O-ring
3. HCM housing
The crankshaft must be locked at the
ignition TDC of the respective cylinder for re- Remove M8 screw with sealing ring blocking ac-
moval and installation work on crankshaft, bal- cess hole.
ance shaft and camshaft.
NOTE: Crankshaft can be locked at ignition TDC
for each cylinder separately.
NOTE: The following procedure is valid for both
cylinders.
Remove upper side panels. Refer to BODYsub-
section.
Remove spark plugs.
Remove valve covers. Refer to CYL//\/DE/? HEAD
AND CYL/NDEF’ subsection.
150 rmr2011-D62
Section 02 ENGINE
Subsection O8 (CRANKCASE AND CRANKSHAFTl
rmr20U8—0'l 5~1 10_a

SM5 MODEL 068015006
1. Access screw “"2 -“
2. Clutch cover SM5 MODEL
1. Allen wrench
;-
R‘. 1
rm'2o08_n53_°a2 3 rmr2008-O53-003,3
7_ Access screw 1. Allen wrench

2. Sealing ring
3. Clutch cover NOTE: When piston is at ignition TDC, the printed
marks ("lN" and "EX") on the camshaft timing
Turn the Crankshaft um“ the Piston is at the igni' gears must be aligned, as shown in the next illus-
tion TDC of the respective cylinder. nation
REQUIRED TOOL
14 MM ALLEN WRENCH
_%.~-‘J
3
.F~*Tiil=*t*fil
"T172008-01 5-007_a
TYPICAL
7. Align marks
rmr201 1-D62 151

i i
Section 02 ENGINE
Use a small screwdriver to check if the groove in NOTICE Components with less than the ser-
the crankshaft is aligned with the hole. vice limit always have to be replaced. lf this is
not observed, severe damage may be caused
to the engine.
Crankshaft Axial Play
NOTE: Axial play needs to be measured before
splitting the crankcase.
Measure play on PTO end, using a dial indicator.
rmr20D3-01 5-0O8_a
TYPICAL
7. Screwdriver
Lock crankshaft.
REQUIRED TOOL rmr200B-01 5-031
PULLER/LOCKING TOOL (P/N 529 O36 O98) CRANKSHAFT AXIAL PLAY

SERVICE LIMIT | 0.7mm (.0276in)
If play is out of specification, replace crankcase
and/or crankshaft.
529036058 Crankshaft Radial Play (MAG/Clutch Side)
Measure crankshaft journal on MAG/clutch side.
rmr2 008-01 5-O64_a

rmr200EH115-ClO9_a
TYPICAL 7. Mlcrometer
1. Crankshaft locking bolt 2. Crankshaft area for clutch side plain bearing
Crankshaft Removal
Refer to CRAN/<CASEin this subsection.
Crankshaft Inspection
NOTE: Check each bearing journal of crankshaft
for scoring, scuffing, cracks or othersigns of wear.
152 rmr2011-062
Section O2 ENGINE
NOTE: Refer to CLUTCH (S/Wflor CLUTCH (SE5)

‘lei subsection.
CRANKSHAFT RADIAL PLAY
(CLUTCH SUPPORT BEARING)
SERVICE LIMIT | 0.065 mm l.oo2ami
Crankshaft Installation
1 Do not mix up the connecting rods of front and
rmi'200B-0 1 506 5_a rear cylinders during installation.
1. Micrometer
2. Crankshaft area for MAG side plain bearing Observe the correct installation po-
sition when fitting the crankshaft with the con-
CRANKSHAFT BEARING JOURNAL necting rods. The connecting rod clutch side
iMAGICLUTCH SIDE) must to face to front cylinder.
SERVICE LIMIT ‘ 45.955 mm (1 .8093in)
To obtain the radial play:

— Compare crankshaft bearing journal to inside di-
‘Zii
ameter of side plain bearing in crankcase.
ifP7
NOTE: Refer to CHAN/<CA5'Ein this subsection.
SERVICE LIMIT l
CRANKSHAFT RADIAL PLAY
lMAGlCLUTCH SIDE)
0.06 mm (.OO24inl
i-
' '3’-. (
rte-st’ r
)sh.
Crankshaft Radial Play V\ ‘I
(Clutch Support Bearing Side)
rmi2DDB-D15-070_a
Measure the crankshaft bearing journal that in- 7. Crankcase half MAG side
serts in the clutch support bearing. 2. Connecting rod front cylinder
3. Connecting rod rear cylinder
CONNECTING RODS
Connecting Rod Big End Radial Play
NOTE: Prior to remove connecting rods from the
crankshaft, mark assembly direction (front cylin-
der and rear cylinder, magneto and clutch side)
and big end halves together to ensure a correct
reinstallation.
Remove connecting rods from crankshaft.
Always replace connecting rod
rmQODB—O15-0fiE_a
screws if removing the connecting rod. It is
1. Micrometer
2. Crankshaft journal (clutch support bearing) also recommended to replace plain bearings,
within an overhaul of the engine.
CRANKSHAFT BEARING JOURNAL
, (CLUTCH SUPPORT BEARING]
SERVICE LlMlT i 29.970 mm ll .l799lnl

- Compare crankshaft bearing journal to inside di-
ameter of plain bearing in clutch housing.
153
rmr2011-062
Section 02 ENGINE
CRANKSHAFT PIN DIAMETER

T-r .:~-»-\ SERVICE LIMIT .
41 960 mm (1 652ll'lI
1 q CONNECTING ROD BIG END DIAMETER
\\- --r’ i SERVICE LIMIT I 42.080 mm (1.6567in)
8 CONNECTING ROD BIG END RADIAL PLAY
vriir2007-037-OU3_a IWITH USED PLAIN BEARINGI
TYPICAL SERVICE LIMIT I 0.07 mm (.0O28in)
1. Connecting rod screws
Clean crankshaft oil orifices and make sure they NOTE: Use NEW plain bearings, when connect-
are not clogged. ing rod big end radial play is out of specification.
Measure crankshaft pin. Compare to inside diam- Connecting Rod/Piston Pin Clearance
eter of connecting rod big end.
Refer to CY/./NDEH HEAD AND CYL/NDEH sub-
section.
»—2 Connecting Rod Installation
For assembly, reverse the disassembly proce-
dure. However, pay attention to following.
Put NEW plain bearings correctly in place and
clean the split surface on both sides carefully
with a clean rag.
§._\ Vi 14 2
.-" '_ P,’ ': _ I
rmi20084115~Ol'>3_a ,."“~ _\ I __
1. Microrneter
2. Crankshaft pin area for plain bearing
To measure the connecting rod big end diameter, 1 ‘V

leave the OLD plain bearings in place.
Install the connecting rod cap and follow the
torque procedure as described in CRANKSHAFT
\»
rri-ir20i]E-O15-lJE7_a
ASSEMBLI/further using the OLD connecting rod 1. Half plain bearing of connecting rod big end
screws. 2. Split surface of the connecting rod
3. Nose of plain bearing in line with connecting rod groove
NOTE: Secure the connecting rod in a vise with
aluminum jaws. Lubricate the plain bearing surface of the connect-
Measure connecting rod big end diameter. ing rod and crank pin before installation.
Q]
NOTICE Properly reinstall connecting rods in
the same assembly direction as marked during
removal.
Printed marks on connecting rod and cap must
point together.
_- €
vrn r2 U06-O44 -O39_
TYPICAL
A. Connecting rod big end diameter (plain bearing in place)
‘I54
rrrir2011-062
Section 02 ENGINE
CONNECTING ROD SCREWS TIGHTENING

SEQUENCE
STEP ‘l 2 Nem (I8 lbfeinl
,’“\ 1 ' '~ ,.= .. STEP 2 30 N°m I22 |bf°ftI
Q I -7 I‘ T-
STEP 3 75°
rmr200E-01 5—Cl5E_a
1. Printed marks
Install connecting rods on crankshaft in a way that

stamped part numbers face together.
1-_
rmr2008-O15-DE9_a
1. Angle torque wrench
NOTICE Failure to strictly follow this proce-

dure may cause screw to loosen and lead to en-
1}~
T‘(I~__| gine damage.
i’-' .4 BALANCE SHAFT
all
, “ .4’ -' . . '1
Balance Shaft Location
rmr2Cl1CH]t3-001_a
1. Stamped marks on connecting rods facing together
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rrrir20080154l71_a
1. Balance shaft
I , .
2. Crankcase MAG
,- " ‘ ,, i
-‘ ' ' "I
. __,..._;.._
rmr2Ul0-DIB-002
. .. . .0! Balance Shaft Removal
TYPICAL - STAMPED MARK Refer to Cl-?ANKCA$Ein this subsection.
NOTICE Always use NEW connecting rod Balance Shaft Inspection
screws for the final assembly of the crank- NOTE: Check each bearing journal of balance
shaft. shaft for scoring, scuffing, cracks or other signs
Apply oil on head of NEW connecting rod screws of wear.
and tighten as per following procedure: Clean balance shaft oil orifices and make sure they
NOTE: Always perform a step on both connecting are not clogged.
rod screws before going to the next step.
155
rmr201 1-062
Section 02 ENGINE
BALANCE SHAFT RADIAL PLAY

(MAG/CLUTCH SIDEI
SERVICE LIMIT I 0.06 mm (.0024 in)
i» ‘I (‘J _‘ C‘ ’
Balance Shaft Radial Play
"i I‘I"“ (Clutch Support Bearing Side)
Measure balance shaft bearing journal on clutch
side (support bearing).
1. Clean oil orifices
Balance Shaft Radial Play (MAG/CLUTCH

Side)
Measure balance shaft bearing journals on
MAG/CLUTCH side.
/—‘I
rrrir2(JO84Z)1 50‘/5_a
1. Micrometer
2. Bearing journal — clutch support bearing
2 BALANCE SHAFT BEARING JOURNAL

(CLUTCH SUPPORT BEARINGI
rmiQOU8-0i&O73_a SERVICE LIMIT I 19.990 mm (.787inI
7. Micrometer
2. Bearing journal — MAG side To obtain the radial play:
— Compare balance shaft bearing journal to inside
diameter of plain bearing in clutch housing.
._ '*
NOTE: Refer to CLUTCH (SM5/or CLUTCH (SE5
subsection.
3‘ BALANCE SHAFT RADIAL PLAY
(CLUTCH SUPPORT BEARINGI
SERVICE LIMIT I 0.06 mm (.0O24in)
Balance Shaft Installation

rmr2OUB-0154)74_a cedure.
1. Micrometer
2. Bearing journal — clutch side
BALANCE SHAFT BEARING JOURNAL

(MAG/CLUTCH SIDEI
SERVICE LIMIT I 3l.980mm(1.2591in)
— Compare balance shaft bearing journal to inside
diameter of plain bearing in crankcase.
NOTE: Refer to CFi’ANKCASEin this subsection.
156
rmr201 1 O62
Section02 ENGINE
Subsection09 (CLUTCH (SM5))
CLUTCH (SM5)
SERVICE TOOLS
BEARING PUSHER/REMOVER ............... .. 529 O36 O95 ....................................... .. 186
BEARING PUSHER .................................. .. 529 O36 096 ....................................... .. 186
BLIND HOLE BEARING PULLER SET ..... .. 529036117 ....................................... ..185
CLUTCH ASSEMBLY HOLDER ............... .. 529 O35 618 ....................................... ..187
ECM ADAPTER TOOL ............................. .. 529 036166 ....................................... ..173
FLUKE 115 MULTIIVIETER ...................... .. 529 O35 868 ............................... .. 172-173
VACUUM/PRESSURE PUMP .................. .. 529 O21 800 ............... .. 165-166, 169, 173
SERVICE PRODUCTS
BRAKE FLUID .......................................... .. 293600131 ....................................... ..163
LOCTITE 243 (BLUE) ............................... .. 293 800 O60 ............................... .. 176, 180
LOCTITE 648 (GREEN) ............................ .. 413 711400 ............................... ..189, 192
PETAMO GREASE GHY133N ................ .. 420 899 271 ............................... .. 187-188
PULLEY FLANGE CLEANER ................... .. 413711809 ....................................... ..185
rmr2011 063
157
Section O2 ENGINE
'
Subsection09 (CLUTCH( SM5))
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158
rmr2011-063
Section 02 ENGINE
i i
I I
11 N_m Loctite _
(97 lbw“) 243 Brake fluid
6 N-m
E2/
(53 lbf~in)
.. Brake fluid
15 N' IT)
(133 Ibf-in) Loctite
243
Brakeé
L Q./°
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fluid
»- °&z Brake
fluid
‘I5 N-m
(133 lbf-in)
19 N-m
has lbf-in) w
11 N-m
(97 lbf-in)
Ag; <3
6 Petamo
Petamo grease
grease Ghy 133n
Ghy 133n
rmr200B-D1 6001_d
159
rrnr2011-063
Section 02 ENGINE
11 N-m
(97 lbf-in)
‘\/ .1.
Engine oil
I 1- W!‘
Engine oil
4?
190 N-m
(140 lbf-ft)
Loctite
648
Petamo
grease
Ghy 133n
I rmr20114114-1 OO_a
‘I60
rmr201 1 U63
Section 02 ENGINE
Subsection 09 (CLUTCH (SM5))
___i_ii__i__\
QT)utch with 1 spring disc \ \ \

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rmr201)-O14-IUIJ
rrnr2011-063
Secti0nO2 ENGINE
GENERAL
NOTE: For a better understanding, many of the
following illustrations are produced with the en-
gine out of vehicle. To carry out the instructions, ,iire,; 0
it is not necessary to remove the engine from ve-
hicle.
Always disconnect the battery negative cable be-
fore working the engine.
NOTICE Always disconnect BLACK (-) cable
*0
first and reconnect last.
During assembly/installation, use torque values
and service products as specified in the exploded
views. rrrir2D0 B-01 5-001 _c

fer to SELF-LOCK/NG FASTENERS and LOCTITE A diaphragm assists the hydraulic system in dis-
APPL/CA7"/ONat the beginning of this manual for placing the pressure plate to disengage the clutch.
complete procedure. The diaphragm is activated by vacuum applied
through an electronically controlled solenoid valve
A WARNING (controlled by the ECM).
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced with new ones.

Avoid spilling brake fluid on plastic,
rubber or painted parts. Protect these parts
with a rag when servicing the hydraulic clutch
system.
NOTICE Sealing washers must be discarded
and replaced with new ones every time a Banjo rn1r2lJO8-016-‘|22_a
fitting is unscrewed. TYPICAL

1 . Sole-no id
Vent to atmosphere
Periodically check the clutch hoses for damages Check valve
or leaks. Repair any damages or leaks. :§F~1.'\> Vacuum to clutch release servo
When the clutch lever is depressed and the en-
SYSTEM DESCRIPTION gine is running, the ECM modulates the clutch
solenoid valve to provide a variable assist to the
The engine on the SM5 model features a hydrauli- clutch.
cally operated pneumatically assisted type clutch
system. The pneumatic assist will vary according to throt-
tle position and to the engine RPM up to approxi-
mately 4000 RPM. Beyond that, there will not be
any pneumatic assist.
— The lower the engine RPM, the greater the as-
sist will be.
— The lesser the throttle opening, the greater the
assist will be.
162 rm r201 1-063

Section02 ENGINE
A check valve is used to allow only vacuum pulses

to go towards diaphragm. Therefore, its orienta-
tion is important for proper operation.
3'»?
, ;=»"‘ _F i‘._
rmoZD‘l (H301 4305
Carefully remove reservoir cap. Pay attention not

to drop the seal.
rmr2008-01 5-123,3
~ J Check clutch fluid level inside the reservoir:
- The fluid must be on the fill level line.
When the clutch solenoid is not activated, the di-
aphragm vacuum hose is opened to atmospheric
pressure which allows the diaphragm to return to
its free position.
NOTE: A damaged diaphragm will cause engine
oil to be drawn into the air intake from the clutch
area. The burning engine oil will produce blue
smoke out of the exhaust system. /"AT '
MAINTENANCE
CLUTCH FLUID
Recommended Clutch Fluid
rmo20‘l0-001-0U6_b
Use only DOT 4 BRAKE FLUID (P/N 293 600 131) or FLUID REMOVED FOR CLARITY PURPOSE
equivalent. 1. Fill level line
To avoid serious damage to the lf the fluid level is lower than specified, add fluid to
hydraulic clutch system, use only brake fluid the reservoir up to the fill level line. Do not over-
of the recommended type from a sealed con- fill.
tainer. Do not use fluid from an old or already
opened container, nor mix different fluids for A WARNING
topping up the system. Avoid getting brake fluid on skin or in eyes,
it may cause severe burns. In case of con-
Clutch Fluid Level Verification tact with the skin, wash thoroughly. In case
Ensure vehicle is on a level surface. of contact with the eyes, immediately rinse
with plenty of water for at least 10 minutes
Set the handlebar in order to position the top of and then consult a doctor immediately.
clutch fluid reservoir horizontally.
Wipe clean the reservoir cap area. NOTE: A low level may indicate leaks or worn
Remove retaining screws of reservoir cap using a clutch discs.
Phillips screwdriver. Reinstall the reservoir cover.
Ensure seal is located inside reservoir cap and the
seal is completely collapsed.
rmr201 1-063 163
Section02 ENGINE
Clutch Fluid Replacement +4
Clutch Fluid Draining

Remove the following RH body panels, refer to
BOD)/subsection: l 6" A
— Top side panel
— Rear side panel.
Remove clutch reservoir cover screws. Do not re~
move cover at this time.
rrnr2OOB-0151 17_a
TYPICAL
Depress and release the clutch lever several times

until no more fluid flows out of bleeder.
rmD20‘l0~OU1-O05
NOTICE Leave cover on reservoir to avoid

spillage during the following procedure.
Connect a clear hose to the clutch bleeder on the
clutch cover.
Insert the other end of the hose in an appropriate
container (such as an empty break fluid bottle).
rrnr20OB~O16-113_a
TYPICAL
‘lighten bleeder.
rmr20U8-016416
TYPICAL
Loosen the clutch bleeder.
164 rmr201 1-osa

Section02 ENGINE
525021 B00
l|'flf2UQ8-U15-'l'l7_b
TYPICAL
Clutch Fluid Filling

Remove reservoir cover.
Turn handlebar fully on right side.
NOTE: Turning the handlebar will help the bleed-
ing process.
Fill reservoir with the HECOMMENDED CLUTCH
FLU/D.
Ensure that clutch fluid reaches the fill level line.
rmr20t1E{l21-015500
Bleed system using the CLUTCH FLU/D BLEED- TYPICAL - PUMP AND msrvrors RESERVOIR INSTALLATION
/NG US/NG A PUMP /SYSTEM COMPLETELY
EMPTY) procedure. Add recommended fluid in the pump remote
NOTE: If a pump is not available, use the CLUTCH reservoir.
FL U/D BLEEDING W/THOUTA PUMP procedure. Set pump to the PRESSURE position.
Loosen clutch bleeder.
Clutch Bleeding Procedures
Clutch Fluid Bleeding using a Pump (System
Completely Empty)
NOTE: If the system is completely empty, it is
easier to bleed the system by pushing the fluid )
from the bleeder to the reservoir. Use the follow-
ing procedure.
Install the VACUUM/PRESSURE PUMP (P/N 529 O21 ,/T.”
800) and the remote resen/oir onto the clutch
bleeder with a clear hose.
rrnr200B-016-1 l 7_a
TYPICAL - LOOSEN CLUTCH BLEEDER
rmr2011-063 165
SectiOnO2 ENGINE
Activate the pump lever several times until "="=~—~ —-N

fluid reaches the clutch reservoir. Then, tighten I
bleeder.
NOTICE Do not overfill reservoir.
-f-.ef-J:-ix; _ flf§i[iT ;;;'.u.- s;
529021800
rrriQO08-021018-501
ACTIVATE PUMP UNTIL FLUID REACHES CLUTCH RESERVOIR
rrnK£0O8-021016500
t-,'fi'i"“if
Q
TYPICAL - PUMP AND REMOTE RESERVOIR INSTALLATION
/I ,"
Set pump to the VACUUl\/l position.
Loosen clutch bleeder.
rrr\r2008-n1&117_b
TYPICAL — T/GHTEN CLUTCH BLEEDEH

T Iv-_
__/‘v-'_ $5'
Depress clutch lever several times. If it feels
spongy, bleed system again using the CLUTCH
FL U/D BLEEDING USING A PUMP (SYSTEM
NOT COMPLETEL YEMPTY) procedure.
Top up fluid reservoir.
Install cover on reservoir.
Clutch Fluid Bleeding using a Pump
(System not Completely Empty) rrrir2ODB{l16-117_a
Install the VACUUM/PRESSURE PUMP (P/N 529 021 TYPICAL - LOOSEN cturc/4 BLEEDER
800) and the remote reservoir onto the clutch
bleeder with a clear hose. Depress and release the pump lever several
times until no more air bubbles flow out of
bleeder. Then, tighten bleeder.
‘I66 rmr201 1 -D83

Section 02 ENGINE
NOTE: Check the clutch fluid level in reservoir of-

ten to prevent air from being drawn into the sys-
t€n'1.
rmr20OB-016-1 16
TYPICAL
rmr?.D(J8-021-016-501
ACTIVATE PUMP UNTIL NO MORE AIR COMES OUT

Loosen the clutch bleeder.
. J,
rrnr2OOH-018-117__a
rmiaooa-01 er 17_b
TYPICAL
TYPICAL ~ TIGHTEN CLUTCH BLEEDER
Depress clutch lever several times. If it feels Depress the clutch lever until it reaches the end
spongy, repeat procedure until system is entirely of its stroke.
bled of trapped air.
Top up fluid reservoir.
install cover on reservoir.
Clutch Fluid Bleeding without a Pump
NOTE: If a pump is not available, use the follow-
ing procedure.
Connect a clear hose to the clutch bleeder.
Insert the other end of the hose into a clean con-
tainer containing enough new brake fluid for the
end of the hose to be submerged.
rmr201 1-063 167

Sect|on02 ENGINE
rmr2DDE01 6-1‘l0_D
TYPICAL
‘lighten the clutch bleeder IMPORTANT: Do not release clutch lever until
bleeder has been tightened.
Repeat this sequence of depressing lever and
loosening/tightening bleeder screw until no more
air bubbles appear in hose.
NOTE: Check fluid level often to prevent air from
being pumped into the system.
Depress clutch lever several times. if it feels
1CI=~—
\’\ spongy, repeat the procedure until system is
entirely bled of trapped air.
Top up reservoir.
Install cover on reservoir.
INSPECTION
CLUTCH OPERATION TEST
Pneumatic Assist Quick Test
With the engine not running, depress the clutch
Release the clutch lever lever a few times.
Note clutch lever resistance.
rmr2D11-D63
SectionO2 ENGINE
52 902 1 BOO
rmr2Cl0B-O16-110_a
TYPICAL
Start engine and let run at idle.

Depress clutch lever a few times.
Compare lever resistance with and without en-
gine running. I _
Lever must be easier to depress when the engine

is running. Otherwise, carry out a l44CUUMLEA/(
TEST
Vacuum Leak Test
Disconnect vacuum hose from clutch cover fit-
ting. rmr2OGE-016-125
TYPICAL
Set the pump to vacuum and activate its lever sev-

eral times until vacuum specified in the following
table is obtained.
VACUUM LEAK TEST
VACUUM TIME WITHOUT LEAK
25 in Hg 30 seconds
If vacuum leaks, check the following:

— Clutch cover screws for tightness
— iightness of diaphragm nut
- Diaphragm.
lf the vacuum leak test was good, check the
vacuum-assist components.
rmr200B-016-124_6 NOTE: lf there is no clutch assist or only partial
assist, the check valve should be suspected.
Install the VACUUM/PRESSURE PUMP (P/N 529 021
800) onto the clutch cover vacuum hose fitting. Remove the vacuumlpressure test pump and
hose.
Install the system vacuum hose on the clutch
cover and secure it as specified in the exploded
VIGW.
rmr201 1-O63 169

Section 02 ENGINE
Hydraulic Operation Test

Remove hydraulic clutch piston cover.
rrnr2Dl]8-D15-12‘l_l)
2 1//-FIB
J. Again, observe the hydraulic piston position.
qgw=q;;~<~.-—- - -—;-—,—- --.—-
rmr2ODB-01 6-D033
7. Screws
2. Clutch piston over
||P" C _
Observe the hydraulic piston position. '3'-ii.l~ I
rmfZD08~O16-1 12_a
MOVEMENT OF CLUTCH HYDRAULIC PISTON
It should move outwards approximately 2mm

(.O79in).
NOTE: Ensure clutch lever adjustment is set to
rmf2OD8-016l11_a allow maximum piston stroke. Also, piston must
CLUTCH HYDRAULIC PISTON maintain its position as long as clutch lever is held
depressed.
Fully depress clutch lever and hold.
lf clutch piston does not maintain its position
while clutch lever is depressed, check the hy-
draulic components.
110 rmr2011-O63
Section02 ENGINE
TROUBLESHOOTING Place master-cylinder reservoir over a drain pan.

Remove the retaining screw and clutch fluid hose
RATTLE AT IDLE oa DURING CLUTCH from the master cylinder.
ENGAGEMENT
1. Check clutch drum and clutch dampener parts IT“ 1*
(spring disc(s) and thrust washer) for any wear.
*~\'\_ _ I‘-:‘_:.\ ‘Ls .
- Replace defective parts in accordance with clutch - _' Q \~__~;:\ V I 1
layout.
OVERHEATEDNVORN CLUTCH PLATES
AND/OR OVERHEATED DIAPHRAGM
1. Faulty pneumatic clutch assist.
- Check CLUTCH SOLENOID VALVE (CSV).
rrnr200B-028-030_a
PROCEDURES TYPICAL
1. Remove screw
CLUTCH LEVER Empty reservoir into drain pan.

Clutch Lever Inspection Tie off clutch hose to handlebar to avoid spillage.
Check clutch lever for cracks or other damages. NOTICE Be sure to protect all pans from the
Replace as required. brake fluid as it will strip the finish off parts.
Clean off any spillage immediately.
Clutch Lever Replacement Discard sealing washers.
Remove screw and nut retaining the clutch lever. Remove clutch switch. Refer to STARTING SYS-
Remove clutch lever. TEM subsection.
Installation is the reverse of the removal. Remove master-cylinder.
MASTER-CYLINDER Master-Cylinder Installation

Master-Cylinder Removal dure, however pay attention to the following.
Drain fluid from clutch system. Refer to CLUTCH If clutch fluid hose was disconnected:
FLU/D REPLACEMENTprocedure in this subsec- - Replace both sealing washers on clutch hose
tion. fitting.
Loosen screw retaining clutch fluid hose to reser- — Bleed clutch system. Refer to CLUTCH FLU/D
voir. in MAINTENANCE in this subsection.
NOTE: Do not remove screw at this time to avoid
spillage. CLUTCH SOLENOID VALVE (CSV)
Remove screws retaining master-cylinder to han-
dlebar. CSV Test with B.U.D.S.
Connect to the lastest B.U.D.S. software, refer to
.1”-' COMMUNICATION TOOLS AND B. U.D.S.
Select the Read Data button.
. E I‘ , I \’ ' : -_ '_ 7 ' _ _' T
Select the Faults page tab.
—- \ --5 ‘yb ' = - '
I‘ _-'-"-ta-11.:-\\f”“‘E‘IIlr
ll) I I.»-‘I - : V‘ \ Check for fault codes.
1 ;II!l‘
- - r ,' ' P"-I *
i\\ ~lIIr‘.I‘_‘.II,ll.I-I.l.II1-I-l ‘ff!-" _ I-(, _'. To test the solenoid valve operation, select the
\ / ‘ I .~ ~ 7 A4 \ 1‘ ,>
Activation page tab and confirm you are on the
Q ‘ ' '1, I ‘ '~ . ECM page.
(II AII11. "IE, .- . . I
rmr2008»D28-029_a Activate the clutch solenoid valve by selecting the
TYPICAL solenoid symbol.
1. Screws
rmr201 H163 171

Section02 ENGINE
¢ . ~ :4»: I my-., -VI-zw I I» -mm, I
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y 1 ....
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rrnr2008-016-D8La
7. Activate here rmr2008-054-003_a
CSV INPUT VOLTAGE TEST
This will validate the clutch solenoid mechanical
and electrical operation. If voltage is out of specification:
If the solenoid valve works, check clutch compo- - Check fuse F12.
nents. — Carry out a CSI/CIRCUITCONT/NU/TY TEST
If the solenoid valve does not work, proceed with If voltage is correct:
a voltage test. — Carry out a CSVRES/STANCE TEST
CSV Input Voltage Test CSV Resistance Test
Remove the RH upper side panel, refer to the Disconnect clutch solenoid valve connector.
BODYsubsection.
Set the FLUKE 115 MULTIMETER (PIN 529 035 868)
Disconnect the clutch solenoid valve connector. to Q.
Turn ignition switch to ON. Measure the clutch solenoid valve resistance as
follows.
CSV RESISTANCE TEST
EN I I
TEsT PROBES RESISTANCE
20°C (68% @
I‘ If E
-. ‘C.-. ".'7'I*f
;?T
Silt N .‘
t\.-I
IT"
\
Solenoid pins 1 and 2 23 1 1.2 Q
\ 1 _ I W‘ I 1)“ ‘- H I
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rmr2UO&O1S-0B4_b
1. Clutch solenoid valve connector

2. Clutch solenoid valve
Set the FLUKE 115 MULTIMETER (PIN 529 O35 868)

to Vdc setting.
CSV INPUT VOLTAGE TEST
TEST PROBES VOLTAGE
rmr2005054-IJOZJ
Clutch solenoid
valve connector Battery ground Bafitery If resistance is out of specification:
Pin 2 "° age - Replace the clutch solenoid valve.
lf resistance is good:
— Carry out a CSV CIRCUIT CONT/NU/TY TEST
172 rmr2011-063
Section02 ENGINE
CSV Circuit Continuity Test Cut Oetiker clamps and remove hoses from clutch
Connect ECM connector A on the ECM ADAPTER valve solenoid.
TOOL (PIN 529 036 166). NOTE: Mark hoses location for reinstallation.
Set the FLUKE 115 MULTIMETER (P/N 529 O35 868)
to Q.
Clutch Solenoid Valve Installation
Measure the circuit continuity resistance as fol- For installation, reverse the removal procedure.
lows.
CHECK VALVE
CSV CIRCUIT CONTINUITY TEST
(CLUTCH SOLENOID VALVE)
TEST PROBES @RESISTANCE
we (68% Check Valve Removal
Clutch solenoid Fuse F12 Remove the air filter housing. Refer to A/R IN-
connector Front fuse box 734/(E SYSTEM subsection.
pin 2 contact A-9 Cut Oetiker clamps retaining the check valve.
_ Close to O Q
Clutch solenoid ECM_A
°°"l‘e°t°’
pin 1
Contact L-3
If resistance is out of specification:

— Repair or replace wiring/connectors.
If resistance is correct, check for the following:
- An obstructed vacuum hose
- A stuck solenoid valve plunger
- A malfunctioning clutch solenoid check valve. \
Repair or replace as applicable.

rrnr2DUB016-082_a
Clutch Solenoid Valve Removal 1. Oetiker clamps
Remove the RH top side panel. Refer to the 2. Check valve
BODYsubsection. Remove the check valve.
Disconnect clutch solenoid valve connector.
Remove screws securing clutch solenoid valve to Check Valve Inspection
support bracket. Using the VACUUM/PRESSURE PUMP (PIN 529 021
800), test the check valve operation.
I l
529021300
rrni’ZO08-054»001_a
1. Solenoid valve
Check Valve Installation
2. Solenoid connector Install the check valve with the flow arrow point-
3. Vacuum hose from throttle body
4. Vacuum hose to clutch housing ing towards the throttle body.
Install NEW Oetiker clamps.
rmr2011-063 173
Section 02 ENGINE
.,_..g,__,,_.,.\
NOTICE Hold the clutch release shaft with

X3 the Allen wrench to avoid twisting and dam-
aging the diaphragm.
Squeeze clutch lever a few times to push hy-
draulic piston out of the clutch cover.
-1 Remove compression spring.
Ir“ - ‘_¢
rmr2008-O16-OBI-l_a
1. F/ow arrow towards throttle body
HYDRAULIC PISTON
Hydraulic Piston Removal 1
I’C
Remove hydraulic piston cover screws.

rmr2OOB-C11 &O53_a
1. Hydraulic piston
2. Compression spring
Hydraulic Piston Inspection

Clean piston with new brake fluid.
Visually inspect piston surface for scoring,
scratches or abnormal wear. Replace if nec-
essary.
rmr2008-01 6-051_a
7. Screws
2. Hydraulic piston cover
Using a 17 mm deep offset wrench, unscrew the

hydraulic piston nut while holding the clutch re-
lease shaft with a 5 mm Allen wrench. The di-
aphragm must not twist.
rmr2008-01 5-OO9_6
.- ,- ,-.1; 1. Check piston surface
Compression Spring
Check free length of compression spring.
rm r2008-D1 5-052
174 rmr201 1-063

Section02 ENGINE
Lift and safely block RH front of vehicle to prevent

_._n~-J
engine oil leakage when removing components (if
._____. -_ . . servicing clutch cover in vehicle).
0... "~ '-
vT(,¢?t.-£21" -’*= ~ --’»=~ ~\..::.~ -1.“-. 1:1 mitt.
’
I. | ‘i
' .
rmr20080lB-010
COMPRESSION SPRING FREE LENGTH

37.10 mm to 42.90 mm
NEW (1.461 in to 1.689in)
SERVICE LIMIT 35.00 mm (1.378inl
If the compression spring is out of specifications, rm|’2UDE-018-iJ51_a
replace it. 1. Screws

Hydraulic Piston Installation Secure hydraulic piston with a large washer and
Replace piston O-rings with NEW ones. a piston cover screw to retain the piston in the
Coat hydraulic piston and O-rings with new brake cylinder and avoid clutch fluid leakage.
fluid.
Install piston with compression spring into hy-
draulic cylinder.
-__ ‘.,s.. . g .
-l_
rm r2 008-01 (:1-053,3 rrnr200B-01S100_a
1. Hydraulic piston PISTON SECURED WITHA LARGE WASHER AND SCREW

Install hydraulic piston cover. hydraulic piston nut while holding the clutch re-
Bleed clutch, refer to CLUTCH FLU/D in this sub- lease shaft with a 5 mm Allen wrench. The di-
section. aphragm must not twist.
NOTICE Hold the clutch release shaft with
CLUTCH COVER the Allen wrench to avoid twisting and dam-
Clutch Cover Removal aging the diaphragm.
Refer to BODYsubsection and remove the follow-
ing:
— Bottom rear side panel
rmr201 1-063 175

Section 02 ENGINE
Ensure slots in diaphragm are properly positioned

on mounting lugs.
., , .,._
L '.‘-
1-' '
P T "'
rmrZDOB~01 6-054_b
1. Hold Allen key

2. Turn wrench counterclockwise _>
Remove clutch cover retaining screws.

NOTE: Disconnect clutch fluid hose and vacuum
hose ONLY if cover must be removed from the
vehicle. Otherwise, omit these steps. TMGOOB-016-108_a
Loosen screw retaining clutch hose. 1. Mounting lug

2. Diaphragm slot inserted on lug
Disconnect hose and discard sealing washers.
NOTE: Install a drain pan under clutch hose to install clutch cover.
Catch the dutch f|uid_ Position cover so that clutch bleeder screw is
Remove vacuum hose from clutch cover. pointing upwards (when engine is on vehicle).
rmK20OB-01605631
1. Clutch hose
2. Vacuum hose
3. Screw rrnr2ClOB-O16-109_a
1. Bleeder approximately vertical

Remove the clutch cover from the engine.
Torque clutch cover screws in a criss-cross pat-
NOTICE Do not let the clutch cover hang 'II8l'l'I.
from the hose and do not stretch or twist the Install clutch fluid hose with NEW sealing wash-
hose. OTS.
Clutch Cover Inspection Apply LOCTITE 243 (BLUE) (P/N 293 800 O60) On the
thread of the hydraulic piston nut.
Clean cover and check for cracks or other damage.
Screw the hydraulic piston nut while holding re-
Clutch Cover Installation lease shaft with a 5 mm Allen wrench. The di-
Installation is the reverse of the removal proce- aphragm must not twist.
dure. However, pay attention to following details.
176 rmr201 1-063
Section 02 ENGINE
NOTICE Hold the clutch release shaft in its

position using the Allen wrench to avoid twist-
ing and damaging the diaphragm.
)1’. L.
GT2
rmr2008~O16057_a
1. Circlip
2. Hydraulic cylinder
Remove hydraulic cylinder from clutch cover.

Hydraulic Cylinder Inspection
Clean parts with new brake fluid.
rmr2008-O15-DU 5_b
Visually inspect cylinder surface for scoring,
Tighten the hydraulic piston nut to specification. scratches or abnormal wear. Replace if neces-
sary.
HYDRAULIC PISTON NUT TORQUE
15 Nvm (133 |bf'in)
Bleed clutch, refer to CLUTCH FLU/D in this sub-

section.
Carry out a vacuum leak test. Refer to CLUTCH
OPERATION TESTin this subsection.
Test clutch operation.
Install hydraulic piston cover and tighten screws
to specification.
HYDRAULIC PISTON COVER SCREWS {
11 N'rn (97 Ibf'in) rrnQO0 B-015-DOB_a
1. lnspect cylinder surface

NOTE: If clutch fluid leak occurred during cover
removal, bleed and refill system as necessary. Replace O-rings with NEW ones.
Also inspect the clutch cover bore for scoring,
HYDRAULIC CYLINDER scratches or other damages.
Hydraulic Cylinder Removal Hydraulic Cylinder Installation

Remove the HYDRAULIC PISTON See procedure Coat hydraulic cylinder and O-rings with new
in this subsection. brake fluid and install the cylinder into the clutch
Remove the CLUTCH COVER. See procedure in cover bore.
this subsection. Ensure the notch in the cylinder is aligned with
Remove the circlip retaining the hydraulic cylinder. the embossment on the clutch cover. See next
illustration.
rmr2011-063 177
M i | M i M
Section02 ENGINE
rrnr2008-016-Cl11_a
1. Hydraulic cylinder notch

2. Clutch cover embossment
install cylinder retaining circlip.

rmr2008-016-102_a
CLUTCH DIAPHRAGM
Diaphragm Removal
Remove disc plate.
Remove the CLUTCH COVER. See procedure in
this subsection.
_ W
Pull diaphragm out of its mounting lugs, then ro-
tate it away from the lugs to avoid damaging the I
diaphragm when removing retaining nut.
rmr2008 016-0583
1. Thrust washer
2. Disc plate
Remove diaphragm.
14:,
rmr2OOB~D1S-‘I 01_a
1. Mounting lugs
2. Diaphragm rotated out of lugs
Unscrew retaining nut while holding release shaft

with a 5 mm Allen wrench.
rmr2008-016055
Remove support disc.
178 rmr2011-053
M
Section 02 ENGINE
i
rmr2006-O16D60_a
1. Support disc

rmr20(IB4)16-103_a
1. Rounded edge here
Ensure support disc is inserted past the groove in

the shaft.
NOTE: Ensure to install the small support disc on
the clutch side. The large disc plate goes on the
outside of the diaphragm (clutch cover side).
rmrZ008-015-061_a
1. Thrust washer
Diaphragm Inspection
lnspect rubber diaphragm for wear, tears, or other
damages. Replace if necessary.
Diaphragm Installation
installation is the reverse of the removal proce-
dure. However, pay attention to following.
Install support disc so that its rounded edge will
be against diaphragm. rmrZ008-OI 6-1 053
1 . Groove
Incorrect mounting position of sup-
port disc will damage diaphragm causing en- install diaphragm.
gine oil to be drawn into the air intake from the
clutch area. NOTICE Do not install diaphragm into its
mounting lugs yet.
rmr201 1-063 179

$ectionO2 ENGINE
-I‘
I
rmr2008-016-1D5_a l
7‘ A/Iounfl-ng lug rrr\r2DOB»Cl16-I07_a
2. Diaphragm out of lug 1. Groove
Install disc plate so that its rounded edge will be Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on the
against diaphragm. release shaft retaining nut threads.
NOTICE Incorrect mounting position of disc Install release shaft nut-
plate will damage diaphragm causing engine Tighten nut while holding release shaft with a
oil to be drawn into the air intake from the 5 mm Allen wrench.
clutch area.
rm mos 016404 a rmr200B-016-‘l 02_h

r - _
7' H°””ded edge hem‘ Tighten release shaft nut to specification.

Ensure diaphragm and disc plate are inserted past RELEASE SHAFT NUT TORQUE
the groove in the shaft.
15 N'm (133 lbf'inl
Position the slots in diaphragm onto the mounting

lugs.
180 rrnr2011-O63
Section 02 ENGINE
rmr2008-O1 6DB3_a
1. Clutch spring
Remove pressure plate.

IMIQOOB-O1 6-1 O8_&
1. Mounting lug
2. Diaphragm slot inserted on lugs
Install clutch cover. Refer to CLUTCH COVER in

this subsection.
PRESSURE PLATE AND CLUTCH

SPRINGS
Pressure Plate and Clutch Spring
Removal
Remove DIAPHRAGM, see procedure in this sub-
section.
Loosen the retaining screws in a crisscross pat- rmrlwwiww
tern, then remove them with the step washers. 1- Pressure plate
Remove clutch release pin from pressure plate.
rmr2008-O1 B-G62_a
1. Retaining screw
2. Step washer rmr200B-016-D65_a
, 1. Clutch release pin
Remove clutch springs. 2. Pressure plate
rrnr201 1-063 181

1 _ Z I I I
Section02 ENGINE
Pressure Plate and Clutch Spring Pressure Plate and Clutch Spring
Inspection Installation
Pressure Plate For installation, reverse the removal procedure.
lnspect pressure plate for cracks or other dam- However, pay attention to the following.
ages. Replace if necessary. Tighten retaining screws in a crisscross pattern to
Check if bearing in pressure plate turns smoothly specification.
and freely. Replace if necessary. PRESSURE PLATE SCREWS TORQUE
lnspect thrust surface for wear or other damages. 11 N~m (97lbf-in)
CLUTCH PLATES
Clutch Plate Removal
._ X. E Remove pressure plate. Refer to PRESSURE
PLATEAND CLUTCH SPRING in this subsection.
Remove friction plates and steel driven plates.
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rmr2Dt1H-016-016_a
1. Bearing
2. Thrust surface
1__
Clutch Spring
Measure each clutch spring free length. Replace
every clutch spring if one is out of specifications.
CLUTCH SPRING FREE LENGTH
rrnr200H-O16-017_a
SERVICE LIMIT I 58.50 mm (2.303inl 7 Steel driven plates
2. Friction plates
\
t1
Clutch Plate Inspection
lnspect each plate for cracks, bent or broken
1
I -I ——v~ v,___ _ __ _ aw-- ~-- - _-5
teeth, missing or excessively worn friction mate-
I2-
D l - 1 (
rial and any other damage.

I" i.
ls -2 ..L.!.‘ ' "" P -'if 'r»_*titi.;..'iil€';L%L.l
Check friction and steel driven plates for warpage.
ifil I
Place plates on a flat surface. Use a feeler gauge
. to measure warpage.
FRICTION AND sTEEi. DRIVEN PLATE WARPAGE
SERVICE LIMIT | 0.15 mm (.0O6in)
vmr2Dl]8-017-O16
Clutch Release Pin

Visually inspect clutch release pin for wear or
other damage. Replace if necessary.
182 rmr2011~063
Section02 ENGINE
i
t
§
2 1
2
VDZDDKA
TYPICAL
rrrii2008-016019 s
Measure the thickness of the clutch plates assem- 1. Hardened steel driven plate
2. Marked with notch
bly (friction plates (9) and steel driven plates (10)).
CLUTCH PLATES ASSEMBLY THICKNESS Then install friction plates and steel driven plates
in alternate order.
SERVICE i_iiviiT | 43mm(1.693inl Place the tabs of the last friction plate into the
shorter slots in the clutch drum.
Tr
rmr2008-O54-50 1 _a rmr200B-O16-020_a
A. Service li'mit 1. Shorter slot

2. Last friction plate
if plates are warped, damaged, or worn out of tol-
erance, replace all clutch plates. Reinstall remaining parts, refer to the applicable
instructions.
Clutch Plate installation
For installation, reverse the removal procedure. CLUTCH HOUSING
However, pay attention to the following. Clutch Housing Removal
Thoroughly lubricate NEW clutch plates with en- Engine Installed in Vehicle
gine oil before assembly to prevent clutch plates
burning during break-in period. Drain engine oil, refer to LUBRICATION SYSTEM
First, install a hardened steel driven plate marked subsection.
with a notch. Drain engine coolant. Refer to COOLING SYS-
TEM subsection.
Remove the bolt securing the top of the coolant
radiator.
rmr201 1-063 183

SectionO2 ENGINE
rmr200H-016-066_a
TYPICAL rrr\r2008-01 6-D68_a
1. Radiator mounting bolt 1. Oil pressure switch connector
I:i€TT‘lOV€ WBTOT pl_ll'T'liD COVGI" SCTBWS. Remove exhaust spring.

Unscrew exhaust clamp and turn it in order to ac-
cess the clutch housing screw behind.
4-
‘I
|J|
r~
rmr2008-016J067_a
TYPICAL
1. Water pump cover screws
Move radiator rearward and unscrew the front en- TYPICAL

rm r2008-01 5-089_a
gine mount bolt. 1. Exhaust spring

2. Exhaust clamp
7
¢. .
Complete the clutch housing removal by following

the steps detailed in ENG/NE REMOVED FROM
VEHICLE
Engine Removed from Vehicle
Place a drain pan under the clutch housing to catch
oil spillage.
Remove starter screws.
Remove all clutch housing screws.
rm r2005-008-Cl39_a
TYPICAL
Remove DIAPHRAGM See procedure in this sub-

section.
Disconnect the oil pressure switch connector.
184
rm r201 1-063
Section02 ENGINE
‘n
lnspect plain bearings for scoring or other dam-
~~1 ages.
Measure plain bearing inside diameters and
compare to the crankshaft and balance shaft
journal diameters (support bearings). Refer to
CRANKCASE AND CRANKSHAFT subsection.
Replace if measurement is out of specification.
rmr200&016-0'i'0__a
1. M6 retaining screws (11)
3. Starter screws
Remove the clutch housing. Gently tap on clutch

housing using a soft hammer to separate it from
the crankcase.
rmr20IJB~0‘l6-D26_a
1. Plain bearing (crankshaft support)

2. Plain bearing (balance shaft support)
A. Measure plain bearing inside diameter
SERVICE LIMIT OF PLAIN BEARING

INSIDE DIAMETER
Crankshaft support
bearing 30.040 mm (1 .1827 .in)
Ba'a"°eb:';§‘:gS“pp°'t 20.000 mm (.7898 in)

rrT1l’ZOOB-U1 8-D24
Clutch Housing Inspection Plain Bearing Replacement in Clutch

Housing
lnspect the clutch housing for cracks or other
damages. Replace if necessary. Plain Bearing Removal
Check sealing surface for flatness. Mark the joint locations of the plain bearing seg-
ments on the clutch housing, prior to removing
Clean oil orifices in clutch housing from contami- the plain bearings.
nants using PULLEY FLANGE CLEANER (P/N 413 711
809), then use an air gun to dw it. Pull out the plain bearings.
REQUIRED TOOL
(P/N 529 O36 117)
rrnr20IJ8-O16-UZ5_a
1. Clutch housing
2. C/ean oil bores
185
rmr201 1-063
Section 02 ENGINE
— l L l
é
at CLUTCH HOUSING PLAIN BEARING I
BORE DIAMETER TOLERANCE GROUP
32.921 mm to 32.930 mm Red
(1.2961 in to 1.2965 in)
32.930 mm to 32.940 mm BIUG
0
(1.2965in to 1.2969 in)
.i‘;W_. T_..-.¢-_=_
32.940 mm to 32.951 mm
(1 .2969in to 1.2973 in) Ye“°W
-.'. . . .t
rmf20DB-O16-027
NOTICE Unless otherwise instructed, never
use a hammer to install plain bearings. Plain
Plain Bearing Installation bearings should only be installed using a
Crankshaft support plain bearings are available in press.
3 tolerance groups (red, blue and yellow). The Heat clutch housing up to 100°C (212°F) before
proper tolerance group is marked with paint on installing plain bearings.
the clutch housing.
Install plain bearings using the appropriate plain
bearing installer.
PLAIN BEARING SERVICE TOOL
Crankshaft support BEARING

PUSHER/REMOVER
beamg (P/N 529 036 095)
rrrir2008016-iJ28_a
1. Clutch housing
2. Paint marking of tolerance group 52903 5095
r‘""——- _.¢: -
If paint marking is not visible anymore, measure
inside diameter of clutch housing bore where plain
bearings are inserted.
l\}
2
..
rmr20D8-016-071
I
PLAIN BEARING INSTALLATION — CRANKSHAFT SUPPORT
BEARING
PLAIN BEARING SERVICE TOOL

vmr2DOB-015029
MEASURE CLUTCH HOUSING BORE DIAMETER
Balance shaft support BEARING PUSHER
bearing (P/N 529 036 O96)
Use the following table to find proper tolerance
group of plain bearing.
186
rmr2011-063
Section02 ENGINE
Clutch Housing Installation

Install a NEW clutch housing gasket and NEW
sealing washers.
52 9036096
Lubricate plain bearings with PETAMO GREASE
,,,,_,......._... . ,..,_,,,,,.,_,_ _ _ _ J " GHY 133N (P/N 420 899 271), before installing
.»
clutch housing.
e _.
i 'l1ghten clutch housing screws to specification as
E
per the following sequence.
CLUTCH HOUSING SCREWS TORQUE
.q';—» .
M8 SCREWS (4) 19N'rT1(l68|bf°in)
’ ".1
Iébl-cl
v_\- — I l\/I6 SCREWS (ill L 11 N'm (97 lbf'in)
WATER PUMP HOUSING SCREWS TORQUE

1 ‘ - ¢-- . 0 E 1
M6 scssvvs (4) | 11 Nvm (97lbf~inl
Hi‘... I.’ L I >v' -‘_, I .. it 'l _‘~_I
rmr20DEl-O16-072
PLAIN BEARING INSTALLATION — BALANCE SHAFT SUPPORT
BEARING
Fit the plain bearings with PETAMO GREASE GHY

133N (P/N 420 899 271).
Support the clutch housing with a suitable support
under the bearing seat. Use an O-ring to hold the Q l
plain bearings together during installation. Then
carefully press-in the plain bearings.
NOTE: Remove O-ring just before plain bearings
are completely pressed in.
NOTICE The plain bearing segments must be
positioned as marked during removal. rmr201 1-O14-O02_a
TIGHTENING SEQUENCE I19 SCREWS)
Reinstall remaining parts, refer to the appropriate

instructions.
CLUTCH HUB
Clutch Hub Removal
Remove the following items, see procedures in
this subsection:
— Clutch cover
- Clutch plates.
Lock crankshaft in TDC position, refer to
rmr200801S-032_a
1. Partition of crankshaft support plain bearing Lock clutch hub.
2. Partition of balance shaft support plain bearing
3. Clutch housing REQUIRED TOOL
CLUTCH ASSEMBLY HOLDER (P/N 529 035 618)
rmr201 1-063
187
Section02 ENGINE
rrnr2flO8016-041_a
528035618 INSPECT GROOVES IN CLUTCH HUB FOR WEAR
Remove the clutch hub locking nut and spring GROOVE DEPTH
washer. SERVICE LIMIT ' 0.3 mm (.012 in)
i ‘T’ ‘" A f-;il§f Clutch Hub Installation

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clutch shaft ahead of clutch drum assembly be-
fore installing the clutch hub.
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rmr2008-O16-073_a '3' ' '..i l"'}"‘ Q-l}.‘i._‘».L~.-),§‘~r “fl iii "‘§'<.l,ill “Till ,I.' "
7. Clutch hub locking nut . ~ ‘ *1‘-'
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Remove clutch hub. ‘
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fr; jf*€:'@...____1__.;{;.,..05.--rtai
T
1. Clutch drum thrust washer
Apply PETAMO GREASE GHY l33N (P/N 420 899 271)

on clutch hub teeth.
Insert clutch hub.
Reinstall spring washer and hub retai ning nut.
. .-< __ _, .»_, _..
'- _. ¢‘.'¢ __ ,i._ >
rmr200B-O1 50743
1. Clutch hub /Q _' I >5’,-_,: "'3"-., 5,1,, ’
1:
Clutch Hub Inspection ". I l-,1 0 .-'-'*,w_)*"’i'xI'b1(_y-
Inspect grooves in clutch hub for dents, damages at __"' .
or wear caused by steel driven plates. Replace if
K-.;-.;"*.1"*"~~<-‘.=’. r ~
necessary. '1
en- a 1
.-
.
_ 5';§\'
I - I ~ .»,;Tu . “ T' 1* 2
V
Q , 2
. ' ' _k _ '->.',.I_
rmr200H-01E‘r073_a
1. Clutch hub retaining nut
2. Spring washer
188
rmr201 1-063
Section 02 ENGINE
Apply LOCTITE 64s (GREEN) (P/N 413 711 400) on Clutch Drum Disassembly
hub Ietainmg nut threada Remove the oil pump drive gear.
‘Tighten nut to specification. Remove retaining nuts_
CLUTCH HUB NUT TORQUE Remove the outer support plate.
190 N-m (140|bf~ft) Remove distance sleeves.
Reinstall remaining parts, refer to the appropriate .-sg-,,, _
instructions in this subsection. N; H} y
1 V . ‘ }'{,"/ 1;
CLUTCH DRUM 4?“

Clutch Drum Removal :'.1~I-I .‘/33
ti
2 "I 1
Remove the following items, see procedures in 1 Xa 0 ?'.Tr‘I'
this subsection. \
— Clutch cover 4
— Clutch diaphragm r.s I 3
— Pressure plate _ ‘;‘§k\§\
_ K2
— Clutch plates "M..
— Clutch hub ,,,,m.,.s.,3,_,,
— Clutch housing. gt/pump drive gear
etaining nuts
Remove the clutch drum thrust washer. 3.' Outer support plate
4. Distance sleeves
/ ...:;.~ NOTE: Mark the position of springs and retainers,
—~ ,.’:,;'§._.-*I‘ Prior to removing them. y
i I, ,1"; '~.5’ _‘ -1%:-'~,.-\i-2 ‘:‘ ' ~. 5-’ . __ A
Remove. clutch drum and
.
gear together
.
as
.
well as
.
I .‘ iii-//t";5;:"‘:~‘*~*‘*it-»I3. ?7"~:".’ Ti Y. both white marked springs and their spring retain-
- L1‘ -ii I erg
r _1.-~it¢3_‘-I-.,:*t;_Rs; "‘""Tb: ,
4 ,-‘-i5.£:""i 1. .'_;‘-1?_ _T";"~3
I I M 1-.:'
* 1, "'it 1" 1' I "-5
1 1 I-Q1-~11-r<»‘7' -I1’.5>'>ii.'Y.-./'7,’-“ /‘ 1
-. ..
H] .,-7‘
~:>.'2~~ .1
-I!‘ -‘;'T»~"
rTr\r2008-01 6-075_a L U
Remove the clutch drum.
rmr2OOB-O16-O3B_a
1. Clutchdrurri gear
2. Springs with white marks
Remove all other springs with their spring retain-

ers.
\—'I
- Remove the spring disc(s).
Remove the thrust washer.
rrnr2008-O1 5-O76_a V
,' Cmch d,,,,,, Remove the inner support plate.
rmr201 1-063 189

Section02 ENGINE
I "'
“J4
P’
Support Plates
5 .f*?~"*;5”
.
lnspect support plates for cracks or abnormal
wear. Replace if necessary.
1 4 lnspect the thrust surface of inner support plate
for abnormal wear or grooves. If necessary,
replace inner support plate, thrust washer and
5 6 spring disclsl as an assembly.
IQ ("-2
*a"‘%3
rmr2OQB~O16Cl39_8
CLUTCH WITH 1 SPRING DISC

1. Outer compression springs
2. inner compression springs
3. Spring retainers
4. Sp ring disc
5. Thrust washer, 0.4mm (.016in)
6. Inner support plate
on AI .,4.-.'. '..-‘L ,_/

4 ~< \ rmr2008-O1 6-049_a
1. lnspect thrust surface of inner support plate
Clutch Drum Gear

lnspect bearing sleeve for scoring and wear.
25
3—>0 A
rrrir2011-014-003_a ,
CLUTCH WITH 2 SPRING DISCS
1. Outer compression springs
2 . Inner compression springs
3 . Spring retainers
4 . Springs discs
5. Thrust washer, 1.6mm l.063inl
6‘. Inner support plate
Clutch Drum Inspection

Compression Springs and Retainers rrnr2010014-0Ol_a
1. Bearing sleeve sunface
Measure free length of each compression spring,
refer to the following table. Measure inner diameter of bearing sleeve.
SERVICE LIMIT
Outer springs and
white marked springs 26.75 mm (1.053ir\l
Inner springs 25.65 mm (1 .01 in)
If a spring is out of specification, replace all

springs as well as all spring retainers.
lnspect spring retainers for wear, cracks or scor-
ing. Replace all springs and all spring retainers as
an assembly.
190
rmr201 1-063
Section 02 ENGINE
-1
rrrir2IJ08-U16-O78_a
A. Inner diameter rmr2008-O1 B»04B_a

1. lnspect spring cavity
BEARING SLEEVE INNER DIAMETER
SERVICE LIMIT I 30.060mm(1.l83inl Clutch Drum Assembly
Assembly of the clutch drum must
lnspect teeth condition for pitting or other dam- be carried out with the utmost care. Failure to
age. strictly follow procedures may cause parts to
Replace clutch drum gear with drive gear if nec- loosen and/or malfunction of the clutch drum
essary. and may lead to serious engine damage.
Clutch Drum Assemble the clutch drum in the reverse order of
lnspect slots in clutch drum for dents, damages or disassembly. However, pay attention to the fol-
wear caused by friction plates. Replace if neces- lowing details.
sary. The position ofthe clutch drum, sup-
port plates and clutch drum gear for assembly
is clearly indicated with location holes in each
part. During assembly, ensure that all location
holes are aligned with each other.
.4 .
‘i
-§CiiJI*F-\
rmr20OB-O16-040_a
INSPECT SLOTS IN CLUTCH DRUM FOR WEAR
SLOT DEPTH
rmr2006-016-D42_a
SERVICE LIMIT I 0.3mm(.0‘I2inl ALIGNMENT OF LOCATION HOLES OF CLUTCH DRUM PARTS

1. Hole in clutch drum
2. Hole in inner support plate
lnspect spring cavities for deep grooves caused 3. Hole in clutch drum Qear
by springs. Replace clutch drum if necessary. 4. Hole in outer support plate
NOTE: Slight markings caused by the springs are Insert the three M8 X 25 flat head screws from the
normal. Do not replace clutch drum needlessly. inside of the drum. Hold the screws in position as
you install the remaining parts.
Install inner support plate on clutch drum, ensure
the location holes are aligned with each other.
rmr201 1-063
191
Section02 ENGINE
Install NEW spring disclsl with the concave side Install both white marked springs with spring
facing the inner support plate according to the retainers into the corresponding spring cavities
clutch type. which are marked with punched holes inside the
NOTICE Do not mix the following clutch parts inner support plate.
between clutch types:
-_a‘V__‘
— Clutch drum
- Inner support plate 4"‘ T'"- Ti’
- Spring discs 2 . 53. " ‘I
- Thrust washer. ."< -.1 ‘. "i \
~‘~~ '\-. I E.’ "~ -. I). ‘
\. \._ _ \_ -
Clutch with 1 Spring D/Isc ‘F ‘L l> -V‘ \_,
\ ~ .“ _ ..
.QTY ' I
.-
1 .,1\;,: 4, .
V
I ‘ / "' 2
L;/'
‘ rmr20OB-D1 60-14_a
1. White marked springs

2. Spring cavities marked with punched holes
Install remaining springs and retainers into spring

cavities.
Install distance sleeves on clutch drum screws,
then outer support plate. Ensure that the location
rml’ZDU5-O16-O43_a
CLUTCH WITH 1 SPRING DISC P!‘

4 I
"g
1. Support plate 3 if ._.Wmr%‘g;_
2. Spring disc
.‘ ,1 ‘w
Clutch with 2 Spring D/lscs .' if I,‘Tf'-.".:% 1
/ l ‘
-H. "0
‘- '. _ 1 ‘I
.5 ~ ,
l./“T-at 1
rmr2008-D16-045_a
1. Distance sleeves
2. Outer support plate
3. Location holes
Install retaining nuts on clutch drum screws.

Apply LOCTITE 648 (GREEN) (P/N 413 711 400) on
threads of clutch drum retaining nuts.
rrnr2011-O14-0O4_a Tighten clutch drum retaining nuts to specifica-
CLUTCH WITH 2 SPRING DISCS tion.
5 i-i?l’$§'Iv‘§§’i§Zi, 1.6mm CLUTCH DRUM NUTS TORQUE I
3. Spring discs
30 Nim (22 lbf'f’tl
All Clutch Types
Install the clutch drum gear, ensure the location Finally install oil pump gear. Ensure that tabs of
holes are aligned with each other. oil pump gear engage in cavities of outer support
plate.
192
rmr201 l -O63
Section O2 ENGINE
-./J
Clutch Drum Functional Test
./ 7E
Prior to finalize installation, try to turn clutch drum
to detect any free-play between clutch drum and
clutch drum gear.
NOTE: Ensure crankshaft is locked at piston TDC.
If no free-play is detected:
[fig-“
-11‘
:t — Finalize installation (clutch hub and other re-
maining parts).
TT L_I‘_‘;q
\TL
fii l i\ 1).I".\-~’r~
T”' sn_...T
-1-'-‘?€‘/3‘T
+ If free-play is detected:
— lnspect clutch drum components. Refer to
rTr\r2008-O16-045_3
CLUTCH DRUM INSPECTION in this subsec-
1. Tabs of oil pump gear tion.
2. Cavities of outer support plate
Clutch Drum Installation

lnsert the first thrust washer on the clutch shaft.
Insert clutch drum on the clutch shaft.
.__%
-
§?s
: \
~
I \"
igini
I
\-_..\ y -_
_~.
‘Six
QQF 3Wm»’N§g7
it
is TE‘-.'\\.
rm r2 D08-01 6-200_a
1. Thrust washer
2. Clutch drum
Install the other thrust washer on clutch shaft.

~ -we5rs,
I
" 1 -1
- ' ‘ 1 ,2: _ji
.- '“ or . .-- :'| - _
_
~ -1. l
.
tjf ‘\
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1.
-i~{:_-Tl. ~
r Ml Q
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4‘ -. -. -Z3.’
_ _. ‘ _
(__/ ,;>,___"-r.,_._.--~\‘r__,.-
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,-‘I .<€i.-('5. ‘ \-—
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(ers.. -*. C»-*'-8
I /'*>
rmi7ClDEI-O16-l]75_a
1. Thrust washer
rmr201 1 -063 193

Section02 ENGINE
Subsection 10 (CLUTCH (SE5))
CLUTCH (SE5)
SERVICE TOOLS
BEARING PUSHER/REMOVER ................................................... .. 529 O36 O95 ....................................... ..211
BEARING PUSHER ...................................................................... .. 529036 O96 ....................................... ..2’I1
BLIND HOLE BEARING PULLER SET ......................................... .. 529 036117 ....................................... ..21O
CLUTCH ASSEMBLY HOLDER .............................................. .. 529036133 ....................................... ..212
CLUTCH PACK COMPRESSION TOOL .................................. .. 529 036144 ....................................... ..207
SERVICE PRODUCTS
LOCTITE 243 (BLUE) ................................................................... .. 293 800 O60 ....................................... ..20'l
LOCTITE 648 (GREEN) ................................................................ .. 413 711400 ............................... ..213, 220
PETAMO GREASE GHY133N .................................................... .. 420899 271 ............................... ..2i1, 213
PULLEY FLANGE CLEANER ....................................................... .. 413 711809 ....................................... ..209
rmr2011~064 195
Section02 ENGINE
Engige 0
11 N'm 19 N-m
(97 (16?|bf-in)
M
6
Eng_i|ne
Tia
OI I
15 N-m 0 1
(133 lbf-in) ¢ 0 ~ 1./"’ Finger tight
Lcémzltéte { {F1
\
1"-@_
/-\)§¥
5'3
lIE1'l—
Engine
4? '|\'i§.=-"Em ,_L
~41
58 §2 33
19 N-m
(168 lbf-in)
\( .\
\\
30 N-m
(22 Ibf-ft)
1
= Comp onent must be replaced when removed.
rmr2DOB-055001 _c
196
rmr201 1-064
Section02 ENGINE
Subsection10 (CLUTCH (SE5))
11 N-m
(97Ibf-inw
6\>~ T
Loctite ' 0* Engine
243 ‘I 3"?’ (K31
=_‘ f _,~
' Engine
_ oil
\*o v 6
4; - 1 "1 .
1 ‘J’ 11,,,-/iv/’ /
< ‘<58 5-2 33
—.|-‘I
"1 Io <~
Engine
oil
0/ 0 '
Loctite ‘\-' I’ ‘
:
0 6 Engine 0 548 [.1 0
9 oil , ‘
6 r '5 6
_ ,» A Petamo grease
Jr Engilne Ghy133n
0|
L O . l
pa % -Q j " 0
Engine j __ ( ‘/-Pvt
of“? Engigeoil
Loctite - "7' w
648
*
/' ' Loctite
” 1
\- 4 Q
30 N-m ‘L
(22 |bf'1'U
rmr2fl1C»O15-O10_a
rmr2011-064 197
Section02 ENGINE
GENERAL
NOTE: For a better understanding, many of the .,‘. .
following illustrations are produced with the en-

gine out of vehicle. To carn/ out the instructions, kt.
it is not necessary to remove the engine from ve- ' ...»", »~Z‘1/
\ .- . » - ~, ’r‘r
hicle. 1', _ ' - ._.', _
Always disconnect the battery negative cable be- -- J’ /‘l-'-""7 IF‘ _. ' _‘\-7
fore working the engine. \ '> \
A WARNING \ l:.l,~_~‘ G1
-' 1-~' . -‘ Ola-<"\.'§T;<’j
Always disconnect BLACK (-) cable first and " -,0 _ ' iv T 'i'_ rm
reconnect last. 1 J 7‘_ _f_‘__.,..

1:‘, O‘ ' L‘.
During assembly/installation, use torque values

and service products as specified in the exploded 2
views. vmr20llH]15~fllJ1_a
7. Solenoid valves
Clean threads before applying a threadlocker. Fle- 2. Hydraulic control module (HCM)
fer to SELF-L OCK/NG FASTENERS and L067‘/TE
APPL/CAT/0Nat the beginning of this manual for One valve engages/disengages the clutch and the
complete procedure. other valve modulates the clutch to control the
speed of the clutch engagement for smooth op-
A WARNING eration.
Torque wrench tightening specifications Depending on which solenoid valve is activated,
must be strictly adhered to. oil flows either from the HCM to the hydraulic
Locking devices when removed (e.g.: locking clutch piston or from the hydraulic clutch piston
tabs, elastic stop nuts, cotter pins, etc.) must to HCM.
be replaced.
V’ /1.’ I
NOTICE Hoses, cables or locking ties re- “ff/,~,r3\\(
-I '/U’ ,'. K».
T‘-Q’? / 1_ 4" fin‘
NOTICE Sealing washers must be discarded
and replaced with new ones every time a Banjo
fitting is unscrewed.
Periodically check the oil hoses for damages or
leaks. Repair any leaks and replace damaged
&___
hose.
rmr200 B-0550043
SYSTEM DESCRIPTION 1. HCM side
2. Hydraulic clutch side
The engine on the SE5 model features a sequen- 3. Oil hose between hydraulic clutch and HCM
tial electronically controlled mechanical 5-speed The SE5 clutch system uses the same oil as the
transmission with a hydraulic type clutch system. engine.
The clutch is disengaged and engaged by 2 valves
in the hydraulic control module (HCM) that are
controlled by the transmission control module
(TCM).
198
rmr201 P064
Section 02 ENGINE
TROUBLESHOOTING
TROUBLESHOOTING
GUIDELINES
SHIFTING PROBLEMS
1. For any shifting problems, refer to TROU-
BLESHOOTING in ELECTRON/C SHIFTS YSTEM
(SE5) subsection.
RATTLE AT IDLE OR DURING CLUTCH
ENGAGEMENT
rmr200B4)55-O06_a
1. Check clutch drum and clutch dampener parts 1. Deep offset wrench
(discs springs and thrust washer) for any wear. 2. Allen wrench
- Replace defective parts in accordance with clutch 3. Hydraulic piston nut
layout.
Remove retaining ring and hydraulic piston nut.
PROCEDURES
HYDRAULIC PISTON "4./QR C
Hydraulic Piston Removal
0.1
l a
rm I2 00&05 5-003_a
1. Hydraulic piston nut
2. Retaining ring
Remove the hydraulic piston, compression spring

and hydraulic cylinder sleeve.
rmr200&055-005_a
1. Screws (x4)
s;
5
lease shaft with a 5 mm Allen wrench.
rmr20lJB-055-UO7_a
1. Hydraulic piston
3. Hydraulic cylinder sleeve
rmr201 14064
199
Section 02 ENGINE
Hydraulic Piston Inspection COMPRESSION SPRING FREE LENGTH

Clean piston and visually inspect piston surface for
scoring, scratches or abnormal wear. Replace if I 32.50 mm to 33.50 rnm
NEW (1.28in to 1.319in)
necessary.
SERVICE LIMIT 32.00 mm (1.26inl
Remove and discard piston seals.
If the compression spring is out of specifications,
replace it.
Hydraulic Piston and Hydraulic
Cylinder Sleeve Installation
Install NEW hydraulic piston seals and hydraulic
cylinder sleeve O-ring.
2 1
rrnr20D8-055~DUB_a a
H 1 2 s
1. lnspect piston surface
2. lnspect piston seals
Hydraulic Cylinder Sleeve Inspection

I-; \f Q
Clean hydraulic cylinder sleeve and visually in 1 ll.‘ ii‘
spect sleeve surface for scoring, scratches 0 l'
abnormal wear. Replace if necessary. 1 I lI if ‘
Remove and discard sleeve O-ring.
Iii ILQ
, _ ll
I
2&_
r, _
\1
IL
rr\'\120l0-015-D05_a
LARGE SEAL POSITIONING

1. Piston
2. Large seal
3. Open side of seal
rmfi00B-(J 55—DOEl_fl
1. lnspect hydraulic cylinder sleeve

Coat hydraulic piston, seals, hydraulic cylinder
2. Discard O-ring sleeve and O-ring with engine oil before installing
them in the clutch cover.
Compression Spring
Check free length of compression spring.
-l
trig
I' ,__1. ' k, 2.
.'
_ i 3»-
-R?
X
-3f
I. o I-‘ii
at “r m _..1“l._.‘qtr.'.‘its
1.
rmr200B-Di 5-010
200 rmr20 1 1 -O64

Section02 ENGINE

lease shaft with a 5 mm Allen wrench.
A
rmr2OU3‘U55-O07_a
1. Hydraulic piston
3. Hydraulic cylinder sleeve
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) to the rrniQO08-O55-006_a
hydraulic piston nut and tighten to specification. 1. Deep offset wrench
2. Allen wrench
D HYDRAULIC PISTON NUT TORQUE | 3. Hydraulic piston nut
15 N'm (133 Ibf'in) Remove oil hose from clutch cover.
Install hydraulic piston cover.
\‘._ _
CLUTCH COVER
Clutch Cover Removal
Remove RH bottom rear side panel. Refer to the
BODYsubsection.
Lift and safely block RH front of vehicle to prevent -2
engine oil leakage when removing components (if
servicing clutch cover in vehicle).
NOTE: Install a drain pan under the clutch cover
and oil line to catch engine oil spillage.
rrni’2008-0550'|0_a
Remove hydraulic piston cover screws. 7. Banjo bolt
2. Oil hose
3. Gaskets
Remove clutch cover retaining screws.
#2/('2
rl1'\r2 008-D5 5-005_a
1. Screws (x4)
rmr201 1-064 201

Section02 ENGINE
NOTE: Install a drain pan under clutch cover to

catch engine oil.
Remove plug screw on top of clutch cover.
Remove pressure retaining valve from clutch
coven
‘es.
rmr200B-0 55-01 1_a
1. Clutch cover
2. Retaining screws
3. Gasket I
Remove clutch cover from the engine.

Clutch Cover Inspection
Clean clutch cover and inspect for cracks or other ,m,,,,M55,,,2_a
damages 1 . Clutch cover
. Pressure retaining valve
Clutch Cover Installation 5; gggggegggnsprlng
Installation is the reverse of the removal proce- 5' P'”g 5°’e""
dure. However, pay attention to following details. Using a flat screw driven remove air Home from
Ensure clutch cover gasket is in good condition Clutch Cover.
and positioned correctly. Replace if necessary.
Ensure the clutch cover is properly positioned on
the two alignment pins on the clutch housing.
ts"
rmr20OH~O55-O13_a
1 1. Air nozzle
wloflaeam-h Pressure Retaining Valve Inspection

1. CI tch cover .
2. Fhgtaining screws (x8) Clean all parts and lnspect for damage.
Z. giiggfrientpins NOTE: Ensure the port in the air nozzle is not
clogged or dirty. Clean as required.
NOTE: Install oil line with NEW gasket rings. _
Compression Spring
PRESSURE RETAINING VALVE Check free length of compression spring.
Pressure Retaining Valve Removal
Remove RH bottom rear side panel. Refer to
BOD)’.
202 rmr201 l-064

Section02 ENGINE
rmQOOB-O1 s-or u
TYPICAL

38.00 mm to 39.00 mm rrnrZD08-O55-015,:
NEW (1 .496 in to tsssmi 1. Inner plate

2. Spring disc
SERVICE LIMIT 36.00 mm (1 .417in)
Pressure Plate Disassembly
If the compression spring is out of specification, Remove pressure plate with retaining ring and
replace it. clutch release pin.
Pressure Retaining Valve Installation NOTE: Remove retaining ring from pressure plate
only if necessary.
NOTE: Install the plug screw with a NEW gasket.
PRESSURE PLATE
Pressure Plate Removal
Remove CLUTCH COVEH, see procedure in this
subsection.
Loosen the inner plate retaining screws using a
crisscross pattern, then remove them.
rrnflO0B-055-01 8_a
1. Retaining ring
2. Pressure plate
3. Clutch release pin
Pressure Plate Inspection

Inspect pressure plate for cracks or other dam-
Inspect pressure plate thrust washer for cracks,
wear or other damages. Thrust washer must fit
tightly in pressure plate. Replace if necessary.
rmr2008-055-014_a lnspect retaining ring for damage or wear. Re-
1. lnner plate retaining screws (x6) place if necessary.
Remove inner plate and spring disc.
rmr201 1-064 203

Section02 ENGINE
\ \ .
1
Q 3
i
rmr200B-lJ55—Ol 7_a
1. Pressure plate
.
I 1;»;
~I g
-
_."-
,-
I
rrni10OB{I5E‘r01 9_a
1. Clutch release pin

2. Trust washer
3. Axial needle bearing
4. Thrust washer
5. Retaining ring
it r
2. Thrust washer Pressure Plate Installation
3. Trust surfaces
4. Retaining ring For installation, reverse the removal procedure.
However, pay attention to the following:
lnspect pressure plate related parts as follows.
NOTE: The pressure plate must show an iden-
Spring Disc tification groove and must be installed with the
lnspect spring disc for cracks, wear or other dam- proper centrifugal clutch assembly equipped with
ages. Replace if necessary. bushing also showing an identification groove.
Place spring disc on a flat surface so that the outer
circumference of the disc is flat on the surface. /
44
Measure the height of the spring in a crosswise \ -/45”". I-
/''7'.- 5
J “I1
.;
direction, with reference to the flat surface.
-4.-=’4,_.
./, ____ ,
SPRING DISC FREE LENGTH
WI
SERVICE LIMIT | 7.00 mm (.2756 in) 2%’ W
i_Wk
__2
‘LI -
‘ __4. _ '. . »
i,. 3:..:»_L
R?’*\;
*4..1‘;
_ »
_ W...-i-. urn»! A
rrnf201(H115-DD2_a
2. Pressure plate
i
‘RV E _ — V//‘ [dz "'1'-,7 1 2 3

Z 2-yi‘ I
. >_/,- . '
rmr2008-05 5-018
MEASURING SPRING D/SC FREE LENGTH § " _ ‘
Rotate tool and measure spring free length across

several of the disc fingers. Replace spring disc if
1;Q . - “gr 1-, eh’;-=,7
out of specification. rmr20'|0—D15-003_a
1. Centrifugal clutch assy
Clutch Release Pin 2. Identification groove
3. Bushing
Visually inspect clutch release pin, thrust washers
and axial needle bearing for wear or other dam-
204 rmr201 1-D64
Section02 ENGINE
AcAuT|ol\l Spring disc must be installed Clutch Plate Inspection

with the concave side towards the pressure lnspect each plate for cracks, bent or broken
plate. Incorrectly assembled spring disc can teeth, missing or excessively worn friction mate-
cause a clutch malfunction. Clutch will not rial and any other damage.
disengage. Check friction and steel driven plates for warpage.
. .”._ / . Steel driven plates must be free of scores and
‘“a.
s s s _“ blueing (overheating).
\\.\ ‘W pa...
,*:‘i"@"?t.-'1)?-‘-'fi'§'g‘I
Q-;.(.,..\'. Place plates on a flat surface. Use a feeler gauge
to measure warpage between plates and flat sur-
: t» § , \\\\\\\..§._
P \ _
face.
»\ \ FRICTION AND STEEL DRIVEN PLATE WARPAGE
é
/
_ '-4——aw:,
_l
SERVICE LIMIT I 0.15 mm (.006 in)

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“.21pl; ~ " r '~.\ -. f._‘,J"'>-1'»*
rmr201 0431 501 4_a
1. Pressure plate
2. Spring disc
3. Assembly direction of spring disc
4. Adjustment plates
5. Friction plate
11ghten retaining screws to specification using a

crisscross pattern.
RETAINING SCREWS TORQUE
11 Nvm (97lbf'in)
VOZDO K;
TYPICAL
CLUTCH PLATES
Plate warpage must not exceed service limit.
Clutch Plate Removal Measure the thickness of the clutch plate assem-
Remove pressure plate. See PRESSURE PLATE, bly (friction and steel driven plates).
SPRING D/SC AND CLUTCH RELEASE P/N in this NOTE: Thickness of the clutch plate assembly is
subsection. measured without the spring disc, the adjust-
Remove friction plates and steel driven plates. ment plate and the 2.5 mm (.098 in) thick plate.
CLUTCH PLATES ASSEMBLY THICKNESS
(FRICTION PLATES (9X) AND STEEL
DRIVEN PLATES I8X))
SERVICE LIMIT | 41.00mrn(1.614in)
rmr2008-055-O46_a
1. Spring disc
2. Adjustment plate
3. Steel driven plates
4. Friction plates
5. Steel plate (2.5 mm l.098in) thickl
rmr201 H164 205

Section02 ENGINE
1 2 3
\ - 1
.»\
l Il
I, ;;,~,li T T
»--l.
“I)i‘ ‘I
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31
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rrnr2008-01 8-020_a
1. Shorter slot
2. Last friction plate
lrnr20(lB-055-55 l_a
1. Spring disc Adjust clutch plate free-play.

2. Adjustment plate
3. 2.5mm (.098inl thick plate Clutch Plate Free-Play Adjustment
A. Service limit
Adjust clutch plate free-play by installing an adjust-
If plates are warped, damaged, or worn out of tol- ment plate of the appropriate thickness.
erance, replace all clutch plates.
Clutch Plate Installation
Soak the NEW clutch plates in engine oil for 30
minutes before assembly to prevent clutch plate
burning during break-in period.
First, install the 2.5 mm (.098 in) thick steel plate.
rrnr20(1B-O55-O48_c
1. Adjustment plate
Use the following adjustment plate kit and proce-

dure to achieve proper clutch free—p|ay.
ADJUSTMENT PLATE KIT PIN 420 281 535
PLATE PLATE
QUANTITY PLATE THICKNESS INCREMENT
THICKNESS
rrrlr2lJOS-D55-O46_b 11 1mmto2mm 0.1mm
1. Steel plate (2.5mm I. 098 in) thick) (.039 in to .079in) (.004in)
2. Friction plate
3. Steel plate
Measurement A
Install friction plates and steel driven plates in al- Install the spring disc (with the concave side to-
ternate order. wards the pressure plate) on the pressure plate
NOTE: Install a friction plate FIRST. and measure the distance from the top of the
spring disc to the machined surface of the pres-
Place the tabs of the last friction plate into the sure plate.
shorter slots of clutch drum.
206 rm r201 1-064

Section02 ENGINE
rw/' “*1 "".___ . V T’ 7

I
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-
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rrrlr200&Cl55047_a
MEASUREMENT A rrnfi0O8-055-BULB
1. Machined surface on pressure plate
2. Spring disc MEASUREMENT B
1. Top of friction plate
Measurement B 2. Top of clutch hub
REQUIRED TOOL Use the following course of calculation to deter-

mine the thickness of the adjustment plate.
CLUTCH PACK COMPRESSION TOOL
(P/N 529 036 144) I ADJUSTMENT PLATE THICKNESS
CALCULATION
B — A - CONSTANT (1 mm (.039in)) =
ADJUSTMENT PLATE THICKNESS
For example: -
EXAMPLE OF CALCULATION
(B - A - CONSTANT = PLATE THICKNESS)
B A CONSTANT RESULT
5290361 44
10.3 mm 7mm 1mm 2.3mm
Install the tool on top of the plate assembly. (4.055 in) (.276 ill) (.039 in) (.906 in)
Install a 2.3 mm (.906 in) thick adjustment plate.

NOTE: If necessary 2 plates of the adjustment
plate kit can be installed to achieve the proper
thickness of the adjustment plate.
T
‘P -. : _
Reinstall remaining parts, refer to the appropriate
instructions.
CLUTCH HOUSING
Clutch Housing Removal
Engine Installed in Vehicle
"sad Refer to BODYand remove the following panels
rmlflflflfl-O55-80 1 _a on the RH side:
7. Tool installed — Middle side panel
Alternately tighten tool screws to eliminate un- — Top side panel
evenness and to recover all play between plates. - Bottom rear side panel
Measure the distance from the top of the clutch - Bottom front side panel
hub to the top of the last friction plate. — Rear side panel.
rmr201 1 -O64 207

Section02 ENGINE
Remove headlight adjustment cable from LH mid-

dle side panel support.
Remove RH middle side panel support.
pg _ I ~ -r I
I
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L t2j=T‘?'
:'*'*“f‘
- .- I " " ‘ I I I 1 - r
% -' '1: l‘ .' -J ,.
P
I15
rmr200B-016-057;:
_ I —~. V, i -.._4“ 4
TYPICAL
' ,/ '. 1 " 0 - 9 ' ' . . ’- 1. Water pump cover screws
z'is\
ii ‘B 1' .""\‘ ~-
I ' V‘ ’ .'_ .', »| it
#—-—-X‘ , _:
W -
Disconnect cooling fan connector.
. ,.l
jl /I‘ .1‘)I
Remove the front engine mount bolt.
- V‘ *~-T - _, ; "
rmr2010-011-001_a
1. Middle side panel support

T- I
I
1
I
Drain engine oil, refer to LUBR/CAT/ONSYSTEII/I. l
Drain engine coolant. Refer to COOLING SYS- I.
TEII/I.
Disconnect coolant hose from top of thermostat.
Disconnect coolant hose from top of radiator.
Disconnect the top coolant hose of the water rrnr20DB-O03-039,6
pump cover. TYPICAL

Remove the radiator retaining bolt. Remove radiator, thermostat and water pump
cover as an assembly.
Remove CLUTCH COVER See procedure in this
subsection.
Disconnect the oil pressure switch connector.
rm r2 D08-O1&086_a
TYPICAL - TOP OF RADIATOR

1. Radiator retaining bolt
RSITIOVG WSTGF DUITID COVSI SCTGWS.
rmr2CI10-D05-008_a
1. Oil pressure switch connector
Remove exhaust spring.

Loosen exhaust clamp and turn it in order to ac-
cess the clutch housing screw behind.
208 rrnr2011-064
Section02 ENGINE
>
la.
. Ma.
rmr2D08-O1 6-U24
rrnI20 08-O15-069_b
TYPICAL
TYPICAL
1. Exhaust clamp
Clutch Housing Inspection
Complete the clutch housing removal by following lnspect the clutch housing for cracks or other
the steps detailed in ENG/NE REMOVED FROM damages. Replace if necessary.
VEHICLE Check sealing surface for flatness.
Engine Removed from Vehicle Clean oil orifices in clutch housing from contami-
Place a drain pan underthe clutch housing to catch nants using PULLEY FLANGE CLEANER (P/N 413 711
oil spillage. 809), then use compressed air to dry it.
Remove starter screws.
Remove all clutch housing screws.
rn1r20OB—01 6-0253
TYPICAL
1. Clutch housing
2. Clean oil bores
rmr2lJ08-D16-D70_a
TYPICAL lnspect plain bearings for scoring or other dam-
2. M8 retaining screws (4) ages.
3. M6 Starter retaining screws (2)
Measure plain bearing inside diameters and
Remove the clutch housing. Gently tap on clutch compare to the crankshaft and balance shaft
housing using a soft rubber mallet to separate it journal diameters (support bearings). Refer to
the from the crankcase. CRANKCASE AND CRANKSHAFT subsection.
Replace if measurement is out of specification.
rmr2011»064 209
i i
Section02 ENGINE
rn1r20(}8-01641263 rmr2008-O16{J2B_a
TYPICAL TYPICAL
7. Plain bearing (crankshaft support) 1. Clutch housing
2. Plain bearing (balance shaft support) 2. Marking of tolerance group
A. Measure plain bearing inside diameter
If paint marking is not visible anymore, measure
PLAIN BEARING INSIDE DIAMETER inside diameter of clutch housing bore where plain
bearings are inserted.
CRANKSHAFT SUPPORT BEARING
SERVICE LIMIT I 30.040 mm <1 .1827in) ¢
BALANCE SHAFT SUPPORT BEARING l\
SERVICE LIMIT I 20.060 mm (.7898 in) .8
Plain Bearing Replacement in Clutch
Housing
Plain Bearing Removal
Mark the joint locations of the plain bearing seg-
ments on the clutch housing, prior to removing
the plain bearings.
rmr2OD8-016-029
Pull out the plain bearings. MEASURE CLUTCH HOUSING BUFIE DIAMETER
REQUIRED TOOL
Use the following table to find proper tolerance
BLIND HOLE BEARING PULLER SET group of plain bearing.
(P/N 529 O36 117)
CLUTCH HOUSING PLAIN BEARING
BORE DIAMETER TOLERANCE GROUP
£-I _
32.921 mm to 32.930 mm
Red
Er (1.2961 in to 1.2965in)
II
32.930 mm to 32.940 mm
la
l1.2965in to 1.2969 in) Blue
V.- ,M;._, .1~
32.940 mm to 32.951 mm
(1 .2969in to 1.2973 in) Yellow
r I
Unless otherwise instructed, never
use a hammer to install plain bearings. Plain
l I ‘ '4 bearings should only be installed using a
rmr2UOBvU16-O27
press.
Plain Bearing Installation Heat clutch housing up to 100°C (212°F) before
Crankshaft support plain bearings are available in installing plain bearings.
3 tolerance groups (red, blue and yellow). The Install plain bearings using the appropriate plain
proper tolerance group is marked with paint on bearing installer.
the clutch housing.
210 rmr201 l~064
I
Section 02 ENGINE
REQUIRED TOOL Fit the plain bearings with PETAMO GREASE GHY
133N (PIN 420 899 271).
BEARING
C‘a“k§§aIr§ns“pP°" PUSHER/REMOVER Support the clutch housing with a suitable support
9 (P/N 529 036 095) under the bearing seat. Use an O-ring to hold the
plain bearings together during installation. Then
carefully press-in the plain bearings.
NOTE: Remove O-ring just before plain bearings
are completely pressed in.
NOTICE The plain bearing segments must be
positioned as marked during removal.
525036095
rrr\r20DB»01607‘l rrnr200B-O1 6»D32_a
PLAIN BEARING INSTALLATION — CRANKSHAFT SUPPORT 1. Piain bearing segments {crankshaft support)
BEARING 2. Plain bearing segments (balance shaft support)
3. Clutch housing
REQUIRED TOOL
Balance shaft support BEARING PUSHER
Clutch Housing Installation
bearing (P/N 529 036 096) For installation, reverse the removal procedure.
Install a NEW clutch housing gasket and NEW
sealing washers.
Lubricate plain bearings with PETAMO GREASE
GHY 133N (P/N 420 899 271), before installing
clutch housing.
529036096 ‘lighten clutch housing screws following the illus-
trated sequence
CLUTCH HOUSING SCREWS TORQUE
M6 screws 11 Nvm (97 lbfvin)
M8 screws 19N~m (168 lbfvin)
rmr20D8-016-O72
PLAIN BEARING INSTALLATION — BALANCE SHAFT SUPPORT

BEARING
rmr2011-064 211
Section02 ENGINE
Z Z I | — 1
__K ,.
rr11r200B{)55-CI22_a
rmr2011-D15-O05_a 1. Clutch hub retaining nut

2. Spring washer
TIGHTENING SEQUENCE
Reinstall remaining parts, refer to the appropriate Remove clutch hub.

instructions.
,1
CLUTCH HUB
Clutch Hub Removal
Remove:
— Clutch cover
— Pressure plate
- Clutch plates.
See procedures in this subsection.
Lock crankshaft in TDC position, refer to
Insert the CLUTCH ASSEMBLY HOLDER (P/N 529 rmr2008-O55-O20_a
036 133) completely to the bottom of the clutch 1. Clutch hub

drum.
Clutch Hub Inspection
Inspect grooves in clutch hub for damages or
wear caused by steel driven plates. Replace if
necessary.
-u~
5290361 33
Remove the clutch hub retaining nut and spring

washer.
rmfl00B055-O21_a
INSPECT GROOVES IN CLUTCH HUB FOR WEAR
212 rmr201 ‘I-064

Section02 ENGINE
Clutch Hub Installation CENTRIFUGAL CLUTCH

Ensure thrust washer is installed on clutch shaft Cent|.ifuga| Cmtch Remova|
ahead of clutch drum assembly before installing _
the Ciutch hub Remove the following components, see proce-
dure in this subsection.
— Clutch cover
— Pressure plate
— Clutch plates
— Clutch hub.
Remove retaining ring.
1-, ‘wt
in T
IHIFZUOH-O55-U35_8 _,.. 1
Apply PETAMO GREASE GHY133N (P/N 420 899 271)

on clutch hub teeth. ;
Insert clutch hub.
Reinstall spring washer and hub retaining nut.
rrn r2 O08-D55-O23_a
1. Retaining ring
Remove centrifugal clutch assembly.
‘RI-.7 T»-».-.\
/
rmr2U08-055-O22_a
1. Clutch hub retaining nut

2. Spring washer
648 413 711 400) On rmr2D08~fl55024_a

hub retaining nut threads, 1. Centrifugal clutch assembly
fighten "UT To Spe°ifi°aTi°"' Centrifugal Clutch Disassembly

CLUTCH HUB RETAINING NUT TORQUE Clean and thoroughly dry the centrifugal clutch as-
190 |\|-m ('|4Q]bfof~[) sembly to remove all lubricating oil.
_ _ _ _ Trace index marks on the following parts with a
Reinstall remaining parts, refer to the appropriate permanent marker for rea5Semb|y_
instructions in this subsection. _ Pressure mate
— Cam
— Centrifugal weights (rollers).
rmr2011-064 213
| W
Section02 ENGINE
9*"? Q
1* ‘K
4 3 ro
Q_
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il4~;J T
if >‘ .r . O, I
r. A
3 rmr20‘II)G‘I 5-D1 1_a
rrr\r20D8-055rO26_a
1. Retaining ring
1. Pressure plate 2. Stop plate
2. Centrifugal weights (rollers) 3. Wave spring
3. Cam 4. Pressure plate
5. Centrifugal weights
Remove retaining ring. 6. Cam
7. Bushing
Centrifugal Clutch Inspection

Inspect stop plate for cracks or abnormal wear.
Replace if necessaw.
-»2
Pressure Plate
lnspect pressure plate for cracks, deformation or
abnormal wear. Replace if necessary.
lnspect the thrust surfaces on both sides of the
pressure plate for abnormal wear or grooves.
imI‘20D8-05 5-025_a
1. Retaining ring
2. Centrifugal clutch assembly
Remove stop plate.

Remove wave spring.
Remove pressure plate.
Remove centrifugal weights.
Remove cam.
rmrZDU3~U55*DZ9_B
INSPECT THRUST SURFACE OF PRESSURE PLATE
Centrifugal Weights
lnspect centrifugal weights for scoring and wear.
Check if needle bearings of centrifugal weights
move freely. Replace if necessary.
Cam
lnspect cam for cracks, deformation or abnormal
lnspect the cam thrust surfaces for grooves or ab-
normal wear.
214 rmr201 ‘I-064
Section02 ENGINE
Centrifugal clutch assembly must be equipped

with bushing showing an identification groove
and must be installed together with the proper
pressure plate also showing an identification
groove.
\ /1
’/ \ _.
rrnr2011-015-101_a
lg
2
rrrir2UOB-055-030_a 2. Snap ring groove

INSPECT THE CAM THRUST SURFACES
Bushing ‘I 2 3
lnspect bushing for cracks, grooves, or abnormal
x la - T;-,;_.' f|_
Measure inner diameter of bushing. . ' ‘ *
.\_ , ‘ '— _ '
rrnr201Cl-01.'>Ci03_a
1. Centrifugal clutch assembly
3. Bushing
1 -"
rrrir20fl8-055-031_a
INNER DIAMETER MEASUREMENT
1. Bushing
k
BUSHING INNEFI DIAMETER
SERVICE LIMIT I 63.10mml2.484in)
Replace bushing if inner diameter is worn beyond
specification.
Centrifugal Clutch Assembly tmr2D10-0\5—00Z_a
Assemble the centrifugal clutch with 1. Identification groove

2. Pressure plate
the utmost care. Failure to strictly follow pro-
cedures may cause parts to loosen and/or mal- Assemble cam and pressure plate so the longer
function of clutch, and may lead to serious en- fingers are facing each other.
gine damage.
Centrifugal clutch assembly is the reverse of dis-
assembly. However, pay attention to the follow-
ing details.
rmr201 1 -O64 215

i M I
Section02 ENGINE
"-’
--‘I
1~_
- E
rm r2008-055-0323 rmr2OOB-055-023_b
PRESSURE PLATE AND CAM ALIGNMENT 1. Centrifugal clutch retaining ring
1. Pressure plate long fingers
2. Cam long fingers
NOTE: Be sure to align corresponding numbers

CLUTCH DRUM
on cam, pressure plate and centrifugal weights Clutch Drum Removal
(rollers) as marked prior to disassembly. Remove the following items, see procedures in
Insert the assembled clutch pressure plate, cam this subsection.
and weights over the bushing with the clutch — Clutch cover
pressure plate on top. — Clutch disc assembly
Install wave spring, stop plate and retaining ring. — Clutch housing
Centrifugal Clutch Installation - Clutch hub
— Centrifugal clutch assembly.
However, pay attention to the following. Remove the clutch drum thrust washer.
Install centrifugal clutch with cam alignment hole
in line with clutch drum alignment pin.
NOTICE Make sure to correctly position cen-
trifugal clutch in the clutch drum.
.4“-
-1
~a»-- "
rmr2ODB-O55~lJ35_a
Remove the clutch drum.
rrri r2 U08-055-034_a
1. Alignment hole in centrifugal clutch

2. Alignment pin on clutch drum
Install centrifugal clutch retaining ring.
216 rmr201 1-064

Section02 ENGINE
T/4
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rn1r2008-0550363 rm r2008-O1 6-037__a
1. Clutch drum 1. Oil pump drive gear
2. Retaining nuts
Remove the thrust washer. 3- 04”’
4. 5“PP°”
Distance Pm’
sleeves
NOTE: Mark the position of springs and retainers,

prior to removing them.
Remove clutch drum and gear together as well as
both white marked springs and their spring retain-
ers.
\ T\
rrri F1008-D5 5-037_a
1. Thrust washer
Clutch Drum Disassembly

Remove the oil pump drive gear.
Remove retaining nuts.
Remove the outer support plate. |rnr200B-055-038_a
1. Clutch drum gear
Remove distance sleeves. 2. Springs with white marks
3. Spring retainers
Remove all other springs with their spring retain-

ers.
Remove the spring discs and thrust washer.
Remove the inner support plate.
rmr201 1-064
217
Section02 ENGINE
1/p
_ r- T/“T.
6 Q’;/" "
5\ II“?
I 1.:‘
,
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.\\ ~\-,,,,;9F
@?"3<¢» ‘*T-_- _ I
1.
2.
tit
Outer compression springs
Inner compression springs
rmr2DU8-016»D49_a
Clutch Drum Gear

1—/I
1. lnspect thrust surface of inner support plate
3. Spring retainers
4. DISC springs lnspect bearing sleeve surface for scoring and
5. Thrust washer wear.
6. Inner support plate
Clutch Drum Inspection

r
1
Compression Springs and Retainers

Measure free length of each compression spring,
refer to the following table.
OUTER SPRINGS AND WHITE MARKED SPRINGS
SERVICE LIMIT I 26.75 mm (1.053in)
INNER SPRINGS "11
..-
-~i. u\w\i‘
SERVICE LIMIT | 25.65 mm (1.01 in)
If a spring is out of specification, replace all rmr201 D-(J1 5~0Od_a
‘J
I
1,“
§f\
<1
springs as well as all spring retainers. 1. Bearing sleeve surface
lnspect spring retainers for wear, cracks or scor- Measure inner diameter of bearing sleeve.
ing. Replace all springs and all spring retainers as
an assembly.
Support Plates I
._ I T "
.;,,.'
J"~'i
- ~_
‘j*‘_
lnspect support plates for cracks or abnormal 4T Tl T‘ 1‘ T ,..
wear. Replace if necessary. S" ___‘ 1‘

-""3 ‘ '
-
l"* .“
lnspect the thrust surface of inner support plate T-T ITTT I
for abnormal wear or grooves. If necessary,

replace inner support plate, thrust washer and -_§
spring disc as an assembly. 91f‘’-}'I‘,“3|
all
r'~T -
-_ I ._"
rmr2008-016-O78_a
A. Inner diameter
BEARING SLEEVE INNER DIAMETER

SERVICE LIMIT | 30.060mn'i(1.183inl
218
rrnr2011~064
Section02 ENGINE
lnspect teeth condition for pitting or other dam-

age.
Replace clutch drum drive gear if necessary.
Clutch Drum
lnspect slots in clutch drum for damages or wear
caused by friction plates. Replace if necessary.
rrnr2008-055-041,a
~.
1. lnspect spring cavities
Clutch Drum Assembly

M
Assembly of the clutch drum must
be carried out with utmost care. Failure to
/M strictly follow the procedures may cause parts
to loosen and/or malfunction of the clutch
rrnr2008~055-04D_a drum and may lead to serious engine damage.
INSPECT SLOTS IN CLUTCH DRUM FOR WEAR
Assemble the clutch drum in the reverse order of
lnspect the slots where there is a small hole. disassembly. However, pay attention to the fol-
lowing details.
Slight markings or grooves caused by the centrifu-
gal clutch are normal. If grooves on the side of the The position of the clutch drum, sup-
rib are deeper than 0.5 mm (.02 in), replace clutch port plates and clutch drum gear for assembly
drum. is clearly indicated with location holes in each
part. During assembly ensure that all location
“"4132
r*T " T
rrrir2008-D55—550_a
1. Slot with a small hole

2. Slight markings or grooves here are normal rrrir2DO8-D55-O42_a
3. Maximum groove depth allowable here is 0.5mm (.02i'nl
ALIGNMENT OF LOCATION HOLES FOR CLUTCH DRUM
ASSEMBLY
lnspect spring cavities for deep grooves, caused 1. Hole in clutch drum
by springs. Replace clutch drum if necessary. 2. Hole in inner stfport plate
Hole in clutch rum gear
NOTE: Slight markings caused by the springs are :I¥$-\> Hole in outer support plate
normal. Do not replace clutch drum needlessly. Insert the three M8 x 25 flat head screws from the
inside of the drum. Hold the screws in position as
you install the remaining parts.
rm r201 ‘I-064
219
Section02 ENGINE
Install inner support plate on clutch drum, ensure 0‘ '

the location holes are aligned with each other.
"I._
2___,--
I rmr200B-05S045_a
1. White marked springs
2. Spring cavities marked with punched holes
rmr200B-055-043_a Install remaining springs and retainers into spring
1. Support plate cavities.
2. Spring discs
3. Drum assembly screw Install distance sleeves on clutch drum screws,
Install thrust washers and spring discs. Position then outer support plate. Ensure that the location
the concave side of spring discs toward the clutch holes aligned with each other.
drum.
, '_ "all "'g§,_ T

,0 "3 ,-~ "‘.
‘I TT §_ ii; "
.
I
I‘ LID 1 2 ‘ ._
Q‘! 1
II i. rmr2008-O16-045_a
.
I
I
1. Distance sleeves
2. Outer support plate
3. Location holes
I.
I Install retaining nuts on clutch drum screws.
rrni2010-0‘l5~013_a
Apply LOCTITE 648 (GREEN) (P/N 413 711 400) on
1. Concave side of spring discs threads of retaining nuts.
"lighten nuts to specification.
Install the clutch drum gear, ensure the location
holes are aligned with each other. CLUTCH DRUM NUTS TORQUE I
Install both white marked springs with spring 30 N°Fn (22 lbf'ft)
retainers into the corresponding spring cavities
which are marked with punched holes inside the Finally, install the oil pump gear. Ensure the drive
inner support plate. tabs on the oil pump gear engage in the drive tabs
on the outer support plate.
220
rmr201 1-064
Section02 ENGINE
- {*4
0"‘ Ya
M
-;i \ \ v
Q /*-_,
rrnr2DD8~O1 6-046_a 3 ‘ I
1. Drive tabs on oil pump gear

2. Drive tabs on outer support plate rrnr2DOB+'J55-O36_a
1. Clutch drum
Functional Test
After assembly of the clutch drum is complete, install the other thrust washer on clutch shaft.
check for torsion of the clutch drum on clutch
drum gear. Proceed as follows.
— Reinstall clutch drum on clutch shaft.
- Ensure crankshaft is locked at piston TDC.
- Try to turn clutch drum.
There must be no free-play between clutch drum
and clutch drum gear.
if free-play has been detected, inspect all clutch
drum components (e.g. spring disc, thrust
washer, inner support plate). Refer to CLUTCH
DRUM /NSPECT/ON in this subsection. -1
V "
Clutch Drum Installation
rmr2ODB4)55035_a
For installation, reverse the removal procedure. 1. Thrust washer
Insert the first thrust washer on the clutch shaft Install clutch hub and all remaining parts. See pro-
before installing clutch drum. cedures in this subsection.
rmr2008-055411-l7_a
1. Thrust washer
insert clutch drum on the clutch shaft.
221
rmr2011-064
Section 02 ENGINE
Subsection 11 (HYDRAULIC CONTROL MODULE (SE5))
HYDRAULIC CONTROL MODULE (SE5)

SE RVICE TOOLS
FLUKE 115 MULTIMETER .......................................................... .. 529 O35 868 ....................................... .. 234
OIL PRESSURE GAUGE .............................................................. .. 529 036142 ....................................... .. 233
SERVICE PRODUCTS
LOCTITE 243 (BLUE) ................................................................... .. 293 800 O60 ............................... .. 236-237
rn 2011 oas 223

Section 02 ENGINE
11 N- 11 N-m
EW—@ <91 ibr-rili (fir-in)
1 U/<1 Loctite 242

' - 19 N-m
£2 ' B Q / § isg§tet?ub€Z:ant) (168 lbqin)
0 Eng_i|ne ’ 19 N'm @!
OI (168 Ibf~in)
I Q
5 N-m
(44 lbf-in)
6 N-m
(53 Ibf-inl
\
X
fig C)O\ ‘ 23 N-m
19 |\|.m (17lbf~f‘t)
Loctite 6 (168 lbf-in)
\
243
X11 N-m
\ (97 lbf-in)
Loctite _/’
243 _Z
,/ Engine oil
/
Q (l N'|'n ‘
{ \ (97 lbf-in) ‘
Engine Engine oil
2 N-m oil ,1
(18 |bf'in)
I
2 3N . m
6
Loctite
243 ‘
(17 lbf'f‘t)
'Q “~\_
NEW
<21 5'51’-‘la (9171 |§;_';2‘)
= Component must be replaced when removed. 11 N-m
\;_-/I" (97 lbf-i n)
rm r2 D08-07 7001 _b
224
rmr201 i-O65
Section 02 ENGINE
GENERAL /if \,
":.;..»§.r .- t — .
~-‘_-._1‘ T‘
>5"...I-v.. . ‘. ~
Always disconnect the negative battery cable be- r _.
V'“\'"‘4 ' '
.
‘G (
fore working on the engine.

~ _ J~ I ‘§e\_~~_
.» ' .1 ‘
. '. " _ I
7.1-,
A WARNING 1-. 1'~*",/ .; I.
Always disconnect the BLACK (-) cable first _ _-., '1'-;;_».,,--‘ ;*.'.
and reconnect last.
:
1+".
‘Ir<’
fr’-(.1 ' -7,17-".5
M \‘
’ w’
I 5"]. ' ' A
Q " Fl r‘§l“."-1.'Z‘:".*”_‘ 1"’ . ' ‘I 2
Always carry out electrical tests on components _ 15'-:’7\.o‘~" A ' .. . ' . ,_ .. _--‘ "5, I
before removing or installing them to ensure their ti. ex“,3' . mg
__ "I
._
‘V
.
ll‘
' L---xi
I‘ -IXI
state of operation.
During assembly/installation, use the torque val- I 1.-»'\-;;'_H
:'§ Hr->1“;. . Ir, "Ti
§;T.;§- f
ues and service products as in the exploded
VIEWS.
»,fat. .'~*;1;‘ ..,1_<.l*5"l§"
1 \ I
;.
1
"" I‘ ~‘* ". —__ _— l.
--; -v_:_ '-; V_,---....o
Clean threads before applying a thread locker. Re- 4 v * “’ __,_4/I
fer to SELF-L 0C/<lNG FASTENERS and ./.06 TlTE 3 3*" "1;-'5 1"” Ki 5
APPL/CAT/0Nat the beginning of this manual for rmIZ010—0i6{J02_a
complete procedure. . Upshift solenoid

Downshift solenoid
Clutch solenoid
A WARNING . Clutch modulation solenoid
S-'1-‘=5-0N‘* Hydraulic control module (HCM)
must be strictly adhered to. Shift Solenoids
tabs, elastic stop nuts, cotter pins, etc.) must The shift solenoids are located on top of the HCM
be replaced. module.
The LH side solenoid function is to upshift to a
higher gear.
NOTICE Hoses, cables and locking ties re- The RH side solenoid function is to downshift to
moved during a procedure must be reinstalled a lower gear.
SYSTEM DESCRIPTION
(COMPONENTS)
The transmission control module (TCM) manages
4 solenoid valves located on the hydraulic control _ 3.)
module (HCM) which control and activate the gear
(K:
shifting process.
NOTE: Consult also the ELECTRON/C SH/F7’
SYSTEM (SE5) subsection for an overview of the
gearshift operation and troubleshooting.
rm r2008-077-02 5,3
1. Shifting valve
2. Upshift solenoid
3. Downshift solenoid
Clutch Solenoids
The clutch solenoid function is to disengage and
engage the clutch when shifting occurs.
For disengaging the clutch, the solenoid is ac-
tivated and oil pressure from HCl\/I moves the
clutch piston.
rmr201 1-065 225

Section 02 ENGINE
At engaging the clutch, the clutch modulation so- ' ‘* -1 v‘ '2 ,

lenoid function is to bleed the oil pressure from . X5 . _ .;.
the clutch piston (through the clutch solenoid) to .-'1'!"
control the clutch engagement speed. '\
fig
“"v
‘ ‘$
."_ ‘
x-. st.‘,.‘1t*‘.-» '}
“r
‘I
. _I
t
“Q
3’,
\~
5'."-~
l -V,._.~v 1
1'-‘
iW:- '1
i
rmr201 0016-DO3_a
\._
TYPICAL
\ 1. OiI tan k
2. Oil supply line to HCM
The HCM includes its own oil pump specifically

used for the clutching and gear shifting.
rrrir20UE-0774J25_h
1. Clutch modulation solenoid

2. Clutch solenoid
Hydraulic Control Module (HCM)

The HCM shares its oil with the engine. The HCM
uses its own oil filter to protect the hydraulic com-
ponents.
rmr2008-078—004_l:
1. Oil pump
2. Oll pressure regulator
The mechanically-driven pump continuously turn,

when engine is running, to feed the oil in the sys-
tem.
The hydraulic system works at approximately
rmfl0D8—O7E-013_b
1 200kPa (174PSl) when shifting. An oil pres-
1. Oil filter sure regulator is used to stabilize the pressure.
A self bleeding regulator valve, located at the
The oil tank supplies oil to the HCM. highest point of the shifting system, is used to
bleed away air trapped in the system back the to
crankcase.
22a rmr201 I O65

Section 02 ENGINE
Subsection 11 (HYDRAULIC CONTROL MODULE (SE5)Il
rmr2008»078-008,31
1mr2008-O78-fl20_a
1. Link rod
2. Hydraulic piston location
The shift shaft is attached by a mechanical link to
the HCM. A hydraulic piston moves the link rod
to either upshift or downshift. The piston moves
when oil is sent through shift solenoids when en-
ergized by the TCM.
's=..:
rmf2DD8-075-O07_a
1. Link rod between HCM and shift shaft
rrnr2011-065 227
Section 02 ENGINE
SYSTEM DESCRIPTION (PRINCIPLE OF OPERATION)

Hydraulic Operation when No Shifting Occurs
When the engine is running and there is no shift selected, oil is supplied from the oil tank to the HCM
oil pump.
Oil is then circulated through a passageway in the clutch solenoid back through the HCM oil pump in a
continuous loop to maintain the oil flow ready for any upcoming shift request.
El
F
G fig
L
tell
I!
rm|’2008078~U D9
I IIEI
I .4 ~ <— an
;- IIQ El
ENG/NE RUNNING, NO SHIFT
1. Oil tank
2. HCM oil pump
3. Clutch solenoid
228
rmr201 1 -O65
Section O2 ENGINE
Hydraulic Operation when Shifting Occurs

When a shift is selected, the clutch solenoid is activated by the TCl\/l and oil from the pressure line is
directed to the clutch servo.
At the same time oil pressure builds and is limited to 1 200 kPa (174 PSI) by the HCM oil pressure reg-
ulator.
That oil, under the same pressure is also available at the shift solenoid valves.
Q 4
iII-'3
, .. "Z
, I fill; Jlli‘
-
| El
'1 '
0,
E
4444 g
rm r2008-07801 0
I-5
CLUTCH DISENGAGEMENT
1. Clutch solenoid
2. Clutch sen/o
3. HCM oil pressure regulator
rmr201 1 065 229

Section 02 ENGINE
After the clutch solenoid is activated and the clutch is disengaged, one of the shift solenoid is then ac-
‘L ivated
by the TCM.
Pressurized oil can then pass through the solenoid valve to one side of the shift hydraulic piston.
The hydraulic piston moves the linkage and a shift is initiated.
As the hydraulic piston moves, oil on the opposite side of the piston is pushed out through the shift
solenoid to the crankcase sump.
1»
(El
4‘-
444I-4
il
"TI
(EL-.210
H
Il. *s@'=*=
L... Zuni
rmr2DUE-O75-011
SHIFTING
1 . Clutch solenoid
Z. Shift solenoid
. Hydrau lic pis'to n
-ix‘-.0
Crankcase sump
230
rmr201 1-065
Section 02 ENGINE
When the TCl\/I determines that the shift has been initiated by the position of the gearbox position sensor
(GBPS), it turns off the shift solenoid and the clutch solenoid.
The TCM then sends a pulse width modulated (PWM) signal to the clutch modulation solenoid.
Oil is then bled off of the clutch servo through a passageway in the clutch solenoid and the clutch mod-
ulation solenoid to the crankcase sump.
The clutch is then smoothly engaged.
W IUI.II.I'UL
Wiffi IZI
i-__
@ El
rm r2DO8~07 8-01 2
CLUTCH ENGAGEMENT MODULATION
1. Clutch solenoid
2. Clutch modulation solenoid
3. Crankcase sump
rmr201l-065 231 I
Section 02 ENGINE
MAINTENANCE
HCM OIL FILTER
NOTE: The HCM uses the same oil as the engine,
but has its own oil filter. T-T
Q) 4:11“
Tfigjg-__
“('5'/(oi)
(,v
.
~;
~
CI
;i'___% -~_— -W _: . <' [gr

HCM Oil Filter Removal
NOTE: Replace HCM oil filter and engine oil fil- $L43€»“‘E"’o:‘i
:. ‘Z’ °
_:;‘_>_i:
or - T 1-» :1.-
J L: v.‘ ‘, -. ,
ter at the same time. Refer to MAINTENANCE

.5‘CHEDULEfor frequency.
Drain engine oil. Referto LUBE’/CAT/ONSYSTEM rmr2DD8-07 7-0O3_a
...- ~.--Us it
‘ -3») — I "_L-.‘)“-
1. Oil outlet orifice to the hydraulic control module /ubncation

subsection. system
2. Oil inlet orifice to the oil pump
Remove oil filter cover screws.
Install a NEW O-ring on oil filter cover.
To ease assembly and prevent displacement of
the O-ring during installation, slightly oil filter and
O-ring, refer to following illustration.
rrnr2DO8-D78-O13_a
1 2 r .__,:_~r_
1. Oil filter cover

2. Cover screws
rrr\r2OOB-07 7-U D1l_a
Remove oil filter cover with O-ring. Discard 1. Apply oil here
O-ring.
Remove oil filter. ||\|$PECT|Q|\|
Dispose filter as per your local environmental reg-
ulations. HCM OIL PRESSURE TEST
HCM ()i| Finer |n5ta||ation Oil pressure test prerequisite:
The installation is the reverse of the removal pro- - Warm engine (80°C (176°F))
cedure. Pay attention to the following. ' The i9¢°mm9il¢I Oil in engine
Check and clean the oil inlet and outlet orifices in - The proper oil level.
hydraulic control module for dirt and contamina- Remove the following LH body panels, refer to
tions. BOD)/subsection
— Top side panel
Remove plug screw located behind HCM oil filter
housing.
232 rmr201 ‘I-065

Section 02 ENGINE
rmr20OB-D77-1D0_a
mnr2OD8-O77-‘l 01
TYPICA L
TYPICAL
Install the OIL PRESSURE GAUGE (P/N 529 036142) NOTE: The nominal oil pressure is only achieved
in HCM oil pressure threaded tap hole. during clutch activation or shifting.
Connect the latest version of B.U.D.S. and logon.
Make sure TCM is operational. Refer to TCM
STATUS MAL/DAT/0Nin the ELECTRON/C SH/FT
SYSTEM (SE5) subsection.
Select the Activation page and TCM folder. Look
at the Routine section of the page.
T"'“"_"_*_“" a-mu-= ’ ' '

*-—-lama.“I
’-uni“
I ml; ‘var:-~
.V ;:
' .
‘ I mu%_wuwc0-at , Q. Iw-1|-undue]
tt
_,_____._l I
‘- __J-
; , Ids I
‘ I I IGWII
I I CIDIIQNI
I G-hltinlhfl I
rmr2008-077-102
TYPICAL
s:\||uuu¥_I _ _ hAV_7 _ 7
5=I1-it iv--We I-H-Ii " T O The oil pressure should be within the following
rm!2IJO8-D78-022
ACTIVATION PAGE, TCM FOLDER
values.
Start engine.
IDLE SPEED,
°"- PRESSURE WHILE SHIFTING
Let engine idle. MINIMUM 900 kPa (131 PSI)
NOTE: If more than 400 kPa (58 PSI) is read when
NOMINAL 1 200kPa (174PSII
the engine is idling, check for blockage in clutch
solenoid valve and in HCM passageways. MAXIMUM 1 600 kPa (232 PSI)
Select Clutch activation on the Routine section
of the B.U.D.S. Activation page. If oil pressure is not within the specifications,
check the following:
While clutch is activating, watch pressure gauge — Oil leaks (internal or external)
and note the value.
— HCM oil filter
— HCM oil pressure regulator
— HCM self bleeding valve
— Hydraulic valvels) and solenoidlsl
rmr201 1-065 233

Section 02 ENGINE
- HCM oil pump

— HCM.
Drain pressure gauge into oil tank.
Reinstall removed parts.
Disconnect B.U.D.S.
PROCEDURES
- ' _\.
SHIFT AND CLUTCH SOLENOIDS ‘\\-.\<\K\\\‘
<.-\_\\k\'
\~\ KKK
Solenoid Activation Test with B.U.D.S.

Connect the latest version of B.U.D.S. and logon.
Make sure TCM is operational. Refer to TCM
STLITUS MAIL/DAT/ON in the ELECTRON/C S/-//FT rmr200B-078-0 25_a
SYSTEM (SE5) subsection.

Disconnect the 8-pin solenoid connector.
Select the Activation page and TCM folder. Look
at the Routine section of the page.
/ion» I -
It
--I C.-'Fw-1 Inn: —-» -—----
.__.1_.__l I 1;; ,,,,,,.,,_,,,,,,,|
it
-:u_-_T-II ) TIIilir__0mluIl3w) I Upgncoudlnil
uncnnimu I ' I
wannnuann] I ,
I I ‘Mo I i
X
I Olfifififl
Gfliflflfllfl
l
l ,;-
.fTF§ _Q_ -_L_.._m_L_

an-null n-A-mm ml _ Q
rmrzouscvsozz
ACTIVATION PAGE, TCM FOLDER
rmr2008-07 8-O29_8
Clutch to activate each solenoids on the Activa-
tion section of the B.U.D.S. Activation page. Ac- Solenoid Resistance
tivate the solenoids in the following order while Use the FLUKE 115 MULTME1-ER (P/N 529 O35 868)
listening and feeling the solenoids. and se|eCt the position Q
T Upshifi solenoid Measure the resistance between the following
— Downshift solenoid pins
- Clutch solenoid
SOLENOID RESISTANCE
— Modulation solenoid. SOLENOID CONNECTOR PIN AT 20°C
Use the following electrical tests if any solenoids (WIRE C OLOR) (68°F)
did not activated. 1 8
Upshift (RED)
2.50 — 2.80 Q
(WHITE)
Solenoid Test
2 7
Remove LH upper side panel. Referto BODYsub- Downshift
(RED)
2.50 — 2.80 Q
(WHITE)
section.
3 6
Disconnect TCM connector. Clutch
(WHITE)
2.50 — 2.80 Q
(RED)
Clutch 4 5
l.OO—1.50Q
modulation (O RANGE) (WHITE)
234 rrnr2011-065
Section O2 ENGINE
Subsection11 (HYDRAULIC CONTROL MODULE ISE5II
If the resistance measuring is not within the spec-

ification replace faulty parts.
Power Circuit
Turn ignition switch ON. ""7".
Set multimeter to Vdc.
Read voltage as follows.
\?
SOLENOID rm 02008-D01 {)23_c
/‘ » .
SWITCH CONNECTOR VOLTAGE REAR FUSE BOX
PIN 1. Sol + TCM fuse
8 and battery If solenoid test succeeded, continue testing.

No voltage
ground
Upshift Contact Circuit
1 and battery Battery voltage
ground Turn ignition switch OFF.
7 and battery Set multimeter to Q.
No voltage
ground Check continuity as follows.
Downshift
2 and battery Battery voltage TCM SOLENOID
ground SWITCH CONNECTOR CONNECTOR RESISTANCE
6 and battery PIN PIN
No Voltage
ground Upshift 32 8
Clutch
3 and battery Battery voltage Downshift 33 7
ground C|utCh 34 5 CIOSG I10 O Q
5 and battery
No voltage Clutch
Clutch ground
modulation 30 5
modulation 4 and battery
ground Battery voltage
.1
<-
rmr20U8-O7%O30_a
rm r2 008-07 B-030_b If a resistance failed, check wiring and connectors

between TCl\/I and solenoid connector.
lf a solenoid test failed, check sol + TCM fuse (2)
in rear fuse box. If it is good, check wiring and Solenoid Removal
connectors between TCM and battery.
Refer to the BODYsubsection and remove the fol-
lowing parts from the LH of vehicle:
— Top side panel
Remove the lateral panel support.
rmr2()1l-065 235
Section 02 ENGINE
Disconnect solenoid connector from wiring har- Solenoid Cleaning

ness. Clean tip of clutch and modulation solenoids with
Remove screws retaining solenoid valve body to a contact cleaner.
HCM.
Remove Allen screws securing the modulation
and the clutch solenoids from the side of HCM.
NOTE: Solenoids are available as single parts, re-
place complete solenoid valve set only if neces-
saw. For removing pins of the connector refer to
CONNECTOR lNFOl-?/WA 7'/ON subsection.
kl
1: "‘ rmQU08-077-02B_a
1. Clean this area with contact cleaner
,.../:13?-'¥:;?:l
Solenoid Installation
‘> I D 5*?§fi"_~"{€i‘f-Z'tT:f
it’ Pay attention to the following details.
’\_l('nr-:€i*Z""-‘»-;- Apply the threadlocker product and tighten sole-
rrnr2ODB-07 7-D275
7. Allen screws noid valve body screws to specification.

2. Solenoid valve body
3. Solenoid valve screws SOLENOID VALVE BODY SCREW ITORX)
Remove solenoids from HCM.
NOTE: Use caution when pulling the shifting
Trttttrsérrr
LOCTITE 243 (BLUE) _.
solenoid from the body as engagement pin and
washer may fall out. (P/N 293 soc 060) 6 N'm (53 'bI "‘I
3
Apply the threadlocker product and tighten sole-
I
noid valve screws to specification.
SOLENOID VALVE SCREW (ALLEN)
THREADLOCKER
PRODUCT TORQUE
LOCTITE 243 (BLUE) .
(P/N 293 soo 060) 2 N'm (18'bf°'“I
Check oil level in oil tank and refill with recom-
mended oil if necessary. Refer to LUBE’/CAT/ON
SYSTEM subsection.
Install pins of the solenoid valves in the correct
place of the connector, refer to following table:
V01 C3EA 1 2 4
TYPICAL
1. Shifting solenoid
2. Engagement pin
3. Washer
4. Valve body
Solenoid Inspection
Check solenoids and gaskets for any damage. Re-
place if necessary.
236 rmr201 1-O65
Section O2 ENGINE
WIRE IDENTIFICATION Oil Hose Nipple Inspection

SOLENOID NUMBER AT CONNECTOR Clean oil hose nipple with a part cleaner, then use
(WIRE COLOR) air pressure to dry it.
1 8
Upshift
IRED) (WHITE) A WARNING
2 7 Always wear skin and eye protection. Chem-
Downshift icals can cause skin rash, skin burns and se-
(RED) (WHITE)
vere eye injury.
3 6
Clutch
(RED) (WHITE)
Check if threads of the oil hose nipple is damaged.
Clutch 4 5 Replace if necessary.
modulation (ORANGE) (WHITE)
Check oil hose nipple for cracks. Replace if nec-
essary.
OIL HOSE NIPPLE
Oil Hose Nipple Installation
The oil hose nipple is located on the front of the
HCM. For installation, reverse the removal procedure.
Apply LOCTITE 243 (BLUE) (P/N 293 800 O60) on
hose nipple threads.
Torque oil hose nipple to specification.
PART TORQUE
,
Oil hose nipple 11 l\l~m (97lbf~in)
Install oil hose.

Refill oil tank with recommended oil and check
engine oil level. Refer to LUBE/CAT/ON SYSTEM
subsection.
rmr200&0770U5_a
7. Oii hose nipple ”lN" HCM OIL PRESSURE
Oil Hose Nipple Removal REGULATOR
Drain engine oil, refer to Ll/BHlCAT/ON SYSTEM The HCM oil pressure regulator is located inside
subsecuon. the hydraulic control module.
Remove oil hose from nipple.
Unscrew oil hose nipple.
lamina
ma;
in-niu
ll,
I. .
,1 Ill
1% l,.
1..1. "il|
"ll,. l<
"1l ¢r.,,‘J,
:@—V,1‘?;i;J.i;rfi
3&1 —
'i§:_ j
1?;
rmr200ErCl77~DD7_a
1. HCM oil pressure regulator location

rrr1r20D3-O77-flO6_a
1. Oil hose nipple HCM Oil Pressure Regulator Removal

Remove oil pressure regulator from HCM.
rmr201 H155 237

Section 02 ENGINE
Refill oil tank with recommended oil and check

*4 engine oil level. Refer to LUBH/CAT/ON SYSTEM
if *5? subsection.
;;_
'=f"‘§ E HYDRAULIC CONTROL MODULE
(HCM)
I’ HCM Removal
-1- »*'f..'/-/‘fa I"
Make sure gearbox is on N position.
rmr2l'.I084)77-O08 a Remove the LH lower side panel. Refer to BODY
Plug screw subsection.
Sealing washer
SP rin Q
swww Pressure regulator piston
Drain engine oil. Refer to LUBI-7/CAT/ONSYSTEM
subsection.
HCM Oil Pressure Regulator Inspection Unscrew bolt securing the ignition coil.
Check:
— Oil pressure regulator bore and its sealing sur- X I rt, *” ';~ ,./
face for wear or scoring -/ - " ti r
_'
T31)‘
7», ( ‘ V .
— Regulator piston and its seat for wear or scoring '
T7 -5:;"“‘:'
A " ""
@ | A .. /"
— If the regulator piston moves easily in the bore. . ‘)1 l%?§‘-""'/
. A-,.-'f'fl i -3‘. -N41
\ .. ‘g
NOTE: A leaking piston causes low oil pressure
and will cause shifting problems. 5 , )'~l N‘ M“
lnspect compression spring for any deformation
it'll
-
\ --f=E§~ '
SIr-‘iii I 9*
“:1; “
.
and free length. R
.\
,_ .
.1;-1 II’ ". - 4 ' /‘1—~“\____' ~“ ‘,. I
"“;':", I ‘l L} '9 1"’. -1~'~ 1 I -‘

1/’ff
rmr2008-077-203_a
|‘)::v)‘\.-1‘:
. I I T)’
ll lthfllit
_NTT_TT
.1;-"_\ \ .
I.
r 1 I
pl‘?-\_ i
- w 1. Ignition coils bolt
r_ lllillllllll ll)‘W
Remove bolt retaining ignition coil support to lat-
eral support.
rn~.r2008-U 77-009
’ -. ' 1 r ts»
fir T /"' “ /'
SPRING FREE LENGTH /I V
/'Q w '
.3 .\\' » . ' ) ." II
I, gL _.» 11-‘
SERVICE LIMIT | 110mm (4.s31m) . _;0-'1 e’ /"T /1—>o~
1. _ "
Replace worn or damaged components. " ’

rT55‘
lg
» .-,,- ‘ =1-P-=—:=
2 »§_ - T g
Clean bore and thread in the hydraulic control unit y~ " “ "*~~~--*4-..
from metal shavings and other contaminations.
HCM Oil Pressure Regulator
/”, \_
\ .
2;? ~\-'-3*-z‘.
K
1».-.:=\r l
.-'—1-\\,‘
.¢=‘.:¥:r I
I
,
_
__
I
r--——_—-—"
4:“ -<~‘-Ir-:~."" _‘
_. _‘
Installation _
33
>% // / a\
\\/ \t\ g
\\\ ___‘
\\“ ‘F,
_ TTT‘--__g_‘
~‘\\‘.___
‘T’
C ‘ '
Y‘
For installation, reverse the removal procedure. / \\§ Y," 1% \_ '

Pay attention to the following details. \»<.
rmr200B-077-204_a
\ .-S. I. I . "' ital
22%
/./FfiLl,-\-‘in-5"‘-'='-°., .
Always install a NEW sealing washer. 1. Remove this bolt
2. Ignition coils support
Torque plug screw to specification. 3. Lateral support
PART TORQUE Unplug the solenoids connector and remove con-

nector housing from the ignition coils support.
O" F“§ffg“'§H'§§V“'a‘°’ 19 N~m (168lbf-in)
238 rmr201 ‘I -065

Section 02 ENGINE
14! w ~_ 1-yr
"/'~"~“’T 1 2"“ ‘ "r ~ 1*‘
H »,*~ ",3; j, L" _A _
' ‘/,/ 5,1,; ‘ilgli Hg ’?‘ ,1 _ If r-_ ' l
... I ‘I’ —‘"='-_ 1- t .
>1» » ' ~- I: .
A4:]____4.@
I
lts‘
“l\if.l '9sf;
. II~ 3“
‘Z
. '-~.z,~: I.’ ~ .
g , _
- 2.? Q
7
II‘ ‘T I
~.
rml'Z008{l77-2fl5_a
LI lltal.;.- at rmr2008-077-208_a
“mi; mi,
TYPICAL TYPICA L
1. Solenoid connector 1. Oil cooler inlet hose
2. Ignition coils support 2. Engine outlet connector tube
3. Oil tank
Remove engine inlet connector tube from
Disconnect the oil tank vent from crankcase. crankcase. Discard O-rings.
.~ I '-»_ k //~¢-'
J '9 *
Ive). .
\I
I’ ‘II,/I
1‘)
Qr/ 5-t’:. ~.= 2/_

y
.
~' ~
l
. '2)?‘ .
‘ IS.
. 4%
'T_j
IT
<1
t~ ’f"’*.
C‘ :1’;-<))l
1’ ~<7.~)'""'-"I ”
- /ii: \\
- I‘ "J
1. ‘ I "Yr
"" '|
/‘T I
1
LIC) 1"’ '_ MN.
" F.“ .i
‘ts
rt~o
/13;,
/.1
''.~;9*-
E, _t
—. /,,/'
i.’
.-. U. at -.,.,_ .
-:5':i*I'-I . =1‘ . Q ‘ .>')I ‘ lo I2 7
rmr20U8-U7 7-209)
rrnr2008—077-206_a
TYPICAL
TYPICAL 1. Engine inlet connector tube bolts
1. Oil tank vent 2. Oil cooler outlet hose
2. Oil tank
Detach the clutch servo hose from the bottom of Move oil tank and oil cooler aside to make room.
oil tank. Remove HCM 0/L FILTER, see procedure above
in this subsection.
...\].
Unscrew the Banjo fitting securing the clutch
hose to HCM. Discard sealing washers.
/‘~ L "‘
},<?oi~t~.;‘_.~ I ~'=“i;s~. ~ .15;

\ \ “.7 I ~ A ,' T f *1-
j
1 lilimtfi 13?
rmfl008-O46-UD3_a
3 2 I.)Léfé
TYPICAL
1. Clutch servo hose
2. Oil tank \ (g;r”""T“ (6
Disconnect oil cooler inlet hose from engine outlet ,m,m,,,,_,,,,,_,
connector tube. 1. Banjo fitting
2. Clutch hose
3. Sealing washers
rrnr20'l1-O65 239
Section 02 ENGINE
Remove circlip of shift linkage.
,1‘
rmr200B-G77-201 _a
1. Circlip Oil Pump Removal
2. Shift linkage
Remove the HCM from the engine, refer to HY-
NOTE: For easier removal of plug screws, loosen DRAULIC CONTROL MODULE IHCMI in this sub
them before removing the HCM from the engine.
Remove screws retaining the HCM to the mag- Remove intermediate OII pump gear
TIGTO COVGI’.
“W ‘1' ‘ /’ ‘S’ i” t
. if Q3 _ I;-‘<\’_;t‘\;. I,‘
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rm r2 008077-202_a
"m __, .‘ 5 1 Intermediate oil pump gear
1. HCM screws Remove retaining ring

Pull the HCM and discard its gasket.
HCM Installation
cedure.
OIL PUMP
The oil pump is located inside the hydraulic control *1
module (HCM). ‘Q
The HM'
C isequippe" a WI'th'tsI ownoi‘I pump _ L‘ ...iini_L.;
imr2008-D77-D1 2_a
1 Retaining ring
2 Oil pump gear
Remove OII pump gear, needle pin and thrust
240
Section 02 ENGINE
~" t wv-1 NOTE: Minimal imperfections or scratches are al-

lowed.
Check inner rotor for corrosion pin holes, pitting or
other damages. If defects or damages are found
replace oil pump inner and outer rotor.
rmr200B-077-U13_a
1. Oil pump gear

2. Needle pin
3. Thrust washer
Remove oil pump cover. Discard the O-ring.
.
rmrZClIJ8-O77-016_a
7 (tin (I. _
TYPICAL
1. Pitting on the teeth
§-
. I“ \
' Q L,‘ ‘ Radial Clearance
M .
‘Q. _- H \.,.
,i Using a feeler gauge, measure the radial clear-
** .‘i'»'-r ' ..,- ance as illustrated. Refer to table following
-O ~_
--as illustration for service limits.
r "'~_
ii
N ./Lu_:< _‘)
."\
V
T‘‘I/:3:-1‘
(A32
_ ’
X' 11;‘ .3!
. ‘ V“-‘Ii
‘
p--I- .g
_
‘-4
rmr2OD8077~Ol4_a
1. Oil pump cover screws
2. Oil pump cover
3. O-ring
Remove oil pump shaft with rotor set.
Q
UV’
1 21% rmrZ0O8-O77-O1T_B
TYPICAL
1. Outer rotor
Q 2. Inner rotor
rrr\r2008~077-015_a OUTER AND INNER ROTOR CLEARANCE

1. lnnerrotor
2. Oil pump shaft SERVICE LIMIT
3. Nee dlepi‘n
4. Outer rotor A
5. Groove
Oil Pump Inspection

—- O-mm <-O<>98r=>
C
Check oil pump cover and hydraulic control mod-
ule surface (where the oil pump cover fits) for If clearance between inner and outer rotors OX-
damage. ceeds the tolerance, replace the oil pump.
lnspect rotor set and oil pump bore for serious
marks, scratches or other damages. If so, replace
damaged parts.
rmr201 1-U65 241
Section O2 ENGINE
If clearance between outer rotor and its bore in Install oil pump shaft.
hydraulic control module exceeds the tolerance, NOTE: The groove must face outwards and be
replace the complete oil pump assembly and/or visible when installing oil pump cover.
the hydraulic control module.
Axial Clearance
Measure outer rotor thickness with micrometer.
ta it.
rmfZ008-077-015_a
1. Inner rotor
2. Oil pump shaft
3. Needle pin
4. Outer rotor
5. Groove
rmr2008-077-018 Assemble oil pump into hydraulic control module.

OUTER ROTOR THICKNESS Markings on inner and outer rotor must face to-
ward oil pump cover.
Using a depth gauge, measure the depth of the oil
pump bore as shown.
imooosorwia 4A
OIL PUMP BORE DEPTH (HYDRAULIC CONTROL MODULE} rrnr20D8<Cl77-01 7_b
MARK/NGS ON INNER AND OUTER ROTOR

Difference between measurements should not 1. Markings
exceed 0.15mm (.O059in). If the clearance is
out of tolerance, replace the complete oil pump Install oil pump cover with a NEW O-ring.
assembly.
NOTE: When the axial clearance of the oil pump
assembly increases, the oil pressure decreases.
Check oil pump gear for serious marks and dam-
age. lf so, replace damaged part.
NOTE: Minimal imperfections or scratches are al-
lowed.
Oil Pump Installation
Clean all metal components in a solvent.
Coat inner and outer rotors with oil.
242 rmr2(l11-065
Section 02 ENGINE
i,‘"_»'-*f}"i"*"."\ g X
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_ ..._____
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rmr2008-O77-O1 1_a
1. Intermediate oil pump gear

rmr20D&D77-O21_a
1. Oil pump cover
2. New Oting
Remove circlip of needle bearing.
HCM Oil Pressure Test é4', if _

After assembly, start engine and make sure HCM
oil pressure is within specifications (refer to HCM
O/L PRESSURE TES Tin this subsection).
Lv
INTERMEDIATE OIL PUMP GEAR I9;
“""'u'7
The intermediate oil pump gear is located on the
backside of the hydraulic control module. H1!»
T»! ‘l,
0&8\_ v§
The intermediate oil pump gear is driven by the ,‘
. ‘Jr I
1
hexagonal nut of the crankshaft and drives the oil 4-LI--I
* 41> A
pump gear. rrnr20U8-O77-023_a
1. Circlip
Remove needle bearing from hydraulic control

module.
It -.I P? ‘ow
_,j-.._;.
_ - ..-Q
fr-an
V » bf,‘
:r"*_i
T--an
. E5i*?‘¢-’i-
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i:.~5'.f.‘3‘_;;_ >11‘
Emil.‘ ‘AI ";.-It -»
ri'|'lr20[]8-077-IJ22_fl
I
1. Intermediate oil pump gear M
2. Hexagonal nut of crankshaft I . \
'9 .
.. ll I E
ntermediate Oil Pump Gear Removal rn1r2008-O77-024_a
Drain engine oil, refer to LUBRICATION SYSTEM 1. Needle bearing

2. Thrust washer
subsection.
Disconnect solenoid connector from wiring har- ntermediate Oil Pump Gear Inspection
ness. Check if teeth and internal hexagon of intermedi-
Remove oil hose from hydraulic control module ate oil pump gear are damaged, check intermedi-
nipple. ate oil pump gear for cracks. Replace if necessary.
Remove hydraulic control module from engine. Clean needle bearing with a part cleaner and I
Remove intermediate oil pump gear. check for any damage. Replace if necessary.
rmr2011-065 243
Section 02 ENGINE
i \\ I}
Check needle bearing journal for any damage or
abnormal wear. Replace hydraulic control module
if necessary.
\ ‘Ir ‘ '
-
._,
- Q‘?~/a”»
‘
{P
1'
' ‘.
Intermediate Oil Pump Gear

Installation
Apply engine oil on needle bearing.
I ‘ ~
I,y
145%-Eégi.I - *—'"'_ “ s~@.2A
Refill oil tank with recommended oil and check , ‘,3
engine oil level. Refer to LUBRICATION SYSTEM
subsection. rmr2 DOS-D7 7-U47
HYDRAULIC PISTON The HCM is still retained by one

screw. This screw is located below oil filter
The hydraulic piston is located on the lower side adaptor. Do not force the HCM to avoid dam-
of the HCM. ages.
The hydraulic piston is activated by the solenoid
:32/es and is shifting the gears via the shifting link-
. . l \_ _1 g .\
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' rrnr200B-O77050_s
I 'H‘~>1'>
by 1. HCM retaining screw
rmr2UD8-077-I’JZ9_a 2. Oil filter adaptor
1. Hydraulic piston
2. Shifting linkage Remove and discard the HCM cover gasket.
NOTE: Before disassembling the hydraulic piston,
check if there is any oil contamination in the area
of the bellow. If there is a leakage it is a indication
for worn out or damaged piston linings, if neces-
saiy replace faulty parts.
. frfldii
in -
Q
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Y
Q_
4Q.
Hydraulic Piston Removal

Drain engine oil, refer to LUBRICATION SYSTEM ’ I)
"il-
.
‘f’,§'m‘
=-r‘Z?
. Q5
5‘..~
_ "0 --I
subsection.
Remove HCM O/L FILTER see procedure above
in this subsection. - ' ~‘-4;: .' 0
Remove the HCM cover by removing the follow- I
ing screws. rrnr20lJE077-O48_a
1. HCM cover gasket
Unscrew Allen screw from gear shift lever and re-

move shift linkage together with gear shift lever
from the shift shaft.
244 rmr201 1 065

Section 02 ENGINE
rmr2D08-O77'031_a
1. Al/en screw l‘rY1l'20UB'U77-Q33_3
2. Gear shift lever 7. Needle bushing
3. Shift linkage
Remove locking tie from bellow and slide bellow
Remove hydraulic piston plug screws. backwards.
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rrnr2008-077-034_a
7. Locking tie
M...‘
rmrlooe-077-o49_a 2. Bellow
7. Plug screws
2. Plug screw O-rings Remove shift linkage from hydraulic piston.
Remove retaining ring from guide pin.
rmr20OB-(J77-D35_a
1. Shift linkage
2. Hydraulic piston
rmr2OOB-O77-OQL8
1. Retaining ring Remove hydraulic piston by sliding it out to either

2. Guide pin side of the hydraulic module.
Remove needle bushing from guide pin.
rmr20‘l1-065 245
Section 02 ENGINE
Hydraulic Piston Installation

-,\_
NOTE: Sealing lip of piston linings must face
away of each other.
rmr2OCl8-077-038_a
1. Hydraulic piston
Hydraulic Piston inspection

Check hydraulic piston and piston linings for any
damage, scores or abnormal wear. Replace parts
if necessaiy
2 rmr200E-077'039_a
7. Position of piston linings
Oil hydraulic piston and piston linings prior of in-

stallation.
NOTE: Make sure not to damage the piston lin-
ings when installing the hydraulic piston.
After completing the installation check oil level in
,m,2,,,,,,,,,,,,,,_, oil tank and refill with recommended oil if nec~
7. Check hydraulic piston in this area for wear e53arV- Refer to LUBE/CA 7-/ON S)/57-E/W5Ub5eC'
2. Piston linings tiQn_
Check hydraulic piston bore inside the hydraulic

control module for any damage, scores or abnor- SH":-r LINKAGE
ma] W63“ Replace parts if necessary" The shift linkage is the link between the hydraulic
Check needle bushing, guide pin and sliding slot piston and the shift shaft.
of needle bushing inside hydraulic control module
for wear, scores and abnormal damage. Replace
parts if necessary.
5
i -
1 P
fl‘Y1l‘20UB-O77~O4D_B
WWW
7. Needle bushing
;%eme
3: gmft shaft
2. Guide pin
3. Sliding slot
246 rmr201 1 -O65

Section 02 ENGINE
Shift Linkage Removal

NOTE: To carry out the following instruction, it is
not necessary to remove the l-lCl\/l from the en-
Q
gine. For better understanding, many of the fol-
lowing illustrations are taken with the HCM re-
moved from the engine.
Select NEUTRAL position. rrrI12OOE-O77-OI\3_3
Remove body panels, refer to the BODYsubsec- 1. Check both ball joints in this area for wear
tion.
Shift Linkage Installation
Remove locking tie from bellow and slide bellow
backwards. For installation, reverse the removal procedure.
For basic adjustment assemble the shift linkage to
approximately 210 mm l8.268inl.
* A4 rrn r2008-077-D44_a
...4.\l SHIFT LINKAGE BASIC LENGTH
rm|’2l]O8077-03Il_a
A. 210mm (8.268in)
1. Locking tie
2. Bel/ow Ball joints must face in opposite direction.
Remove both circlips from shift linkage.
1 v LE 1?E ll
i.
/“
»- itl
1
rn'\r2008-077‘O45_a
1. Position of ball joints
y /" 5 N install NEW locking tie on bellow.

I ~'t~ . "
rmr20iJ8-O77-042_B
71;.
h J. --— _X install the gear shift lever. Align its slot with the
dot on the end of shift shaft.
1. Circ/ips
Shift Linkage Inspection

Check shift linkage rod for bending or any other
damage.
Check both ball joints for abnormal wear.
Check bellow for brittle and cracks.
Replace parts if necessary.
rm 12008-O77-D4E_a
1. Gear shift lever slot
2. Shift shaft dot
rmr20'l 1-065 247

48 l
Section 02 ENGINE
Subsection 12 (GEARBOX)
GEARBOX
SERVICE TOOLS
CRANKCASE SEAL PUSHER ...................................................... .. 529 O36 O92 ................................. .. 257
ECM ADAPTER TOOL................................................................. .. 529 O36 166 ................................. .. 254
FLUKE 115 MULTIMETER .......................................................... .. 529 O35 868 ................................. .. 258
HANDLE ...................................................................................... .. 420 877 650 ............................... .. 256-257
MAIN SHAFT PROTECTOR ......................................................... .. 529 O36 123 ............................... ..256, 268
MAIN SHAFT SEAL INSTALLER ................................................. .. 529 O36 O88 ................................. ..256
MAIN SHAFT SEAL PUSHER ...................................................... .. 529 O36 124 ................................. ..257
OIL SEAL INSTALLER ................................................................. .. 529 O36 O70 ............................... .. 256-257
PROTECTION SLEEVE ................................................................ .. 529 O36 O71 ............................... .. 256-257

SNAP~ON SNAP RING PLIERS ................................................... .. SRP3 ....................................... .. 263
SERVICE PRODUCTS
DOW CORNING 111 ................................................................... .. 413 707 O00 ................................. ..256
rmr2011-066
249
I | i | G
Section02 ENGINE
Subsection12 (GEARBOX)
I 1 I I | i
00
R Engige oil
,1. f
.1-
’,§_1.vf
"Q:
0 I Engige OII
' Q,
21’ Q I
\_ 11 N-m , _,
_6
Engine oil
/x (97 lbf-in) '
Xi‘ Q‘! 1 j
'\ O ‘ ’ "\>'?1.-.:—\
Loctite
6 243 I
Engine is ‘Q3 ‘T 5.5
oil .
6
Engine
oil
6 Dow C0rning111
I,§M5 Models Only
Dow Cornin 111

rrnr20OE051:‘»1 D0_a
250
rmr2011-066
Section02 ENGINE
SM5 Model
Engine oil
6
\,%
11 N-m
(97 lbf-in) i
Engine
oil
Loctiteg xA »j 6Eng_ine
243 > » )1 an
-=.\§
.§”j
11 N-m
(97 lbf-in)
If \*@ 0t’/mi“
c\Engine oil 11 N-m
(97 lbf-in)
~.
'-\.
.\\
»___
sw
‘X
Loctite
@. 243
Loctited To
243
< 809 II)?“'inf1% T“ “-/..

Q
Loctite
/X0 243
11 N'm
(97 lbf-in)

f|'T\f201 I-U17-DUI_3
rmr201 1-O66 251

Section 02 ENGINE
SE5 Model
Engine oil
$5’ 1
{LI
‘Q
Engine oil //
\.
11 N-m 6Engine oil
\
I97 lbf-in)
\ 6Loctite 243 i
\\/j
\.
"t
@@/
OEngine oil 9 N-m
(80 lbf-in)
0
Loctite 243

\' mr 2011-O '| 7-U U2_a
252
rrnr2011 066
Section02 ENGINE
GENERAL 3. On SE5 models, inspect HCM operation. Refer

to HYDRAULIC CONTROL MODULE /SE5)sub-
NOTE: For a better understanding, the following section.
illustrations are taken with engine out of vehicle.
However, it is not always necessary to remove en- PROCEDURES
gine from vehicle to perform some instructions.
Always disconnect the BLACK (-) cable from the REVERSE BUTTON TEST WITH
battery before working on the engine.
B.U.D.S.
A WARNING Connect vehicle to B.U.D.S.
Always disconnect BLACK (-) cable first and Select the TCM tab in the Monitoring page.
reconnect last.
Check the Switch Inputs.
During assembly/installation, use torque values lf LED turns ON when the reverse button is
and service products as in the exploded views. pressed in, it indicates that the button sends the
Clean threads before applying a threadlocker. Re- message.
fer to SELF-LOCK/NG FASTENERS and LOCTITE — On SM5 model, carry out the REl/ERSEACTU-
APPLICATION at the beginning of this manual for ATORACT/MAT/ON W/TH B.U.D.S. in this sub-
complete procedure. section.
- On SE5 model, verify the shift system oper-
NOTICE Hoses, cables or locking ties re- ation. Refer to ELECTRON/C SH/FT S)/STEM
moved during a procedure must be reinstalled ISE5/ and /-/l/DRAUL/C CONTROL MODULE
as per factory standards. (SE5) subsections.
A WARNING If LED does not turn ON when reverse button is
pressed in:
Torque wrench tightening specifications — Check leil multifunction switch (l\/ISL), refer to
must be strictly adhered to. LIGHTS, GAUGE AND ACCESSORIES subsec-
Locking devices when removed (e.g.: locking tion.
be replaced.
GEARBOX POSITION SENSOR
TROUBLESHOOTING (GBPS)
GBPS Reset
TROUBLESHOOTING To reset GBPS, refer to CLOSED THRO77'LE
GUIDELINES AND GEARBOX POSITION SENSOR RESET in
the ELECTRON/C FUEL /NJECT/ON IEF/I subsec-
Gearbox Does not Shift Into Reverse tion.
SM5 Mode/s
GBPS Test
Check fuse F7 of the front fuse box.
Check fault codes in B.U.D.S. software.
Check REVERSE ACTUATOR CABLE ADJUST
MENT See procedure in this subsection. Ensure vehicle is on NEUTRAL.
Unplug the GBPS connector.
SM5 and SE5 Mode/s
Perform the following tests.
Carry out a REVERSE BUTTON TEST W/TH
B.U.D.S. See procedure in this subsection.
Error Code (E) Displayed in Gauge
1. Proceed with CLOSED THROITLEAND GEAR-
BOX POSITION SENSOR RESET Refer to
ELECTRONIC FUEL INJECTION IEFII subsec-
TIOII.
2. Check GBPS. See GEARBOX POSITION SEN-
SOR TESTin this subsection.
rmr201 1066 253

Section02 ENGINE
GBPS Input Voltage Test

MULTIMETER PROBE POSITIONS I VOLTAGE
GBPS connector (pin 1) and GBPS
I connector (pin 3)
5 volts
l Ii jll
i 5290361 66
MULTIMETER PROBE RESISTANCE

POSITIONS @ 20°C
If voltage is adequate, check GBPS communica- (68°F)
tion link (CAN). GBPS connector (pin 2) and ECM
adapter tool on ECM A (pin F4)
If there is no voltage, check each GBPS input as
follows.
“*—@*-
MULTIMETER PROBE POSITIONS VOLTAGE Below 1 Q
GBPS connector (pin 1) and ea. es.-I
battery ground
"Lt IJ"iIIi _ Q 5 volts

. IHI - * if resistance is out of specification, check wires
and connector pins. Repair and reset fault codes.
Ii
GBPS connector (pin 3) and
If resistance is good, replace the GBPS and reset
fault codes.
battery + terminal
GBPS Removal
Make sure that gearbox is in NEUTRAL position.
t" ‘ Battery On SM5 model, remove the control lever and the
~ - + voltage control lever spring.
Remove GBPS screws.
Remove the GBPS.
lf there is no voltage, check wires and connector

pins.
Replace or repair defective parts and reset fault
codes.
GBPS Communication Link Continuity Test
Unplug “A” connector from ECM and connect it ‘(Z 1
‘(O the ECl\/I ADAPTER TOOL (P/N 529 O36 166).
ITHIZODB-(117-003_fl
SM5 MODEL
1. Control lever
2. Control lever spring
254
rm r201 1-O68
Section02 ENGINE
T? OIL SEALS
Oil Seals Access
Main Shaft Oil Seal
Remove FRONT SPROCKET Refer to DRIVE
BELTAND REAR WHEEL subsection.
<--- Gear Locking Shaft Oil Seal (SM5)
‘in
'\ Remove the GEARBOX POSITION SENSOR. See

procedure in this subsection.
Shift Shaft Oil Seal
rmr2DOH-05 E-002_a
SE5 MODEL Remove gearshift lever.
Shift Drum Shaft Oil Seal
GBPS Installation Remove the GEARBOX POSITION SENSOR. See
For installation reverse the removal procedure. procedure in this subsection.
Align GBPS with the flat on the shift drum shaft. 1 'I ll
.1' ‘z l4'll“"-Ir"
ll I
—2
vmr2DDB-017-on-La rmr20D84317-005_a
TYPICAL SM5 MODEL
1. Flat on shift drum shaft 1. Main shaft oil seal
2. Gear locking shaft oil seal
On SM5 model, install the control lever spring as Shift shaft oil seal
Shift drum shaft oil seal
shown in the next illustration.
_______ J
->-p--__
‘-_-
|n|u-no-u-n
,~_-.--_,-
“nun----I
..,_.,,.-u~,,-.¢-
QR
@--up-ur-
-_,-,---i--gm-1
p-1---_-nun
rrnr2ODE-01 7-2D0_a ¢,,~.,.|,-.~.m-
in‘ - A
1. Spring hook rmr2005-O56-lJO3_a
2. Straight end of spring
SE5 MODEL
Proceed with ctosac THRO77'LE AND GEAR- 1- gjairshaftoilseal
BOX POS/T/ON $5/vsoa asset in the 1150- 5; all-ii 375$ Zlliiiaéii seal
TRONIC FUEL IN./ECTION IEFII Subsection.
l'rnr201‘l~OB6 255
Section02 ENGINE
Oil Duct Cover Oil Seal REQ_U|RED '|'QQ|_

F*em°"e The 0/L DUCT 5'9‘/55’ as described I“ I MAIN SHAFT SEAL INSTALLER (P/N 529 oaa 088)
the L UBR/CA T/ON SYSTEM subsection.
HANDLE (PIN 420 877 650)
I . _|
..a
I 1 i-aw-~-.'c
0 I " -\ O I ’&-O’-a"""'
I I
" -.’;.
‘ \‘ ." I -H r I I
I Q 0 .- N~‘ |' ‘I J‘-'\ I
. ‘v__,.-' V':";* I S‘ I , - ' ‘I

"T‘"
w-|>.__§_
T. V» I ‘A I‘1-
U _.p:. 529035088
. "Z Ag Y - , :
. .1" 1| this . I -‘>1-~
rmr2 U08-O1 7-036_a
1 Oil seal il duct cover
2. Main shaft, clutch side
Oil Seals Inspection

Replace oil seals if they are brittle, hard or dam- "°m5°
aged. Gear Locking Shaft Oil Seal
Check running surface of shafts for scratches. Re- Protect gear locking shaft and move oil seal on
place if necessary, refer to SH/FT/NG SYSTEM or shaft.
GEARBOXin this subsection. REQUIRED TOOL
Oil Seals Removal f SLEEVE (P/N 529 036 O71)

PROTECTION
Use a small flat screwdriver to remove oil seals.
NOTICE Avoid scoring surfaces when replac-
ing oil seals.
T T vs-
Oil Seals Installation
NOTICE All oil seals must be installed with
sealing lip towards gearbox. 529U35I-I71
Apply cow CORNING 111 (P/N 413 707 000) inside Push oil seal into place-
each Seal REQUIRED TOOL
Main Shaft Oil Seal OIL SEAL INSTALLER (P/N 529 O36 O70)
Protect main shaft (PTO side) and move oil seal on
shaft.
REQUIRED TOOL
MAIN SHAFT PROTECTOR (PIN 529 O36 123)
529036070
‘ ,.
Shift Shaft Oil Seal

H Protect gear locking shaft and move oil seal on
j shaft.
5290361 2 3
Push oil seal in place.

256 r|'r1r20'l1-O66
Section02 ENGINE
REQUIRED TOOL
PROTECTION SLEEVE (P/N 529 036 O71)
420877 850
, “._V -r.,..>‘, _
. "J."|!P‘ .
Mu?
529036071
Push oil seal into place.

REQUIRED TOOL
OIL SEAL INSTALLER (P/N 529 O36 O70)
rmr2008~O‘l74‘J3E_a
529036070 1. Oil seal installer with handle

2. Oil seal
Shift Drum Shaft Oil Seal 3- Ma'"$"@"’
Put oill seal on shift drum shaft and push oil seal REVERSE ACTUATOR (SM5
into p ace. MODEL)
REQUIRED TOOL
Reverse Actuator Access
CRANKCASE SEAL PUSH ER (P/N 529 O36 O92) _
ing panels:
— LH rear side panel
E — LH bottom rear side panel.
Reverse Actuator Activation with
B.U.D.S.
529°3m 1. Connect vehicle to B.U.D.S.
OII Duct Cover O“ Seal 2. Select the Activation and ACC tabs.
Push OII Seal W0 main Shaft 3. Keep an eye on the reverse actuator.
REQUIRED TOOL 4. Click on the Reverse actuator button.
MAIN SHAFT SEAL PUSHER (PIN 529 036 124)
HANDLE (P/N 420 877 650)
5290361 Z4
l'l‘l’ll'ZD'| l-066 257

Section02 ENGINE
Vnuli I FMIIVIJ I mu.“ I umwi I rn. I -may I

REVERSE ACTUATOR INPUT VOLTAGE TEST
ALIIEFJI
A71 to I TEST PROBES RESULT

-- iii Actuator B
_ ?~2*:=~:~'_ l<*—. congegtgg pin negatifiea/post Battery voltage
Fflvfllfilllfifl I I
If voltage is as specified:
— Carry out a REVERSE ACTUATOR CONTROL
CIRCUIT TEST
If voltage is not as specified:
— Check open circuit between fuse F7 and re-
verse actuator connector.
rmr201 U-O36-201,6 Reverse Actuator Control Circuit Test
TYPICAL A 1. Disconnect the reverse actuator connector.
Step 1: Activation tab
Step 2: ACC tab
Step 3: Reverse actuator button
If actuator operates:
— Check control lever.
1- Check actuator cable and bracket condition.
— Check REVERSE ACTUATOR CABLE ADJUST
MENT
If actuator does not operate:
— Carry out a REVERSEACTUA TOR INPUT VOL75
AGE TEST
Reverse Actuator Input Voltage Test
1. Make sure fuse F7 is good. rmr2010017-O02_c
2. Disconnect the reverse actuator connector. I. FIQVQFSE ECTUETOT COIIIISCTOT
2. Set the FLUKE 115 MULTIMETER (P/N 529 035

868) to Vdc.
3. Have an assistant:
— Taking place on the vehicle.
- Holding the clutch and selecting the first gear
with the engine running.
— Pressing the reverse button.
NOTE: Vehicle must not be moving and engine
speed must be below 1800 RPM.
4. Measure voltage while button is pressed.
NOTE: Once reverse button is pressed, the
rrnr2(ll0-017-002_c
ground signal (control) will be held for 2 to 3
I. FISVQFSQ ECIUBIOT COIIIIECLOT seconds wether the button is held or not. After a
few attempts, it is normal for the system to shut
3. Set the FLUKE 115 MULTIMETER (P/N 529 O35 down the reverse function for a few minutes.
868) to Vdc.
4. Measure voltage as follows.
258 rmr201 1 -066

Section02 ENGINE
REVERSE ACTUATOR CONTROL CIRCUIT TEST NOTE: Start adjustment procedure before in-
stalling the new actuator on the vehicle.
Actuator Battery
ssttatissttsss. Reverse Actuator Cable Adjustment
1. Lay the cable guide bracket on a workbench and
connector pin positive (+) Battery voltage loosen the adjusting nuts.
1 (RD) post
2. Set the lower adjusting nut against the bottom
If voltage is as specified: of the cable guide threads.
— Replace reverse actuator.
— Check open circuit between reverse actuator
connector and cluster connector pin 3.
Reverse Actuator Replacement
1. Disconnect the reverse actuator connector.
rmr2D10-017-‘I01_b
1. Lower nut against bottom of threads.

3. Set the distance between the workbench sur-
face and the cable guide center line to specifi-
cation.
REVERSE ACTUATOR CABLE ADJUSTMENT
37mm :l: 1 mm (1.46in =1; .04in)
rmr201D-O17-OO2__r:
1. RSVEFSS GCTUBTOT COHHECTOF
2. Remove reverse actuator mounting screws.

3. Remove cable guide bracket mounting screws.
mzofomv-1o1_=
A. 37mm 1 1mm(7.46in 1- .04i'n)
4. ‘lighten the upper adjustment screw.

5. Install the cable guide bracket on the engine.
rrnr2010-017-101_c
CABLE GUIDE BRACKET
6. Position actuator on the frame member, then
loosely thread the rear mounting bolt.
4. Detach actuator cable from control lever. NOTE: The actuator center axis must be in line
5. installation is the reverse of removal however, it with the cable guide vertically.
is critical to carry out the HEVERSEACTUATOR
CABLE ADJUST/l//EN7T
rmr201 1-066 259

Section02 ENGINE
55-33 11. Validate that gearbox engages in reverse.
SHIFTING MECHANISM
Parts of the shifting mechanism can be replaced
without removing the engine:
— Shift shaft
_ — Index lever
-
rr\1QO10-O1 7-0O3_a
~ ‘ti - Index shim
ACTUATOR AND CABLE GUIDE IN LINE - |"de>< Spring-
7. Actuator
2- Cable g“""° Shifting Mechanism Removal
7. Place enough shims (P/N 710 002 O24) under- Remove clutch cover and clutch drum. Refer to
neath the actuator mounting plate front hole to the appropriate clutch subsection.
Obtain a"9“me"t- Pull out shift shaft assembly from crankcase.
8. Once parts are aligned, thread the front mount-
ing screw through the shims.
rmr201 D-O1 7-1 DO_a

7. Front mounting screw r""1"11*"741°3_a
2. Shims Typ]cAL
7. Shift shaft assembly
9. fighten mounting screws.
10. Make sure that there is an axial free play at Remove oil pump gear.
actuator rod.
ACTUATOR ROD AXIAL FREE PLAY
Minimum 2 mm (1/16 in)
rmr201 1-017-O04_a
TYPICAL
1. Retaining ring
2. Oil pump gear
3. Needle pin
'm"“‘°-°"*‘°2-“ Use a flat screwdriver to tum index lever counter-

A F’ee Pl” atihe a°’”"’°”°°' clockwise while removing index shim.
260 rmr201 1-oaa
Section02 ENGINE
-1
rrnr2003-U1 7-O16_a
TYPICAL
1. Pa wl
rmr2D‘l1-D17-IJU5_a
2. Spring
TYPICAL 3. Check for free movement
1. Index Iever
2. SGT9 w Index Lever
3. Index shim
Roller of index lever must move freely. Replace if
Remove the following parts: necessary.
- Screw
— Index lever Shifting Mechanism Installation
— Step ring The installation is the reverse of the removal pro-
— Index spring. cedure. However, pay attention to the following.
After installation, check if the gears engagement
is accurate and shifting system works properly.
GEARBOX
#1 / 1
rrnr2011-017-(J08_a
TYPICAL
1. Screw
2. Index/ever
Step ring rrnr20OB-01 7-O1 B_fl
:55-\ Index spring
. 15' speed
. 2"" speed
Shifting Mechanism Inspection . 3'4 speed
-I!=(-u.l\:\-
4!" speed
Shift Shaft 5. 5f" speed
6. Reverse speed
Check shift shaft for worn splines or other dam-
ages. Gearbox Disassembly
Check pawl and pawl spring for wear and proper Remove engine from vehicle. Refer to ENG/NE
operation. REMOVAL AND /NS774LLA T/ON subsection.
Remove FRONT SPROCKET Refer to DI?/I/E
BELTAND HEAR WHEEL subsection.
Remove the SH/FT/NG MECHANISM See proce-
rmr2011-066 261
Section02 ENGINE
Separate both crankcase housings. Refer to P1"

CRANKCASE AND CFFAN/(5HAFTsubsection.
Remove both shift fork shafts from shift forks.
-\
rrr1r2OCl8-D1 7-OI 9_a i

1. Thrust washer
2. Free pinion I15‘ gear)
. 3. Needle bearing
I I
I‘ . 1
1 v
1;-_ l 4. Thrust washer
rrnr200B4J17-Ol4_a 5. Shifting gear I41" gear)
1. Shift fork shafts
2. Shift forks Tap main shaft to assist withdrawing main shaft
assembly together with clutch shaft assembly.
On SM5 model, disengage shift forks and gear
locking shaft from shift drum. REQUIRED TOOL
Remove shift drum and bearing. SOFT HAMMER
{-it
_ I‘
is
_ ‘V . ‘_\ T
U
*3
%
# $-.~" - . '—‘~
~.‘*~'_ ’\
“\~
y .; .1/ #"‘~
X
II . 5‘;
.I ‘\§;it.?;.1;
;i ’*\
‘ . -s
rrnr20H£l-011~015__a
rmr2008-01 7-O20_6
1. Shift forks
2. Gear locking shaft (S/I/l5 Model only) 1. Main shaft assembly
3. Shift drum 2. Clutch shaft assembly
4. Bearing 3. Soft hammer
Before removing the gearbox from crankcase NOTICE Take care not to damage oil seal dur-
withdraw the following separate parts from main ing gearbox disassembly.
shaft. Reverse Intermediate Gear
Remove screws and retaining plate and withdraw
intermediate gear and needle bearing.
262 rmr201 1-D66

Section02 ENGINE
1—>?‘j<-1 .. '»._‘
2%? 3 If‘. \,
-es.
r>i,__;;_}\‘ .\€f;’1".:.~_. K ~
~ .,
w
%_ p
‘II
/'_"_
1:_ Q’Y\_,
’I
I rmr2008-U17-0233
1. Snap ring
rmr20l1E-01 7-D21_a
- ‘Ii; 2|
->. .- 2. Shifting gear (5th gear)
1. Screws
Remove and discard snap ring securing the re-
2. Retaining plate verse gear.
3. Intermediate gear
4. Needle bearing Withdraw free pinion with needle bearing and
bearing sleeve.
Ball Bearings
When gearbox is removed check gearbox ball
bearings for contamination and/or metal shav-
ings. Check if bearings turn freely and smoothly.
Replace if necessary, refer to CRANKCASE AND
CRANKSHAFT
Main Shaft
Remove and discard the snap ring.
“452 \ 3 2
RECOMMENDED TOOL J1
SNAP-ON SNAP RING PLIERS (P/N SRPBI
Remove free pinions and needle bearings.

rmr2008-D1 7-O24_a
. Snap ring
2. Bearing sleeve
3. Needle bearing
jl\_
.,
:\ ~
'
5 4 4. Free pinion (reverse gear)
I ,4 5. Thrust washer
\\ L“: ‘< I w *
S 7 ._ R 3 Clutch Shaft
N2 1
Remove the following parts from clutch shaft.
— Fixed gear
- Free pinion
- Needle bearing
— Thrust washer
rrnfZOOB-Cl17~022_a — Shifting gear.
1. Snap ring
2. Free pinion (3rd gear)
3. Needle bearings
4. Free pinion (2"" gear)
5. Main shaft assembly
Remove and discard snap ring retaining the shift-

ing gear (5111 gear).
Withdraw shifting gear.
rmr2011-O66 263
Section02 ENGINE
.
~.~ \ _..,,. 5
*5
‘Z:
/
O0
Z_'»/1.'. ,_
‘~01
fir}; OJ
Qt
.»I_
“L
J 1 ta~
-b_ inn‘
MT..I
Q_~3' .1‘
';\
'~ ,3‘
,'
rmr20lJ8-O17-O25_a
1.
2.
3.
Fixed gear (reverse gear)
Free pinion (5th gear)
Neeffle b95”T7Q vmr20DB-O19—U5Z_a
, "qr
‘L1‘\_.
V ’_‘
4. Shifting gear (2"'=' and 3'11 gear)
5. Clutch shaft assembly _ FREE FINION
2 Bearing surface
Remove and discard snap ring securing the free 31 Engagement slot
pinion (4"‘ gear).
Withdraw thrust washer and free pinion from
clutch shaft.
—s
/ll;
1’ -P-
(4-‘I
V 21 -2
vmr20oeo1eosa_a
TYPICAL — SHIFTING GEAR
1. Engagement dog
2. Shift fork engagement groove
'”""°°“*‘"°26-“ 3. Inner splines
1. Snap ring
2. Thrust washer Shift Drum
3. Free pinion (4"' gear)
4. Clutch shaftliswearl Check shift drum tracks for scouring or heavy
wear, like rounded engagement slots.
Gearbox Inspection
Always check the following when inspecting gear-
box components: 3 4
Gear teeth damage
Worn or scored bearing surfaces
er
Rounded engagement dogs and slots
Worn shift fork engagement groove
Worn tracks on shift drum
Worn shift fork engagement pins
Worn splines on shafts and gears MGDWME
Bent, worn or scored shift fork shafts _ Tm), )0, 7.)/;,»..1gea,s,,,-,=, ,=,,,,<
Bent, worn or scored shift fork. TracI‘ ”°r 4"’/5"’ gea ’$"”’ "°”‘
FAN“ Track for 2"”/Reverse gear shift fork
4. Track for gear locking shaft (SM5 model only)
Gear Locking Shaft (SM5)

Roller of gear locking shaft must move freely. Re-
place as necessary.
26 4 rmr2011-066
Section02 ENGINE
Shift Fork Gears

Check shift forks for visible damage, wear or bent l\/leasure the width of shift fork engagement
shift fork claws. groove.
Measure the shift fork claw thickness.
vmr20 08-O1 Q-054_a
TYPICAL — SHIFTING GEAR

-1 A. Width of shift fork engagement groove
WIDTH OF SHlFI' FORK ENGAGEMENT GROOVE

4.20 mm to 4.30 mm
vmi2006-022-075_a
NEW 1.1654111 to .1693 in)
TYPICAL SERVICE LIMIT 4.50 mm (.1772in)
1. Micrometer
A. Shift fork claw thickness
Check free pinions for wear.
SHIFT FORK CLAW THICKNESS Measure the inside diameter of free pinion.
4.00 mm to 4.10 mm
NEW (.1575in to .1614in) '
.
.\ E. '4‘
A
_ _:>.;-.={' ~ 1
-
,
'-1., '
‘_:-_ ’ “ ‘ ':
A ’_"~_i>
‘ ____..|
SERVICE LIMIT 3.90 mm (.1535inI
V
._~. ' .3
.1
g- .- _ .-V
.
Measure the shift fork engagement pin diamet 9|’. ..
",1; _.
. l . /
(» -‘V
- ___—;-1;:-.__ rt E
_I Q ' - -‘—
."'
_—\_
I.‘ k ‘xrii; E _’:V_iJTl’T-‘IL ‘_._' ‘ '1':

‘L.
I _ r , N
., _ \ ‘.-U‘
r _ . 1 -
. ;r¢ * 4 i ._;
‘v ._ I-
vmr2008-01905 5_a
TYPICAL
A. Diameter free pinion bearing
MAIN SHAFT FREE PINIONS

NEW
vrrir2006-U22-076_a 2If; GEAR

3'-d
GEAR 29 ~ 007 mm
. to 29 - 020. mm In
IQ
TYPICAL
1. Micrometer
A. Shift fork engagement pin diameter 40.009 mm to 40.025 mm
REVERSE GEAR (1.5752in to 1.5758in)
SHIFT FORK ENGAGEMENT PIN DIAMETER SERVICE LIMIT
5.92 mm to 5.97 mm 15* GEAR
NEW (.2331 in to .235inl 2"d GEAR 29.035 mm (1.l43in)
SERVICE LIMIT 5.850 mm (.2303 in) 3'“ GEAR
REVERSE GEAR 40.040 mm (1.5764inI
rmr201 1-066 265

Section02 ENGINE
II
“..' L
rmr200B-01 7-027_a
(A) -\> -> _-4.]
1. Retaining ring grooves
2. Splines
3. Oil orifices
1mfiU08—017-050_a l\/leasure diameters of main shaft bearing journals.

MAIN SHAFT — FREE PINION
1. 1&1 gear
2. 3"’ gear
3. 2"d gear
4. Reverse gear _. M. i _
.-ti-1 - . ¢ -1 1-2-1-—
ii‘ ‘
1 ~~ -‘ .. 11:. Ir 1 ~.:|
CLUTCH SHAFT FREE PINIONS '1-ii
.-. - . - ._ .
NEW
29.090 mm - 29.100 mm A T w o—>1<~
4"“ GEAR 11.144911 -1.1457111) rrnr20DB-017-D27_I:i
A. Magneto side bearing journal

26.000 mm - 26.013 mm B. Free pinion bearing journal
C. Clutch side bearing journal
5"“ GEAR (1 0236111 - 1.0241 in)
SERVICE LIMIT MAIN SHAFT BEARING JOURNAL
4"‘ GEAR 29.125 mm (1 .1467 in) NEW
5"‘ GEAR 26.025 mm (I .0246 in) MAGNETO SIDE 34.989 mm - 35.000 mm
BEARING JOURNAL (1 .3775 in - 1.378 in)
FREE PINION BEARING 24.980 mm — 24.993 mm
JOURNAL (.9835 in - .984in)
CLUTCH SIDE 19.987 mm - 20.000 mm
4 BEARING JOURNAL (.7869in - .7874in)
I.2...I
1
X’-@111;
SERVICE LIMIT
ifti
E
MAGNETO SIDE
BEARING JOURNAL
34.975 mm (1.377inl
1 2 FREE PINION BEARING

24.970 mm (.9831 inl
rmr2008»0i7-051_a
JOURNAL
CLUTCH SHAFT— FREE PINION CLUTCH SIDE
1. 4"’ gear 19.970 mm (.7862 in)
2. 5'" gear BEARING JOURNAL
Main Shaft Bearing Sleeve

Check main shaft for wear. Check if oil orifices are fr ee. Clean if required.
Check retaining ring grooves.
Check splines for wear and/or damages.
Blow out the oil orifices and check if they are not
clogged.
266 rmr2011-066
Section02 ENGINE
Measure diameters of clutch shaft bearing jour-

nals.
_*
O . ‘,_...”...
_ 1
It
rmr200B-017-029__b
tit
rrr|r2008-017-O2B_a
Magneto side bearing journal
1. Oil orifices Free pinion bearing journal I51" gear)
Free pinion bearing journal I41" gear)
Measure external diameter of reverse gear free DDFQP Clutch side bearing journal
pinion bearing. CLUTCH SHAFT BEARING JOURNAL
NEW
MAGNETO SIDE 19.987 mm - 20.000 mm
BEARING JOURNAL (.7869in - .7874in)
FREE PINION BEARING 21.987 mm — 22.000 mm
JOURNAL I51" GEARI (.8656 in - .8661 inl
FREE PINION BEARING 29.041 mm - 29.054 mm
JOURNAL (4th GEAR) (1.1433in -1.1439in)
CLUTCH SIDE 29.980 mm - 29.993 mm
BEARING JOURNAL (1.1803in -1.1808ir1l
SERVICE LIMIT
rmr2008-01 7-02B_b
A. External diameter MAGNETO SIDE

19.970 mm (.7862inl
BEARING JOURNAL
FREE PINION BEARING EXTERNAL DIAMETER
FREE PINION(SmBEARING
JOURNAL GEAR) .
21.970 mm 1.965111)
34.984 mm - 35.000 mm
NEW (1 .3773 in - 1.378 inl
FREE PINION BEARING .
SERVICE LIMIT 34.970 mm (I .3768inI JOURNAL (4th GEAR) 29.030 mm (1 .1429inl
Clutch Shaft GI-UTGH SIDE

BEARING JOURNAL
29.965rnm 11.179716)
Check clutch shaft for wear.
Check retaining ring groove. Reverse Intermediate Gear
Check splines for wear and/or damages. Check reverse intermediate gear, needle bearing
Blow out the oil orifices and check if they are not and bearing pin visually for wear, pitting and/or
clogged. scoring. Replace parts if necessary.
Gearbox Assembly and Installation
1 For assembly and installation, reverse the disas-
sembly and removal procedures. However, pay
attention to the following.
Install NEW snap rings.
IE2
(TIE
2 3
1
2
NOTICE Snap rings must be installed using a
retaining ring pliers only. Take care not to over-
stress them during installation.
1. Retaining ring groove
2. Splines
3. Oil orifices
rmr201 'l-066 267

Section 02 ENGINE
For gearbox installation, protect the main shaft

(PTO side) in order to avoid damaging main shaft
oil seal.
REQUIRED TOOL
MAIN SHAFT PROTECTOR (P/N 529 036 123)
5290351 Z3
IQ
1 T" -E
9'14
@
'Vt,.
1- \ an §;§vE
A Tno
rrr1r2O08-01 7-031 _a
1. Main shaft protector
2. Main shaft
3. Clutch shaft
Using a plastic hammer, ensure shafts are prop-

erly seated into crankcase housing.
Install the shifting mechanism
268 rmr201 1-066

Section 03 ELECTRONIC MANAGEMENT SYSTEMS
Subsection01 (OVERVIEW)
OVERVIEW
GENERAL
The vehicle senses its surroundings utilizing mul-
tiple on-board electronic control modules. These
sophisticated systems monitor and control a
broad range of functions.
The vehicle features the following systems:
— EMS (Engine l\/Ianagement System)
— VSS (Vehicle Stability System)
— DPS (Dynamic Power Steering).
rmr2011-067 269 ‘
Subsection 01 (OVERVIEW)
ENGINE MANAGEMENT SYSTEM (EMS)

SM5 Model
4- FRONT FRONT -P
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soeno'd AP FII OTI
switch Fu — Cu Coo Sta EV 1gn ¢v 9 CY
switch Gaps T>| _‘__.

?’ ._ iTp5_l_> EA
‘M’ — —MAPs —>
S3311"
-is GI‘ - 1—¢PS'—>
——cAPs—->'
TAS I
I I >> Basic data ,I
"
OPS
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Brake light VYV _
ijt
switch VO
ii ETA
—i<s2—|—> ST
~———icTs—> Correction
factors 4 K51 - ADIO
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inputs
outputs
-4-
rrnr2011-(J6H}01_aen
AAPTS (Ambient Air Pressure and Temperature Sensor) GBPS (Gearbox Position Sensor)
CAN (Controller Area Network) HO2S (Heated Oxygen Sensor)
CAPS (Camshaft Position Sensor) KS (Knock Sensor)
CPS (Crankshaft Position Sensor) MAPS (Manifold Absolute Pressure Sensor)
CTS (Coolant Temperature Sensor) OPS (Oil Pressure Sensor)
D.E.S.S. (Digital Encoded Security System) TPS (Throttle Position Sensor)
DPS (Dynamic Power Steering) TAS (Throttle Accelerator Sensor)
ECM (Engine Control Module) VCM (Vehicle Control Module)
ETA (Electric Throttle Actuator) WPM (Windshield and Parking brake Module)
EVAP Valve lEvap0rative Emissions)
270 rmr201 1-067

Subsection01 (OVERVIEW)
SE5 Model
_ 4-Faont FRONT ID
- i _ ‘E
I ‘ '\1_,| A . ' 1 Injector front

Q?‘ . I-. Q‘) cyl. (no 1)
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Englne Stop i
switch GBP$T>| _‘__.A

- ins E
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Inputs
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outputs
mO
rmr201 1—0614302_aen
AAPTS (Ambient Air Pressure and Temperature Sensor) GBPS (Gearbox Position Sensor)
CAN (Controller Area Network) H028 (Heated Oxygen Sensor)
CAPS (Camshaft Position Sensor) KS (Knock Sensor)
CPS (Crankshaft Position Sensor) MAPS (Manifold Absolute Pressure Sensor)
CTS (Coolant Temperature Sensor) OPS (Oil Pressure Sensor)
D E S S (Digital Encoded Security System) TPS (Throttle Position Sensor)
DPS (Dynamic Power Steering) TAS (Throttle Accelerator Sensor)
ECM (Engine Control Module) VCM (Vehicle Control Module)
ETA (Electric Throttle Actuator) WPM (Windshield and Parking brake Module)
EVAP Valve (Evaporative Emissions)
Section O3 ELECTRONIC MANAGEMENT SYSTEMS
Subsection 01 (OVERVIEW)
A highly advanced engine management system Drowned Mode (Flooded Engine)

(EMS) has been used to ensure a high power out- lf engine is fuel-flooded and does not start, this
put with cleaner combustion. special mode can be activated to prevent fuel in-
There are 6 main systems that are controlled by jection and ignition while cranking. Proceed as fol-
the engine management system (EMS): lows to activate it.
1. Electronic Fuel Injection (EFI) With ignition switch turned ON while engine is
2. Cooling system stopped, twist and HOLD throttle at WOT posi-
Evaporative emission control system (EVAP) tion.
Ignition system Press the start button and hold to crank engine.
. Starting system The mode is now on.
wwew. Engine clutch system. Releasing throttle will bring back the normal
mode.
Engine Control Module (ECM)
The ECM is the central point of the engine man- VEHICLE STABILITY SYSTEM
agement system. It reads the inputs, makes (VSS)
computations, uses pre-determined parameters
and sends the proper signals to the outputs for The VSS helps to maintain vehicle control in nor-
proper engine management. mal riding conditions as well as in emergency
avoidance maneuvers.
I’ //,' I To maintain vehicle stability, the VSS interacts
with the several other subsystems as well as
.l
with the engine management system. Refer to
, 1 '....
the l/EH/CLE S7215/L/7')’ SYSTEM /VSS) subsec-
' T“ a . tion for more details.
DYNAMIC POWER STEERING

smrzoosozmos NW9
TYPICAL — ECM
The Dynamic Power Steering (DPS) system pro-
The ECM is located in front of steering column. vides a computer controlled, variable steering as-
sist achieved by an electric motor to optimize the
.v"\. .' i ' ' I amount of steering input required by the rider.
_‘,2_/q%$?/ v‘ \-.'_"(‘l\\\-\:, A» Refer to the (STEERING /DPS)/4ND WHEELS sub-
-._ -. if 1 {
-‘:--
‘ ( "' section for more details.
1 -7‘, ‘ ""'?;a"\. 7- -\ P
ru-'~ 1;. -\.‘ ~ _i . _> \
. !'1~' ~-‘Q; ~ . ""1 ELECTRONIC SHIFT SYSTEM
-.. \ /’ ' I -in
3-;:»;.'.-I
t¢wQe,w/.~:+; _.\ /' A "i (SE5)
“"'l.‘.;1-"ill-‘-': -:§2~:‘_ "" / 1\.e,-‘E7 9" ;
___>
.
_\»_,i,.;
la.‘ l O1 .\m_ /_‘
I, ~.
v‘.‘ .-1'
\’»- ~>,
A, The SE5 engine features a sequential electroni-
2;; A..\ --. \\ -_/_‘ &"’ cally controlled mechanical 5-speed gearbox with
_J\
Q6?
V") a hydraulically-actuated type clutch system.
§\li\\\_--a-»elITlIi1.. ~ (silt .---/..._it
‘\
NOTE: The SE5 is an electronically controlled ver-

m1r201 D{)190Cl3_a sion of a sequential manual gearbox.
TYPICAL Refer to the /ELECTRON/C SH/FTSVSTEM (SE5)
7. ECM location
subsection for more details.
The ECM features a permanent memory that will l
keep the fault codes, customer information and

other engine information, even when the battery
is removed from the vehicle.
272 rmr201 1-067

Subsection O2 (CONTROLLER AREA NETWORK (CAN))
CONTROLLER AREA NETWORK (CAN)

GENERAL
SYSTEM DESCRIPTION
The CAN (Controller Area Network) protocol is an ISO standard for serial data communication. The CAN
bus links several electronic modules (ECU's) and sensors in the vehicle. 2 wires connect each compo-
nent and they are in constant communication with each other at a rate of about every 20 milliseconds.
CAN lines consist of a pair of wires (WHITE/BEIGE and WHITE/BLACK).
Modules and sensors communicate to others and interact in normal operation. Refer to COMMUN/CA-
T/ON BETWEEN MODULES THROUGH THE CAN BUS in this subsection.
If a component or system malfunction is detected, a module and/or sensor may generate a fault code,
which it transmits through the CAN bus as a coded signal. The fault signal may be used for various func-
tions such as triggering the display of an error message in the multifunction gauge cluster, turning on a
fault indicator light, limiting or inhibiting vehicle or engine operation
Fault codes can be displayed in the multifunction gauge or in B.U.D.S. for troubleshooting.
The CAN is monitored by the:
— ECM (engine control module)
— Multifunction gauge cluster
— VCM (vehicle control module)
— TCM (transmission control module)
— YRS (yaw rate sensor)
— DPS (dynamic power steering)
— Radio
— WPM (windshield and parking brake module).
CAN-HI
Q I R
WH/BE
B-C1 CL-24 DPS1-C SAS-3 YRS-3 DLC-1 MSL3-3 WPM-6 RDO1-16 rcm-19 v¢|vi.3-/
ECM f ___‘ DPS SAS YRS DLC MSL WPM RDO TCM VC
B-C2
PE CL-23 DPS1-D
¢
SAS-4
@
was-2
Q
o|_c-2 MSL3-2
~=ia- WPM-8 RDO1-17 TCM-1 VCM-24
._@%. .__g_. CAN-LO

WHIBK I U
rmr201U-024-001_a
CLUSTER: Multifunction Gauge
DLC: Diagnos t‘/c Lin k Conne ctor
DPS: Dynamic Power Steering
ECM: Engine Control Module
MSL: Multifunction Switch Left
RDO: Radio
SAS: Steering Angle Sensor
TCM: Transmission Control Module (SE5 model)
VCM: Vehicle Control Module
WH/BE: White/Beige
WH/BK: White/Black
WPM: Windshield and Parking Brake Module
YRS: Yaw Rate Sensor
rmr201 1-oes 273

Subsection 02 (CONTROLLER AREA NETWORK (CANII
The MSL broadcast the following signals through

CAN:
— Reverse
— Push to talk (CB PTTI
— Mode
— Set
— Upshift/downshift (SE5 model)
— Windshield up/down
— RECC left/right and up/down (Roadster Elec-
tronic Command Center)
— LH/RH turn signal reset.
NOTE: D.E.S.S. is not linked to CAN, it communi-
cates via radio wave signal with the ECM.
For more information, refer to D/AGNOST/CAND
FAULT CODES.
Communication Between Modules
Through the CAN Bus
The following table shows what modules commu-
nicate with each other.
MODULE/SENSOR COMMUNICATE WITH
MODULE/SENSOR
ECM (engine control
All except SAS and YRS
module)
Multifunction cluster
gauge
All except YRS
VCM (vehicle control
module) All
TCM (transmission
control module) (SE5) Al I except SAS
SAS (steering angle Multifunction cluster

sensor) gauge, VCM, DPS
YRS (yaw rate sensor) VCM, TCM, DPS
DPS (dynamic power
steering) All except MSL
Radio ECM, multifunction

cluster gauge, TCM, DPS
MSL (multifunction All except SAS, YRS,
switch LH side) DPS and radio
WPM (Windshield and All except SAS, YRS,
parking brake module) and radio
274 rmr201 I-068

Subsection O3 (COMMUNICATION TOOLS AND B.U.D.S.)
COMMUNICATION TOOLS AND

B.U.D.S.
SERVICE TOOLS
MPI-2 DIAGNOSTIC CABLE ........................................................ .. 7'lO OOO 851 ....................................... .. 276
MPI-2 INTERFACE CARD ............................................................ .. 529 O36 O18 ....................................... .. 277

MALE-FEMALE EXTENSION SERIAL CABLE ............. .. .............. .. DB9
GENERAL Prerequisite for CAN Communication:

Refer to PROCEDURES in this subsection for in- 1. MPI-2 connected to the vehicle communication
structions on using the communication tools. connector.
If communication problems occur, refer to TROU- 2. Ignition key turned ON.
BLES/-/OOT/NG in this subsection. 3. B.U.D.S. started and logged.
COMMUNICATION PROBLEM (CAN)
TROUBLESHOOTING
STATUS WHAT TO DO
DIAGNOSTIC TIPS — Check connection between MPI-2
Light is and diagnostic cable connector.
MPI-2 Connection Troubleshooting OFF — Check connection between diagnostic
The MPI-2 includes 2 status lights to indicate the cable connector and vehicle
connection condition: USB and CAN. Both lights communication connector.
must be GREEN for the MPI-2 to function prop-
erly. Otherwise, refer to the following charts. Light IS — Check CAN wires/connectors
RED on vehicle.
Communication Problems when Using

B.U.D.S.
Missing Module
Ensure the appropriate number of modules is
shown at the bottom RH side of B.U.D.S. screen.
MODEL NUMBER OF MODULES
vddZ0O5-U01-‘I51 _b
6
Prerequisite for USB Communication: SM5 (ECM, VCM, DPS, WPM,
- PC Computer turned ON LCD and multifunction gauge)
— MPI-2 connected to PC computer. 7
COMMUNICATION PROBLEM (USB) SE5 (ECM, VCM, DPS, TCM.
WPM, LCD and multifunction gauge)
STATUS WHAT TO DO
— Check USB connection between
Light is MPI-2 and PC computer.
OFF — Check USB operation on PC computer
(hardware or Windows drivers).
rmr2011 069 275

Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.)
MPI-2 Power
no
rmr201H)20-(]D2_a
The MPI-2 interface card uses the power from the
PC computer's USB port.
Connecting the PC to the Vehicle
A WARNING
1. Number of modules If the computer you are using is connected to
a power outlet, there is a potential risk of elec-
NOTE: The LCD (liquid crystal display) is part of trocution when working in contact with water.
the cluster. Be careful not to touch water while working
If one or more "ECU" is not communicating with the computer.
with the MPI, refer to D/AGNO.S‘T/C AND FAULT
CODES. 1. Open front storage compartment cover.
No Vehicle is Detected 2. Remove the RH service cover.
If an “X" is shown in the status bar and the pro-
tocol indication is blinking between Kw2000 500K
and KW2000, it means that no "ECU" is communi- Kw: -I <-. _=~_ ‘\ llij, x '.
cating with the MPI.
. "» - '>.;_:’
~ - \_‘w; ‘~-1-,_ ‘ ~71, , J - we
(K ‘ __ ‘t.-' if-... . ___.__- ~
1‘ I J ,. ‘Z
/, ».:>\‘. ~.V‘v____::::?‘:~ I A I \/\r v

r.;:‘:.:_“ “’i‘__-
Y
/ .\ i~.__K!?\\ “Q K\\__\__,
M E ‘:\.::::‘\\‘: lE,;I.__;_ V
\ J) _ ._\:F;_f::i‘x;:_/iv,‘
rmr2Cl10-020009
‘ '" ‘S-~_ "=;~_ "-9*»;-"=:\ 1/’
wt .t~.~
Check the following: rmr201 G-0204)U2_a
1. Service cover
— Connections between the PC computer and the
vehicle 3. Locate the vehicle communication connector.
— The multifunction gauge is powered up.
If B.U.D.S. does not automatically exit the follow-
ing message box, click the Try active detection
mode button. This will manually establish the
communication with the vehicle.
, No venida dc-lease. Malia sizothaltlle MPO! I: propuru corimdaiitolhcvnlicla, the rnodle is

5 1 | pwvwveo-up um (Int you live selected the uwwuuiili motuwt
TIY SCIIYB defimonrncde I M

.1
rmr2l]‘|0-O20-010,6
PROCEDURES
rmr201 O-020-005_a
M U LTI-PURPOSE INTERFACE-2 TYPICAL
(MPI-2) 1. Vehicle communication connector location
The MPI-2 (Multi-Purpose interface-2) in conjunc- Remove the communication connector from its
tion with the MPI-2 diagnostic cable is used with holder (protective cap).
B.U.D.S. to communicate with the Electronic Con- Connect one end of the MPI-2 DIAGNOSTIC CABLE
trol Units (ECUSI. (P/N 710 O00 851) to the vehicle communication
connector.
276 rmr201 1-089
M
,4!
a
710000851
“-
mmr200S-079200
Use B.U.D.S. as described further in B.U.D.S.

topic.
NOTE: An Optional MALE-FEMALE EXTENSION SE-
RIAL CABLE (P/N DB9) available at electronic retail
outlets can be used between diagnostic cable and
MPI-2 interface. Do not exceed 7.6 m (25 ft) or
communication between the vehicle and the PC
computer may be lost.
rmQ0‘l O—DZO-0IJ5_a
.»'
__., A ~kg. . _____..
_ ..
TYPICAL - MPI-2 CONNECTION TO VEHICLE COMMUNICATION
CONNECTOR ._:-':‘~ -_
Connect the other end of the diagnostic cable to

the MPI-2 INTERFACE CARD (P/N 529 O36 O18) con-
nector. \\.- 7. - I,
,
._\ ‘ l
\~\ ‘M. W’ ‘
\ - . '
,(\n iii)
..-- P
4-" l
529035697
OPTIONAL MALE-FEMALE EXTENSION SERIAL CABLE
B.U.D.S.
\ — - .
-.~.~
.\ -.1,
B.U.D.S. (BRP Utility and Diagnostic Software) is
\n-.
designed to allow electrical and electronic compo-
529035018 nent monitoring, activation of certain components .
for testing and diagnostic purposes, and to carry
out setting changes.
Always use the latest applicable B.U.D.S. version
available on BOSSWeb. l
l
For more information pertaining to the use of
B.U.D.S., use its Help menu which contains de-
tailed information on its various functions.
vdd2006-001-151
l
Connect the MPI-2 USB connector to the USB
port on the PC (personal computer).
rmr201 1-O59 277 ‘
I
Reading the Electronic Control Units ‘tr[R(mL-Stilt)V2.3.76.0_l»|3C17.1456111/101l_zuDJu8J1_IJI55[:.mpem nuns illaaiimuj

E!’ In E10 Neill INK Ell"
Using B.U.D.S.
IMPORTANT: Ensure all connections have been
made before starting B.U.D.S. to allow proper
OP
Rea<iDa!a
D if;
mgllllittfewlgiierla ~'.-i'ri~,
ti’-‘ 111;;
Open 7 me.-
operation. Refer to CONNECIING THE PC TO Velticle $""l"*.l I Monitoring I Activation I Fouls I

THE VEHICLE in this subsection. rmr2D1C\-D20-lJ08_a
1. Turn ignition key to ON. 1. Indicate setting or data modified," Write Data to save
2. Start B.U.D.S. and logon. Click the Write Data button.
NOTE: B.U.D.S. will automatically choose the ap-
propriate MPI 2 protocol.
3. Ensure the appropriate number of modules is
shown in the status bar. #- -lieliz
MODEL NUMBER OF MODULES
6
SM5 (ECM, VCM, DPS, WPM,
LCD and multifunction gauge)
l II
7 Wfiteoata‘
SE5 (ECM, VCM, DPS, TCM.
WPM, LCD and multifunction gauge) vmr2DD6-012-100_l::en
NOTE: A message box will confirm a successful

operation.
Disconnect the MPI connections and store the
communication connector in its protective cap.
I":3=T..=..."I
rmr2011-020-002;;
TYPICAL — CONNECTION SUCCESSFUL

1. Number of modules
If the number is less than indicated in table above,

refer to TROUBLESHOOTING in this subsection.
4. Read the ECUs by clicking the Read Data but-
ton.
Mfile 1-fiew I“-i'If_I® l_1j_I_oduIe Tools I

‘ > 7 _" ‘."....:
ii Read Data
.
Write oats
ii.
.. L..." l~'~.....-.......'
W_.-<>‘»-.sS¢-x.,_ »-
rmr201D-020-0U5_a
1. Communication connector stored in protective cap
NOTICE Failure to secure the diagnostic con-

nector in its protective cap may result in corro-
sion or other damage to the terminals.
vmr200G4)12-1 O0_aen
Electronic Modules (ECU) Update

Writing Changes in an ECU
Whenever B.U.D.S. is first connected to a vehicle,
If the word Modified appears at the end of the check for an update icon in the B.U.D.S. status bar
vehicle file name at the top of the B.U.D.S. page, at the bottom of the Vehicle page.
then a change has been made that requires it to
be saved to the proper electronic module.
278 rmr2011-069
M ___. P Elle flew ME_I® lools flelp

‘ " m 7;;TITTJTTT 1' I AIIIIIIf
_ ,,,_, _ _ __ Cluster ’
I ...... I 1 ..... fifi-";""""""""' gcm vi
I T l , °""" '“" . L>_Ps >1 B*e""a°° PI
, *- ~--~ --~--fit e-------A LCM > ..
I *:.::..
I ‘nnmn
2:;
an
I
‘ I
-~
|:§
-~*
nun:
Read PP" ’ ~~"»=‘iilt1i.;.i.>-.
1
mm-no smut
hfiaul n
I _____ I ____9__‘ I ___n__ . __
I .:_____. I W i 7 ii’ 7 i 7 7 fr rmr2o104J2ooo4_a
TYPICAL
l -~ —- ‘ T as-in P P ' ni- 1. Greyed out: No update to pen‘orm
rrn|’2010-O20-003_a Black." Update file available
TYPICAL - UPDATE ICON
If the update icon is visible, B.U.D.S. indicates that

a file is available to update at least one of the elec-
tronic modules.
NOTE: If an update file is available on BOSSWeb
but B.U.D.S. being used is not up to date, the up-
date icon will not appear. Refer to the service bul-
letins to see if there is an update available.
Use the Module submenu and check all modules
one at a time to see which module(s) can be up-
dated.
Ijile flew M_IZI® lools flelp

§Cl’\"I
:_- Cluster II
flJ gcm
Read Data -QP5 ta Data
I [CM
V777???
Vehicle rung
rrnr2011-O70-O10
TYPICAL - MODULE SUBMENU L/S7: SE5 MODEL ILLUSTRATED
1. If the Update option is greyed out, no update

file is available for this module.
2. lf the Update option is black, an update file is
available for this module. Select the update op-
tion and load the proper file.
rmr201 1-oes 279

Subsection 04 (DIAGNOSTIC AND FAULT CODES)
DIAGNOSTIC AND FAULT CODES

GENERAL
MONITORING SYSTEM
The Engine Management System (EMS) and Vehi-
cle Stability System (VSS) (including their sub sys-
tems) feature a monitoring system that self-diag-
nose their electronic components. This mode be-
comes active when the ignition key is turned ON.
NOTE: Some components require the engine to rmi>2010-001-D17_ben
be running for them to be monitored for normal 1. Indicator /amp in multifunction gauge
operation (fuel injectors for example). 2. Digital display
The monitoring system continuously validates The message displayed in the digital display ap-
that the electronic components (control modules, pears over a flashy background color.
sensors and actuators) work in their operating
range and are not faulty or defective. When one
of these conditions is encountered, the related
electronic module(s):
— Sets an active fault code.
— Adapts the proper protection strategy accord-
ing to the failure.
— Sends out signals to the multifunction gauge to
inform the rider of a particular condition.
A fault code is an indication that a glitch or mal-
function is detected by the monitoring system of
the vehicle.
If a minor fault occurs, the engine and vehicle will
continue to operate without noticeable loss of per-
formance. \
If a more significant fault occurs, engine RPM may 1
be limited. The engine/vehicle will continue to op-
rmr201 1-O7 9-0O5_a
erate with reduced performance. 1. Message over a flashy background
If a major fault is detected by the EMS or VSS, en-
gine RPM will be limited as well as vehicle speed. After a moment, the message disappears and is
These strategies are used to protect replaced by an icon in the lower central portion of
engine/electrical system from damage and the digital display.
to maintain safe operation of the vehicle.
Indicator Lamps or Icon for
Problematic Conditions
When a problem is detected, an indicator lamp will
turn on or blink in the multifunction gauge.
Most of the time, a message is displayed in the
digital display to provide additional information
related to the fault that triggered the lamp.
rmr201 1070
281
.5-J.~<tilt>..l.=l,§,,
ME I ' If 1' i ..
22:84-,, _,)__t
qyvfl
I‘-sl
FIT’-3‘
km/h
l
‘I
_:
. '
. IlnE
uazin
RISE O F 0Tll<m
O 3-'3
‘I
rmr201 1-079-0O6_a
7. Icon
INDICATOR LAMPS OR ICON FOR PROBLEMATIC CONDITIONS
INDICATOR MULTIFUNCTION
LAMP OR ICON GAUGE CAUSE ADDITIONAL INFORMATION
MESSAGE
BAD KEY Wrong or defective key Try another key or reprogram key.
REAR STORAGE
COMPARTMENT Top or side storage Turns on when battery voltage is lees
None OPEN compartment cover open than 11. 5 V or higher than 16 V.
Engine RPM is limited to 3700 during
COMMUNICATION CAN (controller area low battery voltage condition to protect
FAULT network) communication engine/electrical system.
problem
HI TEMP Turns on when engine temperature
reaches 113°C (235°F).
@ ON Engine is overheating.
HI TEMP Engine RPM is limited to 3700 to protect
LIMP HOME engine when engine temperature is above
115°C (239°Fl.
Turns on when oil pressure is less
ON NONE Low oil pressure. than 20 kPa (2.9 PSI).
Engine RPM is limited to 3700 to
protect engine.
282
rmr2011-O70
INDICATOR LAMPS OR ICON FOR PROBLEMATIC CONDITIONS

INDICATOR MULTIFUNCTION
GAUGE CAUSE ADDITIONAL INFORMATION
LAMP OR ICON MESSAGE
An engine management Engine RPM may be limited to protect

CHECK ENGINE component is not working engine depending on the fault.
properly. A fault code is active.
Internal DPS fault or Partial or no assist from DPS depending
ON CHECK DPS related part. on the fault.
Engine RPM may be limited.
Internal TCM fault or Shifting may harsh.
C21 CHECK TCM related part. Transmission may not shift or
may have restrictions.
An important engine
management component Vehicle speed and/or engine RPM is
is not working properly or limited.
Blinks LIMP I-l0l\/IE there is a vss fault.
Rider's foot is dragging on Vehicle speed and/or engine RPM is
brake pedal limited.
No ABS operation. Wheel lock may occur
ON ABS FAULT ABS fault or related part. when braking hard.
No EBD operation. Rear wheel lock may
EBD FAULT VSS fault or a related part. occur under hard braking.
Low brake fluid level, Brake pedal may be "spongy".

® ON BRAKE FAILURE possible leak, low brake Check brake pressure, fluid level and
pressureor faulty sensor. check for leaks.
PARKING BRAKE Faulty parking brake or Parking brake cannot be engaged, or
FAILURE component. disengaged.
VSS FAULT VSS or a related Engine RPM and vehicle speed is limited
ON LIMP HOME component is faulty. to maintain safe vehicle operation.
VSS will react as if 2 riders were seated.
SEAT SWITCH Pillion rider switch faulty. Increased feedback may be felt at.
ON DEFECTIVE handlebar, VSS is active more frequentely.
"E" displayed
instead of selected NONE GBPS fault or related part. Limited power steering assist.
gean
£1-It CHECK
TRANSMISSION TCM Pm‘-
O z CHECK DPS DPS fault.
(1%)
§" MANUAL ACS fault.
ii KEY ERR Anti theft.
rmr201)-070
283
Limp Home Mode How to Display Fault Codes Using the

When a major component of the EMS and/or Multifunction Gauge
VSS (including their sub-systems) is not operating NOTE: A fault code must have the "Active" state
properly, fault codelsl will be triggered and limp to be displayed in the multifunction gauge. Other
home mode will be set. fault code states must be read using B.U.D.S.
Engine RPM will be limited and vehicle speed may If a fault is detected, an indicator light and a fault
be limited depending on the failure. message may come on in the gauge.
This mode allows the rider to safely return home. Proceed as follows to view the fault codes:
This would not be possible without this advanced
system. 1. Turn ignition key to ON.
LIMP HOME will be displayed in the multifunction 2. Wait forthe multifunction gauge to complete its
gauge. self test function.
3. Simultaneously press the following three but-
FAULT CODES tons on the LH multifunction switch assembly.
— MODE
Fault Code Categories ~ SET
A fault code consists of an alphanumeric designa- - Turn signal button.
tor followed by a hexadecimal number of 3 digits.
The alphanumeric designator defines the category
of the fault code while the hexadecimal number 2
refers to a unique fault.
FAULT CODE CATEGORIES
-
ALPHANUMERIC MODULEI gXAMP"E
F FAULT
i-'¢“""
DESIGNATOR SYSTEM CODE
From P0 to P3 I Power
andtrain,
DPSTCM P062F
From CO to C3 Vehicle
Systemstability
(VSS) C0031
Communication M10201 0-001 4]20_)
From U0 to U3 between module U0O73 1. MODE button

2. $ETbutton
and sensors 3. Turn signal button
Body If there is no active fault code, nothing will be dis-
From B0 to B3 (including luggage B1000
compartments) played.
RELATED MODULE AND FAULTS How to Read Fault Codes Using

B.U.D.S.
FAULT CODE
MODULE CATEGORY NOTE: All fault code types can be read with
B.U.D.S.
ECM Mainly P and some U
1.Connect vehicle to the latest applicable
TCM (SE5 model) Mainly P and some U B.U.D.S. software. Refer to COMMUNICA-
VCM Mainly C and some U TION TOOLS AND B.U.D.S. subsection.
DPS Mainly P, some C and U
2. Click on the Read Data button.
3. Click on the Faults tab.
Cluster P, B, C and U
WPM
(Windshield and Park P, U and C
Brake Module)
284
rmr201 1-070
‘:9: in- an 5-on twh an

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Coda Sue Modile Cixn Cv aTrm0 ‘ To:alT4me ‘ 3 6 5 2
I 1 Lev-vfurw/‘J @ \
I
rmr201 1070-0O1_a
FAULT PAGE
1 . Fault tab
rmr2U1Hl7D-011;:
24 Fault indicator light
1. Fault tab 3. Fault code state drop box
4 Fault nomenclature
4. Click on the drop-down list on the LH lower cor- 5. More details button
6. C/ear occurred faults button
ner. 7 . Selected fault
5. Choose the fault state to display. FAULT PAGE DESCRIPTION
1 ITEM INFORMATION
l Fault tab Click tab to display the fault page
Fault When flashing, it indicates there is
Imive FaultsI I 1-I Cle-arQcc indicator light active faultlsl
All Faults
Fault code Click drop box to select the type of
Active and Occurred Faults state drop faults to display
box
rrnr20l‘|-021-fl01_a
1. Drop down list Display specific information and
Fauh
statistics related to the fault (see
nomenclature fault nomenclature table)
FAU LT
INFORMATION
STATE To display possible causes and
l\/lore details service actions related to the
Display all possible faults regardless button
All faults of state selected fault
Active Display only faults matching this state Clear To clear all occurred faults in related
faults Empty area if there is no active fault occurred ECUlsl
faults button
Active and Display only faults that have either state
occurred Empty area if there is neither active When a fault is selected, additional
faults nor occurred fault information pertaining to that
fault will be displayed when
Selected clicking the "l\/lore details" button
fault To select a fault, click on the fault
with the mouse or use the cursor up
or down to scroll to the desired fault
rmr201 1-070 285

Subsection O4 (DIAGNOSTIC AND FAULT CODES)
FAULT NOMENCLATURE Click on the More Details button, on the RH lower

COLUMN
corner, to display the "Possible Causes" and the
INFORMATION
"Service Actions" to step further in the diagnosis.
Fault code number.
When 2 stars (**) precedes the
WT i'*"l“i(’”Ilw/II A ‘-- IHETI H
Code code, detailed conditions when the
fault occurred, can be displayed by
clicking the "l\/lore details" button
Display the fault state (active, occurred,
t,» E“
_ wan Cruz’
Z." frrnim Ieu Ilul coma»

flfifidlflflflflfl
State inactive)
Displays the module that reports the ‘I
fault code. This is the module that
detects or has received a message
of an anomaly and reports it. fimnm ‘-3 7 7 I | “no.3 Q1
List of modules:
LCD (liquid crystal display) or rmr201 1-D21-05D_a
Module Cluster (multifunction gauge) 1. Click here

DPS (dynamic power steering) .lW:;,;_....T .._ .. .,,_,,,.,L_ ,
ECl\/l (engine control module)
TCM (transmission control module) §!!_ 7_ _' __---.- . LL. .l
I‘\3.
VCM (vehicle control module) I.."““_..I ‘"' I““‘_‘u1 IOIKNDW
AC!“ EC. I PIA fl',H$§§fiMJ1I
WPM (windshield and parking brake 1°!_'§"Q,fl.....‘,.___. .._...._ .. . . ____ M7

module) .
, wuquiauwwiimtun .oouiuianuin¢wruow4t8
uiiiinsnmuxia\nEO flrAv.m-an
Number of times this fault I)
Count occurred within the driving cycle Swill

rtyvynn MIJTYLE tn! ofipwnx '
Value: From O to 255 Cuaiuitnacwnvw
twunaeo mum 17>-II rwisonte
*5?
;§
m rmwru. s-.-sxvvar-1'-vrxxi nnw.:.~ri-an- u.ir.<i-vs mo-w vvxw
Not to be used
Cycle time Value: From 0 to 255 minutes i§,
I I -'»---i:-=- I
rmr2OI I-070-0D2_a
Total time Not to be used

MORE DETAILS PAGE
Value: From O to 64 255 minutes 7. Possible causes related to the selected fault
2. Service actions
Description Provides a short description of the fault 3. Operating conditions when fault occurred
When reading a fault code in B.U.D.S., pay partic- MORE DETAILS PAGE DESCRIPTION
ular attention to which module reports a fault. It ITEM INFORMATION
is indicated in the Module column.
The Description column gives a short description Possible List the possible causes that
causes triggered the fault
of the fault.
Service List the possible actions to perform
1 2 acflons to solve the fault
Conditions List the operating conditions of the
when fault engine and/or vehicle when the fault
Summary
l its l l occurred was triggered
Code F Mo ule I Des ziptlon Fl,
l Fault Code States
The various electronic control units (ECUs) used in
I". Yi F1"I~( i"i"n>i ll) 1 i1f‘i I l‘ I 1 i‘ :
the vehicle can generate a variety of fault codes
depending on the level of monitoring they are ca-
pable of. Fault codes have 3 possible states:
— Active
rmr201‘!-G21-O02_a - Occurred
SOME COLUMNS REMOVED FOR CLARITY PURPOSE — Inactive.
7. Module that reports a fault
2. Fault description Click the Fault tab then click on the drop-down list
on the LH lower corner.
286
rmr2D1i~D7D
Choose the fault code state you want to display.

1 Clear Qocured Faults I
rm r2 008-OI-19009
CLEAR OCCURED FAULTS
IA¢flv¢.F@"le. . _'-I 7 Clear Qcc
I A1lFauits . This will reset the appropriate counterlsl and will
I .»"~.~Ill~i~9 I‘Ai._1I.II(':~ - I F
. Active and Occurred Faults g I‘ 1 , also record that the problem has been fixed in the
related module memory.
rmr201 ‘H72 1 —OD1_a
TYPICAL
Observe the "Occurred" fault(s). They should all
7. Drop down list disappear. Otherwise, follow this procedure.
- Turn ignition switch OFF.
Active Fault Codes
— Wait 30 seconds.
An active fault code is an indication of a fault that
is currently triggered. — Repeat procedure to clear faults again.
The active fault may or may not compromise nor- FAULT CODE DIAGNOTIC
mal operation of the related systemlsl. Service
action in B.U.D.S. should be used to correct the Missing Module
problem that caused the fault code. If a module is missing, several fault codes will ap-
Once the fault conditionlsl of the active fault is no pear
longer present, its state will change to "occurred". To quickly find which module is missing, perform
Occurred Fault Codes the following:
An occurred fault code indicates a fault that was 1. Connect vehicle to the latest applicable
active, but no longer is. B.U.D.S. software. Refer to COMMUNICA-
The occurred fault does not presently affect sys- T/ON TOOLS AND B.U.D.S. subsection.
tem or component operation but is retained as a 2. Click on the Read Data button.
history of the faults that were detected. 3. Click Module in the menu bar.
Inactive Fault Codes 4. Look at the list of modules.
An inactive fault code represents a fault code that 5. If a module is not visible, then it is not commu-
is neither active, nor occurred. It is simply part of a nicating through the CAN bus (controller area
list of all possible faults which may be monitored network).
by the various ECUs, which may become active
or occurred if the monitoring system detects an fiie flew ME_I® lools flelp
applicable fault.
How to Clear Fault Codes Using B.U.D.S. i §_CM
Connect vehicle to the latest applicable B.U.D.S. I gluster r. I
software. Refer to COMMUN/CAT/ON TOOLS
AND B.U.D.S. subsection.
Click on the Read Data button.
is
Read Dat
,-HU
QP5
nl
te El I§1LE1
Click on the Faults tab. TCM
NOTE: Only the Occurred state faults can be ,............................................
i
. _ mam vvvv
cleared.
Click the "Clear Occurred Faults" button.
Vehicle , tting
rmr2OI1-O70-D10
TYPICAL - MODULE SUBMENU LIST SE5 MODEL
NOTE: The TCM listed is only available with the

SE5 model.
rmr20‘l1-070 287
6. Refer to the following table to find the appropri- This should change the fault state from "Active" to
ate subsection in this manual to diagnose the "Occurred".
missing moduIe- The vehicle should then operate normally.
MISSING If a sensor-related fault persists, you may try
MODULE SECTION TO REFER TO
disconnecting/reconnecting the sensor.
ECM ELECTRON/C FUEL /N./ECT/ON /EF// Read the following for a general approach to trou-
bleshoot fault codes (active or occurred).
Lgfisigf L/GHTS, GA UGEANDACCESSOR/ES
VCM I/EH/CLE $7I4B/L/7')’ SYSTEM /I/55')
STEEFVNG (DPS) AND FRONT
DPS WHEELS
TCM
(SE5 HYDRA UL/C CONTHOL MODULE
model)
WPM BOD)’
Diagnostic Tips
To see the last minute of operating conditions,
click on the History tab in B.U.D.S.
NOTE: The page displays data whatever there is
fault code(s) or not.
I I I I i_ f‘f‘°£'_ '
"”"-~
l
2 ‘X1
Ir I I R9» I kninres) I Min ‘*1 I Irqnv ['1] I an-qlv) I
[Mun-in iv.-tn IS ta I55 I5 A0

0 a 1) 1; II so
Cmrlllwfllax I
rrnr2U'I1-U70-ODILB
1. History tab
2. Additional history pages
HISTORY PAGE DESCRIPTION

ITEM INFORMATION
Display the minimum and maximum
Minimuml
Maximum values encountered. Click "Clear
Min/l\/lax" to reset the values
R ' Display the time
. proportion. in what
.
un “me mode the engine was running in
RPM Display the RPM range proportion in
profile which the engine was running in
When a minor fault occurs:

— Turn ignition key OFF.
- Wait 30 seconds.
— Turn ignition key ON.
288 rmr201 1-070

GUIDELINES TO SOLVE FAULT CODES

CONDITION ACTION
Use B.U.D.S. to:

Read fault codes.
Display "Active" faults to see components currently not operating normally.
Display "Occurred" faults to troubleshoot intermittent problems.
Monitor systemlsl, sensorlsl, switches and actual conditions.
Troubleshooting vehicle Activate componentlsl for troubleshooting.
Set components, bleed brake system etc.
Know the last minute of operating conditions by using the "History" page.
Know the operating conditions, if available, when a fault code occurred by
using the "More details" button in the fault page.
Check sensor connections or mixed up connections.
Before vehicle maintenance:
Read the electronic modules with B.U.D.S.
Save and print the B.U.D.S. file (keep faults option only).
New faultlsi appear after a vehicle
maintenance or repair After vehicle maintenance:
Read the electronic modules with B.U.D.S.
Compare the fault codelsl before and after the maintenance
using the printed copy and the current B.U.D.S. reading.
Investigate only the newly fault codes.
Clear all occurred faults in B.U.D.S.
Communication faults displayed as Normal behavior when flashing a module
"Occurred" after module flashing Clear all occurred faults and check again
Read the fault description in B.U.D.S.
Click on the "More Details" button.
Sensor "Active" fault Look at the "Conditions" when available.
Read the "Possible Causes".
Apply the “Service Actions".
Check related fuselsl and relay.
Check related power and ground wires.
Low system voltage Check for common power supply to several sensors/modules
on one module (refer to POWER D/STR/BUT/ON AND GROUNDS}.
Power problem on sensorls) NOTE: Some sensors are supplied by the battery while others are
supplied by a module.
Low system voltage Check battery condition and connections.
on several modules Check related fuselsl and relay.
(several communication faults Check voltage regulator/rectifier.
will also appear)
A battery charger has likely been used to substitute the vehicle battery.
High system voltage on several Clear all occurred faults and check again.
modules Check voltage regulator/rectifier.
Check the module that is reported as missing.
When all modules report that a Check related fuselsl and relay.
module is missing Check related power and ground wires.
When several modules are in fault Search for a common problem such as a faulty sensor.
When several modules and sensors report that a module is missing.
The missing module may report CAN bus failure, CAN bus off.
Check related CAN wires (continuity, short to
CAN bus failure, CAN buss OFF ground, short between CAN low and high).
Check module pins and wiring terminals.
Then, the other modules should stop reporting that module is missing.
rmr201 1-070 289

GUIDELINES TO SOLVE FAULT CODES

CONDITION ACTION
May have been generated due to a system or component that was
momentarily operating outside normal parameters.
l\/lay be generated when disconnecting and reconnecting a component,
replacing a burnt fuse, or may be due to a momentary high or low voltage.
Before being "Occurred", a fault has always been "Active"
Occurred fault(s) for a certain time, indicating that an unexpected condition
or problem has been present during the driving cycle
A frequent momentarily fault or an intermittent fault may never
be seen as "Active" in B.U.D.S. while there is still a pending problem.
This type of malfunctions can be discovered by looking at
the "Occurred" faults and then by evaluating the fault count.
As long as a fault is present, it is displayed as "Active"
Low value: Suggests handling problems
Fauh count (connections, terminal contact/shape etc.).
l0 - 255) High value: Suggests a frequent and unsolved problem.
The problem should be investigated.
Fault conditions
(l\/lore details button) Look for abnormal, excessive values.
When the basic troubleshooting has been done and the fault
codelsl persists, often the problem is related to the wiring
harness, connections or electromechanical components.
Hard to find problems Short to ground, to battery or between wires.
Wire splices, chafing, terminal problems
(pulled out, bent, out of shape, corroded etc.).
Bad contacts in switch or relay.
290 rmr201 1070

ECUs share information and their systems may in- PRS (Pillion Rider Sensor) Fault
teract with each other. Certain faults may cause When there is a PRS fault, the VSS will operate
more than one ECU to set a fault code or indica- in safe mode as if both a driver and a passenger
tion (pilot lamp or message) as the failure of some were seated. If only the driver is seated, the VSS
components may affect the operation of several will be more active.
systems.
IMPORTANT NOTE Cruise Control Faults
The cruise control system is closely interlinked
The primary electronic systems depend on and dependent on the proper operation of many
other secondary systemls) or sensorisl for their
normal operation. other systems for its’ operation which, may in-
volve several ECUs.
if a primary system generates a fault code, If the cruise system cannot be engaged or dis-
usually the fault belongs to it. However, in plays a fault, check for and correct other system
some cases, the primary system may not faults before assuming the cruise system is at
be at fault. A malfunction in a secondary fault.
system, or a sensor, may be the cause of the
fault code generated by the primary system.
Since proper operation of the primary system
could be compromised by the fault in the
secondary system or sensor, the primary
system generates the fault code to indicate
a malfunction in the system.
Example: If several faults are active at the same
time, such as for the VSS, ABS, EBD and EMS
systems, and you look at the fault codes using
B. U. D. S., you will see many active fault codes
displayed. When looking at them closely, you
will notice that each system share a common
fault; YRS (yaw rate sensor) fault. The culprit
is likely to be the YRS. These primary systems
are all dependent on the YRS for their normal
operation.
SPECIFIC FAULT CODES

The following provides additional information re-
lated to specific fault codes.
VSS Faults
Several modules use signals from the VSS mod-
ule, or from the VSS sensors.
Every time the VSS has an active fault, other mod-
ules may also be in a fault state.
VSS and ABS Simultaneous Faults
The problem is likely to be disconnected or faulty
wheel speed sensoris).
VSS, ABS, EBD Simultaneous Faults
The problem is likely to be a disconnected or
faulty:
- VCM
— Rear wheel speed sensoris).
rmr20lI O70 291

FAULT CODE TABLE

The fault code table use the same acronyms and connector identifications as per wiring diagrams.
EXAMPLES OF ACRONYMS AND CONNECTOR IDENTIFICATION USAGE
USED IN FAULT CODE TABLE MEANING
ECM Engine Control Module
ECl\/IA-l\/ll ECM module, connector A and pin M1
HO2Sl Heater O2 sensor #1 connector
H0281-2 Heater O2 sensor #1 connector, pin 2
l\/lPl2 Multi purpose Interface Card (generation 2)
TAS-B Throttle Accelerator Sensor connector, pin B
NOTE: The following fault code table was up to date as of printing. For the latest fault codes, use
B.U.D.S.
292 rmr201 1 -O70

FAULT REPORTING SERVICE ACTION

MODULE DESCRIPTION POSSIBLE CAUSE
CODE
Disconnect CSS, measure

resistance between CSS-1 and
GND (expected value 18.2 Kohms).
Measure resistance between CSS-5
and GND (expected value 825 ohms).
Measure resistance between CSS-3
and GND (expected value 9.35 Kohms).
. Damaged circuit Disconnect LCS, measure resistance
B1000 CL Luggage/suspension wires or connection, between LCS-1 and LCS-2
SWI damaged resistor. (expected value 1.5 Kohms).
Disconnect TCS, measure
resistance between TCS-1 and
TCS-2 (expected value 2.74 Kohms)
Disconnect RCS, measure resistance
between RCS-1 and RCS-2 (expected
value 5.11 Kohms)
Check VCM motor fuse MFB56.
Measure voltage between harness
connector VCM-1 and ground
(expected value = 11 to 13 volts).
VCM pump supply
Measure resistance from
connector: VCM-36 to GND
C0020 VCM égnirghigfiugotor failure supply line (expected value: < 2 ohms).
broken, fuse blown. Measure battery voltage with
engine stopped (expected
value: 11 to 13 volts).
Check ground and positive connections
on battery.
Check for damage wheel speed sensor.
Check for damage tooth wheel.
Disconnect VCM and VSS1.
Damaged circuit Measure resistance between
wires, damaged harness connector VCM-21 and
wheel speed sensor or VCM-22 (expected value > open).
C0031 vcivi IN(IL‘T§'f:If§:§ 56"“ damaged VCM pins. Measure resistance from
Damage toothed connector: VCM-21 to VSS1-2
wheel or air gap too
big. (expected value: < 2 ohms).
Measure resistance from connector:
VCM-22 to VSS1-1 (expected value: <
2 ohms).
Make sure sensor
connector is fully inserted.
Measure resistance between
Damaged circuit harness connector VCM-21 and
' damaged VCM-22 (expected value > open).
Wheel speed sensor WW5’ Measure resistance from
C0032 VCM 1 (LP) S I fanu wheel speed sensor
Uppy re or damaged VCM connector: VCM-21 to VSS1-2
pins. (expected value: < 2 ohms).
2 ohms).
rmr201 1-O70 293

FAULT REPORTING
CODE MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION

Check for damage tooth wheel.
Damaged circuit Disconnect VCM and V882.
wires, damaged Measure resistance between
Wheel speed sensor wheel speed sensor or harness connector VCM-18 and
C0034 VCM damaged VCM pins. VCM-O6 (expected value > open).
2 (RF) failure Measure resistance from
Damage toothed
wheel or air gap too connector: VCM-18 to VSS2-2
big. (expected value: < 2 ohms).
VCM-O6 to VSS2-1 (expected value: <
2 ohms).
Make sure sensor
Wheel speed sensor wires, damaged VCM-06 (expected value > open).
C0035 VCM wheel speed sensor Measure resistance from
2 (RF) supply failure
or damaged VCM connector: VCM-18 to VSS2-2
VCM-O6 to \/SS2—1 (expected value: <
2 ohms).
Check for damage toothed wheel.
Make sure air gap between sensor
and toothed wheel is acceptable.
Damaged circuit Disconnect VCM and VSS4.
wires, damaged Measure resistance between
C0O3A VCM
Wheel speed sensor wheel speed sensor harness connector VCM-19 and
4 (R) failure or damaged VCM pins. VCM~31 (expected value > open).
Damage tooth wheel Measure resistance from
or air gap too big. connector: VCM-19 to \/SS4-2
(expected value: < 2 ohms).
2 ohms).
Make sure sensor
Wheel speed sensor wires, damaged VCM-31 (expected value > open).
C0038 VCM wheel speed sensor Measure resistance from
4 (R) supply failure
or damaged VCM connector: VCM-19 to VSS4-2
2 ohms).
Mechanical
defect or wrong
Brake pedal switch mounting of BLS. Check BLS fault on ECM.
C0040 VCM Check brake light bulbs.
failure BLS circuit open.
Defective brake light Check BLS.
bulbs.
294 rn'ir2011-O70
FAULT REPORTING POSSIBLE CAUSE SERVICE ACTION

DESCRIPTION
CODE MODULE
Open ECM Monitoring page in B.U.D. S

BLS failure. Press on brake pedal.
Brake pressure Internal pressure Verify brake light switch comes
C0044 VCM sensor failure or sensor failure. on in the ECM Monitoring page.
BLS failure Blown fuse (BLS On VCM Monitoring page, verify that
circuit). brake pressure sensor displays a valid
value.
Verify brake fluid level in both
reservior for proper fluid fill.
Disconnect OLS1 and OLS2.
Brake failure (brake Low brake fluid. pin 1 and 2 of brake fluid level
C0049 VCM
fluid) switch (expected value > open).
Disconnect VCM connector.
Measure resistance between VCM-4
and GND (expected value > open).
Wrong Steering
Angle Sensor
SAS ADAPTATIVE (SAS) mechanical Check SAS mechanical position.
C0051 DPS
FAULT position during reset Perform a SAS initialization in B.U.D.S
or no initialization after
part replacement.
Defective steering Open VCM Monitoring page
angle sensor in B.U.D.S., check if SAS
(SAS), wrong
sensor displays plausible value.
Steering wheel sensor mounting. Check SAS mechanical position.
C0051 VCM position sensor Steering angle Reset steering angle
failure sensor is not yet offset using B.U.D.S.
initialized/calibrated.
Check magnet position on DPS
Loose magnet on DPS
output shaft. output shaft.

connector YRS-4 and ground with
Defective lateral ign on (expected value = 12 volts).
Lateral acceleration acceleration sensor. Measure voltage between harness
C0061 VCM connector YRS-1 and ground with
sensor failure Internal offset fault of
the sensor. ign on (expected value = O volts).
Check YRS mechanical position.
Reset lateral offset using B.U.D.S.
Defective longitudinal connector YRS-4 and ground with
Longitudinal
acceleration sensor. ign on (expected value = 12 volts).
Wrong assembly, Measure voltage between harness
C0062 VCM acceleration sensor mounting, position connector YRS-1 and ground with
failure of the sensor. ign on (expected value = O volts).
rmr2011a070 295
FAULT REPORTING
DESCRIPTION POSSIBLE CAUSE SERVICE ACTION
CODE MODULE

Wrong mounting, connector YRS-4 and ground with
wiring, assembly, ign on (expected value = 12 volts).
C0063
Yaw rate sensor Measure voltage between harness
VCM position of the sensor.
failure connector YRS-1 and ground with
Defective yaw rate
senson ign on (expected value = O volts).
Communication
C006C l\/IE17
VSS CAN message intermittent/erratic External troubleshooting is not possible.
plausibility error and/or Check Sum Check for communication fault.
Error.
C0200 VCM Roller test misusage Engineering DTC
Pillion rider switch Disconnect VCM and PRS connectors.

Pillion rider switch output short Measure voltage between harness
C1083 VCM connector PRS—B and ground
shorted to V Bat to battery +.
Switch defect. (expected value = O volts).
Replace pillion rider switch.
Overheat of ECU Turn ignition key switch off
C1098 VCM Inlet or outlet valve Solenoid valve and let VCM cool down.
coil‘s) fault overheat. External troubleshooting is not
possible.
VCM Steering angle Reset steering angle sensor using
C1100
sensor not calibrated SAS not calibrated.
B.U.D.S.
Longitudinal sensor Longitudinal
C1110 VCM acceleration sensor Check YRS mechanical position.
not calibrated Reset longitudinal offset using B.U.D.S.
not calibrated.
Speed sensor signals
Generic wheel speed are suspicious Check tire pressure.
C1130 VCM for a long time. Check wheel speed sensors starting
sensor fault
Wheel speed sensors with rear sensor first.
are swapped on front.
Check for VCM fault or ECM fault.
connector VCM—32 and ground
Disconnect MPI2 from DLC connector.
Measure resistance between DLC-1 and
Invalid CAN DLC-2 (expected value = 50 to 70 ohms).
C1 150 VCM message received Lost communication
with ECM. Measure resistance between DLC-1 and
from ECM (Msg_ld) ECMB-C1 (expected value < 2 ohms).
ECMB-C2 (expected value < 2 ohms).
Measure resistance between DLC-1
and VCM-37 (expected value < 2 ohms).
296 rmr201 1-O70

FAULT REPORTING
CODE MODULE
Check for disconnected low

pressure switch or damaged wire.
Disconnect VCM and LPS connectors.
Damage circuit wire. Measure resistance between VCM—8
Brake failure (low Low pressure switch and LPS-2 (expected value < 2 ohms).
C1182 VCM
pressure switch) Measure resistance between LPS-3
defective.
and GND (expected value < 2 ohms).
Measure resistance between pin 2 and
3 of LPS on vehicle with brake pedal not
activated (expected value < 2 ohms).
Pillion rider switch Disconnect VCM and PRS connectors.

supply voltage failure Measure voltage between harness
Pillion rider switch or short to GND. connector PRS-A and ground
C1183 VCM
shorted to ground PRS output (expected value = 11 to 13 volts).
short to GND. Measure resistance between VCM-16
Switch defect. Replace pillion rider switch.
Check VCM valve fuse MFB78.
Power supply or (expected value = 11 to 13 volts).
ground circuit Measure battery voltage with
Valve relay fault failure to the VCM. engine stopped (expected
C1200 VCM
Internal valve value: 11 to 13 volts).
relay defective. Check ground and positive
connections on battery.
External troubleshooting is not possible,
if internal valve relay defective, replace
the VCM.
General ABS (all EV Internal EV and AV External troubleshooting is not possible.
C1210 VCM
and AV) valve fault valve problem. Replace the VCM.
General cut
Internal USV1/USV2 External troubleshooting is not possible.
C1220 VCM (USV1/USV2) valve
fault valve problem. Replace the VCM.
General suction
VCM (HSV1/HSV2) valve Internal HSV1/HSV2 External troubleshooting is not possible.
C1230
fault valve problem. Replace the VCM.
Repair any other fault codes first.

lmplausible controller
intervention. Check YRS, check steering angle
C1270 VCM lmplausible control sensor, check wheelspeed sensors.
Wrong signal External troubleshooting is not possible,
(YRS/SASNCM). replace the VCM.
Invalid variant coding.
Variant coding
not supported
variant coding. Set proper VCM variant coding for
C1281 VCM Variant coding failure Variant coding vehicle.
not initialized.
VCM EEPROM
defective.
rrnr2011~070 297
FAULT REPORTING
CODE MODULE
VCM
Brake failure (low Possible hydraulic Check hydraulic brake circuit for a
C1282
pressure detected) brake circuit leak. possible fluid leak.
Disconnect VCM and PRS connectors.
Pillion rider switch connector PRS-A and ground
Pillion rider switch
C1283 VCM
out of range voltage out of range - (expected value = 11 to 13 volts).
switch defect. Measure resistance between VCM-16
Replace pillion rider switch.
Measure battery voltage with
VCM supply voltage value: 11 to 13 volts).
is much too Measure battery voltage with
C1290 VCM VCM voltage failure high or too low. engine running (expected
VCM supply voltage value: 13 to 14.7 volts).
spike glitch. Check connections on voltage regulator.
on battery.
C1300 VCM VCM internal fault VCM internal error. External troubleshooting is not possible.
Replace the VCM.
Make sure sensor
Measure voltage between SPS-5 and
Damaged sensor, SPS-1 (expected value: 4.8 to 5.1 volts)
Suspension
damaged circuit wires, connector:resistance
Measure
CL-13 to
from
SPS-4
damaged connector or
C210E CL position sensor (expected value: < 2 ohms).
range/performance damaged cluster pins,
cluster voltage supply Measure resistance from
Low or high. connector: CL-21 to SPS-5
SPS-1 to GND (expected value: < 2
ohms).
Make sure sensor
Measure voltage between SPS-5 and
Damaged sensor, SPS-1 (expected value: 4.8 to 5.1 volts)
damaged circuit wires, Measure resistance from
Suspension position damaged connector or connector: CL-13 to SPS-4
C210F CL (expected value: < 2 ohms).
sensor 5 Vdc supply damaged cluster pins,
cluster voltage supply Measure resistance from
Low or High. connector: CL-21 to SPS-5
SPS-1 to GND (expected value: < 2
ohms).
298 rmr2011-070
FAULT REPORTING
CODE MODULE

Blown fuse, battery engine stopped (expected
failure, voltage Measure battery voltage with
WPM system regulator failure, engine running (expected
C2210 WPM damaged circuit
voltage Low wires or connection, value: 13 to 14.7 volts).
damaged magneto Check connections on voltage regulator
Check ground and positive
generator. connections on battery
Check ground on vehicle frame.
Damaged regulator. Measure battery voltage with
WPM
WPM system An external battery engine running (expected
C2211
voltage High charger may have value: 13 to 14.7 volts).
been used. Check connections on voltage regulator
WPM
Windshield position Windshield position External troubleshooting is not possible.
C222A
sensor not calibrated sensor not calibrated. Replace the WPM.
Windshield po sition Windshield position External troubleshooting is not possible.
C2225 WPM
sensor sensor not plausible. Replace the WPM.
Open WPM Monitoring page in B.U.D.S.
WPM
Windshield
g U I3/Down Switch out of range - Verify that Switch is functioning
C222E
switches switch defect. as expected when activated.
Check for damaged wires
Windshield rotation
WPM direction not Wrong windshield Open WPM Activation page in B.U.D.S.
C222F
plausible mechanical position. Perform the Windshield sequences.
Damaged park brake

Park brake STROKE Check for wrong park brake cable
C223A WPM cable or wrong park
exceeded brake cable assembly. assembly or broken cable.
Pack brake Damaged park brake

WPM activation/deactivation cable or wrong park Check park brake cable assembly or
C223B
delay exceede d brake cable assembly. check park brake assembly.
Open WPM Monitoring page in B.U.D.S.

Park brake switch Verify that switch is functioning as
WPM PBS switch activation out of range expected when activated.
C223C
- switch defect. Ensure switch connector
is fully inserted.
Check for damaged wire.
rmr2011-070 299
FAULT REPORTING
Check fuse.
Disconnect HO2S1.
Measure voltage between
harness connector HO2S1-1 and ground
Blown fuse, damaged Measure resistance between
or disconnected HO2S1 pin 1 and 3 (expected
HO2Sheater control O2 sensor, value: Before Model Year 2011
P0030 ME17 circuit sensor 1 damaged or = 11 to 15 ohms, Model Year
disconnected circuit 12 and over = 7 to 12 ohms).
wires, damaged ECM Disconnect ECMB.
output pins. Measure resistance between
harness connector HO2S1-3 and
ground (expected value > open).
Measure resistance from harness
connector: HO2S1-3 to ECMB-L2
Check fuse.
Disconnect HO2S1.
HO2S heater control or disconnected H0281 pin 1 and 3 (expected
open circuit or
O2 sensor, value: Before Model Year 2011
P0031 ME17
shorted to ground damaged or = 11 to 15 ohms, Model Year
sensor 1 disconnected circuit 12 and over = 7 to 12 ohms).
Check fuse.
Disconnect HO2S1.
HOZS heater control O2 sensor, value: Before Model Year 2011
P0032 ME17 shorted to battery + damaged or = 11 to 15 ohms, Model Year
300 rmr2011-O70
FAU‘-T
CODE
REPORTING
MODULE
Check fuse.
Disconnect HO2S2.
harness connector HO2S2-1 and g round
H028 heater control damaged or = 11 to 15 ohms, Model Year
P0036 M E17
circuit sensor 2 12 and over = 7 to 12 ohms).
disconnected circuit
Check fuse.
Disconnect H0282.
or disconnected H0252 pin 1 and 3 (expected
HO2S heater control O2 sensor, value: Before Model Year 2011
open circuit or damaged or = 11 to 15 ohms, Model Year
P0037 ME17
shorted to ground disconnected circuit 12 and over = 7 to 12 ohms).
sensor 2
Check fuse.
Disconnect HO2S2.
HO2S heater control O2 sensor, value: Before Model Year 2011
P0038 ME17 shorted to battery + damaged or = 11 to 15 ohms, Model Year
rmr2011-070 301
FAULT REPORTING DESCRIPTION

CODE MODULE POSSIBLE CAUSE SERVICE ACTION
Damaged sensor, Make sure sensor

Manifold absolute damaged circuit wires, connector is fully inserted.
P0106 ME17 pressure circuit damaged connector or Measure voltage between harness
range/performance damaged ECM pins, connector pins 1 and 2 (expected value
ECM voltage supply. 4.8 to 5.1 volts).
Make sure sensor
harness connector pins 1 and 2
Damaged sensor, (expected value: 4.8 to 5.1 volts).
Manifold air pressure damaged circuit wires, Measure resistance from
P0107 ME17 sensor voltage too damaged connector or connector: ECMA-G4 to MAPS-3
Low damaged ECM pins, (expected value: < 2 ohms).
ECM voltage supply Measure resistance from
Low connector: ECMA-H2 to MAPS-2
(expected value: < 2 ohms)
ECMA-B4 to MAPS-1 (expected value:
< 2 ohms).
Make sure sensor
Damaged sensor, (expected value: 4.8 to 5.1 volts).
Manifold air pressure wires shorted Measure resistance from
P0108 ME17 sensor voltage too to battery +, connector: ECMA-G4 to MAPS-3
High ECM voltage supply (expected value: < 2 ohms).
too High. Measure resistance from
connector: ECMA-H2 to MAPS-2
ECMA-B4 to MAPS-1 (expected value:
< 2 ohms).
Make sure sensor
(expected value: 4.8 to 5.1 volts).
Damaged sensor, Measure resistance from
damaged circuit wires, connector: ECMA-F2 to AAPTS-1
Manifold air pressure damaged connector or (expected value: < 2 ohms).
P0112 ME17 Measure resistance from
sensor 1 circuit Low damaged ECM pins,
ECM voltage supply connector: ECMA-H4 to AAPTS-2
Low (expected value: < 2 ohms).
connector: ECMA-G3 to AAPTS4
ECMA-B4 to AAPTS-3 (expected value:
< 2 ohms).
302 rmr201 1-070

FAULT REPORTING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION

CODE MODULE
Make sure sensor

Damaged sensor, connector: ECMA-F2 to AAPTS-1
wires shorted (expected value: < 2 ohms).
Manifold air pressure to battery +, Measure resistance from
P0113 ME17 sensor 1 circuit High ECM voltage supply connector: ECMA-H4 to AAPTS-2
too High. (expected value: < 2 ohms).
connector: ECMA-G3 to AAPTS-4
ECMA-B4 to AAPTS-3 (expected value:
< 2 ohms).
Make sure sensor
Engine coolant Damaged sensor, harness connector pins 1 and 3
temperature wires shorted (expected value: 4.8 to 5.1 volts).
P0116 to battery +,
ME17 sensor 1 circuit Measure resistance from
range/performance ECM voltage supply.
connector: ECMA-F2 to AAPTS-1
Disconnect the sensor and check
for a change in the fault code. If
the fault code stays the same, look
for a short circuit on the harness.
If the fault code is
different, replace the sensor.
Engine coolant Engine temperature Measure resistance from
P0117 ME17 temperature sensor sensor or circuit wires connector: ECMA-A1 to CTS-1
1 circuit Low shorted to ground. (expected value: < 2 ohms).
connector: ECMA-J2 to CTS-2
Measure CTS resistance value
(expected value: 2280 to 2736 ohms at
19 to 21°C (66 to 70°F)).
Check for disconnected
engine temperature sensor.
connector: ECMA-A1 to CTS-1
Engine coolant Disconnected sensor, (expected value: < 2 ohms).
P0118 ME17 temperature sensor or sensor resistance Measure resistance from
1 circuit High too High. connector: ECMA-J2 to CTS-2
Measure CTS resistance value
(expected value: 2280 to 2736 ohms at
19 to 21°C (66 to 70°F)).
rmr2011-O70 303
FAU‘-T
CODE
REPORPNG
MODULE
Make sure sensor

First Throttle Damaged connector: ECMB-K1 to TAS-A
Accelerator Sensor circuit wires, (expected value: < 2 ohms).
P0122 ME17 damaged throttle Measure resistance from
(TAS) Short circuit to
GND position sensor or connector: ECMB-K3 to TAS-B
damaged ECM pins. (expected value: < 2 ohms).
Measure resistance from connector
ECMB-E1 to TAS-C (expected value
< 2 ohms).
Make sure sensor
First Throttle Damaged connector: ECMB~K1 to TAS-A
(TAS) shorted to
battery + position sensor or connector: ECMB-K3 to TAS-B
Measure resistance from connector
ECMB-E1 to TAS-C (expected value
< 2 ohms).
Intake air
P0127 ME17 temperature too Air temperature in
High intake High.
Check fuse.
Disconnect HO2S1.
Damaged O2 sensor, Measure resistance between
LAMBDA sensor damaged circuit wires, HO2S1 pin 1 and 3 (expected
P0130 ME17 1 upstream cat. damaged connector or value = 14 to 15 ohms).
range/performance damaged ECM output Disconnect ECMB.
pins. Measure resistance between
Disconnect HO2S1.
Disconnect ECMB.
Blown fuse, damaged harness connector HO2S1-4 and
or disconnected ground (expected value > open).
LAMBDA sensor 1 Measure resistance from harness
upstream cat. open O2 sensor,
P0131 ME17 damaged or connector: HO2S1-4 to ECMB-D2
circuit or shorted to (expected value: < 2 ohms).
ground disconnected circuit
wires, damaged ECM Measure resistance between
output pins. harness connector HO2S1-2 and
connector: HO2S1-2 to ECMB-J1
304 rmr2Cl11 O70


MODULE DESCRIPTION
CODE
Disconnect HO2S1.
Disconnect ECMB.
Damaged O2 sensor, Measure resistance from harness
LAMBDA sensor damaged circuit wires, connector: HO2S1-4 to ECMB-D2
P0132 ME17 1 upstream cat. damaged connector or (expected value: < 2 ohms).
shorted to battery + damaged ECM output Measure resistance between
pins. harness connector HO2S1-2 and
connector: HO2S1-2 to ECMB-J1
Check fuse.
Disconnect HO2S1.
P0133 ME17 upstream cat. slow damaged connector or value = 14 to 15 ohms).
response damaged ECM output Disconnect ECMB.
Check fuse.
Disconnect HO2S1.
Blown fuse, damaged (expected value = 11 to 13 volts).
or disconnected Measure resistance between HO2S1
pin 1 and 3(expected value: Before
O2 sensor,
LAMBDA sensor 1 Model Year 2011 = 11 to 15 ohms,
P0135 damaged or Model Year 12 and over = 7 to 12 ohms).
ME17 heater circuit disconnected circuit
rmr201 1-070 305

FAULT REPORTING
Check fuse.
Disconnect HO2S2.
range/performance damaged ECM output Disconnect ECMB.
Disconnect HO2S2.
Disconnect ECMB.
Blown fuse, damaged harness connector HO2S2~4 and
or disconnected ground (expected value > open).
LAMBDA sensor 2 Measure resistance from harness
upstream cat. open O2 sensor,
damaged or connector: HO2S2-4 to ECMB-G3
P0137 ME17 circuit or shorted to (expected value: < 2 ohms).
ground disconnected circuit
wires, damaged ECM Measure resistance between
connector: HO2S2-2 to ECMB-H4
Disconnect HO2S2.
Disconnect ECMB.
harness connector HO2S24 and
Damaged O2 sensor, ground (expected value > open).
LAMBDA sensor damaged circuit wires, Measure resistance from harness
P0138 ME17 2 upstream cat. damaged connector or connector: HO2S2-4 to ECMB~G3
shorted to battery + damaged ECM output (expected value: < 2 ohms).
connector: HO2S2-2 to ECMB-H4
306 rmr2011-070
FAULT REPORTING
Check fuse.
Disconnect HO2S2.
LAMBDA sensor 2 damaged circuit wires, HO2S2 pin 1 and 3 (expected
P0139 ME17 upstream cat. slow damaged connector or value = 14 to 15 ohms).
IGSDOFISB damaged ECM output Disconnect ECMB.
Check fuse.
Disconnect HO2S2.
LAMBDA sensor 2 damaged or = 11 to 15 ohms, Model Year
P0141 ME17 heater circuit
disconnected circuit 12 and over = 7 to 12 ohms).
connector: HO2S2-3 to ECMB—L3
System too lean Injection and fuel Check injector and fuel supply system.
P0171 ME17 supply system.
bank 1
P0172 ME17
System too rich bank Injection and fuel
Check fuel pressure regulator.
1 supply system.
ME17
System too lean Injection and fuel
Check injector and fuel supply system.
P0174 supply system.
bank 2
P0175 ME17
supply system. Check fuel pressure regulator.
2
Open ECM ACTIVATION
Power stage sig error ECM injector power page in B.U.D.S.
P0201 ME17
Activate injector and check if
injector 2 stage error.
injector is reacting as expected.
Open ECM ACTIVATION
Power stage sig error ECM injector power page in B.U.D.S.
P0202 I\/(E17
injector 1 stage error. Activate injector and check if
injector is reacting as expected.
rmr201 1-070 307

FAULT REPORTING
CODE MODULE
Engine coolant Check for coolant fluid

P0217 ME17 over temperature Coolant fluid leak and coolant fluid level.
condition temperature too high. Check radiator condition.
Check for other fault, check thermostat
Make sure sensor
Damaged circuit connector: ECMB-J3 to TAS-D
2nd Throttle wires, damaged (expected value: < 2 ohms).
P0222 ME17 Accelerator Sensor throttle position Measure resistance from
(TAS) shorted to GND sensor, or damaged connector: ECMB-B3 to TAS-E
ECM pins. (expected value: < 2 ohms).
ECMB-A3 to TAS-F (expected value: <
2 ohms).
Make sure sensor
2nd Throttle Damaged connector: ECMB-J3 to TAS-D
(TAS) shorted to
battery + position sensor, or connector: ECMB-B3 to TAS-E
ECMB-A3 to TAS—F (expected value: <
2 ohms).
Check fuse.
harness connector FP-B and ground
Blown fuse, damaged (expected value: 11 to 13 volts).
or disconnected Measure resistance on the fuel pump
Fuel pump circuit fuel pump, connector between terminals B
P0231 ME17 shorted to ground, or damaged circuit wires, and C (expected value: < 2 ohms).
open circuit damaged connectors Measure resistance from harness
or damaged ECM connector: ECMB~M1 to FP-C
output pins. (expected value: < 2 ohms).
connector FP-C and ground (expected
value: O volts).
Check fuse.
harness connector FP-B and ground
(expected value: 11 to 13 volts).
Damaged fuel pump, Measure resistance on the fuel pump
Fuel pump circuit damaged circuit wires, connector between terminals B
P0232 ME17 damaged connectors and C (expected value: < 2 ohms).
shorted to battery +
or damaged ECM Measure resistance from harness
output pins. connector: ECMB-M1 to FP-C
connector FP-C and ground (expected
value: 0 volts).
308 rrn r201 1-O70


CODE MODULE
Check fuse.
Disconnect injector 1.
injector pin 1 and 2 (expected
Blown fuse, value = 14 to15 ohms).
damaged or Measure resistance from harness
Cylinder 1 injector disconnected injector, connector: ECMA-J1 to INJ1-1
P0261 ME17 open circuit or damaged or (expected value: < 2 ohms).
shorted to ground disconnected circuit Measure voltage between harness
wires, damaged ECM connector lNJ1—2 and ground
output pins. (expected value: 11 to 13 volts).
Check if HIC connector is connecting
the engine harness to the vehicle
harness.
value = 14 to15 ohms).
Damaged injector, Measure resistance from harness
damaged circuit wires, connector: INJ1-1 to lN.J1-2
Cylinder 1 injector damaged connector or (expected value: > open).
P0262 ME17
shorted to battery + damaged ECM output Measure voltage between
pins. harness connector ECMA-J1 and
ground (expected value: O volts).
harness.
Check fuse.
Blown fuse, value = 14 to15 ohms).
damaged or Measure resistance from harness
Cylinder 2 injector disconnected injector, connector: ECMA-K1 to lN.l2-1
P0264 ME17 open circuit or damaged or (expected value: < 2 ohms).
shorted to ground disconnected circuit Measure voltage between harness
wires, damaged ECM connector lNJ2-2 and ground
output pins.
harness.
value = 14 to15 ohms).
Damaged injector, Measure resistance from harness
damaged circuit wires, connector: lNJ2-1 to lNJ2-2
Cylinder 2 injector damaged connector or (expected value: > open).
P0265 ME17
shorted to battery + damaged ECM output Measure voltage between
pins. harness connector ECMA-K1 and
harness.
rmr2011-070 309
FAULT REPORTING
CODE MODULE
P0300 ME17
Random/multiple Ignition and or fuel
misfire detected system. Check ignition and or fuel system.
Random/multiple
P0301 ME17 misfire detected Ignition and or fuel
system. Check ignition and or fuel system.
cylinder 2
Random/multiple
P0302 misfire detected Ignition and or fuel
ME17
system. Check ignition and or fuel system.
cylinder 1
Knock sensor
P0324 ME17 Knock sensor correlation check Make sure sensor connector is fully
failed. inserted and check knock system.
Damaged knock
sensor, damaged
P0327 ME17
Knock sensor 1 circuit wires, Make sure sensor connector is fully
negative line damaged connector or inserted and check knock system.
damaged ECM output
pins.
Damaged knock
sensor, damaged
P0328 ME17
positive line damaged connector or inserted and check knock system.
damaged ECM output
pins.
Knock sensor
P032A ME17 Knock sensor correlation check Make sure sensor connector is fully
failed. inserted and check knock system.
Damaged knock
sensor, damaged
P0332 l\/(E17
negative line damaged connector or inserted and check knock system.
damaged ECM output
pins.
Damaged knock
sensor, damaged
P0333 ME17
positive line damaged connector or inserted and check knock system.
damaged ECM output
pins.
Make sure sensor
Damaged CPS, connector is fully inserted.
damaged circuit wires, Measure resistance from
P0335 ME17
Crankshaft position connector: ECMA-H1 to CPS~1
pensor damaged connector or
damaged ECM output (expected value: < 2 ohms).
pins. Measure resistance from connector
ECMA-K2 to CPS-2 (expected value:
< 2 ohms).
310 rmr2011 070

FAULT REPORTING
MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION
CODE
Make sure sensor

Damaged CAPS, connector CAPS-3 and ground
damaged circuit wires, (expected value: 11 to 13 volts).
ME17
Camshaft position damaged connector or Measure resistance from
P0340 pensor
damaged ECM output connector: ECMA-E2 to CAPS-2
ECMA-D4 to CAPS-1 (expected value:
< 2 ohms)
Open the ECM Activation
page in B.U.D.S.
Perform an ignition coil
activation and check if ignition
coil is reacting as expected.
Check fuse and HIC connector.
Damaged ignition coil, Measure resistance from harness
damaged circuit wires, connector: ECMA-M1 to COIL-3
P0359 ME17 Ignition coil damaged connector or (expected value: < 2 ohms).
damaged ECM output Measure voltage between harness
pins. connector COIL-2 and ground
Check connector HIC that connects to
engine harness to the vehicle harness.
Refer to the SERVICE MANUAL for
detailed IGNITION COIL TESTING
procedure.
page in B.U.D.S.
damaged circuit wires, connector: ECMA-M2 to COIL-1
P0360 ME17 Ignition coil damaged connector or (expected value: < 2 ohms).
procedure.
rmr2011-070 311
FAULT REPORTING

page in B.U.D.S.
Ignition coil damaged circuit wires, connector: ECMA-M1 to COIL-3
P0361 ME17 range/performance damaged connector or (expected value: < 2 ohms).
(expected value: 11 to 13 volts)
procedure.
page in B.U.D.S.
Ignition coil damaged circuit wires, connector: ECMA-M2 to COIL-1
P0362 ME17 range/performance damaged connector or (expected value: < 2 ohms).
Refer to the SERVICE MANUAI for
procedure.
Check fuse.
Disconnect EVAP.
Damaged EVAP, Measure resistance between EVAP pin 1
Evaporative emission damaged circuit wires, and 2 (expected value = 10 to 20 ohms)
P0443 ME17 system purge control damaged connector or Measure resistance from harness
valve circuit damaged ECM output connector: ECMA-M3 to EVAP-1
connector EVAP-2 and ground (expected
312 rmr2011-070

CODE MODULE
Check fuse.
Disconnect purge valve.
harness connector EVAP-1 and
Blown fuse, damaged ground (expected value: < 2 volts).
purge valve, damaged Measure voltage between
Purge valve shorted circuit wires, damaged harness connector EVAP-2 and
P0458 ME17 to ground or open connectors or
circuit ground (expected value: 11 to 13 volts)
damaged ECM output Measure resistance between EVAP pin 1
pins. and 2 (expected value = 10 to 20 ohms).
harness.
Disconnect purge valve.
connector EVAP-1 and ground
Damaged purge valve, (expected value: < 2 volts).
damaged circuit wires, Measure voltage between harness
Purge valve shorted damaged connector or connector EVAP-2 and ground
P0459 ME17
to battery + damaged ECM output (expected value: 11 to 13 volts).
pins. Measure resistance between EVAP pin
1 and 2 (expected value = 10 to 20
ohms).
Damaged sender,
Fuel sender damaged circuit wires,
P0461 CL range/performance damaged connector or
damaged cluster pins.
Check fuse.
Disconnect relay.
or disconnected relay, terminals 85 and 86 on relay
damaged circuit wires, (expected value: 70 to 90 ohms).
Radiator cooling fan damaged connectors Measure resistance between
P0480 ME17 relay or damaged ECM harness connector FB-C8 and
output pins, damaged ground (expected value > open).
headlamp overrun Measure resistance from harness
switch. connector: ECMB-J4 to FB-C8
Disconnect MPl2 from DLC connector.
VCM to ECM missing Measure resistance between DLC-1 and
Invalid or missing CAN communication, DLC-2 (expected value = 50 to 70 ohms).
P0500 ME17 vehicle speed on Damaged circuit wires Measure resistance between DLC-1 and
CAN or damaged VCM ECMB-C1 (expected value < 2 ohms).
pins. Measure resistance between DLC-2 and
rmr2Cl11-070 313
FAULT REPORTING
Invalid or missing VCM vehicle speed Open the Fault page in B.U.D.S.
P0500 TCM vehicle speed from invalid or vehicle Look for VCM wheel
VCM speed message is speed sensor faults.
missing. Look for VCM faults.
Check for VCM fault.
Vehicle speed not Vehicle speed Open the VCM Monitoring
P0501 ME17 correlation check page in B.U.D.S.
plausible
failed. Verify that speed sensors are
working as expected.
Open the ECM Monitoring
page in B.U.D.S.
Press on brake pedal.
Brake signal not Brake signal vs brake Ensure that brake switch light
P0504 ME17 pressure correlation comes on ECM Monitoring page.
plausible
check failed. Verify that brake pressure
sensor displays a valid value
on VCM Monitoring page.
Check fuse F5.
Check fuse.
Blown fuse, damaged Disconnect prestarting relay.
or disconnected relay, Measure resistance between
damaged circuit wires, terminals 85 and 86 on relay
(expected value: 70 to 90 ohms).
P0512 ME17 Starter control circuit damaged connectors Measure resistance between
or damaged ECM
output pins, damaged harness connector FB-C4 and
headlamp overrun ground (expected value > open).
switch. Measure resistance from harness
connector: ECMB-C4 to FB-C4
Measure resistance between harness
connector EOP and ground when engine
stopped (expected value < 2 ohms).
Damaged switch, Measure resistance between harness
Engine oil pressure damaged circuit wires, connector EOP and ground when
P0520 ME17 sensor circuit damaged connector, engine running (expected value = open).
malfunction damaged ECM pins. Measure resistance from harness
connector: EOP to ECMA-E3
Check if HIC connector is properly
connected (engine harness to the
vehicle harness).
Damaged switch, Measure resistance between harness
Engine oil pressure damaged circuit wires, connector EOP and ground when
P0523 ME17 damaged connector, engine running (expected value = open).
sensor sticking Measure resistance from harness
damaged ECM pins.
connector: EOP to ECMA-E3
vehicle harness).
314
rmr201 1 -070
FAULT
CODE
REPORTING
M ODULE

Damaged switch, connector EOP and ground when
damaged circuit wires, engine running (expected value = open).
Engine oil Pressure damaged connector,
P0524 ME17 too Low Measure resistance from harness
damaged ECM pins. connector: EOP to ECMA-E3
vehicle harness).
TOROUE_SENSOR_ External troubleshooting is not possible.
P0551 DPS Damaged DPS. Replace the DPS.
OPEN
SHORT GND
SI-lORT_5V
Control intervention External troubleshooting is not possible.
counter exceeded
Battery failure, voltage engine stopped (expected
regulator failure, value: 11 to 13 volts).
damaged circuit Measure battery voltage with
wires or connection, engine running (expected
Non-plausibility error damaged magneto
P0560 ME17 value: 13 to 14.7 volts).
on system voltage generator. Check connections on voltage regulator.
An external battery Check ground and positive
charger may have connections on battery.
been used. Check ground on vehicle frame.
Blown fuse FC, Measure battery voltage with
battery failure, voltage engine stopped (expected
regulator failure, value: 11 to 13 volts).
damaged circuit Measure battery voltage with
wires or connection, engine running (expected
P0562 ME17 System voltage Low damaged magneto value: 13 to 14.7 volts).
generator. Check connections on voltage regulator.
An external battery Check ground and positive
charger may have connections on battery.
been used. Check ground on vehicle frame.
Blown fuse FC, value: 11 to 13 volts).
battery failure, voltage Measure battery voltage with
regulator failure, engine Running (expected
P0562 CL System voltage Low damaged circuit value: 13 to 14.7 volts).
wires or connection, Check connections on voltage regulator.
damaged magneto Check ground and positive
generator. connections on battery.
rrnr20'l 1 -070 315

FAULT
CODE
REPORTING
MODULE
Check DPS motor fuse MFB56.

Blown fuse, battery Measure voltage between harness
failure, voltage connector DPS2-A and ground
regulator failure, (expected value = 11 to 13 volts).
P0562 DPS System voltage Low damaged circuit Measure battery voltage with
wires or connection, engine stopped (expected
damaged magneto value: 11 to 13 volts).
generator. Check ground and positive connections
on battery.
Damaged regulator. Measure battery voltage with
P0563 ME17 System voltage High An external battery engine running (expected
charger may have value: 13 to 14.7 volts).
been used. Check connections on voltage regul BIO)’.
Damaged value: 11 to 13 volts).
voltage regulator. Measure battery voltage with
P0563 CL System voltage High An external battery engine Running (expected
charger may have value: 13 to 14.7 volts)
been used. Check connections on voltage regul ator.
Rectifier failure, Measure battery voltage with
P0563 DPS system voltage High damaged circuit wires engine running (expected
or connection. value: 13 to 14.7 volts)
Check connections on voltage regul BTOT
Check ground and positive connect (ODS
on battery.
Open WPM Monitoring page in B.U. D.S
P0571 WPM HBS switch fault Activated park brake Verify that switch is functioning
detection switch fault. as expected when activated.
P0601 CALIBRATION DPS not calibrated or
DPS Try updating the DPS.
FAULT damage DPS.
P0601 WPM
WPM calibration WPM not calibrated or
fault damaged WPM. Try updating the WPM.
EEPROM
P0605 DPS COMMUNICATION Internal error or External troubleshooting is not possible
FAULT damaged DPS. Replace the DPS.
316
rrnr2011~O70
FAULT RE PORTI NG POSSIBLE CAUSE SERVICE ACTION

CODE MODUL DESCRIPTION
Try updating the ECM calibration.

Faulty calibration. If the problem persists, reflash ECM.
Control module Faulty programming.
P0606 ME17 If the problem persists, replace the
processor Damaged ECM. ECM.
Make sure sensor
connector: ECMB-K1 to TAS-A
connector: ECMB-K3 to TAS-B
Throttle Accelerator Throttle Accelerator Measure resistance from
Sensor (TAS) connector: ECMB-E1 to TAS-C
Sensors (TAS)
P060D ME17 synchronistic error plausibility check (expected value: < 2 ohms).
between sensor 1 error. Measure resistance from
and 2 connector: ECMB-J3 to TAS-D
connector: ECMB-B3 to TAS-E
ECMB-A3 to TAS-F (expected value: <
2 ohms).
Disconnect TPS.
harness connector TPS-1 and TPS-3
(expected value = 4.8 to 5.1 volt).
Measure resistance between TPS pin 1
and 3 (expected value = 3K to 5K ohms).
Throttle position TPS plausibility check Disconnect ECMA.
P060E ME17 error.
performance Measure resistance from harness
connector: TPS-2 to ECMA-F3
connector: TPS-4 to ECMA-K3
Faulty variant coding. Try updating the ECM
Faulty programming. variant or calibration.
P0610 ME17 Variant coding error Wrong ECM after If the problem persists, reflash ECM.
replacement. if the problem persists, replace ECM.
External troubleshooting is not possible.
P0613 TCM TCM internal fault TCM internal error. Replace the TCM.
Vehicle speed Message counter Open the VCM Monitoring
P062C ME17 message on CAN plausibility check of page in B.U.D.S.
not plausible vehicle speed failed. Verify that speed sensors are
working as expected.
P062F ME17
Internal control
module EEPROM
error
Faulty calibration or
transmission variant.
Faulty programming.
Damaged ECM.
Try updating the ECM
transmission variant or calibration.
If the problem persists, reflash ECM
If the problem persists, replace ECM.
I
rmr201 1 -070 317 I
FAULT REPORTING
CODE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION
MODULE
Check DPS motor connections.

Check DPS motor fuse MFB56.
Blown fuse, damaged Measure battery voltage with
P0636 MOTOR LOW engine stopped (expected
DPS circuit wires or
CURRENT FAULT value: 11 to 13 volts).
connection.
Check connections on voltage regulator
on battery.
P0637
MOTOR HIGH Internal error or External troubleshooting is not possible
DPS
CURRENT FAULT damaged DPS. Replace the DPS.
P0658 DPS PHASE A_LOW DPS motor supply.
Damaged DPS. Check DPS motor connections.
P0659 DPS PHASE A_HlGH DPS motor supply.

Damaged DPS. Check DPS motor connections.
TEMPERATURE Internal temperature External troubleshooting is not possible
P0666 DPS
SENSING FAULT error or damaged DPS. Replace the DPS.
Warning DPS DPS has operated No Troubleshooting is needed.
P0667 DPS low temperature in the temperature This is a warning that DPS is operating
operating limitation limitation rang of (O to in the temperature limitation rang of (O
-10). to -10).
Check fuse.
Disconnect Main relay 2.
harness connector FB-D5 and ground
Blown fuse, damaged Measure voltage between harness
or disconnected relay, connector FB-C5 and ground
damaged circuit wires, (expected value: 11 to 13 volts).
P0685 ME17 Main relay 2 circuit Measure resistance from harness
damaged connectors
or damaged ECM connector: ECMB-J2 to FB-C6
connector: ECMB-J2 to JMP1-C
Measure resistance between terminals
85 and 86 on the 2 relays (expected
value: 70 to 90 ohms).
318
rmr2011»070
Subsection 04 (DIIAGNOSTIC AND FAULT CODES)

CODE MODULE DESCRIPTION POSSIBLE CAUSE
Check fuse.
Blown fuse, damaged connector FB-C5 and ground
or disconnected relay, (expected value: 11 to 13 volts)
Main relay 2 circuit damaged circuit wires,
P0686 ME17 shorted to ground or Measure resistance from harness
damaged connectors connector: ECMB-J2 to FB-C6
open circuit or damaged ECM (expected value: < 2 ohms).
output pins. Measure resistance from harness
Check fuse.
Damaged relay, connector FB-C5 and ground
damaged circuit wires, (expected value: 11 to 13 volts)
Main relay 2 circuit damaged connector or Measure resistance from harness
P0687 ME17 shorted to battery + damaged ECM output connector: ECMB-J2 to FB-C6
Check fuse.
Disconnect radiator fan relay
connector FB-D7 and ground
Blown fuse, damaged (expected value: 11 to 13 volts).
or disconnected Measure resistance between
Radiator fan circuit fan relay, harness connector FB~C8 and
P0691 ME17 shorted to ground or damaged circuit wires, ground (expected value: open).
open circuit damaged connectors Measure resistance from harness
or damaged ECM connector: ECM~J4 to FB-C8
85 and 86 on relay (expected value: 70
to 90 ohms).
rmr201 1—070 319

FAULT REPORTING
Disconnect radiator fan relay.

Damaged fan relay, Measure voltage between
Radiator fan circuit damaged circuit wires, harness connector FB-C8 and
P0692 ME17 damaged connector or ground (expected value: 0 volts).
shorted to battery +
damaged ECM output Measure resistance between terminals
pins. 85 and 86 on relay (expected value: 70
to 90 ohms).
Open TCM Monitoring page in B.U.D.S.
Verify that gear position information
change when you change the
position of gear on vehicle.
Disconnect GBPS.
Fluctuation detected Expected GBPS signal harness connector GBPS-1 and GBPS-3
P0709 ME17
on GBPS signal plausibility check (expected value: 4.8 to 5.1 volts).
exceeded. Measure resistance from
connector: ECMA-F4 to GBPS—2
connector: ECMA-G1 to GBPS-3
Replace GBPS sensor.
Open TCM I\/lonitoring page in B.U.D.S.
PO71A TCM
Reverse switch Reverse switch out of Verify that reverse switch is functioning
detection problem range - switch detect. as expected when activated.
Check for ECM fault.
Gear info message Open ECM Monitoring page in B.U.D.S.
from ECM is different Verify that gear position
from the calculated information changes with gear
P0730 TCM Incorrect gear ratio selection changes on vehicle.
gear in TCM (using
RPM and vehicle Disconnect GBPS.
speed) Measure voltage between
harness connector GBPS-1 and GBPS-3
PO81 I ME17 Clutch slippage Excessive clutch
detected slippage. Check clutch for proper clutch behavior.
Check fuse.
Pre-starting relay damaged circuit wires. terminals 85 and 86 on relay
damaged connectors (expected value: 70 to 90 ohms).
PO81A ME17 short circuit to Measure resistance between
ground or damaged ECM
switch. Measure resistance from harness
320 rmr2011-070
FAULT
CODE
REPORTING
M ODULE
Check fuse.
or disconnected relay, terminals 85 and 86 on relay
damaged circuit wires,
Pre-starting relay damaged connectors (expected value: 70 to 90 ohms).
P081 B ME17 Measure resistance between
short circuit to V + or damaged ECM
switch.
Open TCM Monitoring page in B.U.D.S.
Shift Up/Down Shift Up/Down switch Verify that Up/Down switch is
P0826 TCI\/I switch detection out of range - switch
functioning as expected when activated
problem defect. Check for damaged wires.
VCM supply voltage Measure battery voltage with
is much too low. engine running (expected
P0882 TCI\/l System voltage Low VCM supply voltage value: 13 to 14.7 volts).
spike glitch. Check connections on voltage regulator
on battery.
VCM supply voltage
is much too high.
P0883 TC|\/I System voltage High engine running (expected
VCM supply voltage
spike glitch.
value: 13 to 14.7 volts)
Check connections on voltage regulator
on battery.
Disconnect clutch
modulation solenoid valve.
Damaged clutch Disconnect clutch solenoid valve.
modulation valve Measure voltage between
Clutch modulation circuit, damaged harness connector GSC-5 and
solenoid shorted ground (expected value: O volts).
P0900 TCM circuit wires,
to ground or open damaged connector or Measure voltage between harness
circuit damaged TCM output connector GSC-4 and ground
pins. (expected value: 11 to 13 volts).
Measure resistance between solenoid
connector.
rmr201 1-070 321

FAULT REPORTING
CODE MODULE
Check fuse.
Disconnect clutch solenoid valve.
Damaged clutch valve Measure voltage between
Clutch solenoid circuit, damaged harness connector GSC-6 and
P0902 TCI\/I shorted to ground circuit wires, ground (expected value: O volts).
or open circuit damaged connector or Measure voltage between harness
damaged TCM output connector GSC-3 and ground
connector.
Damaged clutch valve Measure voltage between
circuit, damaged
harness connector GSC-6 and
Clutch solenoid ground (expected value: 0 volts).
P0903 TCM shorted to battery circuit wires,
damaged connector or Measure voltage between harness
+
connector.
Check fuse.
Disconnect shift UP solenoid.
Damaged shift UP Measure voltage between
Shift UP solenoid solenoid valve circuit, harness connector GSC-8 and
P0973 TCM shorted to ground or damaged circuit wires, ground (expected value: 0 volts).
open circuit damaged connector or Measure voltage between harness
connector.
Disconnect shift UP solenoid.
Damaged shift UP Measure voltage between
solenoid valve circuit, harness connector GSC-8 and
P0974 TCM
Shift UP solenoid damaged circuit wires, ground (expected value: 0 volts).
shorted to battery + damaged connector or Measure voltage between harness
connector.
Check fuse.
Disconnect shift DOWN solenoid.
Damaged shift DOWN Measure voltage between
Shift DOWN solenoid
solenoid valve circuit, harness connector GSC-7 and
P0976 TCM shorted to ground or damaged circuit wires, ground (expected value: O volts).
open circuit damaged connector or Measure voltage between harness
connector.
322 rmr2011-O70
FAULT REPORTING DESCRIPTION SERVICE ACTION

POSSIBLE CAUSE
CODE MODULE
Disconnect shift DOWN solenoid.

Damaged shift DOWN harness connector GSC-7 and
Solenoid valve circuit, ground (expected value: 0 volts).
P0977 TCM
Shift DOWN solenoid damaged circuit wires, Measure voltage between harness
shorted to battery + damaged connector or connector GSC-2 and ground
damaged TCM output (expected value: 11 to 13 volts).
pins. Measure resistance between solenoid
COITFIGCIIOF.
Check fuse.
Disconnect HO2S1.
harness connector HO2S1-1 and gro U1’) d
P1030 IVIE17
circuit sensor 1 disconnected circuit 12 and over = 7 to 12 ohms).
harness connector I-IOZS1-3 and
Check fuse.
Disconnect HO2S2.
harness connector HO2S2-1 and gro un d
P1036 ME17
circuit sensor 2 disconnected circuit 12 and over = 7 to 12 ohms).
Wrong Throttle Wrong TPS

P1120 ME17 Accelerator Sensor sensor position. Check TPS adjustment.
(TPS) position Both TPS position
failed test.
rmr201 1—070 323 (

FAULT REPORTING
DE MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION
CO
Check fuse.
Disconnect HO2S1.
harness connector H0231-1 and ground
Lambda sensor damaged circuit wires, H0281 pin 1 and 3 (expected
sig-error damaged ECM output Disconnect ECMB.
harness connector HO2S1~3 and
Check fuse.
Disconnect HO2S2.
LAM BDA sensor damaged circuit wires, HO2S2 pin 1 and 3 (expected
intermittent/erratic damaged ECM output Disconnect ECMB.
harness connector H0282-3 and
connector: HO2S2—3 to ECMB-L3
ME17
P1171
bank 1 supply system. Check injector and fuel supply system.
P1172 l\/IE17
1 supply system. Check fuel pressure regulator.
P1174 l\/IE17
bank 2 supply system. Check injector and fuel supply system.
P1175 ME17
2 supply system. Check fuel pressure regulator.
Damaged knock
sensor, damaged
P1327 l\/IE17
Knock sensor 1 circuit wires,
negative line damaged connector or Check knock system.
damaged ECM output
pins.
Damaged knock
sensor, damaged
P1328 ME17
positive line damaged connector or Check knock system.
damaged ECM output
pins.
324 rmr201HJ70
FAU‘-T
CODE
REPORPNG
MODULE
Damaged knock
sensor, damaged
P1332 I\/IE17
negative line damaged connector or Check knock system.
damaged ECM output
pins.
Damaged knock
sensor, damaged
P1333 ME17
positive line damaged connector or Check knock system.
damaged ECM output
pins.
Deactivated park Open WPM Monitoring page in B.U.D .S

P1571 WPM
HBS switch brake detection switch
Verify that switch is functioning
deactivation fault fault. as expected when activated.
P1606 ME17
Control Module Internal ECM problem.
Processor External troubleshooting not possible
Disconnect ETA.
Damaged ETA, Measure resistance from
Electrical Throttle damaged circuit wires, connector: ECMA-L1 to ETA-3
P160E l\/IE17 Actuator (ETA) damaged connector or (expected value: < 2 ohms).
control fault damaged ECM output Measure resistance from connector:
pins. ECMA-L2 to ETA-4 (expected value: <
2 ohms).
Disconnect ETA.
Electrical Throttle damaged circuit wires. connector: ECMA-L1 to ETA-3
P1610 l\/IE17 Actuator (ETA) damaged connector or (expected value: < 2 ohms).
shorted to \/ + damaged ECM output Measure resistance from connector:
2 ohms).
Disconnect ETA.
P1611 l\/IE17 Actuator (ETA) damaged connector or (expected value: < 2 ohms).
shorted to ground damaged ECM output Measure resistance from connector:
2 ohms).
Disconnect ETA.
Electrical Throttle damaged circuit wires, connector: ECMA~L1 to ETA-3
P1612 ME17 Actuator (ETA) si gnal damaged connector or (expected value: < 2 ohms).
not plausible damaged ECM output Measure resistance from connector:
2 ohms).
rmr2011-D70 325
FAULT REPORTING
Disconnect ETA.
P1613 ME17 damaged connector or (expected value: < 2 ohms).
Actuator (ETA)
damaged ECM output Measure resistance from connector:
2 ohms).
Check throttle mechanical adjustment.
Check idle stop for wear.
Throttle mechanical Ensure throttle plate is
Throttle idle position adjustment. against throttle stop.
P1614 l\/IE17 failure on throttle No initialization Check throttle angle at idle.
release after throttle body/ Perform THROTTLE POSITION
ECM replacement. SENSOR RESET in B.U.D.S.
with throttle completely OFF.
Refer to the SERVICE MANUAL
for more details.
Throttle mechanical Ensure throttle plate is
adjustment. against throttle stop.
P1615 l\/IE17 TPS position Check throttle angle at idle.
No initialization
deviation fault Perform THROTTLE POSITION
after throttle body/
ECM replacement. SENSOR INITIALIZATION in B.U.D.S.
for more details.
Throttle Ensure throttle plate is
Throttle mechanical stop. against throttle stop.
P1616 l\/IE17 limp-home-position No initialization Check throttle angle at idle.
failed after throttle body/ Perform THROTTLE POSITION
for more details.
Wrong throttle Check THRO1TLE cable adjustment.

body mechanical Check idle stop for wear.
TPS adaptation position during Ensure throttle plate is
P1619 l\/IE17 against throttle stop.
failure reset of closed TPS
or no initialization after Perform THROTTLE POSITION
Wrong throttle Check cable adjustment.
body mechanical Check idle stop for wear.
TPS adaptation position during Make sure throttle plate
P1620 ME17 is against throttle stop.
failure reset of closed TPS
or no initialization after Perform THROTTLE POSITION
326 rmr2011~O70
FAULT REPORTI NG
CODE M ODUL E
Check cable adjustment.

Ensure throttle plate is
Throttle against throttle stop.
TPS adaptation mechanical stop,
ME17
cancelled lower No initialization Check throttle angle at idle.
P1621
mechanical stop after throttle body/ Perform THROTTLE POSITION
failed ECM replacement. SENSOR INITIALIZATION in B.U.D.S.
for more details.
Check cable adjustment.
Ensure throttle plate is
Throttle against throttle stop.
mechanical stop.
No initialization Check throttle angle at idle.
P1622 l\/IE17 TPS adaptation failed Perform THROTTLE POSITION
after throttle body/ SENSOR INITIALIZATION in B.U.D.S.
ECM replacement.
for more details.
Check multi switch left.
Disconnect headlamp relays.
Damaged relay, Measure voltage between
damaged circuit harness connector FB-C10 and
Headlamp relay wires, damaged ground (expected value: 0 volts).
P1675 l\/IE17 circuit shorted to multi switch left, Measure voltage between
battery + damaged connector or harness connector FB-C12 and
damaged ECM output ground (expected value: O volts).
pins. Measure resistance between terminals
85 and 86 on relays (expected value:
70 to 90 ohms).
Check fuse and multi switch left.
Blown fuse, damaged
Disconnect headlamp relays.
damaged circuit
Headlamp relay wires, damaged
terminals 85 and 86 on relays
multi switch left (expected value: 70 to 90 ohms).
circuit shorted to
P1676 l\/(E17 ground or open damaged connectors Measure resistance between
or damaged ECM harness connector FB-C10 and
circuit ground (expected value > open).
output pins, damaged
headlamp overrun connector FB-C12 and ground (expected
switch. value > open).
Blown fuse, damaged Check fuse and multi switch left.

or disconnected relay, Disconnect headlamp relays.
damaged circuit Measure resistance between
wires, damaged terminals 85 and 86 on relays
Headlamp relay multi switch left (expected value: 70 to 90 ohms).
P1677 l\/IE17
circuit damaged connectors Measure resistance between
or damaged ECM harness connector FB-C10 and
output pins, damaged ground (expected value > open).
headlamp overrun connector FB-C12 and ground (expected
switch.
value > open).
rmr201 1-070 327

FAULT
CQDE REPORTING
MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION
Check fuse F2.

Damaged clutch valve harness connector CSV-1 and
circuit, damaged ground (expected value: O volts).
Clutch valve circuit Measure voltage between harness
P1696 ME17 shorted to ground or circuit wires,
damaged connector or connector CSV-2 and ground
open circuit
damaged ECM output (expected value: 11 to 13 volts).
pins. Measure resistance between CSV pin 1
and 2 (expected value = 20 to 30 ohms)
connector: CSV-1 to ECMA-L3
Damaged clutch valve harness connector CSV-1 and
circuit, damaged ground (expected value: O volts).
Clutch solenoid valve circuit wires, Measure voltage between harness
P1697 ME17 circuit shorted to damaged connector, connector CSV-2 and ground
battery + damaged ECM (expected value: 11 to 13 volts).
output pins, Measure resistance between CSV pin 1
circuit shorted to and 2 (expected value = 20 to 30 ohms).
battery +. Measure resistance from harness
Check fuse F2.
Damaged clutch valve harness connector 6-CSV-1 and
circuit, damaged
circuit wires, Measure voltage between harness
P1698 l\/(E17 Clutch valve circuit connector 6-CSV-2 and ground
damaged connector or
damaged ECM output (expected value: 11 to 13 volts).
pins. Measure resistance between CSV pin 1
and 2 (expected value = 20 to 30 ohms)
P16C0
ECU ADC plausibility Monitoring plausibility
ME17 Check for ECM fault.
check check failed.
ECU ADC test failed Monitoring plausibility

P16C1 l\/IE17
check failed. Check for ECM fault.
P16C2 l\/IE17 ECU monitoring error Monitoring plausibility Check for ECM fault.
check failed.
Throttle Accelerator
P16C3 ME17
Sensors (TAS) Monitoring plausibility
monitoring check check failed. Check for ECM fault.
fault
Engine speed
P16C4 ME17 monitoring check Monitoring plausibility
fault check failed.
328 rmr2011-070
FAULT REPORTING
CODE MODULE
Safety fuel cut-off Monitoring plausibility

P16C5 ME17 activated monitoring Check for ECM fault.
check failed.
checkleveli
Safety fuel cut-off Monitoring plausibility
P16C6 ME17 activated monitoring Check for ECM fault.
check failed.
check level 2
Throttle valve Monitoring plausibility
P16C7 ME17 plausibility check Check for ECM fault.
failed check failed.
Permitted throttle
valve position Monitoring plausibility
P16C8 ME17 Check for ECM fault.
monitoring check check failed.
exceeded
Gear position Damaged circuit Open the Fault page in B.U.D.S.
P1730 TCM sensor signal wires, damaged GBPS Look for ECM gearbox position faults.
intermittent/erratic or damaged ECU pins. Look for ECM faults.
Damaged circuit Disconnect main relay.
Main relay wires, damaged
P20EB ME17 de-energized too connectors or
85 and 86 on relay (expected value: 70
late or sticking damaged ECM output to 90 ohms).
pins.
Ensure sensor connector
is fully inserted.
Damaged TPS, connector: ECMA-A2 to TPS-1
2nd Throttle damaged circuit wires, (expected value: < 2 ohms).
P212C l\/IE17 Accelerator Sensors damaged connector or Measure resistance from
(TPS) low damaged ECM output connector: ECMA-K3 to TPS-4
ECMA-K4 to TPS-3 (expected value: <
2 ohms).
is fully inserted.
Damaged TPS, connector: ECMA-A2 to TPS»1
2nd Throttle damaged circuit wires, (expected value: < 2 ohms).
P212D ME17 Accelerator Sensors damaged connector or Measure resistance from
(TPS) high damaged ECM output connector: ECMA-K3 to TPS-4
ECMA-K4 to TPS-3 (expected value: <
2 ohms).
Vehicle speed not Vehicle speed
Open VCM Monitoring page in B.U.D.S
P2159 l\/IE17
plausible correlation check
failed.
Verify that speed sensors are
functioning as expected.
rmr2(]11-(170 329
FAULT REPORTING

is fully inserted.
Damaged sensor, Measure resistance from
damaged circuit wires, connector: ECMA-F2 to AAPTS-1
Ambient pressure (expected value: < 2 ohms).
P2228 M E17 sensor shorted to damaged connector or
damaged ECM pins, Measure resistance from
ground connector: ECMA-H4 to AAPTS-2
ECM voltage supply
low. (expected value: < 2 ohms).
ECMA-B4 to AAPTS-3 (expected value
< 2 ohms).
is fully inserted.
Damaged sensor, connector: ECMA-F2 to AAPTS-1
P2229 ME17 Ambient pressure wires shorted (expected value: < 2 ohms).
sensor short to V + to battery +, Measure resistance from
ECIVI voltage supply connector: ECMA-H4 to AAPTS-2
too high. (expected value: < 2 ohms).
ECMA-B4 to AAPTS-3 (expected value
< 2 ohms).
Intake air system Check for cracked
P2279 ME17
leak Intake or throttle body air leak.
plenum.
Wrong O2 sensor
P2416 l\/IE17
O2 sensor signals position after
swapped O2 replacement Swap O2 sensor wires.
or wire replacement.
Ignition switch state Ignition key switch
P2530 l\/IE17 connection or internal Check ignition key contacts and wire
not plausible switch fault. connections.
Throttle Accelerator
Wrong TPS sensor
P2620 ME17 Sensors (TPS) Check TPS adjustment.
position position.
330 rmr201 1-070


CODE MODULE DESCRIPTION POSSIBLE CAUSE

is fully inserted.
First Throttle damaged circuit wires, (expected value: < 2 ohms).
P2621 ME17 Accelerator Sensor damaged connector or Measure resistance from
(TPS) low damaged ECM output connector: ECMA-F3 to TPS-2
ECMA—K4 to TPS-3 (expected value: <
2 ohms).
is fully inserted.
First Throttle damaged circuit wires, (expected value: < 2 ohms).
P2622 ME17 Accelerator Sensors damaged connector or Measure resistance from
(TPS) high damaged ECM output connector: ECMA-F3 to TPS-2
ECMA—K4 to TPS-3 (expected value: <
2 ohms).
DPS motor supply.
P2670 DPS PHASE B_LOW Damaged DPS.
Check DPS motor connections.
DPS motor supply.

P2671 DPS PHASE B_HIGH Check DPS motor connections.
Damaged DPS.
Open ECM Monitoring page in B.U.D .S
Verify that gear position
information changes with gear
selection changes on vehicle.
Damaged circuit Disconnect GBPS.
wires, damaged Measure voltage between harness
Gear position sensor gear position sensor, connector 5-GBPS-1 and 5-GBPS-3
P2801 I\/IE17
invalid range damaged ECM (expected value: 4.8 to 5.1 volts).
pins or damaged Measure resistance from connector:
transmission. 5-ECM-B13 to 5-GBPS-2
5-ECM-B22 to 5-GBPS-3 (expected
value: < 2 ohms).
rmr201 1~07O 331

FAULT REPORTING
Open ECM Monitoring page in B.U.D.S.

Verify that gear position
information changes with gear
selection changes on vehicle.
Damaged circuit Disconnect GBPS.
Gear position sensor wires, damaged Measure voltage between harness
P2806 I\/(E17 angle defined area vs gear position sensor, connector 5-GBPS-1 and 5-GBPS-3
position not plausible damaged ECM (expected value: 4.8 to 5.1 volts).
pins or damaged Measure resistance from connector:
transmission. 5-ECM-B13 to 5-GBPS-2
5-ECM-B22 to 5-GBPS-3 (expected
value: < 2 ohms).
CAN-Bus failure,
Damaged circuit wires DLC-2 (expected value = 50 to 70 ohms).
U0073 CL or damaged CLUSTER Measure resistance between DLC-1
CAN—Bus OFF
pins. and CL-24 (expected value < 2 ohms).
and CL-23 (expected value < 2 ohms).
U0073 TCl\/I
CAN~Bus failure, Damaged circuit wires DLC-2 (expected value = 50 to 70 ohms).
CAN—B us O FF or damaged TCM pins. Measure resistance between DLC-1
and TCM-19 (expected value < 2 ohm s).
and TCM-1 (expected value < 2 ohms).
CAN Bus failure,
Damaged circuit wires DLC-2 (expected value = 50 to 70 ohms).
U0073 VCl\/I or damaged VCM Measure resistance between DLC-1
CAN-Bus OFF
pins. and VCM-37 (expected value < 2 ohm sl.
and VCM-24 (expected value < 2 ohm s).
CAN-Bus failure, Damaged circuit wires DLC-2 (expected value = 50 to 70 ohms).
U0073 WPl\/I
CAN-Bus OFF or damaged WPM Measure resistance between DLC-1
pins. and WPM-6 (expected value < 2 ohm s).
and WPM-8 (expected value < 2 ohm s).
332 rmr201 1-O70

FAULT REPORT ING DESCRIPTION POSSIBLE CAUSE SERVICE ACTION

CODE M ODU L E

connector ECMB-A2 and ground
Missing CAN connector ECMB-M4 and ground
ID from ECM. (expected value = 11 to 13 volts).
Lost communication Internal module error. Disconnect MPl2 from DLC connector.
U0100 CL with ECM (lost of Damaged circuit wires Measure resistance between DLC-1 and
CAN lD's) or damaged module DLC-2 (expected value = 50 to 70 ohms).
and ECMB-C2 (expected value < 2
ohms).
Damaged circuit DLC-2 (expected value = 50 to 70 ohms).
Lost communication wires, damaged ECM Measure resistance between DLC-1 and
U0100 DPS with ECM (lost of or damaged DPS/ECM ECMB-C1 (expected value < 2 ohms).
CAN lD's) pins. Measure resistance between DLC-2
ohms).
Open the Fault page in B.U.D.S.
Damaged circuit Check for ECM fault.
Lost communication wires, damaged ECU Disconnect MPl2 from DLC connector.
U0100 TCM with ECM (lost of or damaged TCM/ECU Measure resistance between DLC~1
CAN lD‘s) pins. and 1—DLC-2 (expected value = 50 to 70
ohms).
connector ECMB-A2 and ground
Missing CAN connector ECMB-M4 and ground
ID from ECM. (expected value = 11 to 13 volts).
Lost communication Internal module error. Disconnect MPl2 from DLC connector.
U0100 WPM with ECM (lost of
Damaged circuit wires Measure resistance between DLC-1 and
CAN (D's) or damaged module DLC-2 (expected value = 50 to 70 ohms).
ohms).
rmr2011-070 333
FAU‘-T
CODE
REPORPNG
MODULE
Check for TCM fault or ECM fault.

connector TCM-4 and ground
Missing CAN ID Disconnect MPI2 from DLC connector.
220h from TCM. Measure resistance between DLC-1 and
Lost communication DLC-2 (expected value = 50 to 70 ohms).
U0101 ME17 with TCM (lost of Module internal error.
CAN ID's) ECMB-C1 (expected value < 2 ohms).
or damaged module
(expected value = 11 to 13 volts)
220h from TCM.
U0101 CL with TCM (lost of Internal module error.
or damaged module
Measure resistance between DLC~1
220h from TCM. Measure resistance between DLC-1 and
U0101 VCM with TCM (lost of Module internal error
Damaged circuit wires Measure resistance between DLC~1 and
or damaged module
Invalid engine Damaged circuit
wires, damaged ECU Open the Fault page in B.U.D.S.
U0116 TCM temperature Look for ECM engine temperature fault.
received from ECM or damaged TCM/ECU
pins. Look for ECM faults.
334 rmr201 1 -070

FAULT
CODE
REPORPNG
MODULE
Missing CAN ID Measure resistance between DLC-1 and
020h from VCM. DLC-2 (expected value = 50 to 70 ohms).
Lost communication Module internal error. Measure resistance between DLC-1 and
U0122 l\/IE17 with VCM (lost of Damaged circuit wires ECMB-C1 (expected value < 2 ohms).
CAN ID's)
or damaged mo dule Measure resistance between DLC-2 and
pins. ECMB-C2 (expected value < 2 ohms).
Lost communication Module internal €I'I'Ol'.
U0122 ME17 with VCM (lost of Measure resistance between DLC-1 and
Damaged circuit wires ECMB-C1 (expected value < 2 ohms).
CAN ID's) or damaged mo dule Measure resistance between DLC-2 and
Lost communication Module internal GITOT. Measure resistance between DLC-1 and
U0122 ME17 with VCM (lost of Damaged circuit wires ECMB-C1 (expected value < 2 ohms).
CAN ID's) or damaged mo dule Measure resistance between DLC-2 and
rmr201 ‘I-070 335

FAULT REPORTING

Missing CAN (expected value = 11 to 13 volts).
Lost communication ID from VCM. Disconnect MPI2 from DLC connector.
U0122 CL with VCM (lost of Internal module error. Measure resistance between DLC-1 and
CAN ID's) Damaged circuit wires DLC-2 (expected value = 50 to 70 ohms).
or damaged module Measure resistance between DLC-1
pins. and VCM-37 (expected value < 2 ohms).
VCM fault active, Measure resistance between DLC-1 and
Lost communication damaged circuit wires, DLC-2 (expected value = 50 to 70 ohms).
U0122 DPS with VCM (lost of damaged VCM or Measure resistance between DLC-1 and
CAN ID's) damaged DPSNCM ECMB-C1 (expected value < 2 ohms).
pins. Measure resistance between DLC-2
ohms).
Damaged circuit Measure resistance between DLC-1 and
Lost communication DLC—2 (expected value = 50 to 70 ohms).
U0122 TCM with VCM (lost of wires, damaged
VCM or damaged Measure resistance between DLC-1
CAN ID's) and VCM-37 (expected value < 2 ohms).
TCMNCM pins.
Missing CAN (expected value = 11 to 13 volts).
Lost communication ID from VCM. Disconnect MPI2 from DLC connector.
U0122 WPM with VCM (lost of Internal module error. Measure resistance between DLC-1 and
CAN ID's) Damaged circuit wires DLC-2 (expected value = 50 to 70 ohms).
or damaged module Measure resistance between DLC-1
pins. and VCM-37 (expected value < 2 ohms).
Check for DPS fault.
connector YRS-4 ancl ground
Damaged circuit (expected value = 11 to 13 volts).
Lost communication wires, damaged YRS Disconnect MPI2 from DLC connector.
U0123 DPS Measure resistance between DLC-1 and
with YRS or damaged YRS/VCM
pins. DLC-2 (expected value = 50 to 70 ohms).
and YRS—3 (expected value < 2 ohms).
and YRS-2 (expected value < 2 ohms).
336 rm r201 1-070

Subsection 04 (D AGNOSTIC AND FAULT CODES)

MODULE DESCRIPTION POSSIBLE CAUSE
CODE

connector YRS-4 and YRS-1
Lost communication wires, damaged Measure resistance between DLC-1 and
U0123 TCM with Yaw Rate Yaw Rate Sensor DLC-2 (expected value = 50 to 70 ohms).
Sensor (YRS) or damaged TCM/YRS Measure resistance between DLC-1
pins. and YRS—3 (expected value < 2 ohms).
Check for DPS fault.
Damaged circuit connector SAS-1 and ground
wires, damaged
Lost communication Steering Angle Disconnect MPI2 from DLC connector.
U0126 Measure resistance between DLC-1 and
DPS with SAS Sensor (SAS) DLC-2 (expected value = 50 to 70 ohms).
or damaged DPS/SAS Measure resistance between DLC-1
pins.
and SAS-3 (expected value < 2 ohms).
connector SAS-1 and SAS-2
Damaged circuit Disconnect MPI2 from DLC connector.
Lost communication wires, damaged SAS Measure resistance between DLC-1 and
U0126 VCM with SAS or damaged VCM/SAS DLC-2 (expected value = 50 to 70 ohms).
connector DPS1-A and ground
Lost communication Internal module error. Measure resistance between DLC-1 and
U0131 CL with DPS (lost of Damaged circuit wires DLC-2 (expected value = 50 to 70 ohms).
CAN ID's) or damaged module Measure resistance between DLC-1
pins.
and DPS1-D (expected value < 2 ohms).
and DPS1-C (expected value < 2 ohms).
rmr201 1 -070 337

FAULT
CODE
REPORUNG
MODULE

connector DPS1-A and ground
Lost communication Internal module error. DLC-2 (expected value = 50 to 70 ohms).
U0131 VCM with DPS (lost of Damaged circuit wires Measure resistance between DLC-1 and
CAN lD‘s) or damaged Module ECMB-C1 (expected value < 2 ohms).
and DPS1-D (expected value < 2 ohms).
and DPS1-C (expected value < 2 ohms).
Check for cluster fault or ECM fault.
connector CL-8 and ground
Missing CAN ID. Measure resistance between DLC-1 and
Lost communication Module internal error. DLC-2 (expected value = 50 to 70 ohms).
UO155 ME17 with CLUSTER (lost Damaged circuit wires Measure resistance between DLC-1 and
of CAN (D's) or damaged module ECMB-C1 (expected value < 2 ohms).
and CL—24 (expected value < 2 ohms).
Damaged (expected value = 11 to 13 volts).
Lost communication circuit wires, Disconnect MPI2 from DLC connector.
UO155 TCM with CLUSTER (lost damaged cluster Measure resistance between DLC-1 and
of CAN ID's) or damaged TCM/YRS DLC-2 (expected value = 50 to 70 ohms).
Missing CAN ID. (expected value = 11 to 13 volts).
Lost communication Internal module error. Disconnect MPI2 from DLC connector.
UO155 WPM with CLUSTER (lost Damaged circuit wires Measure resistance between DLC-1 and
of CAN lD's) or damaged module DLC-2 (expected value = 50 to 70 ohms).
338 rmr201 1-070


DESCRIPTION POSSIBLE CAUSE
CODE MODULE

connector MSL2-1 and ground
connector MSR2-6 and ground
Missing CAN ID. Disconnect MPI2 from DLC connector.
Lost communication Module internal error. Measure resistance between DLC-1 and
U0259 ME17 with MSL-MSR (lost Damaged circuit wires DLC-2 (expected value = 50 to 70 ohms).
of CAN ID's) or damaged module Measure resistance between DLC-1 and
and MSL3-2 (expected value < 2 ohms).
U0259 CL with MSL-MSR (lost Damaged circuit wires DLC-2 (expected value = 50 to 70 ohms).
Missing CAN ID. connector MSR2-6 and ground
Lost communication Module internal error. (expected value = 11 to 13 volts).
U0259 TCM with MSL-MSR (lost Damaged circuit wires Disconnect MPI2 from DLC connector.
pins. DLC-2 (expected value = 50 to 70 ohms).
rmr201 1-070 339

FAULT REPORTING

U0259 VCM with MSL-MSR (lost Damaged circuit wires DLC-2 (expected value = 50 to 70 ohms).
U0259 WPM with MSL-MSR (lost Damaged circuit wires DLC-2 (expected value = 50 to 70 ohms).
of CAN lD‘s) or damaged module Measure resistance between DLC-1 and
Incorrect ECM
Invalid security or CLUSTER, Install the proper ECM
U0300 ME17 or CLUSTER on vehicle.
exchange received Incorrect software
version. Update security coding using B.U.D.S.
Variant coding
manual transmission, Faulty calibration or Try updating the ECM
U0302 l\/IE17 software transmission variant. transmission variant or calibration.
incompatibility with Faulty programming. If the problem persists, reflash ECM.
transmission Damaged ECM. If the problem persists, replace ECM.
Variant coding
automatic Faulty calibration or Try updating the ECM
U0303 ME17
transmission, transmission variant. transmission variant or calibration.
software Faulty programming. If the problem persists, reflash ECM.
incompatibility with Damaged ECM. If the problem persists, replace ECM.
transmission
Variant coding
U0400 DPS failure software Faulty variant coding.
Faulty programming. Try updating the variant or calibration.
incompatibility
340 rmr201 1-070


DESCRIPTION
CODE MODULE
TCM variant coding Faulty variant coding.

U0400 TCM failure, software Try updating variant or calibration.
Faulty programming.
incompatibility
CAN-Bus failure: Damaged circuit wires DLC-2 (expected value = 50 to 70 ohms).
VCM not able to or damaged VCM Measure resistance between DLC-1
U1101 VCM
send messages on pins. and VCM-37 (expected value < 2 ohms).
CAN Measure resistance between DLC-2
Lost communication wires, damaged ECU Measure resistance between DLC-1 and
U1150 VCM ECMB-C1 (expected value < 2 ohms).
with ECM or damaged VCM/ECU
pins. Measure resistance between DLC~2
ohms).
connector YRS-4 and YRS-1
Lost communication wires, damaged
U1160 VCM with Yaw Rate Yaw Rate Sensor DLC-2 (expected value = 50 to 70 oh ms).
Sensor (YRS) or damaged VCM/YRS Measure resistance between DLC-1
pins. and YRS-3 (expected value < 2 ohms).
Damaged circuit
Invalid gearbox wires, damaged ECU Open the Fault page in B.U.D.S.
U1201 TCM position value or damaged TCM/ECU Look for ECM gearbox position fault.
received from ECM Look for ECM fault.
pins.
Invalid gearbox wires, damaged ECU Measure resistance between DLC-1 and
U1201 VCM position value or damaged VCM/ECU ECMB-C1 (expected value < 2 ohms).
received from ECM pins. Measure resistance between DLC-2
ohms).
Message counter External troubleshooting is not possible.
Invalid message plausibility check Check for communication faults in
U2100 TCIVI
Counter ECM failed. B.U.D.S.
Message counter External troubleshooting is not possible.
Invalid message Check for communication faults in
U2122 TCM plausibility check
Counter VCM failed. B.U.D.S.
External troubleshooting is not possible.
Invalid check sum Check sum error. Check for communication faults in
U220A TCM
from ECM message B.U.D.S.
rmr201 1-070 341

FAULT REPORTING
CODE MODULE
Invalid check sum Message counter

U220A WPl\/I plausibility check External troubleshooting is not possible
from ECM message Check for communication fault.
failed.
U220B I\/IE17
Invalid check sum External troubleshooting is not possible
from VCM message Check sum error.
Check for communication fault.
U220B ME17
from VCM message Check sum error.
Check for communication fault.
U220B
ME17 Check sum error.
from VCM message Check for communication fault.
U220B TCM Check sum error. Check for communication faults in
from VCM message
B.U.D.S.
Invalid check sum Message counter
U220B WPM plausibility check External troubleshooting is not possible
from VCM message Check for VCM Communication fault
failed.
U220C
I\/IE17 Check sum error.
from TCM message Check for communication fault.
Invalid check sum
U220E l\/IE17 from CLUSTER Check sum error. External troubleshooting is not possible
message Check for communication fault.
Invalid check sum Message counter External troubleshooting is not possible
U220E WPM from CLUSTER plausibility check Check for CLUSTER communication
message failed. fault.
Invalid check sum
U220F l\/IE17 from MSL-MSR Check sum error. External troubleshooting is not possible
message Check for communication fault.
U220F TCM from MSL-MSR Check sum error. Check for communication faults in
message B.U.D.S.
U220F WPM from MSL-MSR Check sum error. Check for MSL-MSR communication
message fault
Invalid message plausibility check External troubleshooting is not possible
U2259 TCM Check for communication faults in
counter MSL-MSR failed.
B.U.D.S.
342 rmr2011»070
Section 04 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))
ELECTRONIC FUEL INJECTION (EFI)

SERVICE TOOLS
ECM ADAPTER TOOL ................................................................. .. 529 036 166 351, 353, 359, 362, 366, 369,
372, 374, 377, 379, 382-383
FLUKE 115 MULTIMETER .......................................................... .. 529 035 868 ...................... .. 351-352, 359.
363, 365-366, 371
SERVICE PRODUCTS
LOCTITE 243 (BLUE) ................................................... .. ...... .. 293 800 060 364, 378
LOCTITE 767 (ANTISEIZE LUBRICANT) ..................... .. ...... .. 293 800 070
GENERAL NOTICE Never use a hose pincher on injec-

tion system high pressure hoses. Replace any
A WARNING damaged or deteriorated fuel line.
Fuel is flammable and explosive under cer- When the repair or test is completed, ensure that
tain conditions. Ensure work area is well ven- all hoses are connected and secured. Perform the
tilated. Do not smoke or allow open flames or
sparks in the vicinity. FUEL SYSTEM PRESSURE TEST and the FUEL
SYSTEM LEAK TESTas explained in FUEL T4NK
AND FUEL PUMP subsection.
A WARNING
Always disconnect battery prior to working A WARNING
on the fuel system. Always disconnect bat- Always perform the fuel pressure test if any
tery exactly in the specified order, BLACK (-) fuel line has been disconnected from a com-
cable first. It is recommended to disconnect ponent, or the fuel component has been re-
electrical connections prior to disconnecting moved. A pressure test must be carried out
fuel lines. before turning the ignition key to ON. The fuel
pump is activated each time the ignition key
A WARNING is turned ON.
Fuel lines remain under pressure at all times.
Always proceed with care and use appro- Hoses, cables or locking ties removed during a
priate safety equipment when working on a procedure must be reinstalled as per factory stan-
pressurized fuel system. Wear safety glasses. dards.
Proceed with care when removing/installing
pressure test equipment or disconnecting SYSTEM DESCRIPTION
fuel line connections. ECM
To release fuel pressure prior to removing a hose,
disconnect the fuel pump electrical connector and /aw?/r/g//;//,,,,,, ,
crank the engine.
,- . ‘.
Cover the fuel line connection with an absorbent ' I’ 1 , I
shop rag before disconnecting it. Slowly discon- ¢ .-Ah
nect the fuel hose to minimize spillage. -.2 ' ‘I F j
A WARNING
“I Ti. l
smr2009-O27-005
Do not allow fuel to spill on hot engine parts TYPICAL - ECM
and/or on electrical connectors. Wipe off any
fuel spillage in the engine compartment.
rmr2011-071 343
Section04 FUEL SYSTEM
The ECM reads input signals from various sensors

that provide it with an indication of the engine op-
erating conditions at micro-second intervals.
The ECM calculates the appropriate amount of air,
fuel, and ignition timing required, and activates
the outputs to the injectors, ignition coils and
electric throttle actuator (ETA).
EFI Sensors
The TAS (Throttle Accelerator Sensor), CPS
(Crankshaft Position Sensor), the MAPS (Man-
ifold Absolute Pressure Sensor), and the TPS
(Throttle Position Sensor), are the primary sen-
sors used to control the injection. Other sensors (ITITZOI 0-008-0O6_a
such as temperature sensors are used as sec- H0282 LOCATION

ondary inputs. 7. Oxygen sensor
2. Rear head pipe
The AAPTS (Ambient Air Pressure and Temper-
ature Sensor) functions in conjunction with the Closed loop system operation (also called a feed-
MAPS. The AAPTS reading is compared with the back system) regulates the air/fuel ratio based on
MAPS reading. The ECM uses the comparative predetermined values stored within the ECM. The
results to improve engine operation in high alti- stored values are used in relation to the informa-
tude areas. tion received from the input sensors and the resid-
ual amount of oxygen In the exhaust-gas, which
The injection system is a closed loop type. This is measured by the oxygen sensors (Lambda sen-
is achieved by the addition of two heated oxygen sors).
sensors (HO2S1 and HO2S2).
The engine will begin to operate in open loop
HO2S1 is located on the front cylinder exhaust when first started, and switch to closed loop
pipe, HO2S2 is located on the rear cylinder ex- operation when the oxygen sensors reach their
haust pipe. operating temperature. At high engine loads, the
engine reverts again to the open loop.
_ its " -‘jg \_~.4 Throttle Body

‘rig
-,_-3.,’ '
>:;*).-.';re-s=6;§rir,*:'»!!-'--*-:1:~!§\_
‘IL’ __ I. W 1' -.~\ J
Ilib A 51 mm (2 in) twin draft throttle body is mounted
O
s >
-'1: , "*-.~‘ 7111243‘ : 5% directly on the intake flange of each cylinder. The
'II Ill ""‘ "*“"“e--E.-.-?.‘.».*"=-\: 1 TPS and the MAPS are fitted on the throttle body.
,
.. ~ -/Csltnils, ». ~ \®-- i, .\,\
' 1 ‘ \. ‘ T . - - r
\k ér‘ \ ya‘ I 2
' I - I ‘I a-ff'S""5":.
rmr2010-D08-OD5_a
H0281 LOCATION
1. Oxygen sensor
2. Front head pipe -1 _~ I - _
‘9".\. i
\>% -4‘ ILA
ii
"TJ I
\_':
I L-
rrnrZ010-02 2-O02_a
‘\\‘
‘- Q-I _§:c?“j<_~v‘.
ff’ '
~I 7.. L‘2.I1-.
/T’/%‘A‘.
‘T’ 1.3?“
i\
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r
I
1. Twin draft throttle body

2. TPS
3. Fuel pressure regulator
4. MAPS
5. Electric throttle actuator (ETA)
344 rmr2011-071
Section O4 FUEL SYSTEM
An electric throttle actuator (ETA) is used to con- TAS Operation

trol air delivery by opening or closing the throttle The ECM provides a supply voltage and a ground
plates. lt allows the ECM to electrically control the to each hall effect sensor. The hall effect sensors
position of the throttle plates throughout the full in the TAS each produce a command signal volt-
range of engine operation. age that is proportional to the throttle position.
The TPS provides the ECM with a signal of the Turning the throttle grip varies the two command
actual angle position of the throttle plates. When signal voltages produced by the TAS accordingly.
the ETA changes the position of the throttle The ECM will then power the ETA to open or close
plates, the ECM uses the TPS signal to monitor the throttle plates in the throttle body according to
the throttle plate position, and modulate the ETA the torque commanded by the operator, or other
through pulse width modulation to move the inputs such as cruise control or transmission con-
throttle plates until the targeted position of the trol module (SE5 model).
throttle plates is achieved. lf the brake pedal is depressed and the throttle is
The use of an ETA controlled by the ECIVI also al- not released, engine torque remains the same if
lows for an electronic cruise control function. both TAS sensors are operating normally. If only
If there is a system malfunction and the ETA is one TAS sensor is operating normally when brak-
not powered by the ECM, return springs move ing is applied, and the throttle is not released, en-
the throttle plate back to the LIMP HOl\/IE posi- gine torque will be reduced to idle. Normal engine
tion against a mechanical stop, not the idle posi- control will resume when braking action is ceased.
tion. The throttle plates are electrically driven to
the idle position by the ETA when commanded by Fuel Injector
the ECM. Two fuel injectors mounted on the throttle body
lone per cylinder) are used to inject fuel into the
E714 Closed Throttle Feature 2077 Mode/s intake port of the cylinder head.
For quicker engine restarts, the ETA is powered
by the ECM to electrically hold the throttle plates
closed for 40 minutes anytime the ignition key is
turned to the OFF position. During this period, a
high frequency sound can be heard from the ETA
if you pay close attention.
This ETA closed throttle feature on KEY OFF must
be deactivated when working on the throttle body,
as well as when testing most of the engine man-
agement sensors and their circuits. This is accom-
plished by deactivating main relay 1 (R7).
Throttle Accelerator Sensor (TAS)
rm r201 O-D22-0O3_a
TAS Description 1. Fuel injector
2. Fuel rail
This vehicle is designed with an electronic throt- 3. Banjo fitting for fuel pressure hose
tle accelerator sensor (TAS) that is used to deter-
mine the driver requested torque. There are no The fuel pump pressure hose is connected to the
mechanical cables between the throttle grip and fuel rail on the RH side of the throttle body. The
the throttle body. This is often referred to as a LH and RH fuel rails interconnect through a port in
"throttle by wire" system. the throttle body to provide fuel pressure to both
The TAS sensor is composed of two magnets and injectors. The fuel pressure regulator mounted on
a double output hall effect sensor that are incorpo- the LH fuel rail bypasses excess fuel flow to the
rated within the throttle grip assembly. fuel pump
The double hall effect sensor TAS is used for
redundancy. If one sensor is inoperative, throttle
control will be maintained, but a check engine
light and a check engine message will appear in
the gauge cluster, and a relevant fault code will
be recorded in the ECM.
rmr201 1-071
345
ADJUSTMENT
IDLE SPEED 2v woo
LE L
<48":
trneuwuwisuiw
L I l -~ l
Mwnwq Mnfli» was
l
l rnulw F
l
Idle speed is not adjustable. It is controlled by Xfnlolbqunj
the engine management system through modula-
tion of the throttle plates and the ignition timing. y H j , .-.___, at _A..
'-1- ~-— —
l<—lEl
~ ---
THROTTLE POSITION SENSOR am I

Yam muwi
RESET
General Information M l
This operation performs a reset of the values
stored in the ECM for the TPS when it is at the Ii] W i_,_%*r:_.... l
closed position and at the limp home position. uculgggjvrujv-s QT W '
The TPS position is used to determine the basic rmr201 D-O22-ll07_a
parameters for all fuel mapping and several ECM Step 1: Click on Read Data
calculations. Step 2: Click on Setting page tab
Step 3: Select the ECM page tab
A reset must be carried out each time any of the Step 4: Click on TPS Reset button
following situations has occurred: NOTE: A message will be displayed to confirm
— Throttle position sensor (TPS) has been loos- whether or not the operation was successful.
ened, removed, or replaced. Follow instructions in the displayed message.
— Throttle body has been replaced. If the operation was not successful, the ECM
— ECM has been replaced. will generate a fault code and will not accept the
NOTE: The TPS is not adjustable. The ECM must setting.
learn the TPS values when carrying out the Throt- 7. Start engine and make sure it operates nor-
tle position sensor initialization reset procedure mally throughout its full engine RPl\/l range. If
in B.U.D.S. An improperly set TPS may lead to fault codes appear, refer to D/AG/\/OST/CA/VD
poor engine performance. Emission compliance FAULT CODES subsection for more informa-
could possibly be affected. tion.
TPS initialization TROUBLESHOOTING
1.Connect vehicle to the latest applicable
B.U.D.S. version. DIAGNOSTIC TIPS
2. Turn the ignition key to ON. Do not start the
engine. The first step in troubleshooting the EFI system
is to check for fault codes using B.U.D.S.; refer
3. ln B.U.D.S., click on the Read Data button. to D/AGNOST/C A/\/D FA ULTCODES subsection.
4. Click on the Setting page tab. However, engine problems are not necessarily re-
5. Select the ECM page tab. lated to the electronic fuel injection system.
6. In the Throttle position sensor initialization It is important to ensure that the engine, fuel de-
box, click on the Reset button. livery system and electrical system are operating
normally.
Engine Related Problems
The following items should not be overlooked:
— Inappropriate engine valve clearance
- Poor or unequal engine compression.
346
rmr201 i-O71
SectionO4 FUEL SYSTEM
Fuel Delivery System Related After a problem has been solved, always clear the
Problems fault(s) in the ECM (and other ECUs as applicable)
using the B.U.D.S. software.
The following items may affect the fuel injection
system: Check related circuit fuse solidity and condition
- Faulty fuel pump with an ohmmeter. A visual inspection may lead
to a false conclusion.
— Faulty fuel pressure regulator
— Dirty or clogged fuel filter Temperature Sensors
— Leaking, kinked, or obstructed fuel line. When measuring the resistance with an ohmme-
ter, all values are given for a temperature of 20°C
Electrical Related Problems (68°F). The resistance value of a resistance varies
It is important to check that the following items in with the temperature. The resistance value for
the electrical system are functioning properly: commonly used resistors or windings (such as in-
— Battery jectors) increases as the temperature increases.
However, temperature sensors normally used in
- Fuses this vehicle are NTC types (Negative Temperature
— Relay(s) Coefficient), which means that the resistance
— Ignition (misfiring spark plug) value decreases as their temperature increases.
— Ground connections This must be taken into account when measuring
— Wiring connectors. them at temperatures other than 20°C (68°F).
Pay particular attention to ensure that pins are not The resistance value of a temperature sensor may
out of their connectors or out of shape. test good at a certain temperature but may not be
within acceptable limits at other temperatures. If
When probing terminals, pay attention to the in doubt, try a new sensor.
condition of terminal pins and sockets. Be sure
not to bend the terminal pins. Multimeter probes Also remember that this validates the operation
should never be inserted in terminal sockets as of the sensor at room temperature. It does not
this could deform the socket and create a loose validate the functionality of the sensor at higher
connection that would be difficult to troubleshoot. (or normal) operating temperatures. To test it, the
Always use special tools (such as an ECM adapter sensor could be removed from the engine and
tool) when carrying out electrical tests. Refer to heated with a heat gun while it is still connected
l/l//H/NG HARNESS AND CONNECTORS subsec- to the harness to see if the ECM will detect the
tion for more details on electrical connectors. high temperature condition and generate a fault
code.
Never use a battery charger to temporarily substi-
tute the battery, as it may cause the ECM (engine Fuel Injection Related Problems
control module) to function erratically, or not at all.
Also check for the following items:
A WARNING — Leaking/faulty injectorls)
Some EMS components are continuously — Kinked or leaking vacuum tubes
powered when the ignition key is turned on. - Dirty or obstructed air orifices
The ECM switches the circuit to the ground — MAPS sensor vacuum tubes and nipples for
to complete the electrical circuits it controls. cracks, bending, obstruction, leakage or dam-
Take this into account when troubleshoot- age. Ensure that the tube lengths are correct.
ing. Always disconnect the battery prior to Refer to MAPS SENSOR in this subsection.
disconnecting any electric or electronic com- — Throttle body, nipples, air passages, gaskets
ponent and O-rings for leakage or obstructions
- Intake flanges for leakage.
Ensure that all electronic components are genuine
OEM parts (original equipment manufacturer) rec-
ommended by BRP. Any modification to a circuit
may generate fault codes or result in bad system
operation.
NOTE: For diagnostics purposes, use the latest
applicable B.U.D.S. software version. See DIAG-
NOST/C AND FAULT CODES subsection.
rmr2011-071 247
PROCEDURES
FUEL RAIL
Fuel Rail Replacement
Fuel Rail Removal
./ l
l. ‘I
1. Remove the required body parts to access top -__
of engine and fuel tank connector. Refer to

BODYsubsection.
2. Disable fuel pump by removing the electrical
connector from the fuel pump.
3. Crank engine to relieve the fuel pressure in the
fuel system.
2077 Models
rn1r2ODB4J2‘l~OB2__b
4. Deactivate main relay 1 (R7) via B.U.D.S.; re- TYPICAL
fer to POWER OISTR/BUT/ONAND GROUNDS
subsection. 8. Remove fuel pressure regulator retaining
screws (LH side).
All Models
9. Remove MAPS sensor retaining screw (LH
5. Remove the air filter housing. Refer to A/R /N- side).
7§4KE SYSTEM subsection.
6. Disconnect the injector connectors.
-1
rmr2010-O22-014_a
7. Pressure regulator_retaining screw

2. MAPS sensor retaining screw
rmr201 1-071 -0O2_a 10. Move MAPS sensor and fuel pressure regula-
TYPICAL - RH INJECTOR CONNECTOR tor away (LH injector only).
11. Unscrew fuel rail retaining screws.
7. Unscrew banjo fitting (RH side).
348
rmr201? 071
rrnr2U10022-018_a
TYPICAL - RETAINING SCREW LOCATIONS RH FUEL RAIL
rrnr2UDB-C121-064_b
TYPICAL
5. Install fuel rail while carefully inserting injector

in throttle body.
ng-_ ~
rr'nr2D08-O21-067_b
TYPICAL — RETAINING SCREW LOCATIONS LH FUEL HAIL
12. Pull out fuel rail and injector from throttle body.
Fuel Rail Installation
rm r2008-D2 1 -06B_a
TYPICAL
1. Install NEW fuel rail gaskets. 6. Turn injector to allow proper installation of its
2. Always use NEW O-rings, even if you reinstall connector.
a used injector.
3. Apply a thin film of engine oil on O-rings to ease
injector insertion in fuel rail.
4. Firmly push injector in fuel rail until it bottoms
out.
rmr201 I-O71
349
Fuel Injector Functional Test Using

B.U.D.S.
1. Refer to BODYsubsection and remove:
C L_
— Both upper side panels
— Both acoustic panels.
2. Turn ignition key ON.
3. Using the latest applicable B.U.D.S. version, en-
ergize the fuel injectorls).
3.1 In B.U.D.S., click on the Read Data button.
3.2 Click on the Activation page tab.
3.3 Select the ECM page tab.
3.4 Click on the fuel injector to be tested to
rrnr200B-021-069_a activate it.
TYPICAL
vnm I Sn»-9 I M0-lkxnq ‘ ecmvw Fat: I H uuy
7. Install fuel rail retaining screws. aw. 7"
NOTE: "lighten screws a little at a time each side 1" It

until specified torque is obtained.
M6 SCREW TORQUE (ALL) I
!.‘\\\
_ 1*
9 N'm (80lbf'in)
8. Install banjo fitting and tighten as specified.

BANJO FITTING TORQUE
22 Nvm (16lbf~ftI
9. Reconnect fuel pump connector.

gm It-\m§fi1ui\6».i&r.El' if H 7'
A WARNING rrnr2010022-Cl12_a
Perform a FUEL SYSTEM PRESSURE TES TYPICAL — FUEL INJECTOR ACTIVATION

and ensure that there is no fuel system leak. You should hear the injector working.
Refer to FUEL 7I4NK AND FUEL PUMP sub-
section. This will validate the injector's mechanical and
electrical operation.
FUEL INJECTOR If the injector does not function, carry out an IN-
JECTOR RES/S774NCE TEST
Fuel Injector Connector Access
1. Refer to BODYsubsection and remove the fol- Injector Resistance Test
lowing: (at ECM and Fuse Box)
- Middle and Upper side panels 1. Turn ignition key OFF.
— Acoustic panel. 2077 Models
2. For the RH injector connector (front injector), 2. Deactivate main relay 1 (R7) via B.U.D.S.; re-
also remove the fuel tank covers. Refer to fer to POWER D/STR/BUT/ONAND GROUNDS
FUEL 774N/(REMOVAL in the FUEL 7I4N/(AND subsection.
FUEL PUMP subsection.
All Models
Fuel Injector Leak Test 3. Open front storage compartment.
The fuel injector leak test is carried out when per- 4. Remove fuse box access panel.
forming the fuel system pressure test. Refer to
FUEL 7Z4N/<’ AND FUEL PUMP subsection. 5. Remove fuse box cover.
350
rmr2011-071
6. Remove ignition coils and injector fuse

(F11), refer to POWER DISTRIBUTION AND P’ r
GROUNDS subsection. '\
\
I
7. Remove LH sen/ice cover. xy

8. Disconnect ECM-A connector from the ECM;
refer to ECM CONNECTOR ACCESS in EN-
G/NE CONTROL MODULE /ECM) in this sub-
section.
9. Check injector resistance using the following
tools.
,,;j,FLUKE 115
~,;11ig§ggg,, ECM ADAPTER TOOL
(PIN 529 036 166,
rmr2Cl0B-021-062_a
TYPICAL
If reading is not as specified, replace injector.

If reading is as specified, carry out a:
— CONT/NU/TY TEST OF INJECTOR POWER
FUSE CIRCUIT
C1-OR ECM Box RESISTANCE
INJE ,, .,
ADAPTER CONTACT @ 20 C (68 F) — CONT/NU/TY TEST OF INJECTOR CONTROL
C/RCUITin this subsection.
FRONT J1
A7 11.4 - 12.6 Q Injector Input Voltage Test
REAR K1
1.Turn ignition key OFF.
If resistance value is as specified, the injector and
it's circuits from the fuse contact are good. Refer 2077 Models
to INJECTOR INPUT VOLTAGE TESTin this sub- 2. Deactivate main relay 1 (R7) via B.U.D.S.; re-
section. fer to POWER DISTR/BUT/ONAND GROUNDS
lf resistance value is NOT as specified, refer to subsection.
INJECTOR RESIS734 NCE TEST IA T INJECTOR) in A/I Models
this subsection. 3. Disconnect the electrical connector from the in-
Injector Resistance Test jectorls).
(at Injector)
1. Remove parts required to access fuel injector
connectors, refer to FUEL INJECTOR CON-
NECTORACCESSin this subsection.
2. Disconnect injector electrical connector.
3. Check resistance value between injector pins
as follows.
INJECTOR INJECTOR PIN RESISTANCE
20,6 (68,,F) @
FRONT
1 2 11.4 - 12.6 o
REAR
rIl'Ir2U'I0-022-019_8 T
TYPICAL - REAR INJECTOR (LH SIDE)
rmr2D11-D71 351
rmr20‘l1-D71-0D2_a rr'rir2OOB-U21-O61__a
TYPICAL - FRONT INJECTOR (RH SIDEI
If the injector input voltage is good, the injector
NOTE: It is not necessary to activate the injec- problem may be mechanical.
tor(s) since they are continuously powered when
the electrical system is ON and Main relay 1 is If the injector input voltage is not good, check fuse
closed. The ECM controls the injectors by provid- F11 (15 amp ignition coils and Injectors fuse) in the
ing a ground to each injector independently. front fuse box. If the fuse is good, the problem
may be in the power distribution system before
4. Turn ignition key to ON. the fuse, or in the ECM (does not provide a ground
5. Using a FLUKE 115 MULTIMETER (P/N 529 035 signal).
868) set to Vdc, measure the injector input volt-
age as per following table. Continuity Test of Injector Power
Circuit
2077 Models
1. Deactivate main relay 1 (R7) via B.U.D.S.; re-
fer to POWER D/STRIBUT/ONAND GROUNDS
subsection.
A/I Models
2. Open the front cargo compartment cover.
3. Remove fuse box access panel.
4. Remove fuse box cover.
529035868
5. Remove the 15 amp ignition coils and Injectors
INJECTOR CONNECTOR fuse (F11) in the front fuse box.
CYLINDER WIRE MEASUREMENT 6. Using a FLUKE 115 MULTIMETER (P/N 529 035
868) set to "Q", test for continuity of the injec-
FRONT VIOLETI tor power circuit as per following table.
REAR BLUE
VIOLEW Batte FY
ground Battery voltage
GREEN
529035868
352 rmr201 1-071

INJECTOR CIRCUIT
CYLINDER |N_,EcT0n F28? MEASUREMENT
WIRE BOX PIN
FRONT VIOLET/BLUE A7 Ejosetom
REAR VIOLETIGREEN lwntinullvl
j E...tEEt ......._s~. j
E ,5-‘fr 529036166
l. .3r;'T*;.*:'1.+.:+-1~.'<.~:~
Ah’ ’:~.—.r',v-..'.--'>'~_'TF-. -. z. '. .
+- l"
,=t»;¥Ii:r.?*,..I»i1ifi.“1\.."g =».+'a‘Ci.L\ '7I1I'.i+i' -;+¢ L+.. l
‘IE.
ECM ADAPTER
‘I ;c_t'.'¢,_¢_f___j:.'~ _.__H;f ,-_ __ A

, j '.:.I""'!?-I‘l'iI".I'-:t'lI‘-‘ti’
t " ';‘|’=-'
. .
F +~ + +~ +‘I ‘+< ‘I I I
; . I-* ‘I I.‘
I 4. Remove parts required to access injector con-
| §~"._\.}<~t§.ii-jatggata-;1,+i. I43 <11
I -1F I ,(PI
nector ls), refer to INJECTOR CONNECTOR
ACCESS
» '-1-j
'I . V '\r‘_ fl '~.
I“.
.1 i
.3? .9‘
I
5. Test the injector ground circuit continuity be-
tween the injector and ECM adapter as per fol-
1 >12 lowing table.
rmr2U10-O25-OD1_a
FRONT FUSE BOX PIN-OUT

INJECTOR ECM “A”
CYLINDER °°""E°T°" °°""E°T°" MEASUREMENT
If continuity is good, carry out the CONTINUITY WIRE PIN
TEST OF INJECTOR CONTROL C/RCUITin this
subsection. FRONT BROWN/HED J-1 Cmsetofln
If continuity is faulty, repair wiring or connector be- REAR BROWN/BLUE K-1 lwniinuitvl
tween fuse box and injector.
If control circuit is faulty, repair wiring or connec-
Continuity Test of Injector Control tor.
Circuit
Injector Replacement
2077 Models
Injector Removal
fer to POWER D/S TRIBUT/ON AND GROUNDS 207 7 Models
subsection. 1. Deactivate main relay 1 (R7) via B.U.D.S.; re-
All Models fer to POWER DISTRIBUT/ONAND GROUNDS
subsection.
2. Remove the LH service cover to access ECM
connectors. All Models
3. Disconnect connector "A" from the ECM and 2. Remove fuel rail. Refer to FUEL RAIL in this
install it on the ECM ADAPTER TOOL (PIN 529 O36 subsection.
166). Refer to ECM CONNECTOR ACCESS in 3. Pull injector out of fuel rail.
ENGINE CONTROL MODULE (EC/I/U further in
this subsection.
rmr201 1-O71 353

To deactivate the ETA closed throttle feature and

remove power from the ECM and the engine man-
agement circuits, main relay 1 (R7) must be deac-
tivated via B.U.D.S.; refer to POWER DISTRIBU-
TION AND GROUNDS subsection.
IVUTICE When working on the throttle body,
ensure the ETA closed throttle feature is deac-
tivated and the ECM is NOT powered.
Throttle Body Mechanical Inspection
207 I Models
1. Deactivate main relay 1 (R7) via B.U.D.S. to de-
activate the ETA closed throttle feature; refer to
rm r2 008-021-O64_a
POWER DISTRIBUTION AND GROUNDS sub-
TYPICA L
section.
2. Slowly and alternately rotate the throttle plates
Injector Installation by hand between the full open and full close
For the installation, refer to FUEL RA/L in this sub- stops. Ensure throttle plates move freely,
section. smoothly, and return to the limp home posi-
tion.
A WARNING
Perform a FUEL SYSTEM PRESSURE TES The ETA drives the throttle plates
and ensure there are no fuel system leaks. through a gear drive mechanism. Open the
Refer to FUEL 774NK AND FUEL PUMP sub- throttle plates slowly to avoid damaging the
section. mechanism.
Never attempt to adjust the sealed
THROTTLE BODY stop screws on the levers between the throt-
tle body and the ETA. They are precisely cali-
Throttle Body Description brated at the factory.
A 51 mm twin draft throttle body with an electronic
throttle actuator (ETS) is used. 3. Before replacing the throttle body, check the
following as these could be the root cause of
a related throttle body problem.
- Throttle body stop screwlsl are loose or
worn.
— TPS is loose or not reset correctly.
— MAPS vacuum tubes are leaking, kinked,
blocked, disconnected or not of the proper
length.
— The MAPS plastic manifold and fittings for
cracks, blockage or leakage.
- ETA (Electric Throttle Actuator) not respond-
ing, bad electrical connection.
rmr201D-O22-UD3_b — Dirty throttle body.
1. Twin draft throttle body
2. ETA (Electric Throttle Actuator) Throttle Body Cleaning
ETA Closed Throttle Feature (2011 Models) 207 1 Models
The ECM will power the ETA to electrically hold 1. Deactivate main relay 1 (R7) via B.U.D.S. to de-
the throttle plates closed for 40 minutes after any activate the ETA closed throttle feature; refer to
ignition key OFF selection. POWER DISTRIBUTION AND GROUNDS sub-
section.
354 rmr2D11-071
All Models A WARNING

2. Refer to BODYsubsection and remove the fol- Use the cleaning product in a well ventilated
lowing: area. Refer to product manufacturer's warn-
— LH and RH upper side panels ings.
— LH and RH central panels
— LH and RH acoustic panels. 7. To avoid getting dirt in the engine, spray cleaner
3. Remove air filter housing cover. Refer to A/R on a clean rag, then rub rag against throttle
INTAKE SYSTEM subsection. plates and bores. A toothbrush also works
well.
4. Check throttle body cleanliness using a flash-
light.
5. With throttle plates fully open, inspect each of
the following:
— Throttle body bore
— Throttle plate edge .>~,.-
— Air orifice.
rmr200&021-002
TYPICAL
8. Hold throttle plates fully open to reach all sur-
faces.
9. To remove residual dirt, spray cleaner on throt-
tle plates and on bores.
rmrZOD&021001_a
10. Spray cleaner inside air orifices.
TYPICAL
1. Throttle plate edge
2. Throttle body bore
3. Air orifice
Look for:
- Dirt
— Oily surfaces
— Carbon deposits on throttle plates and the sur-
rounding bores.
6. Clean as necessary using a throttle body
cleaner such as Gunk Intake Medic or the
equivalent.
Only use an appropriate throttle
body cleaner that will not damage O-rings,
MAPS sensor, and catalytic converter. Do not
spray any cleaning fluid on the ETA (electric
throttle actuator). rmr2U08~O21-OO3_a
TYPICAL
1. Air orifice
rmr201 1-071 355

I
Throttle Body Synchronization

Throttle bodies are precisely synchronized at the
factory. Replacement throttle bodies do not re-
quire synchronization to a specific engine.
NOTE: Under normal conditions, the ECM has
the ability to compensate for throttle body vari-
ations between both cylinders using the fuel
injection system.
Do not attempt to adjust the syn-
chronization screws on the throttle body. Any
tampering with the factory settings may result
in reduced engine efficiency.
Throttle Body Replacement rmr201 11022021 _a
LH SIDE
Throttle Body Removal Step 1: MAPS connector
Step 2: Fuel injector connector
1. Remove air filter housing. Refer to A/R INTAKE
SYSTEM subsection. 7. On RH side of the throttle body, disconnect
2. Remove fuel tank covers and disconnect the items listed in the following illustration.
fuel pump electrical connector, refer to FUEL
TANK AND FUEL PUMP subsection.
3. Crank engine to release fuel pressure in the sys-
tem.
2077 Models
POWER DISTRIBUTION AND GROUNDS sub-
section.
AII Models
5. Disconnect TPS connector from the throttle rmr201 0022-022_a
RH SIDE
body. Step 1: ETA connector
Step 2: Injector connector
Step 3: Banjo fitting from fuel rail
Step 4: Clutch valve solenoid hose
Step 5: EVAP canister purge hose
w-. NOTE: Discard compression washers on banjo fit-

s_ ,1
ting.
8. Remove retaining screw from fuel pressure
regulator.
9. Remove MAPS retaining screw and vacuum
hoses from throttle body.
rm|?(110-022020_a
1. TPS connector
6. On LH side of the throttle body, disconnect

items in the following illustration:
356 rmr2011-071
THROTTLE POSITION SENSOR

(TPS)
General
The throttle position sensor (TPS) is a twin poten-
tiometer that sends two signals to the ECM, that
are proportional to the throttle shaft angle. The
TPS is mounted on the throttle body.
rmr201 04122-O1 4_b
1. Pressure regulator retaining screw

2. MAPS retaining screw
3. MAPS vacuum hoses
10. Loosen clamps that secure throttle body to air

intake adapters.
NOTE: Take note of the position of the clamps for
reinstallation.
11. Detach throttle body from intake flanges.
Throttle Body Installation
Installation of the throttle body is the reverse of rn1r201U4)22~O2IJ_i:
the removal procedure however, pay attention to TYPICAL

1. Throttle position sensor (TPS)
the following details. 2. Throttle body
1. Tighten air intake adapter clamps as specified. IMPORTANT: Prior to testing the TPS, ensure
INTAKE ADAPTER CLAMP TORQUE I throttle body components are properly installed
and connected.
2 N'm (18lbf°in)
Use the latest applicable B.U.D.S. version to
2. Ensure all electrical connectors, vacuum hoses, check for related fault codes the EMS may have
and fuel hoses are properly connected. generated. Refer to D/AGNOSTIC AND FAULT
3. Install NEW compression washers on banjo fit- CODES subsection for more information.
ting of fuel pressure hose and tighten banjo fit- TPS Faults
ting as specified.
The TPS is a redundant sensor with two opposite
4. Install and tighten banjo fitting as specified. outputs.
BANJO FITTING TORQUE NOTE: If a TPS fault occurs, the ECM will trigger
23 Nvm (I7Ibf'ft) a fault and the vehicle will be in limp home mode.
TPS Plausibility Error or Deviation Fault
5. Reconnect fuel pump.
These faults are caused by the sensor reading.
6. IMPORTANT: Turn ignition key to ON to pres-
surize the fuel system and carry out a leak test
of all fuel hose connections to the throttle body.
7. IMPORTANT: Carry out a Throttle Position
Sensor Initialization reset in B.U.D.S. Refer
to ADJUSTMENTS at the beginning of this
subsection.
8. In B.U.D.S., check for and reset fault codes.
Refer to DIAGNOSTIC AND FAULT CODES
subsection.
rmr2011-071 357
Subsection O1 (ELECTRONIC FUEL INJECTION (EFI))
POSSIBLE CAUSES ACTION TPS Wear Test

Check if connector is 1. Disconnect the ETA (electric throttle actuator)
disconnected from TPS Fix. connector.
‘lighten and reset 2. While engine is not running, manually rotate
Check if sensor is loose Throttle Position throttle open and close on the throttle body to
Sensor. ensure smooth operation of the throttle plates.
Replace and reset 3. Connect the vehicle to the latest applicable
lnspect sensor for B.U.D.S. version, refer to C0/I///‘l//UN/CA7"/ON
damage or corrosion Throttle Position
Sensoh TOOLSAND B. U.D.S. subsection.
lnspect wiring 4. Turn ignition key ON to energize electrical sys-
(voltage test) Repair. tem.
If bad wiring, repair. NOTE: Do not start the engine.
lnspect wiring and
sensor (resistance test) If bad TPS, replace and 5. Ensure engine stop switch is set to RUN.
reset Throttle Sensor.
6. In B.U.D.S., click on the Read Data button.
Test sensor operation Replace and reset
Throttle Position 7. Then click on the Monitoring page tab, then
(wear test) select the ECM tab.
Sensor.
8. l\/lonitor the Throttle Opening indication.
NOTE: The TPS sensor reset (initialization) is car-
ried out using B.U.D.S.
TPS Adaptation Fault
.
1»-tll*l*¥"-1il“~*‘I'l~l l
in do
m ,,;, M
I Swim "WWW
.. _ _
l Mame»
.
E Fili i bwmi I
The following problems can be caused by a TPS )“"'L“‘§,_

I" W.....r.._ __........_.__% ‘MST’;
adaptation failure fault, or a TPS adaptation can- w hm ‘g I ' ’ w
celed fault: 1
HE
‘ Qgq ._ . QIM1 r )_J'*4A\/kl
— Idle speed is out of range. ‘

‘ u, Rn‘
firm
2""
_, _g _ ,___
F"
“W ' . W
‘\ _\“
N‘-"H _
in
— Engine stops when throttle is released quickly. Ema." “Wu Ox1qIn5InIor$tIhn2 ‘ ammun- W15“,
T " "ii Ti»: L '1» "=1
— Engine runs inconsistent in low partial loading Qfinmpdflwmntfi i .- | a zvj‘ia_ii¢ Eng?“
or low RPIVI limp home. TPS?!) ‘
T55“)
POSSIBLE CAUSES ACTION _ .4 _. . ¢°:“"°"’°"!=' _ _ .
flu!-Iqxfb ‘Milk-v:{51 nun’: Q >--,¢-(.uiw1~<§
Sensor has been 1 we swam» ov;gmSvur2".?»
replaced and TPS Reset Throttle Position ui-we-vw~" oimcaus <3 cumfl
initialization was not Sensor. gm K51 ‘TAT ‘T r' W’ TTTT ”
performed rmr20‘l CHJ22-0‘l6_B
Throttle body and TPS Reset Throttle Position Step 7: Click on Read Data
has been replaced Step 2: Click on Monitoring page tab
Sensor. Step 3: Select the ECM monitoring page
Step 4: Monitor the Throttle Opening indication
ECI\/l has been replaced
and TPS initialization was Fleset Throttle Position
not performed
Sensor. A CAUTION Before manually rotating the
throttle plates with electrical power ON, be
Tighten and reset sure to disconnect the ETA to prevent it from
Sensor is loose Throttle Position being activated by the ECM.
Sensor.
9. Slowly rotate throttle plates at an even pace and
Tighten and reset observe the indication in B.U.D.S.
Throttle bracket is loose Throttle Position
Sensor. The indication in B.U.D.S. must change gradually
and smoothly as you move the throttle plates. If
NOTE: The TPS sensor reset (initialization) is car- the indication is erratic, suddenly drops off, or if
ried out using B.U.D.S. software. any discrepancy between the throttle plate move-
ment and indication is noticed, it may indicate that
the TPS needs to be replaced.
358 rmr201 i~O71

NOTE: The data transfer rate of the PC computer NOTE: Throttle plate must be manually opened or
used may be too slow for real-time display. closed.
TPS Resistance Test FULLY CLOSED FULLY OPEN
EM THROTTLE THROTTLE
207 7 Models ADAPTER PLATE Hi PLATE
1. Deactivate main relay 1 (R7) via B.U.D.S. to de- RESISTANCE IQI at 20°C I68°FI
activate the ETA closed throttle feature; refer to PIN MIN. MAX. MIN. MAX.
POWER D/.S‘7'R/BUT/ON AND GROUNDS sub-
secflon. A-K4 A-A2 700 1300 700 1300
A// Mode/s A-F3 A-K3 2445 3.255 2445 3.255

2. Open the front storage compartment cover. (ll To obtain the fully closed position, it is necessary
to push against throttle plate in throttle body with
3. Remove the LH service panel to access ECM your fingers and hold it in this position for the
connectors on LH side of forward frame mem- ITI98SUT8I'TT6I'I'II.
ber. Refer to BODYsubsection.
4. Make sure TPS is properly connected to wiring NOTE: The resistance value should change
harness. smoothly and proportionally to throttle move-
ment. Otherwise, replace TPS.
If resistance values are correct, perform the TPS
/NPUT VO./.7I4GE 7'E57'in this subsection.
If any resistance values are incorrect, check
wiring harness continuity between ECM and TPS.
If wiring is faulty, repair/replace as required. If
wiring is good, replace TPS.
7. Reconnect ECM connector.
TPS Input Voltage Test
we
POWER D/.S‘7'R/BUT/ON AND GROUNDS sub-
section.
rmr201D4]224)20_a
A// Models
1. TPS connected
2. Disconnect connector from TPS.
5. Disconnect the ECM-A connector and connect 3. Turn ignition key ON.
it to the ECM ADAPTER TOOL (P/N 529 036 166).
Refer to ECM CONNECTOR ACCESS in this 4. Measure for voltage at TPS harness connector
subsection. as follows.
CONNECTION VOLTAGE
Pin 3 with battery ground 3.3 V
Pin 1 with battery ground 0 V
I ‘Q.
vmi2008-O22-00531
6. Using a FLUKE 115 MULTIMETER (P/N 529 O35

868) set to check resistance values at ECM
adapter as per the following table.
rmr2011-O71 359
. __...., 3... 1
" 1
~_
rmr2 CI1 CI-D 22-023 _a rmr201 D-O22-O23__b
TPS INPUT VOLTAGE TEST TYPICAL

1. TPS connector
If voltage test is not good, test and repair the wire 2. Retaining screws
from ECM to the TPS as required. Refer to appli- 4. Remove TPS from throttle body.
cable W/F’/NG D/A GRA/I//.
NOTE: Install the new TPS.
If wire is good, refer to EC/I/I REPLACE/I//EN7'in
this subsection. 5. Be sure to align tab on TPS with tab on throttle
body lever as per following illustration.
If voltage test is good, test for continuity of the
signal wires and the ground wire between the TPS
and ECM. Referto applicable W/R/NG DIAGRAM
TPS Replacement
201 7 Mode/s
section.
A// Mode/s
2. Disconnect TPS connector.
3. Remove TPS retaining screws.
rrnrZOD8-021 {I73_a
TYPICAL
1. Tab on TPS
2. Tab on throttle body lever
6. Slightly tighten retaining screws.

7. Reconnect TPS connector.
8. Refer to TPSADJL/S7'MEN7'in this subsection.
TPS Adjustment
NOTE: There is no adjustment that can be carried
out on the TPS, however a TPS P05/7'/ON SEN-
SOR /N/7'/AL/ZA 7'/ON reset must be carried out
when the TPS has been removed or replaced. Re-
ferto ADJUST/l4EN7'Sin the beginning of this sub-
section.
aso rrn|QD11 O71

While using B.U.D.S., check for and reset fault CPS Resistance Test
codes. Refer to DIAGNOSTIC AND FAULT
CODES subsection. 2077 Models
1. Deactivate main relay I (R7) via B.U.D.S.; re-
CRAN KSHAFT POSITION fer to POWER D/STRIRU T/ONAND GROUNDS
subsection.
SENSOR (CPS)
All Models
CPS Location
2. Remove required body parts to access the CPS
The CPS is located on top of the clutch cover on connector. Refer to the CPS CONNECTORAC-
the LH side of the engine. CESSin this subsection.
3. Disconnect CPS connector.
.\n4
rmr2008-O21-037,3 ‘I, 0
\ ‘@
TYPICAL - CPS LOCATION
TIHFZUUE-QZ'I~U75_fl
CPS Troubleshooting TYPICAL - CPS CONNECTOR LOCATION
When troubleshooting a CPS fault, take into ac- 4. Set multimeter to selection and probe CPS
count that a CPS fault can be triggered by bent or terminals as per following table.
missing encoder wheel teeth.
CPS CONNECTOR MEASUREMENT
First check for applicable fault codes, refer to D/-
AGNOSTIC AND FAULT CODES subsection. PIN RESISTANCE Q
@ 20°C (68°F)
If there is a fault code and the CPS and its circuit
test good, check the encoder wheel teeth condi- 1 | 2 700-soon
tion, refer to MAGNETO AND S7I4RTER subsec-
tion.
NOTE: After servicing the engine, if the CPS and
knock sensor connectors to the main harness are
swapped, the engine will not start. There will not
be any faults registered in the ECM or visible on
the Faults page in B.U.D.S., and the RPM indica-
tion on the monitoring page will remain at zero
when cranking the engine.
CPS Connector Access
ing:
— LH upper side panel
— LH middle side panel
— LH acoustic panel. rr1'ir2008-021-076_a
rmr2011-071 361
If resistance is not within specifications, replace

the CPS.
If the CPS resistance tests good, reconnect the
CPS connector arid carry out the CPS C/RCU/T
CONTlNU/ TY TEST
CPS Circuit Continuity Test
207 7 Models
1. Deactivate main relay 1 (R7) using B.U.D.S.; re-
fer to POWER DIS TR/BUT/ONAND GROUNDS
subsection.
All Models
2. Open front storage compartment cover and re- Al
move the LH service panel, refer to BODYsub- rmr200B-021-037,b
section. 1. CPS
2. Retaining screw
3. Remove connector "A" from the ECM and con-
nect it t0 the ECM ADAPTER TOOL (P/N 529 036 4. Install new CPS as per following table.
166).
CPS INSTALLATION
4. Using a multimeter, recheck resistance as per
following table. PRODUCT ON SCREW
THREADS TORQUE
LOCTITE 242 (BLUE) _.
(P/N 293 aoo 060) II N"“ I97 'bI "'I
5. Secure CPS wire harness using locking ties and
clamp as per factory installation.
CAMSHAFT POSITION SENSOR

(CAPS)
CAPS Location
vrnr20OB-D2200 5_a
ECM ADAPTER MEASUREMENT

PIN RESISTANCE Q
@ 20°C (68°F)
H1 | K2 700-soon
If resistance value is incorrect, repair or replace
wiring harness between the ECM and CPS con-
nectors.
CPS Replacement
1. Disconnect the CPS connector.
2. Cut locking ties and remove clamps that secure
CPS wire harness to the engine.
rmr2fl08-O21-03B_a
3. Remove the CPS. TYPICAL - LH SIDE OF FRONT CYLINDER VALVE COVER
362 rmr201 1-071

CAPS Input Voltage Test EAPS CAPS CONNECTOR VOLTAGE

NOTE: First ensure the CAPS connector is not CONDITIQN
ITIIXBCI Up WI'[I‘I TITS MAPS COI'II'IGC’[0l'. F QRANGE/ yE|_|_O\/W @036 to
1. Turn ignition key ON. Fee GREEN GREEN 0 Vdc
2. USITIQ 8 FLUKE I15 MULTIMETER (P/N 529 O35 .
868) set to Vdc, back-probe CAPS connector as
per following table.
CAPS CONNECTOR VOLTAGE
ORANGEIGREENI BLACl<lGREEN
T
rmr2008-021-078_a
TYPICAL
CAPS
_ CONDITION CAPS CONNECTOR VOLTAGE
OI‘I§:.:§1"g‘n ORANGEI YELLOWI Battery

S9 HSOT
GREEN GREEN voltage
rm(zO08-O21 -o77_a
TYPICAL
If input voltage is good, carry out the CAPS OU71

PUT VOLTAGE TEST
If input voltage is not good, repeat test as per fol-
lowing table.
PROBE VOLTAGE
CAPS CONNECTOR V MCI Bafie H ,,.\___’_
e e ry . -
ORANa/IIEI/S BEEN ground voltage
If input voltage is not good, repair or replace

wiring/connectors between CAPS and fuse F12.
Refer to applicable W/R/NG DIAGRAM.
CAPS Output Voltage Test
1. Remove MAPS sensor from throttle body and I-r;1¢2()03.021-0793
move down for access to CAPS. TYPICAL
NOTE: OnIV remove the MAPS mounting screw" lf voltage does not change check continuity of
It IS l'iO’£ HGCGSSEITV t0 CIISCOHHOCI the Wire .I:I.OI,n' to
2. Remove CAPS sensor from engine. tests good, try a new CAPS.
3. Make sure CAPS connector is properly con-
nected.
4. Using a multimeter set to Vdc, back-probe con-
nector as per following tables.
rrnr201I-071 363
Subsection 0'I (ELECTRONIC FUEL INJECTION (EFIII
CAPS Replacement MANIFOLD ABSOLUTE

207 7 Models PRESSURE SENSOR (MAPS)
1. Deactivate main relay 1 (R7) via B.U.D.S.; re- MAPS Location
fer to POWER D/S TRIBUT/ONAND GROUNDS
subsection.
All Models
2. Disconnect electrical connector from CAPS.
3. Remove the CAPS retaining screw and replace
the CAPS. Be sure to install a new O-ring on the
new CAPS.
" '\.
"‘ /1
I
rl'n!2UiD-U21-D14_C
7. MAPS
MAPS Troubleshooting
The sensor continuously measures the manifold
absolute pressure.
When troubleshooting, ensure the MAPS sensor
vacuum tubes, fittings and manifold are:
- Properly connected
— Not leaking
rrnr2008—D2 1 —O3B_l1
— Not kinked
7. CAPS
2. Retaining screw — Not damaged.
CAPS INSTALLATION Tube length is calibrated and should not be tam-
pered with. lf otherwise, the engine may be im-
PRODUCT ON SCREW
THREADS SCREW TORQUE properly calibrated.
If you suspect incorrect tube lengths, measure
LOCTITE 243 (BLUE) them. Each tube length should be as illustrated.
(P/N 293 800 060) 5 N"“ I44'bI'i"I If tube lengths are incorrect, install new tubes.
4. Reinstall removed parts.
364 rrnr2011-071
The manifold pressure read should be between

300 mbar to 700 mbar (4 PSI to 10 PSI).
60 80
40 ‘IUD
20 I» /120
kPa
Manifold abs. press. cyl.1

rrnr2008-(J21-039_a
TYPICAL rmr2010-022-024
A. 85 mm (4.33 in) long
5. As you throttle the engine, read the manifold
MAPS Access pressure. The value should become more
Refer to BODYsubsection and remove: stable and move as you throttle the engine.
— LH upper side panel Otherwise, perform the MAPS INPUT VOLT-
AGE TEST
— LH acoustic panel.
NOTE: If there is no reading, first make sure the
MAPS Test Using B.U.D.S. MAPS connector is not mixed up with the CAPS
connector. If the problem persists, perform the
1. Connect vehicle to the latest applicable MAPS INPUT VOLTAGE TESTand the MAPS CIR-
B.U.D.S. version, refer to COMMUNICATION CUIT CONT/NUITY TEST
TOOLS AND B. U.D.S. subsection.
2. Start engine. MAPS Input Voltage Test
3. Click on the Read Data button. 1. Deactivate main relay 1 (R7) via B.U.D.S.; re-
4. Click on Monitoring tab, then on ECM tab at fer to POWER DISTRIBU T/ONAND GROUNDS
the bottom LH corner of the page. subsection.
All Models
¢El‘*l';1l§lil-Pl
;-l-~ L_““"‘LI"""°"I ~- l »-l
2. Disconnect the MAPS connector.
4. Using a FLUKE 115 MULTIMETER (P/N 529 O35
--.=.'1".;;~,,,, in * * 868) set to Vdc, measure the MAPS input volt-
m
wl W W—‘ “_"._‘_’“
OAypI§onwrStl1mt
Iéi i EUT ATITT if T E
age as per following table.
II
. .‘l ‘W
(KID
F.1. . 7 .._..__ I’ X“
\_\\’
V Y1) CONNECTION VOLTAGE
“gnaw” WWI Osrygensltllflffihtiazil ,““,"'_I'mMI
"E ET IL 7L 1: 1| 1|: vi ‘
Terminal 1 with engine ground 5 V
Gun napalm (MPH): "' E“ Id; E Eugflg
Teens) E I
Terminal 2 with engine ground O V
TASDU I C” Terminal 3 with engine ground O V
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c§~lq~s;ril’y_€aJ.§s§.i191.l.t'~;P;al§s¢;.l I ' "T TT’

rmr201tl-022-016_b
Step 1: Click on Read Data
Step 2: Click on Monitoring page tab
Step 3: Select the ECM monitoring page
Step 4: Read the Manifold abs. press. cyl. 1 indication
rmr2U11-071 365
MAPS Replacement
207 7 Mode/s
fer to POWER D/S TH/BU7'/ON AND GROUNDS
subsection.
All Models
2. Carefully disconnect vacuum tubes from MAPS
sensor
rmrzoos-021-osu_a
TYPICAL — MAPS INPUT VOLTAGE TEST
If voltage test is good, replace the MAPS.

If voltage test is not good, carry out the MAPS
C/HCU/7' CON7'/NU/ 7')’ TEST
NOTE: The ECM provides a common voltage
to the MAPS and AAPTS (Ambient Air Pres-
sure/Temp Sensor).
rmr200&021-0U9_a
MAPS Circuit Continuity Test TYPICAL — MAPS VACUUM TUBES
207 7 Mode/s 3. Remove MAPS sensor.
1. Deactivate main relay 1 (R7) via B.U.D.S.; re- 4. Install the new MAPS sensor.
fer to POWER D/S TH/BUT/ONAND GROUNDS
subsection. 5. Properly position sensor tabs as shown.
All Models
Remove connector "A" from the ECM and install
it on the ECM ADAPTER TOOL (P/N 529 O36 166).
Using a FLUKE 115 MULTIMETER (P/N 529 035 868)
set to test the continuity of the MAPS circuit
wiring as per following table.
MAPS CIRCUIT CONTINUITY TEST
ECM MAPS RESISTANCE
ADAPTOR CONNECTOR READING
Pin 1
B4 (PINK/BLUE)
Pin 3 Close to O S2
G4 (WHlTE/BLUE) (continuity) rmr2008-021-D81_a
Pin 2 TYPICAL - POSITION OF MAPS LOCATION TABS

H2 (BLACK/BLU El
6. Carefully connect vacuum tubes.
If continuity is not good, repair the connectors or 7. Install MAPS connector.
replace the wiring harness between ECM connec-
tor and the MAPS connector. 8.1‘|ghten screw.
366 rrnr2011»O71
AMBIENT AIR PRESSURE Monitoring I

AND TEMPERATURE SENSOR 5 Gear Position
(AAPTS) A ,
‘
Engine Temp
22 cc loll nleutral
Fuel Leve
AAPTS Location
\
‘1
> r~ T-
,1 ' I , _.i .
"‘l
,~' >\'
‘V ;‘,§"r \‘ '» l z\ ‘ flh
. >7"
illllllllflllllllll
,__i__________;
l l l l fil l
___________.
1 ... .
»_-Q
‘IF
’ (Kmm)_
I
rmr200B-021-041_b
Ambient Temp ('C): I24
Atmospheric Presswe (kPa); I100
- 1
TYPICAL - ATMOSPHERIC PRESSURE INDICATION IN B.U.D.S.
6. Blow some compressed air in the sensor area

as you observe the atmospheric pressure indi-
cation. The reading should change.
...-IM.r..?.mt-.....M_.........-n
rrnr2008—D21-04u__a
TYPICAL - AAPTS LOCATION
The sensor continuously measures the atmo-

spheric air pressure and temperature.
AAPTS Test Using B.U.D.S.
AAPTS Pressure Function Test
1. Connect vehicle to the latest applicable
B.U.D.S. software version, refer to COMMU-
N/CA 7'/ON TOOLS AND B.U.D.S. subsection.
2. Remove the RH air duct panel. Refer to BODY
subsection.
4. In B.U.D.S., select the following:
rmr2OOE-D21-082__a
— Read Data button TYPICAL
— Monitoring page tab
— Cluster page tab. If there is no reading or if it does not change, carry
out the AAPTS INPUT l/01.73465 TEST
5. Read the atmospheric pressure indication.
If you doubt the AAPTS reading, compare it to an
NOTE: The atmospheric pressure indication is vis- atmospheric pressure gauge (barometer), or try a
ible near the center of the page.
new AAPTS.
When comparing the readings, values must be
within i 3.4 kPa (.5 PSI).
If the vehicle AAPTS value is out of this range, re-
place it.
AAPTS Temperature Function Test
1.With the ignition key ON and the vehicle con-
nected to B.U.D.S. as in the previous AAPTS
PRESSUREFUNCT/ON TEST read the ambient
air temperature indication.
rmr2011-O71 367
Monitonng I I I 3. Using a multimeter set to Vdc, test the voltage

output from the ECM to the pressure sensor as
5 Gear Position"
EnglneTemp . , , FuelLeve per following table.
22°C Iiiiiwmei
NOTE: This test may first be carried out at the
PTS connector located just above the RH front
suspension. If test is good at PTS connector,
then repeat test at AAPTS connector.
llh _;-_-~—--- ulllllllllllllll

_(Kmlm_ I-——-0
Il/I
l l fll l flAmbientTemp('C)I
ll |24
Atmospheric Pressure (kPa); I100
rm!2CI08-02 1 -Cl41_a
TYPICAL - AMBIENT TEMPERATURE INDICATION IN B. U.D.S.
2. Using a heat gun, carefully heat the sensor as

you observe the ambient temperature indica-
tion. The reading should change.
rmr2010-O22-0'l0_a
TYPICAL - PTS CONNECTOR
AAPTS CONNECTOR MEASUREMENT

PIN VOLTAGE
1 | 3 5 Vdc
rmr2008-021-O84
TYPICAL
If there is no reading or if it does not change, carry

out an AAPTS INPUT l/OLIZIGE TEST
If you doubt the temperature reading, compare
it with a known good thermometer, or try a new
AAPTS.
When comparing, readings must be within 1 2 O C rmr200B-U21-OB3_a
l3°F). TYPICAL
If the vehicle AAPTS value is out of this range, re-
place it. If voltage test is not good, carry out the AAPTS
CIHCUI T CON77NU/TY TEST
AAPTS Input Voltage Test If voltage test is good and the problem is related to
1. With the ignition key turned to OFF. disconnect the temperature indication, carry out the AAPTS
AAPTS connector. RES/S7I4NCE TEST If the problem is related to
2. Turn ignition key ON. the pressure function of the AAPTS, carry out the
AAPTS C/RCU/ T CONT/NU/TY TEST
368 rmr2011-071
Subsection 01 (ELECTRONIC FUEL INJECTION (EFIIII
AAPTS Circuit Continuity Test

2077 Models
fer to POWER DISTR/BUT/ON AND GROUNDS
subsection.
All Models
2. Remove parts required to access ECM connec-
tor, refer to ECM CONNECTOR ACCESS fur-
ther in this subsection.
3. Remove connector "A" from the ECM and in-
stall it On the ECM ADAPTER TOOL (P/N 529 036
166).
rmr201 002201 D_a
PTS CONNECTOR
Repair or replace wiring/connectors.

AAPTS Resistance Test
1. Disconnect PTS connector.
NOTE: The PTS connector is located just above
the RH front suspension.
52 90361 E5
4. Using a multimeter set to test wiring har-

ness continuity between ECM and AAPTS as
AAPTS CIRCUIT CONTINUITY TEST
ECM AAPTS
ADAPTER CONNECTOR RESBTANCE
F2 Pin 1
H4 Pin 2 Close to O Q
G3 Pin 4 (continuity)
B4 Pin 3
rrnr2010-022-01U_e
PTS CONNECTOR
If continuity test is good and the problem is re-
lated to the pressure function, replace the AAPTS. 2. Using a multimeter set to test the resis-
If the problem is related to the temperature func- tance of the sensor as illustrated. Compare re-
tion, carry out the AAPTS RES/STANCE TEST sult with the sensor temperature table.
If continuity is not good, carry out same test at AAPTS
the PTS connector. Refer to applicable W/R/NG
DIAGRAM for details. i Pin 1 | Pin 2 i
NOTE: The PTS connector is located just above If an open circuit or an abnormal resistance value
the RH front suspension. is measured, remove the required body parts to
access the AAPTS on the RH side of the storage
bin, and repeat the test at the sensor.
rmr201 1-O71 369

4. When installing sensor, be sure to position

foam around sensor tip.
rmr20flB-021-085_a
SENSOR TEMPERATURE TABLE
TEMPERATURE RESISTANCE
(ohms) .m.mam6_.
“C °F AUAPTS
-30 -22 26860
-20 -4 15614 COOLANT TEMPERATURE
-1O 14 9425 SENSOR (CTS)
O 32 5587 CTS Location
20 68 2510 "__
30 86 1715
40 104 1200
50 122 850
60 140 610
70 158 445
80 176 330
90 194 245
100 212 185
110 230 140
120 248 110 rmr2D08-021-043,3
130 266 85 TYPICAL - u-/ SIDE OF ENGINE

lf resistance value measured is not close specifi CTS Access I
Cation, rep|aCe the AAPTS Refer to BODYsubsection and remove:
lf resistance tests good, carry out the AAPTS C/R- ' I-H upper Ride pane‘
CU/T CONT/NU/TY rest — LH acoustic panel-
R9p|aQem9nt TEST USIFIQ
’]_ Remove paf-ts required to access See COITTIGCL VehICIe TO Iatest applicable
,44p7'5 L034 7"/0/\/_ version, refer to COMMUNICATION TOOLS
2. Loosen AAPTS retaining screw. AND B.U.D.S. subsection.
. 2. In B.U.D.S., select the following:
3. Slide AAPTS out. _ Read Data button
370 rmr2011-D71

— ECM page tab.
1')‘
0
2 ———>f zawgc
60 80
40 _ 100
20 120
5“ E-L.
“H
I up 1 -—~>
. 5‘
Manifold abs. press. qL1 ,
a 10 12 14 16 1a Q, rmr200B-D21-O44_a
“*—‘—‘—‘t§“‘—‘—‘_*",|,,
7 Engine TYPICA L
l SENSOR TEMPERATURE TABLE

rrni’Z01l-O71-001_a
1. Engine temperature {analog readout) RESISTANCE
2. Engine temperature (digital readout) TEMPERATURE (ohms)
If engine temperature indicated in B.U.D.S. is cor- °C °F CTS

rect for actual engine temperature, the CTS and
it's circuit is functioning normally. - 30 - 22 28600
If there is no temperature reading, or if reading - 20 - 4 16200

does not reflect actual engine temperature, pro- - 10 14 9560
ceed with CTS RES/S7I4NCE TEST
0 32 5880
CTS Resistance Test 20 68 2450
207 7 Models 30 86 1650
1. Deactivate main relay 1 (R7) via B.U.D.S.; re- 40 104 1140
fer to POWER D/STR/BUT/ON AND GROUNDS 50 122 808
subsection.
60 140 584
All Models
70 158 430
2. Remove parts required to access CTS, refer to
CTS ACCESS in this subsection. 80 176 322
3. Disconnect CTS connector. 90 1 94 245
4. Using a FLUKE 115 MULTIMETER (P/N 529 035 100 212 189
868) set to measure the resistance through
110 230 148
the CTS resistance and compare the resistance
value obtained to the sensor temperature table. 120 248 117
CTS SENSOR 130 266 90
Pin 1 Pin 2 If resistance measured is out of specification, re-
place the CTS.
If resistance measured is within specification,
reconnect the CTS and carry out the following
steps.
2077 Models
fer to POWER D/STR/BUT/ON AND GROUNDS
subsection.
rrnr2011-071 371
Subsection 01 (ELECTRONIC FUEL INJECTION (EFIII
A/l Models HEATED OXYGEN SENSOR

6. Disconnect ECM connector "A" from the ECM (HO2Sl
and connect it to ECM ADAPTER TOOL (P/N 529
O36 166). Refer to ECM CONNECTORACCESS HO2S Locations
in this subsection. This vehicle is equipped with 2 heated oxygen
sensors, one on the forward head pipe, and one
on the rear head pipe. Both are located upstream
of the catalytic converter.
<
~.
.\ 7- \ \ - be,-.i|iE_.-.;,
-Jail? --_- ‘V cR_\“_, -
529036166 i"\ 1 (I i WTT I‘ T" .-i',‘=-‘=9
1,4:\'- i i M i I
7. Using a multimeter, recheck resistance at the i7 311-1.. @-
ECM adapter as per following table. rmr201 0008-DD5_a
1. Oxygen sensor
ECM CONNECTOR MEASUREMENT 2. Front head pipe
PIN RESISTANCE S2
@ 20°C (68°F)
A1 J2 Refer to TEMPERATURE
SENSOR 7I4i5’LEabove /l
Iii-§. '..‘
lf resistance value is incorrect, repair the connec-
tors or replace the wiring harness between ECM
connector and the CTS. if/T;
/'
»- - k
CTS Replacement
207 7 Models
fer to POWER DIS TR/BUT/ONAND GROUNDS
subsection.
rrrir20‘l D-D08-O05_D
All Models 7. Oxygen sensor

2. Rear head pipe
2. Disconnect CTS connector and remove CTS 3. Catalytic converter
from engine. H028 Access
3. Install new CTS and tighten as specified. Refer to BODYsubsection and remove the follow-
CTS TORQUE ing to access H028 and it‘s connectors:
17 N-m (150 lbfein) — LH and RH upper side panels
— LH and RH middle side panels
4. Reinstall remaining removed parts. — LH and RH acoustic side panels.
5. Refill and bleed the cooling system, refer to
COOL/NG Sl/S TEM subsection. Oxygen Sensor General Precautions
6. Use the latest applicable B.U.D.S. version to Take the following precautions to avoid sensor
check for and reset fault codes. Refer to DIAG- malfunction:
NOSTIC AND FAULT CODES subsection. — Do not use any product on sensor probe.
— Do not expose sensor to water, oil, windshield
cleaner, anticorrosion oil, grease, terminal
cleaner, etc.
372 rr‘nr2U‘l1~071
- Do not drop or use an oxygen sensor that has If a fault code related to an oxygen sensor is ac-
been dropped. tive, the oxygen sensor indicator will not turn on.
— Do not use any compound on sensor threads The fault code(s) need(s) to be solved first.
unless labeled as compatible with oxygen sen- When a properly functioning oxygen sensor cir-
sor. cuit is first initiated, the oxygen sensor heats up
— Do not use impact wrench or conventional and the ECM is operating in a closed loop con-
socket type wrench to install sensor. trol mode. The status of the O2 sensor circuit will
— Do not allow sensor or wire to touch exhaust change from "lnit" to "Active" as it progresses
system or any other hot component. through a series of steps. These steps may be
viewed on the ECM Monitoring page of B.U.D.S.
Oxygen Sensor Service Life in the Oxygen Sensor Status window.
The following tips may indicate whether a sensor NOTE: The steps listed in the following sensor
has reached the end of its service life and need to status table may not all be displayed, and may
be replaced: vary from one time to the next. The steps dis-
- Poor fuel economy played will depend on the engine operating status
— Higher exhaust emissions and O2 sensor operating status.
— Engine surging and/or hesitation LIST OF OXYGEN SENSOR STATUS
— Roughidhng INDICATIONS
— Catalytic converter failure lnit
— Check engine light is ON Heating Active
- An oxygen sensor fault code can be read in Control Active
B.U.D.S.
Error
NOTE: Most sensors slowly degrade in terms of
performance, sending an excessively enriched When the oxygen sensors reach the "Active"
signal to the ECM, causing the engine to run too state, they become operational and their indica-
lean. However, a failure may happen at any time tors will turn on in B.U.D.S.
and is usually due to contamination.
H028 Test Using B.U.D.S.
1. Using the latest applicable B.U.D.S. version,
monitor the oxygen sensors.
etlfrlslsltl l
Wm I am I Mun-aw I am Pun I RIM; I
no "“ van I i
2. Click on Monitoring tab, then on ECM tab. ‘ an ‘4“~ um
iC_UiTi'ROL_A_CTiVE""W 7'5‘:
35- 1 u 1'0 I
3. Start engine. Z _ O“§fl\$gyg@i-Q» _ 5 )—--L,_ ll
4. Observe the Oxygen Sensor Status indica- Z. _ / W

;f_
K”
. . CONTROLACTIVE
/ sf’
tions in B.U.D.S. eons,“ ow“ ,,,,,,,,,,,m"§,_._.W,,
"TTTT F ll Ii 11 ‘ll in in
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Vehicle I Setting I M°"l°"l‘I9 Activation
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somamrow rm r201 O-022-02 B_a
IUD sum‘
IINIT NOTE: Engine needs to run for approximately
acm_ emu
2 - 3 minutes before the oxygen sensors become
HM __mw Oxygen Sensor Status 1 CONTROL ACTIVE and their indicator lights turn
on in B.U.D.S.
mm I 1\
If a sensor status does not change or does not
E1 RP" <i2ooo reach the CONTROL ACTIVE state, or the oxygen
Oxygen Sensor Status 2
Engirii-i Spat-iii 0 RPM sensor indicator light does not come on, try a new
rrnr2010-022-017_a
oxygen sensor.
OXYGEN SENSOR STATUS INDICATIONS
rmr2(111-O71 373
NOTE: Before replacing a sensor, check wiring, 4. Turn ignition switch ON.
terminals and sensor condition. 5. Using a multimeter set to Vdc, read the input
HO2S Input Voltage Test voltage provided to the sensor heater.
1. Remove the required body parts (LH and RH OXYGEN SENSOR
sides) to access both HO2S sensors. Refer to CONNECTOR
BOD)/subsection. (HARNESS SIDE) MEASUREMENT
PIN
207 7 Models
2. Deactivate main relay 1 (R7) via B.U.D.S.; re- C I Battery ground Battery voltage
fer to POWER D/S TR/BU T/ONAND GROUNDS If Input voltage is good, carry out an HOZS RESIS-
subsection. T4NCE TESTand an HOZS C/RCUITCONT/NU/TY
All Models TEST
NOTE: This test validates the heater element cir- If input voltage is not good, test the wire continu-
CLIIT. ity between pin 1 of sensor connector to fuse F12.
3. Disconnect the oxygen sensor connector from Refer to the applicable W/R/NG DlAGRAMfor de-
each sensor. tails.
lf input voltage wire continuity is at fault, repair or
replace wiring or connector.
HO2S Resistance Test
Test the resistance value of the oxygen sensor be-
tween the sensor pins as follows.
H025 PIN
RESISTANCE
@ 20°C (68°F)
I C I D Approximately
-119
If reading is not within specification, replace the

.‘
._‘\1$-. oxygen sensor.
rr‘rv2010-022-i'.)OS_a
1. LH O2 sensor connector location HO2S Circuit Continuity Test

NOTE: The LH O2 sensor connector is attached NOTE: This test validates the heater element cir-
to the LH lateral frame member. cuit and the sensor circuits.
2077 Models
/,-’,,..___.
3/ __, .__ 1. Deactivate main relay 1 (R7) via B.U.D.S.; re-
fer to POWER D/STR/BUT/ONAND GROUNDS
subsecfion.
AII Models
2. Remove connector “B" from the ECM and con-
nect it to the ECM ADAPTER TOOL (P/N 529 O36
166). Refer to ECM CONNECTOR ACCESS in
this subsection.
<\
t 1' l;w\\
rrnrZ01lH)22-0O'2_ii
7. RI-I O2 sensor connector location
NOTE: The RH O2 sensor connector is located

just ahead of the air filter.
374 rmr201 1-O71
52 S0361 66
3. Using a multimeter set to test for continuity

between the oxygen sensor harness connector rmr201 D-O22-008_a
and the ECM adaptor as per following tables. 7. LH O2 sensor connector location
|-|0zs1 NOTE: The O2 sensor connectors are secured to

the lateral supports.
OXYGEN ECM RESISTANCE
SENSOR PIN CONPIQCTOR @ 2o°c l68°Fl /,1
/1.’?
l,— -
A J1
B I-2 Close to O Q
C D2
HOZSZ
ECM
OXYGEN CONNECTOR RESISTANCE
SENSOR PIN "B" @ 20°C (68°FI
A H4
____--&_
/'
B I-3 Close to O Q »/T V-M-_ 1%
rmi1U10-022-009_a
C G3 7. RH O2 sensor connector location
If a resistance value is NOT as specified, repair or 3. Disconnect oxygen sensor connector.

replace the wiring and connectors. 4. Cut locking ties securing oxygen sensor har-
ness lateral supports.
Oxygen Sensor Removal
5. Unscrew O2 sensor from head pipe.
207 7 Models
Handle oxygen sensor with clean
1. Deactivate main relay 1 (R7) via B.U.D.S.; re- hands. Oxygen sensor probe must remain free
fer to POWER D/S TR/BUT/ON AND GROUNDS of oil, grease, antiseize lubricant and any other
subsection. foreign matter that could affect its operation.
All Models
2. Remove the required body parts to access the
oxygen sensors and their harness connectors,
refer to HO2SACCESSin this subsection.
rmr201 1-071 375

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rmr2D1O-O08-D054!
A
1. Oxygen sensor
2. Front head pipe
VISUAL
ASPECT CAUSE REMEDY
Replace sensor.
Shiny Drain fuel tank
A deposits Lead in fuel and refill with
the recommended
unleaded fuel
Excessive
B carbon/thick Too rich a fuel mixture Replace sensor
soot deposits or faulty sensor heater
Silicone contamination
by use of adhesivesl Replace sensor.
C White Use only products
deposits silicone-based
products on sensor compatible with
oxygen sensors
or threads
rmr201Cl-003-005_ I1
1. Oxygen sensor Replace oxygen sensor as required.

2. Rear head pipe
3. Catalytic converter
The cause of a problem should be
rectified and the sensor changed to avoid
Oxygen Sensor Inspection further problems including damage to the cat-
A visual inspection is usually insufficient to deter- alytic converter.
mine whether the oxygen sensor is functioning
correctly. However, the following should be Oxygen Sensor Installation (Same
checked: Sensor)
— Signs of erosion If the same oxygen sensor is installed, apply LOC-
— Overheating TITE 767 IANTISEIZE LUBRICANT) (P/N 293 800 070)
— Carbon build up on its first two threads.
— Obstruction of the holes in the probe.
I fir".
2.1 l<-
rm r2008~D4E-OO3_a
1. Apply antiseize lubricant first two threads

2. Must be free of any product
NOTICE Do not apply any antiseize lubricant

to the sensor probe as it could affect its opera-
tion.
376 rrnr2U11{l71
Screw sensor in the applicable exhaust pipe. — An internal engine knock

02 SENSOR TORQUE ‘ — An induced knock (or vibration) due to a loose
part external to the engine
43 N'm (32 lbfIft) - Knock sensor and CPS sensor harness connec-
tors swapped (mixed up).
KS Dynamic Test
Oxygen Sensor Installation (New
Sensor) 1. Using the latest applicable B.U.D.S. software
version, monitor the knock sensors using the
If a new oxygen sensor is installed, threads are Faults section.
already coated with an anti—seize product. Sensor
is ready for installation. 2. Start engine and throttle up to above 5000
RPl\/I.
lnstall sensor in the applicable exhaust pipe and
tighten to specification. 3. Look for a knock sensor fault code in B.U.D.S.
lf no fault code occurs, the knock sensor is good.
02 SENSOR TORQUE V
If a fault occurs, do the following:
40 Nvm (30 lbf'ftl
- Ensure sensor and cylinder head contact sur-
Install all other removed parts. faces are clean.
- Ensure mounting bolt and washer are correct
and properly torqued down.
KNOCK SENSOR (KS) - Carry out a knock sensor resistance.
This engine is equipped with two knock sensors
(KS1 and KS2). KS1 is located on the RH side of KS Resistance Test
the front cylinder, KS2 is located on LH side of the 1. Open the front storage compartment cover
rear cylinder under a heat shield. and remove the LH service panel to access the
If the ECM receives a signal of a KNOCK condition ECM connectors, refer to ECM CONNECTOR
from either sensor, the ECl\/l will adjust ignition ACCESSin this subsection.
timing by retarding it to correct the situation. 2. Remove connector "A" from the ECM and con-
nect it tO the ECM ADAPTER TOOL (P/N 529 O36
166).
t-tifm 3. Using a multimeter set to "Q", measure the
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knock sensor circuit resistance as per follow-
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7. Knock sensor (KS2)
l til‘. ’
2. Connector K52
3. Connector KS1
up A P(‘E !-!'!-"!-
Knock sensor problems may be related to, but not .35.:
limited to any of the following items: :0

0ow 9.8.!'
— Loose or improperly torqued knock sensor -—-_"

— Dirty or corroded mounting surface
vmrZOO8 U22-DU 5_6
— Cracked knock sensor from over torquing
— Bad wiring and connections
rmr201'l-O71 377
Subsection 01 (ELECTRONIC FUEL INJECTION (EFIII
If knock sensor circuit resistance is as specified, 8. Install new locking ties as per factory specifica-
wiring harness is good. tion.
If resistance measured at ECM connector is not 9. Reinstall all remaining removed parts.
close to specification, carry out the following
steps. THROTTLE ACCELERATOR
4. Remove the required body parts to access the SENSOR (TAS)
applicable knock sensor connector.
5. Disconnect the knock sensor connector. TAS Troubleshooting
6. Using a multimeter, measure the resistance be- When troubleshooting a throttle related problem,
tween both terminals on the knock sensor and proceed in this order:
compare the measurement with the preceding — Check for an applicable fault code using the lat-
table. est applicable B.U.D.S. software version.
If resistance is not as specified, replace knock - Carry out recommended service actions.
senson — Carry out the 7345 l/OLMGE TEST
If resistance is good at the knock sensor, carry NOTE: With vehicle electrical power ON and
out a continuity check of the wiring between the engine not running, the throttle plates will not
knock sensor connector and ECM connector "A". move when the throttle grip (TAS) is rotated.
Refer to applicable I/l//F?/NG D/AGFBA/I/7for details.
NOTE: Although the knock sensor resistance is
TAS Resistance Test
as specified, it may still be at fault as it may not The throttle accelerator sensor is a double hall ef-
be producing a signal within its design specifica- fect sensor. A resistance test cannot be carried
tion. out.
Repair or replace wiring and connectors between TAS Voltage Test
the ECM and knock sensor.
KS Replacement lowing:
1. Remove the required body parts to access - LH upper side panel
knock sensor. - LH acoustic panel.
2. Disconnect KS sensor connector and cut lock- NOTE: The TAS harness connector is located
ing ties securing wire harness. above and to the rear of the air intake resonator.
To identify the correct connector, refer to the
3. Remove knock sensor mounting screw. connector pin color codes in the following table.
4. Clean knock sensor contact surface on cylinder.
Also clean threaded hole. "Y -C " ’_;_V‘ j 1 " a‘v“._
5. Apply LOCTITE 243 (BLUE) (P/N 293 800 O60) in ,- ‘ I-J .-

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threaded hole.
6. Install new knock sensor and tighten as speci- $.51.‘
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Improper torque may prevent sen- 0. Pl . -'. .- . i _ . . I :‘:§::\?:~s
sor from functioning properly and lead to rr11l1OID-0341-(]‘IO_B
severe damage of internal engine compo- 7. TAS harness connector location

nents. 2. Turn ignition key to ON.
7. Ensure knock sensor connector is clean and 3. Set engine cut-off switch to RUN.
corrosion free before connecting it.
378
rmr201 1-O71
1 M I M I

4. Using a multimeter set to Vdc, back-probe the

TAS connector pins as per following table.
TAS VOLTAGE TEST
VDC AT
VDC AT WIDE
TAS CONNECTOR PINS IDLE OPEN
POSITION POSITION
Pin A (RD) Engine 4.5 - 5.5

Pin D (VI) ground
rn'\r2010-D2 Z-O22_b
Pin A (RD) Pin B (BK)
4.5 — 5.5 1. ETA Connector
Pin D (VI) Pin E (BR) 2. ETA
3. Throttle body
0.495
Pin c lGN) Pin B (BK) 0 597' 2.87 - 2.97 ETA Access
0.248 - 1.385 - Refer to A/R /N7I4KE5YSTE/Wand remove the air
Pin F (BU) Pin E (BR) 0.348 1.485 filter housing.
If voltage readings are as specified, the TAS and ETA Resistance Test
its wiring are in good working order. 207 7 Models
If no voltage is measured between any of the pin 1. Deactivate main relay 1 (R7) via B.U.D.S.; re-
combinations in the table, test for continuity of the fer to POWER D/STR/BUT/ONAND GROUNDS
applicable wiring between the TAS harness con- subsection.
nector and the ECM connector before concluding
that the problem is related to the TAS, or to the All Models
ECM. Refer to the W/R/NG DIAGRAM for details. 2. Disconnect the ECM A connector and connect
it to the ECM ADAPTER TOOL (P/N 529 O36 166).
TAS Replacement Refer to ECM CONNECTOR ACCESS in this
If one or both sensors are not functioning nor- subsection.
mally, the entire throttle grip assembly must be
replaced. Refer to the STEERING AND FRONT
WHEELS subsection.
ELECTRIC THROTTLE ACTUATOR

(ETA)
An electric throttle actuator (ETA) is used to vary
the position of the throttle plates in the throttle
body.
When troubleshooting, first check for an applica-
ble fault code in B.U.D.S. and follow service action 529038166
recommended. 3. Set multimeter to selection and measure

ETA Location the ETA motor coil resistance as per following
table.
The ETA is mounted to the front end of the throttle
body. ETA RESISTANCE TEST
ECM ADAPTER PINS RESISTANCE
9.5 Q
If resistance measured is not close to specifica-

tion, remove the upper RH body panels and repeat
test at the ETA connector. If resistance is still not
to specification, replace the throttle body.
rmr201 1-O71 379

If resistance is also as specified at ETA, carry out a Should it be necessary to disconnect the ECM
continuity test of the wiring from ECM connector and the engine management sensors or compo-
to ETA connector. Refer to applicable W/R/NG D/- nents and power has been turned ON then OFF
AGRAMfor details. Repair or replace wiring and within the last 40 minutes, main relay 1 must be
connectors as required. deactivated. Refer to POWER D/STR/BUT/ON
If the wiring and ETA test good, inspect the throt- AND GROUNDS subsection.
tle body. Refer to T/-/RO77'LE BOD)’MECHAN/- ECM Power Supply and Ground Pinout
CAL /NSPECT/ON and THRO 77'LE BOD Y CLEAN-
/NG. FUNCTION CONNECTOR PIN I
If the throttle body checks good, refer to ENG/NE l\/lain 12 Vdc power ECIVIB-l\/14
CONTROL MODULE (EC/I/0 in this subsection.
Initialization 12 Vdc ECMB-A2
The problem may be related to the ECIVI.
NOTE: ECl\/I requires proper signals from the TAS Grounds ECIVIB Pins L1, M2, l\/I3
(throttle accelerator sensor) and the TPS (throttle
position sensor) for proper control of the ETA.
ENGINE CONTROL MODULE .

’/(((~'/
(ECM) ‘In
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smr2009-027-D05
ECM CONNECTORS
ECM Troubleshooting
Turn the ignition key to ON and look for the items
in the following two lists to come ON.
|\/Iain relay 2 (R3) will provide power to the:
— Cluster
- Analog fuel gauge (optional)
rmr201 U022-CIO6_a - Analog coolant temp gauge (optional)
— Light in the parking brake switch.
Power Supply to ECM Main relay 1 (R7) will provide power to the:
When the ignition switch is turned to ON, the - ECI\/I (main power)
ECM receives 12 Vdc initialization voltage to — Fuel pump.
wake up the ECM.
NOTE: The previously listed items provide a vi-
The ECM then provides a ground to the main sual or audible indication that the ECM is initial-
power relays (R3 and R7) which close their con- ized. Other electronic modules and engine electri-
tacts and provide power to a large portion of the cal components not listed will be powered when
electrical system. these relays close.
When main relay 1 (R7) closes, it provides the
main 12 Vdc battery power to the ECM. If none of the items previously listed come on, the
ECIVI may not be initialized. Carw out the follow-
207 7 Models ing:
Anytime the ignition key is turned to the OFF — ECM /NPUT VOLTAGE TEST //GN/T/ON
position, the ECM will maintain main relay 1 (R7) $W/TCH/
energized for 40 minutes, therefore maintaining - ECM GROUND C/RCU/ T TEST
the ECl\/I and the engine management circuits - Ignition switch test (refer to /GN/T/ON SYS-
and sensors energized at a ready state. This is TEM) subsection.
required for the ETA closed throttle feature.
380
rmr2011 071
If only items listed under one of the two main re- 4. Reach in through the opening and disconnect
lays do not come on, the ECl\/I is initialized and the ECM connectors. Refer to W/R/NG HAR-
the related main relay or its circuit may be at fault. NESS AND CONNECTORS subsection for de-
Refer to POWER D/STR/5’U77ONAND GROUNDS tails on removing ECM connectors.
subsection.
If the fuel pump does not cycle on for a few sec-
onds when the ignition switch is first turned on,
and the engine will not crank, the ECM may not
receive its main 12 Vdc or is at fault. Test the fol-
lowing:
— ECM fuse (F10) in fon/vard fuse box
- ECM main 12 Vdc input (refer to ECM /NPUT
VOLTAGE TEST (B/l77'ERY/I T/'
— I\/lain relay 2 (R3), refer to POWER D/STR/BU- _ 4
T/ON AND GROUNDS subsection.
If these items test good, connect vehicle to the A
*i*.%\
->_
zT\\~.
latest applicable B.U.D.S. software version and rrnr20104'J224)01_a
look for relevant fault codes before replacing an 1. ECM

2. Connector "A"
ECM. 3. Connector "B"
ECM Fault (U0300) 5. Slide your hand down the ECM wiring harness
If a fault code indicating wrong engine control until you reach the plastic clamp that secures
module (ECM) is generated, the installed ECM is the ECM harness to the frame. Unlock the
not appropriate for the vehicle. Engine will crank clamp by pressing on the tab.
but will not start. Refer to PARTS CA7I4LOG for
appropriate ECM part number according to vehi-
cle.
ECM Connector Access
1. Open the front storage cover.
201 7 Mode/s
fer to POWER D/S TR/BUT/ON AND GROUNDS
subsection.
All Mode/s
3. Remove the LH service panel. Refer to BOD)’ rmr201 0-022-OO4_3
subsection. 1. Press here to release clamp
tj ‘ ~ *-'-""1 6. Pull the ECIVI wiring harness out of the clamp,

then pull the connector out through the LH ser-
vice panel opening.
'/“ 1' . '~?E.<
'
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1. LH service panel
rmr201'l-071 381
ECM Input Voltage Test (Battery)

1. Ensure ignition switch is set to OFF.
207 7 Mode/s
fer to POWER D/S TR/BUT/ONAND GROUNDS
subsection.
All Mode/s
3. Remove connect “B" from the ECM and con-
nect it to the ECM ADAPTER TOOL (P/N 529 O36
166). Refer to BODYsubsection.
rrnr2CI'l (H322-005
ECM CONNECTOR THROUGH LH SERVICE PANEL OPENING
ECM Input Voltage Test (Ignition

Switch)
207 7 Mode/s
fer to POWER D/STR/BU T/ONAND GROUNDS
subsection. 529036166
All Mode/s 4. Install an appropriate insulated jumper wire be-

2. Remove connector "B" from the ECl\/I and con- tween ECM adapter pin H2 and chassis ground.
nect it to the ECM ADAPTER TOOL (P/N 529 O36 NOTE: This provides a ground to energize closed
166). main relays 1 (R7) and 2 (R3). R7 provides the
main 12 Vdc to the ECM.
5. Set multimeter to Vdc.
6. Read voltage as per following table.
ECM CONNECTOR "B" MEASUREMENT
PIN VOLTAGE
M-4 I Battery ground Battery voltage
If battery voltage is not measured, test the follow-

ing:
i529036'| 66
— Fuse F10
3. Turn ignition switch ON. — Relay R7 (refer to POWER D/STR/BUT/ONAND
4. Using a multimeter set to Vdc, test for ignition GROUNDS subsection)
switch voltage (ECl\/I initialization voltage) as — Continuity of wiring and connectors from ECM
per following table. to R7 (refer to VI//R/NG D/AGRAM subsection).
ECM CONNECTOR "B" MEASUREMENT If battew voltage is measured, carry out an ECM
GROUND C/RCU/ T TESTas follows.
PIN VOLTAGE
A2 I Battery ground Battery voltage ECM Ground Circuit Test
2077 Models
If battery voltage is not read, test ignition switch
circuit. Refer to /GN/T/ON S)’STEMsubsection. 1. Deactivate main relay 1 (R7) via B.U.D.S.; re-
fer to POWER D/S TR/BUT/ONAND GROUNDS
5. Turn ignition switch OFF. subsection.
282 rrnr20l1~071
All Models 5. Disconnect the VCM connector, refer to VEHI-

2. Remove connect "B" from the ECM and con- CLE STAB/L/TYSYSTEM (VSS) subsection.
nect it to the ECM ADAPTER TOOL (P/N 529 036 6. Measure ECM CAN resistor through DLC con-
166). nector as follows.
NOTICE To avoid damaging the connector,
probe only the terminal tip.
ECM CAN RESISTOR TEST
PROBE otc CONNECTOR MEASUREMENT
Pinl I Pin2 110-isoo
If the ECM is not communicating through CAN
and the resistance value measured is as specified,
ECM CAN resistor and CAN lines are good. Re-
529036166 place ECM.
3. Connect the alligator clip of a 12 Vdc test light If the resistance value is NOT as specified, carry
to the battew positive terminal. out the ECM CANL/NE CONT/NU/TY TESTin this
subsection.
4. Connect the probe of the test light to each
ground circuit as per following table to test 7. Reconnect VCM connector and diagnostic con-
ECM ground circuit. nector.
ECM GROUND CIRCUIT TEST ECM CAN Line Continuity Test
BATTERY ECM "B" CONNECTOR 2077 Models
Pin L-1 1. Deactivate main relay 1 (R7) via B.U.D.S.; re-
Positive terminal (+) fer to POWER DIS TR/BUT/ONAND GROUNDS
subsection.
Pin M-3
All Models
If the test light does not come ON (or is dim) when 2. Disconnect diagnostic connector.
testing any of the ground circuits, check wiring
and connector pins for corrosion, loose pins, cut 3. Disconnect ECM-B connector and connect it to
wire or broken wire at a connector pin. Repair or the ECM ADAPTER TOOL (P/N 529 O36 166).
replace as applicable.
ECM CAN Resistor Test
The ECM contains a CAN line termination resistor.
If the resistor value is not correct, or the resistor
is open circuit, the ECM will not be able to com-
municate with the other modules.
To check the CAN resistor within the ECM, carry
out the following steps.
1. Turn ignition switch to OFF.
529036166
207 7 Models
4. Test for circuit continuity between diagnostic
2. Deactivate main relay 1 (R7) via B.U.D.S.; re- link connector (DLC) and ECM as per following
fer to POWER DlS TR/BU T/ON AND GROUNDS table.
subsection.
NOTE: Refer to ECM POWER SUPPLY GROUND
All Models AND CAN P/NOUTin this subsection for pin iden-
3. Disconnect diagnostic link connector (DLC). tification.
4. Ensure the ECM connectors are properly con- NOTICE To avoid damaging the connector,
nected. probe only the terminal tip.
rmr201 1-071 383

ECM CONNECTOR
CAN* PROBES RESULT
Diagnostic
High ECM-B pin
link
C1
connector
pin 1 Close
_ _ to O Q
D'a9"°3t'° (continuity)
Low ECM-B pin link
C2 connector
pin 2
* CAN: Serial data communication rmr201 (1-022-GD6_lJ
If continuity is not good, check wiring and con- ECM Installation

nectors from diagnostic link connector (DLC) to 1. Install the ECM in vehicle.
ECM connector. Refer to applicable W/R/NG Dl-
A GR/I/I//. 2. Reconnect ECM connectors.
If everything tested good and ECM does not work, 3.lf a new ECM is installed, enter data and
try a new ECM. perform the required resets using the latest
applicable B.U.D.S. version. Refer to ECM
5. Reconnect DLC and ECM connectors. REPLACEMENTfurther in this subsection.
ECM Removal 4. Reinstall the 40 A main power fuse (M FB34 (4))
NOTE: If a new ECM is to be installed, first read 5. Reinstall air intake resonator, refer to A/R /N-
the procedures in ECM REPLA CEMENTfurther in TAKE SYSTEM subsection.
this subsection. 6. Reinstall all removed body parts, refer to BODY
1. Open the seat to access the main fuse box subsection.
(MFB).
ECM Replacement
2. Remove the 40 A main power fuse (MFB34 (4))
that powers F1, F2, F3, F4 and R7. 1. Prior to replacing a possibly faulty ECM, ensure
the following:
3. Remove the air intake silencer to access the
ECM. Refer to A/R /NT4/(E SYSTEM subsec- — Check for an applicable fault code using the
tion. latest applicable B.U.D.S. software version.
Carry out service actions and clear fault
.-1» /" - ' codes.
.»"‘“.t‘it\;\'-j'?”;'
.- ~'- -' -:».*\'\. .- /\ - - ECM power supply and all grounds have
been checked for proper contact/cIeanli-
1 “'~1-.“""'¥.'. - .,, 2/ ness, tightness and continuity.
.1-7‘? - T T /I I‘ - Make sure terminals are free of corrosion
..~ ‘iii’
.~'.'T'I.'
Q4_ or moisture, properly crimped on wires and
.4». .--1. locked in connector housing.
-T‘§_
'\:'‘.,_ V. ' .a_
8%‘ ._
‘
\.//2’; ‘IV _‘V.; I '1 — Check wiring harness for any signs of scor-
*1.
\.
_r :- _ I _ . :;1fi:‘;“_r
_‘ ‘
I
” .\\ sf‘ V ‘
--._§'_\_°@ 4 T ‘IV ‘\- F». _ ,. v ing, cuts, bare or pinched wires that may
\IIx\
3;.
I I--r*"’TI T“
i ‘-2:
o
-A ~
{Y
;{L
TIT‘?l
:1
o ‘I
I;/x
I 5 T I
I/III;
\'/&\\‘
I ‘
cause short or open circuits.
— All the other recommended tests have been
t\))\\:
rmr20I04119003_a
II. rs Qt. carried out.
7. ECM location 2. Collect the following data and settings required
for entry into new ECM:
4. Disconnect both connectors from the ECM.
5. Unscrew retaining screws and remove the
ECM from vehicle.
384 rmr2011-071
There are 2 possible methods to collect the re-

quired information. The 1$f being the easiest. My I133 auosP2.3.1a vl 4=- El Cit *
— Use B.U.D.S. software and retrieve the data
from a saved .mpem file on your PC computer. OM Earn»
fit0.istomcrs iiirisve
Refer to 757 COLLECT/NG METHOD." RETR/El/- Eaoeu \*:,upaa=a=iie
lNG DAT4 FROM A SAVED .MPEM FlLE i_';‘3£nu
Qasu
— Collect the information from the vehicle figrtn
and BOSSWeb. Refer to 2/VD COLLECTlNG
METHOD: COLLECT THE INFORMA T/ON
FROM THE VEHICLE AND BOSSWEB.
3. Replace the ECM. mam IMPEMlilee(‘.mpeml I 3] Cancel I
4. Carry out an ECM /N/T/ALIZATION RESET in |T\n'\r2009-023-08Z_a
B.U.D.S.
NOTE: You may have to go to another AutoSave
15* Collecting Method: Retrieving Data from a folder from a previous version of B.U.D.S.
Saved .mpem File
Choose the latest file saved for this specific vehi-
1.Connect vehicle to the latest applicable cle.
B.U.D.S. software version.
2. Tum the ignition key to ON. Open
3. In B.U.D.S.. click on the Open button. 1.ookjn'ItiJAutoSave -I <:= iii 531+ -
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P2,3.22.12_2BP‘5CX9859VOGOI01_20090229_l04558.mpam
_ P2.3.22.I2_2BPSCX9BS9VOO01£l1_20090229_1HS58.mpem
"lo Y
Fienamuc I5za2z1z,2aPsskscsevom1ss_2ooso2ns_ I Qpen
Open Fkwuwe: l~iPsmmr'.m»1

srni200&D304II0 6
_-,l flaw I
mmr2D09-023-GEO
IMPORTANT: Ensure to use the file that specifi- I
Click once on the Folder Up button in the Open cally matches the vehicle you are servicing.
box. NUTE: The file name structure is as follows: I
BUDS version_VlN_data read (yyyymmddl_hour read
Open
lhhmmsslmpem
I Lookjnc Customer: vI 4- Ifiv —
Example:
/ P2.3.22.12_2BPSBK8C68V000168_20(]90206_111640.mpem
Therefore:
B.U.D.S. version: P2.3.Z2.12
-
tr
..... VIN: 2BPSBK8C68VUOU168
Date: 2009 D2 06 '
Fivnflw Hour: llh 16m 40s
ramuwe; IMPEMfiles('.mpem] LI On the Vehicle page, collect the following infor-
mrnr200&O23-081_a mation. I
1. Customer name
Double click on the AutoSave folder.
2. V.l.N. (Vehicle Identification Number)
3. Engine serial number (without the leading
HM")
rmr2011-071 ass .
4. Vehicle model number

5. Total hours.
T“***TI 2’ l--l-l - I --I

fifllll r |1@l ' T T T T
3 vmwm +CDonu Fin I

T.;.->- ........ ......
,-....._....__................
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I
Ffiflflllfifil Qlllflflhllltlg I Milfilflfl
10% Iflhlltitéfi I
rrr\r2010-0224J2E_a rmr2U10-022-O31_a
DATA T0 RETRIEVE ENGINE SERIAL NUMBER LOCATION (CRANKCASE)

7. Customer (name)
2. Vehicle (V/.N.) 2. Record the following numbers using
3. Engine (serial number)
4. Model BOSSWeb. Look in Service menu and
5. Total hours choose Unit history.
Enter recorded data in ECM as detailed in ENTER- 3. 1. Customer name
/NG THE COLLECTED DAII4 /N THE ECM 2. V.l.N. (Vehicle Identification Number)
2"d Collecting Method: Collect the 3. Vehicle model number
Information from the Vehicle and BOSSWeb
1. Record engine serial number.
NOTE: The engine serial number may be obtained
from the 2 locations on the engine. From a bar I’.!'.$§.‘.‘fl%'I‘?
code sticker on top of the rear cylinder head as I':I\TI
_ -i—
I ‘TTT
D¢\lI'l'lII'\
,,, -‘B1
seen from the RH side of the vehicle, or etched on -
- - - - - Unit Claim
the engine crankcase as seen from the RH side. 5 am Clntrn
' ..,1 -L-.
-.
i , _,_ __ _ _ , Clothing Chin
_ Cllln M.-
II ll" _ Nr‘Hl'W_rn
~__ ‘S
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ga
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em um
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M
l- - T -—-I I - - 1 )-
mmr20fl9-118-D11
SERVICE, UNIT HISTORY
4. Enter the recorded data in ECM as detailed

in ENTERING THE COLLECTED DATA IN THE
ECII/I.
Entering Collected Data in the ECM
1.After the ECM is replaced, connect vehicle
rm!2(l10-02Z~D30_a to the latest applicable B.U.D.S. software ver-
ENGINE SERIAL NUMBER LOCATION (REAR CYLINDER HEAD sion. Refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection.
2. In B.U.D.S., click the Read Data button to load
the information from the faulty ECM.
386 rmr201 1 -O71

. . . .p. I ..
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AC ;l\osl!|an 15
lg.101 Position 0 “M
vmr2006-U1 2-1 0O_aeri
AGE LOW Fuoitbn O fieyq I
3. On the Vehicle page of B.U.D.S., enter cus-

tomer and vehicle data in ECM. 2
‘*1-*I2i~»-1»--i--I--I ~ I
.‘i£IBfl!£IE.I.Ei.,£X‘_i_I
3 M:-A \ ‘I _;:... F‘-T-v1<T"—— rmr2U1()O22-O2 9_0
'TW\* _..-.... M . -2 1. Setting page tab
um»-you mlmvl
2. ACC page
,1"/Y 3. AC$box
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tun-1 mu
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M." M‘,
7. Click on History tab.
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wmn
11 VOIIWIA
tum
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to mm 8. Click on Part Replacement tab.
in-in tum
'NOIK4|¢\l QM
9. Click on Add Part in History tab.
nmnqmgn 9104170; mums imugwu
.............,, I ultl!L\> :4%I\} Ww-\‘»<v.; ~;..-L... :,.-. H-:1-1 I

rrnr2 010-02 2-026_b we-r-ni rmmm I 11$»! rt. v.» Pm E -we ¢Yv’I
DATA TO ENTER IN VEHICLE PAGE OF B.U.D.S.
7. Customer (name) I 1“. T "I" '.....i..I'_T TI T ...».-......TTI
2. Vehicle (I/.l.N.)
3. Engine (serial number)
4. Model I
I
4. Click on Setting tab.

5. Click on the ACC tab at the bottom of the SET-
TING page.
6. In the Vehicle Configuration field, click in the 1111901 ">1‘:>r
ACS box to tell the ECM the vehicle is equipped rrnr20U8-D21-021_a
with an air controlled suspension (as applica-

ble). 10. In the Part Type field, choose the ECM and
add the ECM serial number.
- Part Tyne
7' EIIQIIII
r= ecu-(i 1
1' cluster
Senor Number XXXI23455
I Ce.-lcel I
rmr2OIO-O22-027_a
1. ECM selection
2. Enter ECM serial number here
rmr201 ‘I-071 387

11. Click OK to save the ECM serial number and

exit the Add Part In History window.
12. Carry out the ECM F/Fi’S7'//V/7'/AL/ZAT/ON HE-
‘ii ii ‘E’ l “i xii- oi
HT” no
vss.» , »'4='-6
-
\ wrimm
£44m»;
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Dam
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r
SETprocedure in this subsection. =-..=.;.;... ¢\\D\!Il.\l>fi

rwmw we 0'09/Q
Security Exchange
Eva I
.__ _ __ __ __,\__
lf the warning message in the following illustra- csapiwwzavvntvlmmsvm — J
tion appears when B.U.D.S. is connected to the
vehicle, the installed ECM is not the appropriate uh-0' nun vaaunm
Em:
ECM for the vehicle, or its calibration has been

changed. -1». - |
Fflum ivlllirvfim
% if l
The cluster codinc does notlmatch with _ Fm Lggvw av"; §lC'i 7 7'
’ ‘ the ECM connected. Do you want to change it? rmrZO1CHI)22-0D7_b
1. Click on Setting page tab

2. Choose ECM page
—- is .l. 3‘. Click on ECM first initialization reset button
NOTE: The ECIVI will carry out a Throttle posi-

vrnr20l]6-O2 O-Ci58_a
tion sensor initialization reset, a Gear position
lf it occurred just after replacing the ECM, refer sensor initialization reset, and a Brake pressure
to the PARTS CA7I4LOG to obtain the appropriate adaptation reset.
ECl\/l required for the vehicle type. NOTICE When carrying out the ECM first ini-
if this message appears after the ECM calibration tializationprocedure, ensure the brake pedal is
has been purposely changed, click Yes to update fully released.
the system, and to allovv engine starting.
3. Clear all faults from the newly replaced ECM.
NOTICE It is not recommended to start an en- 4. In B.U.D.S., click the Write Data button to save
gine with the wrong calibration. the information to the ECM.
ECM First Initialization Reset
1. Click on the Setting page tab and choose the
ECM page. Miew MEI‘? Modde locals flelp l
2. IMPORTANT: On the ECIVI Setting page, click
on the ECM first initialization reset button.
' .
Q ea
Read Data
. _ ..
Write Data
..._W.__~ v—7~< _._ 3
l
‘
vmr20OG-D12-100_ben
5. Take vehicle out for a test drive. Ensure proper

operation of vehicle, and that every gear posi-
tion is correctly indicated in the multifunction
gauge.
NOTE: The gear position sensor initialization reset
is not complete until the transmission has been
shifted into each gear. On models with a semi-au-
tomatic transmission, it is extremely important to
ensure the transmission can be shifted into each
gear after the reset.
388 rmr201 1-071

Subsection O2 (FUEL TANK AND FUEL PUMP)
FUEL TANK AND FUEL PUMP

SERVICE TOOLS
ECM ADAPTER TOOL ................................................................. .. 529 O36 166 ............................... ..403, 41 O
FLUKE 115 MULTIMETER .......................................................... .. 529 O35 868 ............................... ..404, 409
FUEL HOSE ADAPTER ................................................................ .. 529 O36 O23 ....................................... .. 394
OETIKER PLIERS ......................................................................... .. 295 OOO O70 ............... ..392, 397, 399, 419
PRESSURE GAUGE ..................................................................... .. 529 O35 709 ....................................... .. 394
VACUUM/PRESSURE PUMP ...................................................... .. 529 O21 800 ....................... ..393, 408, 411
rmr201 1-072 389

Subsection 02 (FUEL TANK AND FUEL PUMP)
29 N-m NEW
(21 lbf-ft) <-5
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W = Component must be replaced
when removed
Rmr201D-023-OD] b
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e
i
390 rrnr2011 072

GENERAL SYSTEM DESCRIPTION

WARNING The fuel tank and fuel pump system main compo-
nents are:
must be strictly adhered to. Locking devices — A fuel tank
must be replaced when removed (e.g.: lock- — An electric fuel pump module
ing tabs, elastic stop nuts, cotter pins, etc.). - An in line fuel filter
- An evaporative emission system
WARNING — A purge valve.
Always disconnect battery prior to working
on the fuel system. Fuel Pump Module
The fuel pump module is inserted through the top
WARN EG) of the fuel tank. It includes an electric fuel pump
and a float type fuel level sensor that varies in re-
Fuel is flammable and explosive under cer- sistance according to fuel level.
tain conditions. Always work in a well venti-
lated area.
WARN Eca
Do not allow fuel to spill on hot engine parts
and/or on electrical connectors.
WARNI Z GD
Always proceed with care and use appropri-
ate safety equipment when working on pres-
surized fuel system. Wear safety glasses.
‘Ii
When replacing a fuel line, be sure to use BRP

approved fuel hoses as available from the BRP
parts department. This will ensure continued
proper and safe operation. rrnr2D08-01 9-006,3
TYPICAL
Fuel lines remain under pressure at all times. 7. Fuel pump
Proceed with care when removing/installing high 2. Fuel level sensor
pressure test equipment.
Fuel Pressure Regulator
Disconnect fuel pump electrical connector to dis-
able fuel pump and crank engine to release fuel The fuel pressure regulator is mounted on the LH
pressure prior to disconnecting any fuel hose. side of the throttle body. It controls the fuel pres-
sure in the system and allows excess fuel to re-
Cover the fuel hose connections with an ab- turn to the fuel tank.
sorbent shop rag and carefully disconnect them
to minimize spilling. The fuel pressure regulator is referenced to atmo-
spheric pressure. A small filter is attached to the
Wipe off any fuel spillage. atmospheric pressure port.
Hoses, cables or locking ties removed during a
dards.
A WARNING
Replace any damaged, leaking or deterio-
rated fuel line. Use of damaged fuel lines, or
fuel lines not approved by BRP, could com-
promise fuel system integrity.
n'nr20l 1-072 391

l I
As the vehicle is sitting and not running, fuel evap-

orates within the fuel tank.
The fuel tank vent is connected to an EVAP can-
ister (charcoal) that is used to trap any hydrocar-
bon emissions from the evaporated fuel prevent-
ing them from escaping to the atmosphere. The
fuel vapors are absorbed by a charcoal medium in-
side the canister.
An EVAP purge valve is used in conjunction with
the EVAP canister. A hose connects the solenoid
operated valve to a vacuum port on the throttle
body.
rmr2010-O23-00235
TYPICAL Once the engine is running and reaches a prede-

7. Fuel pressure regulator termined engine RPM, the ECM energizes the
2. Filter
3. Fuel return line to fuel tank purge solenoid valve open. Thus, vacuum from
the engine draws (or purges) the hydrocarbon
Evaporative Emission System (EVAP) emissions from the canister and burns them dur-
ing the combustion process. The ECM cycles the
solenoid ON and OFF as necessary.
@- Should the canister overfill with liquid fuel, an
Z//y overflow hose is provided to direct the fuel under
.r"T/ the vehicle.
.n ,_. _...--'
INSPECTION
FUEL SYSTEM LEAK TEST
1. Remove body parts on the RH side of the ve-
hicle as required to access fuel system compo-
nents. Refer to the BODYsubsection.
2. Fill up fuel tank (recommended).
rmr2008-019-DOB
3. Disconnect vent line from EVAP canister.
TYPICAL - EVAP CANISTER
REQUIRED TOOL
L‘
Q-..K
2 55000070
rm|'1lIl11-O72-006_a
TYPICAL
1. EVAP canister
. EVAP purge solenoid valve
Ve nt hose from fuel tank
Vacuum hose from throttle body
F-Y'l:°~9J'\1 Overflow hose
392 rmr201 I-O72

_/‘ \-,
FUEL SYSTEM LEAK TEST
6 TIME WITHOUT
7‘ \
PRESSURE PRESSURE DROP
Q - 28 kPa (4 PSI) 10 minutes
lit s~.'t€
If pressure drops, locate fuel leak(s) and
repair/replace leaking componentls).
NOTE: To ease locating leak(s), spray a solution of
soapy water on hoses and components. Bubbles
will indicate leak location(s). When testing is com-
plete, thoroughly rinse off the soapy water solu-
tion with clear water to prevent premature deteri-
oration of components.
rm|’2011-0724)07_b
6. Reinstall fuel tank vent hose on EVAP canister.
TYPICAL - EVAP CANISTER VENT LINE 7. Reinstall all removed body parts, refer to BODY
1. Remove vent line here subsection.
4. Install VACUUM/PRESSURE PUMP (P/N 529 021
800) onto EVAP canister vent line. FUEL SYSTEM PRESSURE TEST
The fuel system pressure test provides an indica-
tion of the available pressure in the fuel system.
It validates the pressure regulator, the fuel pump
and allows checking for leaks in the fuel system
(high pressure side).
Fuel System Pressure Test (Static)
This test allows the following fuel system checks:
— Internal component and external fuel system
leak checks (high pressure system)
- Static fuel pressure test (engine not running).
529021 B00 Proceed as follows to conduct test:
1 . Ensure the battery is fully charged. Battery volt-
age must be over 12 volts.
2. Ensure there is enough gas in fuel tank.
3. Remove body parts on the RH side of the ve-
nents. Refer to BODYsubsection.
4. Remove RH fuel tank cover.
rrnr200B-O22-(J1 5_a
TYPICAL
5. Set hand pump to pressure and pressurize fuel

tank as per following table.
rrnr2D11-Q72 ass
8. Remove main relay 1 (R7) in front fuse box to

remove power from the ECM, refer to POWER
D/5 TH/BUT/ON AND GROUNDS subsection.
9. Disconnect the pressure hose from the fuel
pump module.
A WARNING
Cover the fuel hose connection with an ab-
sorbent shop rag. Slowly disconnect the fuel
hose to minimize spilling. Wipe off any fuel
spillage.
TYPICAL FUEL TANK co VER PUSH LOCKS

5 Disconnect fuel pump electrical connector
rrnr20[18-022-006,8
TYPICAL - PUMP MODULE PRESSURE HOSE
10. Connect a fuel PRESSURE GAUGE (P/N 529 035

1 Fuel pump electrical connector 709)
O23) to the FUEL HOSE ADAPTER (P/N 529 036
6 Release fuel pressure in system by cranking the

engine prior to disconnecting any fuel hose
7 Remove fuel filter retaining screw
.
- X if *1
.i§- ii‘ ; .
~__.-
529035709
TYPICAL FUEL FILTER FIETAINING SCREW
rmr201 1-072
.5‘ Fuel System Pressure Test (Dynamic)

This test validates the following components in
the fuel system:
— Fuel filter (if badly clogged)
- Fuel supply and return hoses
l - Fuel pump (under partial load)
- Pressure regulator.
529036023 1. Follow the instructions in the FUEL SYSTEM
PRESSURE TEST/S7I4T/C) procedure to discon-
11. Install gauge T-fitting between disconnected nect the fuel pump pressure hose and install
fuel system hoses (in-line installation). the pressure gauge.
2. Start engine.
3. Increase and vary engine RPM.
4. Observe fuel pressure.
FUEL SYSTEM PRESSURE TEST (DYNAMIC)
330 kPa i 20 kPa
FUEL PRESSURE I (48 PSI i_ 3 PSI)
5. If pressure is not within specifications, refer to

DIAGNOSTIC FLOW CHART (FUEL PUMP) in
TROUBLESHOOTING in this subsection.
6. Stop engine and turn ignition key to OFF.
7. Release fuel system pressure by disconnecting
fuel pump electrical connector and cranking en-
gine.
rn-\i2008-022-007
TYPICAL - PRESSURE TEST GAUGE INSTALLATION
D/STR/BUT/ON AND GROUNDS subsection.
12. Reconnect fuel pump electrical connector. 9. Remove all test equipment.
13. Reinstall main relay 1 (R7). 10. Reconnect fuel hoses.
14. Set engine stop switch to RUN. NOTE: Be sure to reconnect the quick connect fit-
15. Turn ignition key to ON. Do not crank engine. ting on the fuel pump pressure hose with the flat
16. Observe fuel pressure on test gauge. portion facing down.
17. Turn ignition key to OFF.
18. Repeat the test 3 - 4 times to ensure a consis-
tent pressure reading.
FUEL SYSTEM PRESSURE TEST (STATIC)
330 kPa 1 20 kPa
FUEL PRESSURE l (48 PSI i 3 PSI)
If pressure is not within specifications, refer to

DIAGNOSTIC FLOW CHART (FUEL PUMP) in
TROUBLESHOOTING in the shop manual back
cover
if pressure is within specifications, carry out the
FUEL SYSTEM PRESSURE TEST (D YNAM/C).
rmr201 1-072 395 l

2. Fuel system pressure out of specification.

3. Air intake system leak.
ENGINE BACKFIRING OR MISFIRING
1. Inadequate fuel system pressure.
. ., '
2. EVAP purge valve hoses incorrectly installed.
DIAGNOSTIC FLOW CHART

(FUEL PUMP)
~ \, '>.'
Use the diagnostic flow chart located in the shop
manual back cover.
'
*1 ‘J
"1 ‘ "\.$3'
rn'\i2008-022-0 1 4_a
PROCEDURES
TYPICAL - FLAT SIDE FACING DOWN
FUEL FILTER
11. Reinstall fuel pump electrical connector.
12. Reinstall fuel filter retaining screw. Fuel Filter Removal
13. Reinstall main relay 1 (R7). 1. Remove body parts on the RH side of the ve-
14.Reinstall all removed body parts, refer to nents. Refer to the BODYsubsection.
BODYsubsection.
2. Remove RH fuel tank cover.
When reinstalling fuel tank covers, pay attention
to the following.
rrnfl 0084!22—D02_a
TYPICAL — FUEL TANK COVER PLASTIC RIVETS (RH SIDE
Irrn(ZO0B-022-0UZ_b - ILLUSTRATED)
TYPICAL
1. Align locating pin 3. Disconnect fuel pump electrical connector and
2. A/ign locking tab release fuel system pressure. Refer to FUEL
SYSTEM PRESSURE TES TIS714 T/C) in this sub-
Use locking ties to secure wiring and hoses as per section.
factory specifications.
TROUBLESHOOTING remove power from the ECM, refer to POWER
D/STR/BU77ON AND GROUNDS subsection.
TROUBLESHOOTING TIPS 5. Remove the Oetiker clamps retaining the fuel
hoses on each side of the fuel filter.
ENGINE SURGING OR NOT HOLDING A
STEADY SPEED
1. EVAP purge valve stuck opened.
396 rmr2011-072
REQUIRED TOOL NOTE: Be sure to install the fuel filter with the
flow direction arrow on the fuel filter in the direc-
OETIKER PLIERS (P/N 295 000 O70) tion of fuel flow; from fuel pump towards throttle
body.
Qt;
295000070 A-.\
,,.__-
_.___-"—'
.,...._-
Pt.“
pa—@~
rmr2 (J1 1-O7 Z-O0B_b
TYPICAL
1. Direction of flow arrow on fuel filter
fi-\
2. Install new Oetiker clamps on fuel filter hoses.
M..--
A WARNING
§
,____--——
___7--—
Always install new Oetiker clamps as per
PARTS CATALOG.
rmr201 1-072-008,6
REQUIRED TOOL
TYPICAL - FUEL FILTER OETIKER CLAMPS OETIKER PLIERS (P/N 295 O00 O70)
6. Remove fuel hoses from fuel filter.
7. Remove fuel filter support retaining screw.
‘.
V \\
4'0
295000070
3. Secure fuel filter to chassis.

FUEL FILTER SCREW TORQUE
1ON°m (89Ibf'in)
4. Reconnect fuel pump electrical connector.

rn'ir2008-02 2-0OB_a
5. Reinstall main relay 1 (R7).
TYPICAL - FUEL FILTER RETAINING SCREW
Fuel Filter Installation

1. install fuel filter.
rmr201l-O72 397
6. Turn ignition switch ON to activate fuel pump

and check for:
— Proper fuel pump operation I
I
- Fuel leaks in the system.
When checking for fuel system
leaks, pay particular attention to the hose
connections that were disconnected for the
procedure.
7. Reinstall all removed body parts, referto BODY
section.
FUEL TANK
l
Fuel Tank Draining '""’°°‘*‘“*’°’-“
TYPICAL - FUEL TANK COVER PLASTIC RIVETS (RH SIDE
Siphon fuel from tank into an approved fuel stor— /LI-USTFIATEDI
age container.
4. Disconnect fuel pump connector.
Fuel Tank Removal 5. Crank engine to release fuel pressure in the fuel
pump pressure hose.
‘C
DISTRIBUTION AND GROUNDS subsection.
7. Remove the rear cargo compartment assembly,
refer to BOD Ysubsection.
8. Disconnect parking brake cable from actuator
pulley, refer to BRAKE SYSTEM subsection.
9. Remove the RH lateral frame support, refer to
%-w
FRAME subsection.
Ea
-,,.,_ >‘—_t__
_ _ Ii
'
/erg;
.-ign V
I -A -‘- 1-
-.-
'l'i~ifI‘—
‘Y’:
F >4
.
ii.1.
_1_-2',-
, '.-1?
T T
F1‘ 4/
rmr2OU8-019-004_a
‘
' , kizl-=I'.:*(‘i;'uI,.{ 6‘
TYPICAL
1. Fuel tank A -=-ee.-.g _fl;-.,, , -- ,.'-_4
. . . - "
2. Fuel pump
3. In-line fuel filter
\. E1‘l|_t:v(,-
L>__'i\,__ M _ jw ' ;§T,f‘ * ‘
4. Fuel supply hose . .‘ ' ' -' ‘I / I .- ~.-.' .
5. Fuel return hose
; \“=';=*-_;::-=;-_. II “T I
1. Siphon fuel tank.
2. Remove body parts on both sides of the vehi- iii" T‘ TWTTTET E_\<-Ii -
:I ~ I " I I ‘
cle as required to access the fuel tank, refer to rmr201D-O23-0D6_a I
BODYsubsection. Step 1: Disconnect parking brake cable here
3. Remove both fuel tank covers. step 2‘ ”"”'°"e 'a’e"" (‘Ema “PR0”
10. Remove 2 retaining screws from the master
cylinder.
398
rmr2D11-072
Q-1;’;
_.___,._
.- X
__..-A
-— _/-- __,..._,—-
'_’_N_,__..,-
M"
IITIIZOUB-D22-0'1 B_a 1 Fuel tank

T\/PICAL _ MASTER CYLINDER RETAINING SCREWS 2 RQITIOVQ TRIS bUSI'lll'IQ and grommet (LH aft DOII I‘l0I6)
11. Remove the remaining screws that secure the I5 Dl5°°"l1eCl fuel $uPPlV and lllel lelllm hoses
RH foot peg support to the frame, and remove from fuel Pump
The SUDDOFT TF0") the Velll¢le- 17 Disconnect fuel tank vent hose from fuel tank
NOTE: The remaining screws are screwed into Velll Valve
the rear face of the foot peg support. REQLHRED TOQL
WK
5 \\
rmr2010-023~0O‘I__a
1. RH foot peg support
12. Cut locking ties securing master cylinder _<-"1"
hoses coming from brake oil reservoirs (as
required).
13. Remove the two brake oil reservoir retaining
screws, refer to the BRAKE SYSTEM subsec-
tion.
14. Remove fuel tank retaining bolts.
15. Remove the bushing and grommet from the
LH aft fuel tank mounting bracket.
TYPICAL VENT HOSE DISCONNECT

1 Fuel tank vent valve
2 Disconnect vent hose here
rmr2011-O72
18. Pull fuel tank up and out from RH side of ve-

hicle. I: r_,f"» k
NOTE: Move master cylinder from side to side as ' .1g___
necessary to allow removal of fuel tank. Be spe- 9
cially careful not to damage brake oil hoses and ,~- --2 " I’ ¢ "--tr -3“- 1.
fittings.
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rmr201 1-U72-0U5_a
1. Install fuel tank ground wire here (RH aft bolt).
2. Torque fuel tank mounting screws as specified.

FUEL TANK RETAINING BOLTS
7.5 N°m (66lbf¢in)
3. Reinstall foot peg support. Refer to the BODY

subsection.
rrnr2U08-022-0Z0_B 7 4. Properly reinstall the following parts, refer to
TYPICAL - LIFTAND PULL OUT OVER BRAKE OIL HOSES the BRAKES subsection:
— Brake system master cylinder
Fuel Tank Inspection — Brake system reservoir
lnspect fuel tank for any damage or cracks which - Parking brake cable on actuator pulley.
may result in fuel leaks. Replace fuel tank as re-
quired. A WARNING
Be sure to carry out a leak test and an opera-
Fuel Tank Installation tional test of the brake system as indicated in
Reverse the removal procedure. However, pay at- the BRAKES subsection.
tention to the following:
1. Reinstall fuel tank. Install hardware as illus- 5. Use locking ties to secure wiring and hoses as
trated in exploded view at the beginning of this per factory specification.
subsection. 6. Connect fuel supply hose and fuel return hose
NOTE: Be sure to install ground wire on the RH quick connects. Flat section of quick connect
aft fuel tank mounting bolt. must face down towards fuel tank.
400
rmr201 1 -072
FUEL PUMP
Fuel Pump Location
The fuel pump module is mounted on top of the
fuel tank.
\.
%_7.;’_ZLj; .
rmr2008-022-014_a
TYPICAL — FLAT SIDE DOWN 1?
7. Install the fuel tank vent hose on fuel tank vent

valve fitting. 2—>'-
8. Reconnect fuel pump electrical connector after rrnr200B—IJ19-0U6_a
all fuel hoses have been connected. TYPICAL - FUEL PUMP MODULE
1. Fuel pump (in pump reservoir)
9. Reinstall main relay 1 (R7). 2. Fuel level sensor
10. Refill fuel tank. Fuel Pump Quick Test
11. Pressurize fuel system by turning ignition key 1. Open the seat for access to top of fuel tank.
ON, and checking for leaks. Refer to FUEL
SYSTEM LEAK TESTin this subsection. 2. Apply the metal end of a screwdriver to the top
of the fuel pump module and, the other end
12. Reinstall lateral frame support, refer to against your ear.
FRAME subsection.
3. Turn ignition switch to ON and listen for the fuel
13. Install fuel tank covers. Ensure proper inser- pump.
tion of alignment pins.
The fuel pump should run for a few seconds to
build up pressure in the fuel system, and then
shut off. If you do not hear the fuel pump func-
tion, check fuse F12 (front fuse box). if fuse is
good, carry out a FUEL PUMP POWER CIRCUIT
TEST USING A TEST LIGHT
NOTE: lf fuse F12 is blown, the PRE-STARTING
RELAY (R2) will NOT be energized closed and the
starter solenoid will not function when the start
button is pressed, even if all cranking conditions
are met.
Fuel Pump Power Circuit Test Using a
Test Light
1. Remove the RH upper side panel, refer to
1rnr2U08-O22-Cl02_b BODYsubsection.
TYPICAL 2. Remove the RH fuel tank cover, see FUEL
1. Align locating pin
2. Align locking tab TANK REMOVAL in this subsection.
14. Reinstall rear cargo assembly and all other re- 3. Disconnect fuel pump electrical connector.
moved body parts, refer to BODYsubsection.
rmr2011 072
401
I Z I I M I M

l Ensure normal pump circuit polarity is respected

as illustrated.
_._.-.—-P-* -tn. "
>4 --. 1‘-T, - " ' <1-' '

.,i 1_, l I " . .
ri-nr2U7i1-072-O02_a I C I E I
1. Fuel pump electrical connector
4. Connect a 12 Vdc test light between the fuel BAT ~-‘

pump harness connector pins "B" and rmr20D8-022-025_a
5. Turn the ignition switch to ON. The test light TYPICAL

should turn ON for a few seconds, then turn NOTICE Running the fuel pump connected in
OFF. reverse polarity for a few minutes can damage
the pump motor.
If pump does not function, replace it.
Fuel Pump Power Circuit Voltage Test
Turn ignition switch to ON.
Probe fuel pump harness connector as illustrated
using a multimeter set to 12 Vdc. When turning
ignition switch ON, you should read close to bat-
tery voltage.
rrnr2008-O22-026_d
TYPICAL
6. Turn the ignition switch to OFF.

if test light came ON for a few seconds and then
turned OFF, the fuel pump circuit and ECM are
functioning normally. Carry out the FUEL PUMP
OPERATIONAL TEST
If the test light came ON dim or not at all, carry
out the FUEL PUMP POWER C/RCU/T VOL7I4GE
TEST rmr2008-022-O26_lJ
TYPICAL
Fuel Pump Operational Test
Install small insulated jumper wires between the if battery voltage is not read, carry out a FUEL
fuel pump module connector and a known good PUMP POWER C/RCUIT CONT/NUITY TEST
12 volt battery as in following illustration. If battery voltage is read, carry out a FUEL PUMP
POWER C/RCU/7' CONTINUITY TEST
402
rmr2011 072
if voltage is low to battery ground, test for a short FUEL PUMP CIRCUIT CONTINUITY
or partial short circuit to ground with the pump (CONTROL WIREI
circuit isolated from parallel circuits, refer to the ECM PUMP
W/RING DIAGRAM CONNECTOR HARNESS as SISTA C
., N ., E
NOTE: A fault in the ECM or in a parallel circuit "B" connecton @ 2° C I68 Fl
may prevent fuel pump operation. Use B.U.D.S. Pin M-1 Pin C Close to 0 S2
to check for fault codes.
If test failed, repair or replace the faulty wiring.
Fuel Pump Power Circuit Continuity
Test If test succeeded, wiring is good. Try a new ECM.
1. Remove fuse F12 in front fuse box. 4. Reinstall main relay 1 (R7).
2. Disconnect fuel pump connector. Fuel Pump Removal
3. Set multimeter to O and test circuit continuity 1. Remove fuel tank, see FUEL 7I4NK REMOVAL
as per following table. in this subsection.
FUEL PUMP POWER CIRCUIT CONTINUITY TEST 2. Use an appropriate screwdriver to carefully pry
PUMP out the tapered end of fuel pump retainer ring.
FUSE BOX HARNESS RE§$§gA'\g§E
CONNECTOR @ I6 Fl
Pin A-9 Pin B Close to O Q
If test failed, repair or replace the faulty wiring.

If test succeeded, wiring is good. Perform the
!
‘ “V.
FUEL PUMP CONTROL C/RCU/T CONT/NU/TY
TEST Ath-
if ~
0
Fuel Pump Control Circuit Continuity \ i
Test
2. Disconnect ECM connector "B" and install it on rmr2008-O22-021_a
the ECM ADAPTER TOOL (P/N 529 O36 166).

3. Remove and discard retainer ring.
4. Carefully pull out fuel pump paying attention to
float arm.
5290361 06
3. Set multimeter to Q and test circuit continuity

as per following table.
403
rmr201 1-072
3. index fuel pump tab with notch in fuel tank

.l')
and ensure pump and O-ring seal are properly
seated.
rmr20(J8-022-022
Step 1: Rotate pump backward .771’
Step 2: Pull our pump
5. Discard O-ring seal on pump module.

rrnr2OO5J022-(124_a
Fuel Pump Installation TYPICAL - PUMP INDEXING

1. Index tab with notch
Reverse removal procedure. However, pay atten-
tion to the following: 4. Install a new fuel pump retaining ring.
A WARNING A WARNING
install a new fuel pump ring seal and retainer Ensure retainer ring is properly seated and
ring. locked.
1. Install and hold a NEW ring seal against fuel 5. Turn ON ignition key to activate fuel pump and
pump flange. pressurize fuel system, then check for fuel
leaks. Refer to FUEL SYSTEM LEAK TEST
NOTE: Apply some oil on ring seal to ease instal-
lation. FUEL LEVEL SENSOR
2. Carefully insert pump in fuel tank; be careful not
to damage the float arm on the fuel level sen- Fuel Level Sensor Resistance Test
sor. I/I/Irh Digital Fuel Indication In Multifunction
Gauge
1. Remove the multifunction gauge (cluster), re-
fer to the LIGHTS GAUGEANDACCESSOR/ES
subsection.
2. Disconnect the multifunction gauge connector.
3. Set the FLUKE 115 MULTIMETER (P/N 529 O35
868) to Q selection.
4. Alternately fill and empty fuel tank, and mea-
sure the fuel sensor resistance through the
wiring harness as per following table.
rrn1200B—022-023_a
TYPICAL - PUMP RING SEAL INSTALLATION
404
rmr201 1-072
FUEL LEVEL SENSOR RESISTANCE TEST Continuity Test of Fuel Level Sensor
Wiring
RESISTANCE
FUEL LEVEL CLUSTER READING 1. Disconnect the fuel pump module electrical
CONNECTOR 21°C 00°F)AT COFIHGCTOF.
Empty pin 15 to Approx. 290 Q l/Vith Digital Fuel Indication in Multifunction

|:u|| chassis ground Approx 80 Q Gauge
2. l\/leasure for continuity of the wiring from the
fuel pump connector (FP) and the multifunction
gauge cluster connector (CL) as per following
table. Refer to l/V/RING DlAGRAMfor details.
CONTINUITY TEST OF FUEL LEVEL
SENSOR WIRING
RESISTANCE
PROBE CONNECTORS READING AT
21°C (70°F)
|:p_A CL-15 CIOSG IO 0 Q
(BU Wire) Chassis ground OL (infinite)

HOOTBOSGDOZJ
FP-D
CLUSTER CONNECTOR PIN our (BK Wire) Chassis ground Close to O Q
If resistance readings are not as specified, carry
out the CONT/NU/TY TEST OF FUEL LEVEL SEN-
SOR W/R/NG.
lf resistance readings are as specified, fuel level
sensor and harness wiring are good. Carry out a
WOW test of the multifunction gauge using appli-
cable B.U.D.S. Refer to LIGHTS) GAUGEANDAG
CESSOR/ES subsection. Check for proper opera-
tion of the fuel level indication during the WOW
test.
With Analog Fuel Gauge
1. Remove the analog fuel gauge connector lFG1). Q’
is?--w ...-- -
2. Carry out a fuel level sensor resistance test as
TEST PROBES rmr2 B08022-02 6_c
TYPICAL CONTINUITY TEST OF FUEL LEVEL SENSOR WIRING
I FG1 pin S I Chassis ground i 1. Cluster connector
2. Fuel pump module connector
FUEL LEVEL SENSOR RESISTANCE TEST
If resistance readings are as specified, refer to
FUEL LEvEL RESISTANCE READING
AT 21°C (WF) THE FUEL LEVEL SENSOR BENCH TEST
lf resistance readings are not as specified, carry
Empty Approx. 290 Q out continuity test at DIC1-D connector pin. Re-
Full Approx. 80 S2 pair or replace wiring and connectors as required.
NOTE: The DlCl connector is located between
If resistance readings are as specified, the fuel the air inlet resonator and the instrument console.
level sensor and it's wiring harness are good. Re-
fer to the L/GHTS, GAUGE AND ACCESSORIES With Analog Fuel Gauge
subsection. l\/leasure for continuity of the wiring from the fuel
If resistance readings are not as specified, carry pump connector (FP) and the analog fuel gauge
out the CONT/NU/TY TEST OF FUEL LEVEL SEN- connector (FG) as per following table. Refer to
SOR W/R/NG that follows. W/R/NG D/AGRAM for details.
rrnr2011-O72
405
Section D4 FUEL SYSTEM
CONTINUITY TEST OF FUEL LEVEL

SENSOR WIRING
_ f{""_!‘. !lI
RESISTANCE -;.lI t"
PROBE CONNECTORS READING AT
|:G1_S FF’-A
21°C (70°F)
Close to 0 Q
1r ‘ '. _ 3-fir)
I ..l
(BU Wile)
(BKFP-B
wire)
Chassis ground
Chassis ground
OL (infinite)
Close to O Q i'
l /‘ 2
li
ll
l,lIi;
llll.~
‘ll,
_-.
W’ E-
If resistance readings are as specified, refer to

FUEL LEVEL SENSOR BENCH TEST €.~N$5 H. i_-
If resistance readings are not as specified, carry
out continuity test at DIC1-D connector pin. Re- I\'~
pair or replace wiring/connectors as required. \ l
NOTE: The DIC1 connector is located between

the air inlet resonator and the instrument console.
rmr20! 1-0824105;
2 |
Fuel Level Sensor Bench Test 7. Full position
2. Empty position
1. Remove fuel pump module from fuel tank, refer
to FUEL PUMPin this subsection. If fuel level sensor fails bench test, replace the
2. Ensure the fuel level sensor is properly con- fuel pump module.
nected in the fuel pump module.
3. Measure the resistance at the fuel pump mod- FUEL PRESSURE REGULATOR
ule connector, pins A and D. The fuel pressure regulator is mounted to the fuel
FUEL LEVEL SENSOR BENCH TEST rail on the Ll—l side of the throttle body.
FLOAT ROTATIONAL The fuel pump pressure hose is connected to the
PROBE POSITION ANGLE RESISTANCE fuel rail on the RH side of the throttle body. It pro-
vides the full fuel pump pressure to both injector
Empty 0.0“ 290 1 3.5 Q fuel rails through an interconnecting port within
A to D
Full 85° 80 1 3.0 Q the throttle body.
The pressure regulator regulates the pressure
from the pump by bleeding away excess pres-
sure in the fuel rails and returning it to the fuel
pump.
406
rmr201 PO72
' “'52.
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rm r201 O-023-OO4__&
TYPICAL
1. Fuel pressure regulator TYPICAL - PURGE VALVE ACTIVATION IN B.U.D.S.
2. Filter Step 1: Select Activation page tab
3. Fuel return hose to fuel pump Step 2: Choose ECM page
Step 3: Click on purge valve icon
Fuel Pressure Regulator Test You should feel the solenoid within the purge
Refer to FUEL SYSTEM PRESSURE TESTin this valve operating.
subsection for testing procedure. If operation of the solenoid is felt when activated,
carry out the EVAP PURGE VALVE OPERATION
Fuel Pressure Regulator Replacement TEST
For replacement of the fuel pressure regulator, re- If solenoid does not function, carry out the EVAP
fer to FUEL RA/L REPLACE/‘l/lENTin the ELEC- PURGE VALVE SOLENO/D TEST
TRON/C FUEL /N./ECT/ON (EFI) subsection.
EVAP Purge Valve Solenoid Test
EVAP PU RGE VALVE 1. Disconnect the purge valve connector.
2. Connect small jumper wires to the purge valve
solenoid.
A
3. Momentarily connect the jumper wires to a re-
mote 12 Vdc battery.
rmr201 1-072-ODE_b
TYPICAL
7. EVAP purge valve
EVAP Purge Valve Test Using B.U.D.S.

l. Remove RH side panels as required to access
the purge valve. Referto the BOD Ysubsection. rmr2008-O21-070_a
TYPICAL
3. Using B.U.D.S. software, activate the purge If the solenoid does not function, replace it.
valve as per following illustration.
rmr2G11-072
407
ectlon 04 FUEL SYSTEM
If the solenoid functions, carry out the EVAP

PURGE V4LVE INPUT VOLTAGE TEST
EVAP Purge Valve Operational Test
1 Disconnect purge valve vacuum hose from the
throttle body
Cit
rmr2008-021-071
TYPICAL
3. Set pump to vacuum function.

4. Activate pump lever until vacuum reach the
specification. Air should not come through
rmr201 ‘l -072 006 c
the purge valve. Otherwise, replace the purge
TYPICAL - valve.
I Purge V8/V6 VECUUFTI /7086 8!“ I/TTOTT/8 DOCIY
2 Install the VACUUM/PRESSURE PUMP (P/N 529 345 kpa (5 P5|) for 1 minute
021 800) on the vacuum hose
Iv I‘ A
I _.
-Q JN
rrrir20lJ8-021-O7l_a
TYPICAL

6. Using the applicable B.U.D.S. software, ac-
tivate the purge valve as illustrated in EVAP
PURGE VALVE TEST USING B. U.D. S.
Air should now flow through the purge valve when
you apply vacuum with the hand pump. Other-
wise, replace the valve as it does not open when
the valve solenoid is activated.
rmr201 1-072
rmr 2005-02 ‘I 4')70_b

rmr200B-D21 ~O7'l_h
TYPICAL
TYPICAL
7. Remove the hand pump and reconnect the vac- If input voltage is as specified, carry out the
uum hose on the throttle body. PURGE VALVE CONTROL CIRCUIT TEST
8. Install all removed parts in the reverse order of If input voltage is not as specified, check fuse F12.
removal. NOTE: If fuse F12 is open, the starter solenoid
will not function either.
EVAP Purge Valve Input Voltage Test if fuse is good, carry out a PURGE VALVE INPUT
1. Disconnect the purge valve connector. C/RCU/T TEST ICONTINUITYI in this subsection.
2. Turn ignition switch to ON.
EVAP Purge Valve Input Circuit Test
3. Using a FLUKE 115 MULTIMETER (P/N 529 035 (Continuity)
868) set to Vdc, measure for input voltage at the
purge valve connector (EVAP) as per following 1. Remove main relay 1 (R7) in front fuse box to
table. remove power from the ECM, refer to POWER
DISTRIBUTION AND GROUNDS subsection. ,
2. Remove fuse F12 in front fuse box.
3. Disconnect the purge valve connector.
4. Set multimeter to Q and test for continuity of
the purge valve input circuit (12 Vdc) as per fol-
lowing table.
EVAP PURGE VALVE INPUT CIRCUIT
TEST ICONTINUITYI
l
EVAP PURGE
VALVE FRONT RESISTANCE
529035863
HARNESS FUSE BOX @ 20°C (68°F)
I CONNECTOR
EVAP PURGE VALVE INPUT VOLTAGE TEST
. . Close to O Q
PURGE VALVE SOLENOID
Pm 2 Pm A9 (continuity)
(HARNESS SIDEI MEASUREMENT
PROBE
Pin 2 (OR/GR) I Battery ground Battery voltage
rrnr2011~O72 409
l
2 ~ - - - >12»
rmr201 D-O23~DO5_8
TYPICAL — FRONT FUSE BOX PIN-OUT
If continuity is not good, repair or replace wiring

and connectors between fuse box and valve con-
nector. rmr200B-021-07 0_g
If continuity is good, carry out the EVAP PURGE

VALVE CONTROL C/RCU/T TESTin this subsec- If ground circuit is faulty, repair/replace wiring/con-
tion. nector.
4. Reinstall main relay 1 (R7).
EVAP Purge Valve Control Circuit Test
(Continuity) EVAP Purge Valve Replacement
1. Remove main relay 1 (R7) in front fuse box to EVAP Purge Valve Removal
DISTRIBUTION AND GROUNDS subsection. 1. Disconnect purge valve connector.
2. Disconnect "A" connector from the ECM and 2. Remove Oetiker clamps securing hoses to
connect it to the ECM ADAPTER TOOL (P/N 529
purge valve.
O36 166). REQUIRED TOOL
3. Set multimeter to Q and test for continuity of OETIKER PLIERS (P/N 295 O00 070)
the purge valve control circuit (ground) as per
following table.
EVAP PURGE VALVE CONTROL CIRCUIT TEST
EVAP PURGE
VALVE
ECM
RESISTANCE TM?» \\
HARNESS C°N',)'§,9TOR @ 20°c (68°F)
CONNECTOR 4,0!
. Close to 0 S2
Pm I M3 (continuity) /
295000070
410
rmr201 1-O72
rmr2008-O21-070_f
7. EVAP purge valve

2. Oetiker clamps
3. Pull hoses off valve.

EVAP Purge Valve Installation
1. Carry out a functional test of the purge valve
prior to installation using a remote 12 Vdc bat-
tery and the VACUUM/PRESSURE PUMP (P/N 529
021 800) as described in PURGE VALVE OPER-
ATIONAL TESTin this subsection.
2. Install purge valve with flow arrow pointing
away from the EVAP purge canister.
1
rrI\r2011-023-UO3_,lJ
1. Purge valve location
3. Secure hoses to the purge valve using NEW

Oetiker clamps.
4. Reconnect purge valve connector.
rn'ir2011-O72
411
Section 05 ELECTRICAL SYSTEM
Subsection 01 (POWER DISTRIBUTION AND GROUNDS)
POWER DISTRIBUTION AND GROUNDS

GENERAL
POWER DISTRIBUTION DIAGRAM
L — + RFB
STARTER
SULENUID
FUSEBDA
REGULATOR
RECTIFIER
CRIJSIA
mivwsmawuzu-~n
REAR FUSE BDX

S
MFI 40A
IGNITION
SWITCH LIGHTS wlweon
-,,---s~a TCM ' MF2 20A
f FRONTFUSE BOX : gLélgI5ER
nu:
1* IGNITION SPARE
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SWITCHES ILLUMINATION
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STORAGE CUVER ACTUATOR
MFP ->0A
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M A
HAZARD VCM ' MF6 MIA

SWITCH
ison
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FILnwa.M!’-licfi =sw= .m»<.e*

HEADLIGHTS HIILO
RELAY BEAM RELAY MG
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RADIO E
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REVERSE ACTUATOR SHEDDING
I TRAILER MODULE RELAY
CLUSTER
SUSPENSION RELAY
HEATED GRIPS
FOG LIGHTS
I2 V POWER
OUTLETS “URN
IGNITION COIL CAPS

INJECTURS CSV
FUEL PUMP
3
E33
'_".'I‘l' I\>—O E
S83
55$J>I}>l-Il>J>> nmqiw-nvmmwr xm—m n-am’ B‘l$Ui:I=rw~Ifl
PRE-STARTING RELAY
~fl'Bwvml_~!|‘1UHwIt'¢knR!<“Frm1‘—D\4u'¥§.<!)_IYm$£\>u=sz§¢Iin
.. ,. .. WI - . . at .3 omen SENSOR HEATERS
LOAD SHEDDING RELAY TURNS on AT sou RPM. EVAP
MAIN RELAY 1 TURNS arr APPROX. 40 MINUTES AFTER KEV OFF
MAIN RELAY 2 TURNS urr APPROX. so SEBUNDS AFTER KEY nrr.
rmr201 1-O734)D1_aeri
ri"nr2011-073 413
Subsection O1 (POWER DISTRIBUTION AND GROUNDS)
ACRONYM DESCRIPTION
BLS Brake lights switch
/
@
CAPS Camshaft position sensor
CSV Clutch valve solenoid
CTG Coolant temperature gauge
DLC Diagnostic link connector
DPS Dynamic power steering
ECM Engine control module rmo2010-001-1 D8,a
UNDER SEAT — PARTS REMOVED FOR MORE CLARITY

FG Fuel gauge
FSCL Front storage compartment light NO. DESCRIPTION
MSR Multifunction switch right Accessories (supplies fuses F6, F7, F8
MF1 40A
and F9)
PBS Parking brake switch
MF2 TCM valves (SE5 model) 20A
PRS Pillion rider (passenger) switch
MF3 Spare fuse 60A
SAS Steering angle sensor
MF4
l\/lain fuse (supplies fuses F1, F2, F3
TCM Transmission control module and F4) 40A
VCM Vehicle control module MF5 Dynamic Power Steering (DPS) motor 40A
WPM Windshield and parking brake module MF6 VCl\/I pump 4OA
YRS Yaw rate sensor Lights (supplies relays R6, fuse F5 and
MF7 30A
relay R8 control)
REAR FUSE BOX MF8 VCl\/I valves 25A
Rear Fuse Box Location The fuse box is a single bus bar type which feeds
The rear fuse box is located under the seat on the power to each fuse through its lower contact.
right side of the vehicle. Power comes either directly from the battery, or
from the voltage regulator/rectifier through RFB
in-line fuse.
The top contact receives power through the fuse
and distributes it to the subsystem, or compo-
nent
VOLTAGE
REGULATOR/RECTIFIER
FUSE
The voltage regulator/rectifier fuse (RFB, 60 A) is
on the voltage regulator/rectifier output wire.
RFB fuse is located near the starter solenoid. To
access, refer to BODYand remove LH rear side
rrrioZO10—O0l-013_a
paneL
7. Rear fuse box (master)
Fuse Identification
The rear fuse box contains the main fuses. They
protect the beginning of the circuits or high am-
perage components.
414 rmr201 1 -O73

Section O5 ELECTRICAL SYSTEM
1 — I
Fuse Identification
rrnr2OI ‘I-O73-0O2_B
1. Voltage regulator/rectifier fuse
FRONT FUSE BOX rrno2010-O01-109_a

TYPICAL
Front Fuse Box Location
The front fuse box is located under the RH plastic N°- DESCRIPTION
cover inside the front storage compartment. Direct battery power:
— Cluster (clock)
- D.E.S.S.
F1 — Diagnostic link connector (DLC) I5 A
Through ignition switch:
— Lights
Direct battery power:
- Main relays control
Through ignition switch:
4'1!!! - Steering angle sensor (SAS)
.
— Yaw rate sensor (YRS)
1;
4 F2 - Vehicle control module (VCM) IO A
— Engine control module (ECM)
rmr201 1-O73-D03_a
- D.E.S.S.
INSIDE FRONT STORAGE COMPARTMENT
1. Front fuse box - Pillion rider switch (PR8)
— Multifunction switch, right (MSR)
Front Fuse Box Pin Identification Direct battery power:
- Main relay 2 power
._L. Aid ______._g Through main relay 2:
E V; //,f_;:..:qri__L'_.:7;7'|.__ _.__._» _.-f_-at %‘\‘
— Windshield and parking brake module
""
I . . ‘ I, <(Iii (WPM)
I
. ._ . '1,I — Cluster (power)
»i'4 F3 - Fuel level gauge 25 A
A
-.23
‘en-. ;-E-r"-i :
-‘FY50-g-+1-I-'
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'f :'T‘f rl'1'i “»s-1-“i-‘o-‘ -I- ,-' €¢'~I4~'
4+‘-v .‘-Iv-I _-9 ,
~~J‘/. 4 i
VI NI’ -i -‘.¢-‘ - +-1—i- I-r‘-2-. 1-' rt-r -r=z-1 :¢~r-' for — Coolant temperature gauge
— Switches illumination
4!T‘IfT‘f?h
' Q1-1-. ‘i-1-I it - Diagnostic link connector (DLC)
If-+1-Ax-'-.-so-'-i-‘ >12 — Storage cover actuator l
I
l
rmrZO10-025-OO1_a - Transmission control module (TCM) I
FRONT FUSE BOX PIN IDENTIFICATION — Dynamic Power Steering control (DPS)
F4 Direct battery power: 15 A
— Cooling fan relay
rmr2011-073 415
NO. DESCRIPTION Relay Identification

¥,,~¢-\.t~~.t-I .......W; ~*
,,
F5 — Hazard switch 10 A
- Brake light switch
F6 Directbattery power: 15 A
— Radio
F7 — Reverse actuator 10 A
— Trailer module
— Horn
— Load shedding relay
F8 Through load shedding relay: 20 A
— Suspension relay
— Heated grips
— Fog lights rmo201&U01-109_b
F9 12 volt power outlets 10 A NO. DESCRIPTION
Through main relay 1: R1 Air controlled suspension
F10 — Engine control module (ECM) 5A
Through main relay 1: R2 Pre-starting
F11 — Ignition coil 15A R3 Main relay 2
- Fuel injectors R4 Cooling fan
Through main relay 1:
- Fuel pump motor R5 Load shedding relay
— H2OS (oxygen sensors) heaters R6 Headlight relay
F12 — Pre-starting relay 15 A R7 Main relay 1
- EVAP purge valve
— Clutch valve solenoid R8 Headlights high beam/low beam relay
— Camshaft position sensor (CAPS)
Relays
R E LAYS NOTE: The 4-pin relays can be inverted at 180° at
installation.
Relay Location Relay Activation
The relays are located in front fuse box.
RELAY ACTIVATION CONDITION
Main 1 _ _ _4
_ When turning ignition key to ON
|\/Iain 2
Load
Shedding When engine speed reaches 800 RPM
;!l'/X -'
I
11¢
rrnr20‘|1~U73-003__a
7. Relay location
416 rmr201 1-073

Relay Deacfivatiofl MAIN RELAY 2 ins) PIN IDENTIFICATION

RELAY DEACTIVATION CONDITION FUSE
FUNCTION BOX CONDITION
Main 1 Approx. 40 minutes after ignition key
PIN
has been turned to OFF Ill
Direct battery power
l\/lain 2 _ _ _ 12 V input
Approx. 30 seconds after ignition key at winding
Load has been turned to OFF From l\/IF4 then F2
shedding
Grounded by ECM B,
pin J2 with Key ON
I11 l\/lain relay 1 may be deactivated faster as follows: Control
— Turn ignition key to ON. Turns OFF approx. 30
— Connect vehicle to the latest applicable B.U.D.S. seconds after key OFF
software. Refer to COM/MUN/CAT/ON TOOLS
A/VD B.U.D.S. subsection. Direct battery power
12 V input
— In B.U.D.S., click the Read Data button. at contacts From l\/IF4 then F3
— Turn ignition key to OFF.
— After approx. 30 seconds, main relay 1 will be 12 V See PO WER D/STE’/BUT/ON
disabled and all its power-dependent devices will output D/AGF1‘/IM
be cut.
- B.U.D.S. may be disconnected as desired. LOAD EDDING RELAY (R5) PIN
IDENTIFICATION
Relay Pin Identification FUSE

MAIN RELAY 1 (R7) PIN IDENTIFICATION
FUSE 12 V input
Direct battery power
at winding
PIN From MF1, then F8
12 V. input
. B1 Direct battery power Grounded by Cluster, pin
at winding From l\/IF4 then F2 Control 1 when engine reaches
800 RPM
Grounded by ECM B,
A3 pin H2 with Key ON Direct battery power
Control 12 V input
Turns OFF approx. 40 minutes
at contacts From l\/IF4
after key OFF
12 V input Direct battery power 12 V output
See POWER D/STH/BUT/0/V
at contacts A1 y Frorn l\/IF4 D/A GRA/I/1'
12 V B3 See POI/I/EH D/STH/BUT/ON
output D/AGFIAM
rmr2011»O73 417
"v-Qm
GROUNDS
Ground Location
._ I . W I- ~/ -2.-
,;__g;~_;_.§:. W 3.:_6..;.,..
-
14; . {F l~ . ~.--~- E»? . - _.(§_' . ;~.,r»":~._-#.r.";,.__-1:->-»—
i tied12'.
I
it \§ '1 I 0 I r
ITII s_<1”->4
:2: »__=~ L
iv“-Ti , _ _ ,. ,* , -4 " ‘~ ' ' x a ' I,
_/'0
/_’/A we?
” 1 ‘Iii ‘;:li.__ ' I‘
.‘»
tt
.' flj.'.€,i. ~ I ~. -, ,_..____ _ ‘ 1: 1 -
;:.-_. O_ 01 '=+;7I.
A
’:~ In
1 .3;."L"~‘O" 3'.’ I: I
1 ______“
t -:__~d
i §\ ~- ._
I. "
‘if
.._ g
d‘
1
“.\ -Q4’
I
1 ‘
I N * I7“-I’ xi; “I
Ii‘: "- 2
7..-; 0
'*
% L
- ~
tr
4
' '°‘
“$~/~*
L »
rmr201 1—O7$Cl0S_a
J
x
&‘\‘. - -,~— r<'*.,-'i
REAR GROUNDS — RH SIDE OF FRAME, BEHIND REAR FUSE

‘TL. 1*" ' (.5-1-:1? W I BOX
1. Rear fuse box
2. Battery ground
‘IASi \"4r _w :P“~1“_T.Z’
‘iyi .I~"I__='é_;
3. Fuel tank ground
P1‘!-.-_.-0 V. i. >7
rmr201 1-073-O04_a
FRONT GROUNDS — LH FRONT SIDE OF FRAME, NEAR OIL

TANK
7. Oil tank
2. Wiring harness ground
3. Ignition coil ground
4. Engine ground
5. DPS (dynamic power steering) ground
"‘>..%y
rmr201 I-073—0D7__a
_,,_.?-LN. §n>- I -Ir.-- J;
ANTENNA GROUND — LH REAR SIDE OF FRAME, BEHIND
BATTERY
1. Battery
2. Antenna
3. Ground strap
4. Ground location
rmr201 1-073-OO5_a
ENGINE GROUND — RH SIDE OF ENGINE, UNDERNEATH

CLUTCH RELEASE COVER
1. Clutch release cover
2. Engine ground
418 rmr2011-073
Subsection 02 (WIRING HARNESS AND CONNECTORS)
WIRING HARNESS AND CONNECTORS

SERVICE TOOLS
CRIMPING TOOL (HEAVY GAUGE WIRE) .................................. .. 529 035 730 ....................................... .. 448
CRIMPING TOOL (KOSTAL) ........................................................ .. 529 035 909 ...................................... .. 445
ECM ADAPTER TOOL ................................................................. .. 529 036 166 ....................................... .. 442
ECM TERMINAL REMOVER 2.25 ............................................... .. 529 036 I75 ....................................... .. 442
ECM TERMINAL REMOVER 3.36 ............................................... .. 529 036 I74 ....................................... .. 442
KOSTAL DIE ................................................................................ .. 529 035 906 ....................................... .. 445

DELPHI TERMINAL EXTRACTOR ............................................... .. 12094429 ....................................... .. 444
TOOL ........................................................................................... .. AM P- ............................... .. 444-446
755430-2
HTIIZUII 074 419

Subsection O2 (WIRING HARNESS AND CONNECTORS)
GENERAL
The illustration in this subsection are typical. Several variants of the connector types, such as different
number of pin cavities, are used on the vehicle.
CONNECTOR ABBREVIATION DESCRIPTION

ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION
Adjustable Suspension
ACS Compressor FRF Front Right Flasher PICI
Panel Inter-connector
AUX Audio Connector FRH Front Right Heated Grip PIC2
BA Backup Actuator FRSI PL Licence Plate Light
Front Right Speaker
BLS Brake Light Switch FRS2 PRC Passenger Radio Control
CES Clutch Switch GBPS Gearbox Position Sensor PRS Pillion Rider Switch
CF Cooling Fan GND1 RBHL Right Bottom Headlight
Ground
CGT1 Coolant Temperature GND2 RCS Right Case Switch
CGT2 Gauge GPSI RDOI Radio
GPS Audio
CICI GPS2 RDL Right Daylight
CICZ Cargo lnterconnector GSC
Gear Solenoid Right Headlamp
Connector RHL
ClC3 HA Hood Actuator RHS Heated Grip Control
CL Cluster Parking Brake Light
HBS
Switch RLH Rear Left Heated Grip
DCI HIC Harness Inter-Connector RLSI
Rear Left Speaker
DCZ HN3 Horn RLS2
Accessories 12 V DC
DC3 H0281 RRH Rear Right Heated Grip
Oxygen Sensor
DC4 H0282 RRSI
Rear Right Speaker
DICI IK Ignition Key Switch RRS2
Right Tail Light
DIC2 Dashboard Inter-connector JMPI RTL (Brake, position and
Jumper turn signal lights)
DIC3 JMPZ SAS Steering Angle Sensor
DLC1 LBHL Right Bottom Headlight Suspension Position
SPS
Sensor
DLC2 Diagnostic Link Connector LCS Left Case Switch Suspension Release
SRS
Sensor
DLC3 LDL Left Daylight STSI
Starter Solenoid
DPS1 DPS Power LED Front Case LED STS2
DPSZ Power Steering LHL Left Headlamp TAS
Throttle Grip Position
Sensor
ECl\/IB Engine Control Module LPS Low Pressure Switch Transmission Control
TCM
Module
Left Tail Light
EOP Engine Oil Pressure Switch LTL (Brake, position and TCS Top Case Switch
turn signal lights)
FB Fuse/Relay Box MFBI VCM Vehicle Control Module
FCS Front Case Switch MFB34 VIMI Vehicle Immobilizer
Master Fuse Box Module
FG1 MFB56 VIM2 (theft protection device)
Fuel Gauge
FG2 MFB78 \/R Voltage Regulator
420 rmr201 1-O74

ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION

Front Left Flasher MSL2 Left Multifunction .
VSS1
Front Left Heated Grip MSL3 Switch VSS2 Vehicle Speed Sensor
Right Multifunction VSS4
MSRZ
Front Left Speaker Switch
OLS1 WM1 Adjustable Windshield
Brake Oil Level Switch
Fuel Pump OLS2 WM2 Motor
PBMI WPM Windshield Power Module
1i_-M Front Position Lights Parking Brake Motor
PBM2 YRS Yaw Hate Sensor
WIRING HARNESS ROLTING
-L
-..-r:_ .*/_ -
_{5'“-"
UNDERNEATH RH PASSENGER HANDHOLD

1 Secure cargo harness and passenger radio control wire to cargo base
2 Secure cargo harness to cargo base
3 Secure cargo harness and antenna ground to cargo base
421
.7’ .,
I
x .
;-'..». :,.fi'_:a
‘,;L.i,- .-:\_ \
'5,-,.- _'¢.__
\ -.1‘--'1“
__.
5 |'
.,.‘_ ‘J’7'
u _s If;
5‘
\
’ ":>I."
.~sZ*'
..
. ' v .. ‘ ' n. i‘.. '
i-' l 4-I.—.r i.‘L
-‘L-, ._ - j H it Y
J —
rrnr2011—D74»O13_a
UNDERNEATH RLH PASSENGER HANDHOLD

1. Secure cargo harness and antenna ground to cargo base
2. Secure cargo hamess to cargo base
‘ -
v.>|‘i Alt
._:,:,-;
, .
‘ L-
.~ "1 ~
rl'1\fZD1 1-074-014_a
INSIDE THE RH SIDE OF THE REAR CARGO MODULE

1. Secure sensor wire and opening cable of the top storage compartment
2. Secure top storage compartment sensor wire and RH storage compartment cable
422 rmr201 I-O74

.,‘
__i
3-— Yl_‘
rmf201‘l-O74-015_a
INSIDE THE LH SIDE OF THE REAR CARGO MODULE

1. Secure speakers and 12-Volt power outlet harness to top storage compartment
2. Clips (2x) retaining license plate light harness to top storage compartment
ID \__~‘&,‘
~€
---_~r-»»~»-M" ~-~—-‘ '-k
3.
._ , ,L;_;.;_|;‘
_ --
-< _'
-0 V Q
da-
.8J";
, Ir
T/T
ii. ..i
'-
IF
AI
rrr\r2lJ1‘l-074-016_a j _
UNDERNEATH THE REAR OF FRAME - CARGO MODULE REMOVED
1. Secure harness branch of MFB, VSS4 and OLS to battery support
2. Secure VSS4. OLS1 and OLS2 connectors together
3. Secure MFB and STS harness branches together
4. Attach SR5, LPS and BLS harness branch to brake reservoir hoses
5. Secure ACS sensor wire to ACS compressor retaining collar
rmr201 I-074 423

I
I IT . ‘tr?’-1";_I" JP». --
‘Fol _,-
T’,l?'!"' ‘
‘ I-’
—a
I”
£3‘-‘ '
14 ‘#:-
.en -.“ -
.- 2
rmr201 I-D74-DI 7_fl
LH REAR SIDE OF VEHICLE

1. Secure harness branch of MFB, VSS4 and OLS to battery support
2. Secure VSS4. OLS1 and OLS2 connectors together
3. Attach SRS, LPS and BLS harness branch to brake reservoir hoses
4. Secure ACS sensor wire to ACS compressor retaining collar
5. Insert rubber grommet into the external opening oft e frame bracket
._;.\
‘R T .. §.__ -. g
\:~ _
:- _—
__t E
-,,-_.-gun-nun-"“"‘“"""'_‘
.\_ 2'“
/E’
rmaoi 1-074-01 B_a

LH SIDE OF VEHICLE
1. Voltage regulator/rectifier wire
2. Secure voltage regulator/rectifier wire to LH fuel tank cover
3. Clip retaining voltage regulator/rectifier wire to frame bracket
424 rmr201 1-074

F
s
rm|10‘l1-(174-O19_a
LH SIDE OF VEHICLE — OIL TANK AREA
1. GBPS Wire
2. Clib retaining the GBPS wire to LH bottom platen
3. Attach GBPS and clutch servo hose together
4. Clips retaining GBPS wire around oil tank
rmr201 1-O74 425

--__
I
J
‘_===‘§2 Ina?»
'-‘S
I
€_I
.
wf ‘
K ... __
rmr201 H174-020_a
LH SIDE OF VEHICLE - BEHIND MIDDLE AND TOP SIDE PANELS
7. Secure GBPS and ignition coil wires to Ignition coil frame
2. Secure main harness, voltage regulator/rectifier wire and H0251 wire to LH lateral support
3. Secure switches harness, voltage regulator/rectifier wire and spark plug cables to LH lateral support
4. Attach switches harness, rear knock sensor wire and ECM wire together
5. Secure rear knock sensor and ECM wires to air intake silencer
6‘. Attach switches harness, rear knock sensor wire, ECM wire and CPS wire together
7. Attach rear knock sensor wire and CPS wire to front spark lug cable
8. Secure rear knock sensor wire and GBPS wire to breather goss-
9. Secure spark plug cables, GBPS wire and voltage regulator/rectifier wire to LH lateral support
426 rmr2011~074
.\ ’ .
_-1”
/we
,-
Anni
rmr201 1-074-0223
RH SIDE OF THE VEHICLE — LTD MODEL SHOWN

T. GPS harness (LTD model only)
2. Secure GPS hamess, H0282 wire, YRS/FP harness branch and coolant tank overflow hose to HH lateral support
3. Secure H0282 wire, YRS/FP harness branch and coolant tank overflow hose to RH lateral support
4. Secure main harness, coolant tank overflow hose and GPS harness to FlH lateral support
5. Secure H0282 wire, YRS/FP harness branch, coolant tank overflow hose, parking brake motor connectors and parking brake light
switch connector to RH lateral support
6. Attach hose and wire of purge valve with EVAP canister hose, YRS/FP harness branch and front knock sensor wire
rmr201 ‘I -O74 427

‘ 1
~. .-
'1»,
1.-<;.~;»-¢=1~.‘t<>_.
nun I
-pa
rmr201!-074-O2 'l_a
RH SIDE OF VEHICLE - BEHIND THE FRONT SIDE PANEL

1. Secure main harness, coolant tank overflow hose and GPS harness to RH lateral support
2. Secure main harness and coolant tank overflow hose to RH lateral support
3. Secure main harness, VIM wire and coolant tank overflow hose to RH lateral support
4. Attach RH headiight harness to frame
428 rmr2D1H)74
‘meg
I
*r~.
rrnr201 1-074-024_a
LH FRONT SIDE OF VEHICLE
1. Secure ignition switch wire on the top of frame
2. Secure all separated wires in the support
3 . Attach main hamess and multifunction switch wires_togeth_er
4 . Attach main harness, engine harness and multifunction switch wires together
5. Secure main harness to LH lateral support
rmr201 1-074 429

ll-
nu
rmr201 1-D74-O25_a
1. Secure main harness, voltage re ulator/rectifier wire and H025 7 wire to LH lateral support
2. Attach LH headlight harness to game
3. Clip retaining LH headlight wire to frame
4. Secure LED and DC7/DC2 wires to frame
5. Secure main harness to frame
430 :mr20n I-074

WIRING HARNESS SPLICE LOCATION
r /D‘.
V. A .7 ii ~ J) I 2
I
y
./'
As’
““"'
A’
'
6
1 . _/-‘ .- 1'
. ,.\
,,;o.
,__.»/ if
' I ‘=.'4"T'~\.
.\. ., /I \
\ \ ’
/' / -
‘AI. :;,_\/r/1‘ ‘
"I
\
/,_, :2 3 .
C
/_,
rmr201 14174-D1 1_a
rrnr20‘I1 O74 431

Vehicle Harness
rmr20i1-O74-O30_a I -V
REAR OF VEHICLE -— REAR CARGO REMOVED
/Ki
rmr201 1-074-031_a
RIGHT SIDE OF VEHICLE— NEAR AIR INTAKE SILENCER
432 rmr2011 O74

,/
DLCI
E‘
RBHL
rmr201 1-074~O32_a
RIGHT SIDE OF VEHICLE — BEHIND COOLANT TANK
‘,5.
ii
rmr201 ‘H174-0333
FRONT OF VEHICLE, RIGHT SIDE — FRONT STORAGE COMPARTMENT REMOVED
rmr20'I1-074 433
1 I I Z 1
rrr|r2U‘I 'I~D74-O34_a
FRONT OF VEHICLE, LEFT SIDE — FRONT STORAGE COMPARTMENT REMOVED
rmr201 I-074-035_a
FRONT OF VEHICLE, RIGHT SIDE — OVER DPS UNIT INTO DIAGONAL FRAME MEMBER
434 rrnr201I-O74
\ //
l Q
rrnr2U11-D74-036_a
FRONT OF VEHICLE, LEFT SIDE — OVER AIR INTAKE SILENCER
rmr201 ‘I -O7 4-D37_a
FRONT OF VEHICLE, LEFT SIDE — BESIDE AIR INTAKE SILENCER
rmr20I1 074 435

Cargo Harness
ll
\ 1.=~-
1
HRS1
“J ) SFf_BK7
- - SP BK8 I I—' U) _.
BEE . .%"" ' SPWH2 1
I I SVPTPK/BE
I ,* SPEK11 '
,
--~. _/" ‘V
4 Piv
\§_. _ .
SP LT GNIRD II U G _.
SP LT GNIGY3
-
Y.»
as;
i/ C ><
ca»-
iqll
no:c/an .""j51I"
1.‘
rmr201 1 -074-009_a
rmr201 1-074
Steering Harness
SP URIRD2
iiVt
(“Jon I.‘ SP Brim =- SP GN/WH
SP BK/VI
SPG Y/BEZ
PG
E
#5151-». ‘
nh'— ~ =
I G I-
D-
-p
T4“
E
a "TI I or IEE
Ii
I SP WH/BE5
.I.' FE
:3‘
LII II .
1| 1' D|C2
OJ Z Q
m 2011-D74-OIIJ B
rmr2011 074 437

PROCEDURES F K
WIRING HARNESS \' 1 A_
Wiring Harness Replacement Si Mk ‘ g, ' 1
The wiring harness is routed through the center of H ' Ar
the SSTTM frame. 1
#2,, ,.... 'w1VVI' Th’ .. .,... .
rddZO‘l1-O01-O25
Begin by taping all the connectors together flat

and lined up behind one another.
rdd2OI I ~0Ol -O23
It exits through the bottom rear of the SST frame.
rdd20'| 'I~DO'H)26_a
1. Upper frame member opening
Leave the pull through loop that is incorporated

____¢---—-1 into the harness exposed.
>?- -til
____.
rdd2011-001024
All these connectors need to be pulled through

the frame.
1dd2OI ‘l-001-U27
438 rmr2011 074

Snake a pull wire through the frame and loop it

through the pull loop. Secure the pull wire so it - _ --
does not come out of the loop. Spray the harness '
and top frame tube inside liberally with WD-40® or
equivalent.
Carefully pull the harness through the frame from
the front to the rear.
F1 BZOLA
_q-
TYPICAL
1. F/at screwdriver
2. Deutsch connectors
rdd2011{>O1-O28
DEUTSCH CONNECTOR
Deutsch Connector Identification
The Deutcsh connectors are easily identified by
the orange secondary lock inserted in front of the
female terminals.
3 + 1 FIBZUNA 2 1 y
= TYIZCAL h
?~
‘ :
41/
\ * _
1
J
3
*7 ,
I
$1 P;:eL.Jsl:€eI¢(a::aJ.;7e7%(i1t t£>Sri
Deutsch Terminal Replacement
NOTICE Do not apply dielectric grease on ter-
minal inside connector.
2 . .
To remove terminals from connector, proceed as
/'
so follows:
FDOH1CA
— Using a long nose pliers, pull out the lock.
. Male connector
Female connector
Secon da ry lock
:\F~>!\ “ Sealing cap
Deutsch Connector Removal

To disconnect the Deutsch connectors, twist a
small flat screwdriver between each housing to
disengage, press the release button and discon-
nect them.
rr1'l!ZQ11-D74 439
I
\ 1
,»_ .'
W "-‘ ‘i 1"' ' T4r",'; ‘,1
Ewli l"€ ‘J i’ "7";
/ I . , _' I 5 \ , .fi-I ‘:k- -

I T - " _- _».._ J,_____I........_.
I .‘.* . ‘ 7 _v ‘~
'- ‘TC ‘I T 1" “T” ._ I
I ~.
."I \‘ I; \ I
.L~% ~" . ‘; .
"T _i W I’
l\_.; I 4
“ »: ‘- . >'~' I‘
Aw _‘ M I O» L " ' -oi" l
. _ ' ;1
I KI ' 1 Q‘
I'__1’_ ("51 .. r * <-‘ ‘ I
i_
:4‘__“‘*7.
I-9-1
\ » ‘ I-I _ E‘
1- ‘- I‘ I '
I ;
~,~'i J§s.. i"_.
ii’...H s,_V_ '7. I‘§‘%‘;Ia!‘
it 3I'<—l:..
—~"SI
_.§_~.-=5 1
\\ “fir. “’ ' I an ,3
1
.(_H _
I _/ II‘
-.\, _H _ ‘ . 5.
I-7% I '
vutsucm 1
§r__“i 3».
'1L _
TYPICAL — FEMALE CONNECTOR
V01GOOA 1 1. Retaining tab
TYPICAL - FEMALE CONNECTOR To install;
7. Female lock
3. For insertion of a terminal, make sure the lock
is removed.
4. Insert terminal into appropriate cavity and push
as far as it will go.
5. Pull back on the terminal wire to be sure the
retention fingers are holding the terminal.
'4?‘
6. After all required terminals have been inserted,
the lock must be installed.
I ,_....~
-Lia __
_,..-_.._---_\
,
g
I."
-
-‘1
,_ P.-
V0‘lGOPA 1
TYPICAL — MALE CONNECTOR

1. Male lock
NOTE: Before extraction, push wire forward to re-

lieve pressure on retaining tab.
1. Insert a 4.8mm (.189in) wide screwdriver FDAHSLA I
blade inside the front of the terminal cavity.
TYPICAL
2. Pry back the retaining tab while gently pulling 7. Wire identification numbers
wire back until terminal is removed.
MOLEX CONNECTOR (ECM)
There are 2 connectors on the ECM. The engine
wiring harness connector is connected on the
ECM connector A and the vehicle wiring harness
connector is connected to the ECM connector B.
Each ECM connector has 48 pins.
440 rmr2D'I I-O74

Do not apply any lubricant product to the pins of

the connector on the ECM.
///i’\ 1/ r"
,i'
I /,
m
5mr2009-027-005
ECM CONNECTORS
MOLEX Connector Removal smr2009-O45-Cll 3_a
T h ECl\/I , f ELECTRON/C .
,_i°U,i;‘jaj’N,ECT,(§,§°,“,}‘Z‘;)“;Lb'§e§§§,.‘j_ MOLEX Connector Installation
Push and hold the locking tab of the desired con- FUIIV Open Connector I°CI<-
nector.
smr2009-045-O13_b
5mrZQQg.(]45.(]1'|_a C ” ” ” ' Install connector to ECM.

Rotate connector lock until it snaps locked.
Rotate connector lock until it stops.
SVTHZOOQ-045-O1Z_fl
srm’ZO09—D45-D1 1 _b
/ l
J’
Pull out connector. l~ L°¢'<@d hem‘
rmr2011-074
441
i i I M M — 1

I 1 3 t —
MOLEX Connector Probing

The most recommended and safest method to l
I
probe ECM connector terminals is to use the ECM
ADAPTER TOOL (P/N 529 O36 166). This tOOI WIII I I
prevent deforming or enlarging terminals which
would lead to bad ECM terminal contact creating
intermittent or permanent problems.
5290361 75
Remove rear protector from connector.

Pull out the connector lock.
529036166
Disconnect the desired ECM connector and re-

connect on the probing tool. Probe required
terminals directly in the tool holes.
Q‘
smr2OD9-O45025_a
-
Insert tool to unlock terminal.
vrr\r2UO8-I 39-01 6_a
TYPICAL
7. ECM connector
2. ECM adapter
Never probe directly on ECM har-

ness connector. This could change the shape
or enlarge the terminals and create intermit-
tent or permanent contact problems.
MOLEX Terminal Replacement smr2009—045-026_a
(Harness Connector) 7. Unlock here
To remove a signal terminal from ECM harness
connector, use the ECM TERMINAL REMOVER 2.25
(P/N 529 O36 175). To remove a power terminal,
use the ECM TERMINAL REMOVER 3.36 (P/N 529
036 I74).
442
rmr201 I D74
_~_
rmr200&O7B053_a
TYPICAL - TCM CONNECTOR
1. Retainer
2. Tab (one on each side)
12009045-U27_a
sm Cut locking tie securing connector housing to har-
A WARNING ness-
Before terminal installation, ensure all ter- Open housing by lifting 3 tabs.
minals are properly crimped on wires. After
plugging connectors, ensure they are prop-
erly fastened.
PACKARD CONNECTOR (TCM

AND GAUGE)
Packard Connector Removal
Firmly push down tab and hold to unlock connec - '0-‘*1
tor while pulling it out.
i_-.I"
rmr20D8~O7B-054_a
TYPICAL — TCM CONNECTOR
1. Tabs
Lift the top plastic lock of the female terminal to

be removed and hold in position. Lift the female
terminal to unlock from the housing and push out
of housing.
vm r2006-O32{>01_a
TYPICAL — GAUGE CONNECTOR
Packard Connector Terminal

Replacement
Push on both tabs to remove retainer.
rmr2011-O74
443
smr2009-D4501 5_a
A WARNING
Before terminal installation, ensure all ter-
erly fastened.
TYPICAL
1. Lift and hold plastic lock
AMP MULTILOCK CONNECTOR
2. Lift to unlock and push out
Connector Disassembly (Male
A WARNING Housing)
Before terminal installation, ensure all ter-
erly fastened.
DELPHI CONNECTORS (DPS)

__ ....
\
-i\~_,...
I
I*
Delphi Connector Terminal
Replacement
To remove a terminal from connector, use a spe-
cial tool such as the DELPHI TERMINAL EXTRAC-
TOR (P/N 12094429).
NOTE: Grinding the tool end to make it smaller is I
required.
_ I
k —- —-->_. _ ________‘ __‘ 1‘ .04 .
‘L AEHZOZIA . . .. . .. , .. .. .
Insert TOOL (P/N AMP-755430-2) under lock and

twist to lift it.
I 1
smr2OU9045014_a
1. Unlock terminal here
444
rmr201 1-074
ASZZOSA 1
FEMALE HOUSING — CUFAWAY

1. Lock
Terminal Crimping (Multilock and AMP

A3110“ 8-circuits)
'V'ALEH°U5'N‘3—CUT'AWAY To crimp a new connector terminal, use the
1' Lock CRIMPING TOOL (KOSTALI (P/N 529 O35 909) and
Female terminals can be removed from housing the KOSTAL DIE (P/N 529 035 906).
with sharp head pin.
Connector Disassembly (Female
Housing)
szsnesaos
CRIMPING TOOL
To properly crimp the wires, strictly follow this pro-

cedure.
Strip the wire to a maximum of 3 mm (1/8 in).
A32E2OA
A32Z04A
TYPICAL
A. 3 mm (1/8 in) max.
Insert TOOL (P/N AMP-755480-2) under lock and Position Wire in terminal
twist to lift it. '
Squeeze the terminal tabs with your fingers to
temporarily retain terminal in place.
rmr201 I-074 44 5
Z
{I
A3 3204A 1
A32E3YA
1. Lock
Insert TOOL (P/N AMP-755430-2) under tab and pry

Insert terminal with wire in crimping pliers and po- it to free connector. Pull on the female terminal
sition so that top of terminal tabs are flush with wire to remove female terminal from housing.
pliers edge or a little bit lower as shown.
Yr . I
'<'fiIDII'vv$ -< - r \- )
A33ZO5A 1
AMP 8-CIRCUIT CONNECTOR — CUTZAWAY

7. Tab
Terminal Crimping
Wt Refer to TERMINAL CR//l//P/NG (MULTILOCK
A32 EBZA
AND AMP 6’-C/RCU/7'S/ for procedure.
1. Top of terminal tabs
2. Align tabs with piiers edge
BOSCH CONNECTOR (VCM)
Crimp terminal. Ensure no tiny wire goes out of
terminal. This might cause strange problems of VCM Connector Removal
the electrical system.
A WARNING
AMP CONNECTOR (8-CIRCUIT) VCM motor and valves are continuously
powered from battery. Always disconnect
Connector Disassembly the battery prior to disconnecting VCM con-
Pry housing to release lock. nector.
NUTICE Improper connector handling may

lead to breakage.
Unlock the RED locking device.
446
rmr2011 074
VCM Connector Disassembly

Cut locking tie that retain the harness.
rmr2Cl11-0Z54326_a
1. RED locking device
Press the locking tab while pulling the locking

lever. rm|1011-025025
T T " i ' W T'»‘Z"’I1“““Cfi Slide the protective cover to unlock it.
rrnK201 1-025~D27_a
1. Locking tab
Pivot lock lever until it reaches the end of its rmr201 Hl2!'rD30_a
stroke. 1. Protective cover
Lift up the protective cover and remove it.
rmr201 1-025-02831 i
1. Lock lever fully open
Pull out connector.

VCM Connector Installation rrnr2(I11-O25-O31_a
Position the connector on the ECM. Step 1: Lift up the protective cover
Step 2: Tip up the protective cover to remove It
Pivot lock lever to the end of its stroke until you
hear a "click". This validates mechanism is prop- To Extract a Terminal
erly locked. 1. Remove the terminal cover.
Push on the RED locking device to secure the 1.1 Turn connector upside down.
locking lever.
rmr201 l-D74 447
1
1.2 Insert a small screwdriver, or any other W

similar tool, into a cover slot.
A32E2QA
A. 73mm (7/2/'n)
NOTE: Make sure not to cut wire strands while

stripping the wire.
Install the appropriate terminal on the wire ac-
cording to the requirement. Refer to appropriate
PARTS CA7I4LOG.
rmr201l-O25-032_a
7. Terminal cover . I
2. Terminal cover slot —',
1.3 Gently, pry out each corner to remove the

covet
2. Insert a small tool under tab and pry it to free _>
connector. Pull on the female terminal wire to
remove female terminal from housing. A32E2RA
INSTALLATION OF TERMINAL
Follow the instructions provided with the CRIMP-

ING TOOL (HEAVY GAUGE V\/IRE) (P/N 529 035 730)
to select the proper position of the tool.
,..~»___
‘- L _ . lYl|(k:->v>A . M, W
’_M__M _M___,__=,;2
. L.________k
' T’ '*'s__ _
529035730
rmfZ01 1-O25-0333!
.
1. Terminal unlock - ready to remove
NOTE: Different
.
wires require different crimp
.
pli-
2_ Termfflg//ggk-fgadyfg use ers settings, so make sure to follow the instruc-
tion supplied with the tool.
3. Remove the contact from the connector by
pulling on the wire attached to it.
BATTERY CABLE TERMINAL

Terminal Installation
Carefully strip the wire approximately to 13mm
(1/2in) in length, using a wire stripping tool or
sharp blade/knife.
448 rmr2(J11-O74
.r[ g Subsection 02 (WIRING HARNESS AND CONNECTORS)
NOTICE Never solder the wire to the termi-

nal. Soldering 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.
AIIZEZSA
POSITIONING THE CRIMP PLIERS

Step 1: Press
Step 2: Rotate
After positioning the crimp pliers, crimp the termi-

nal already installed on wire.
A32E2TA
CRIMPING OF WIRE
A32E2UA
PROPERLY CR/IVIPED 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.
rmr201 1-O74 449

45
Subsection03 (IGNITION SYSTEM)
IGNITION SYSTEM
SERVICE TOOLS
ECM ADAPTER TOOL................................................. .. ...... .. 529 036166 457
SERVICE PRODUCTS
HEAT-SINK PASTE P12 ................................................ .. ...... .. 420897186
GENERAL The ECM is programmed with data (ignition map-

pings) that it uses to provide optimum ignition tim-
A WARNING ing.
Torque wrench tightening specifications It receives signals from a variety of sensors that
must be strictly adhered to. tell it what the engine is doing and what are the
Locking devices when removed, must be operating conditions. It compares all the data it
replaced (e.g.: locking tabs, elastic stop nuts, receives with the ignition mappings and uses it
self-locking fasteners, cotter pins, etc.). to control the ignition spark timing, duration and
firing order to ensure optimum engine operation.
Hoses, cables or locking ties removed during a The crankshaft position sensor (CPS), the man-
procedure must be reinstalled as per factory stan- ifold absolute pressure sensor (MAPS) and the
dards. throttle position sensor (TPS) are the primary
A WARNING sensors used to control the ignition timing.
Never check for engine ignition spark from Engine RPM Limiter
an open coil and/or spark plug as spark may The ECM will limit the maximum engine speed by
cause potential fuel vapors to ignite. Always cutting off ignition spark and fuel at a predeter-
use an approved spark tester. mined engine RPM.
SYSTEM DESCRIPTION ENGINE SPEED LIMITATION ‘
9500 RPM
The engine management system (EMS) controls
the ignition system as well as many other engine
related functions. It can detect many abnormali- TROUBLESHOOTING
ties including an open or short circuit in the pri-
mary winding of the ignition coils as well as its as- It is good practice to check for fault codes using
sociated circuits. B.U.D.S. as a first troubleshooting step. Refer to
DIAGNOSTIC AND FAULT CODES subsection.
The battery supplies power to the primary side of
the ignition coils through a relay while the ECM Refer to POWER D/STR/BUT/ONAND GROUNDS
completes the circuit to each coil primary winding for fuses and relays information.
by switching it to ground at the appropriate mo- Always refer to the W/R/NG DIAGRAM when
ment. troubleshooting an electrical circuit.
With the primary coil circuits switched ON and NOTE: Install a battery charger on battery termi-
OFF by the ECM, the secondary coil circuits sup- nals (under seat) for any tests that involve a pro-
ply the high energy to fire the spark plugs as re- longed "key ON“ period. If battery voltage gets too
quired for proper engine operation. low, some accessories are shut off by the ECM
and test results can be altered.
Ignition 1"iming
NOTICE Never force a multimeter probe into
Ignition timing is not adjustable. an electrical terminal.
rrnr2011-075 451
Subsection 03 (IGNITION SYSTEM)
TROUBLESHOOTING 3. Multifunction gauge connector, and associated

GUIDELINES circuits
Lights or Gauge Do not Come on 4. Carry out an /GN/ T/ON SWl TC/—I OUTPUT I/OL71
AGE TEST (TO ECM).
when the Ignition Switch is Turned ON
1. Check battery and cables condition. Ignition Switch Output Voltage Test
2. Carry out an /GN/T/ON SWITCH OPERATION (to ECM)
TESTsee procedure in this subsection. 1. Remove front fascia and the LH headlight.
2. Disconnect ECM connector For connector
Misfires or no Ignition Spark on One identification, refer to W/R/NG HARNESS AND
or both Cylinders CONNECTOR subsection.
1. Check fuse F11 in front fuse box. 3. Connect ECM ADAPTER TOOL (P/N 529 036 166)
2. Check spark pluglsl, refer to SPARK PLUGSin on ECM connector
this subsection.
3. Check spark plug cablelsl, refer to SPARK
PLUGS CABLES in this subsection.
4. Carly out an ignition coil test with B.U.D.S. See
/GN/T/ON CO/LS in this subsection.
PROCEDURES
IGNITION SWITCH
Ignition Switch Operation Test 5290361 G6
Turn ignition switch ON. The following should

come on: 4. Set multimeter to Vdc.
- Multifunction gauge (assuming it works) 5. Turn ignition switch ON.
— LH and RH marker lights NOTE: Because of lights and accessories current
- License plate light consumption, a slight battery voltage drop is nor-
— Taillight. mal.
6. Measure voltage between pin A2 and ground.
If Nothing Came ON, Check the Following in
this Order:
1. The 40 A main fuse (MF4) in rear fuse box
2. Fuses F1 and F2 in front fuse box (both must
be blown for complete quick test failure).
Check voltage at MF4 fuse input terminal.
If there is no voltage at MF4 fuse input terminal,
check for an open circuit between b8IZ’[8l'Y and rear
fuse box.
I
If there is voltage at MF4 fuse input terminal,
check for an open circuit between MF4 fuse and smrZ009-O30-O10_d
fuses F1 and F2 in front fuse box.

If Lights Came ON but the Multifunction
Gauge did not, check the Following in this
Order:
1. Fuse F2 in front fuse box.
2. Check main relay 1 and related circuits, refer to
section.
452 rmr201 I -O75

IGNITION SWITCH OUTPUT VOLTAGE IGNITION SWITCH CONTINUITY TEST

TEST (TO ECM) IGNITION SW IGNITION SW
TEST PROBES OFF ON
TEST PROBES VOLTAGE
E A—G Infinite (OL) Close to O Q
C.I\é..C§En§g[Or Ground Battery voltage
B — F Infinite (OL) Close to O Q
If there is voltage at pin A2 with the ignition switch M — I Close to O Q Infinite (OL)
ON, check ECM input voltage from main relay 1 Any other pin
and ECM ground circuits, refer to ELECTRON/C Infinite (OL)
combinations Infinite (OL)
FUEL /NJECT/ON /EF/I.
If there is no voltage at pin A2 with the ignition A“ pl“
battery 1°
ground lnf'ini"t e (OL) Infinite (OL)
switch ON, isolate the open section of the circuit:
— Between MF4 fuse and F2 fuse The following gives the circuit functions through
— Between F2 fuse and ignition switch pin A ignition switch:
- Between ignition switch pin G and ECM. IGNITION SWITCH CIRCUIT FUNCTIONS
If no wire is open, carry out an /GN/T/ON SWITCH PINS CIRCUIT FUNCTIONS
CONT/NU/TY TEST
NOTE: Use B.U.D.S. to reset fault codes gener- A— G Ignition
ated when voltage check was carried out with B — F Lights
ECM adapter. M - l Ignition circuit to ground
Ignition Switch Continuity Test If you do not obtain the above resistance values,
Remove the ignition switch (refer to /GN/T/ON replace the ignition switch.
SWITCH REMOIAAL). NOTE: Replace ignition switch and D.E.S.S. mod-
Set multimeter to Q. ule as a unit.
Probe switch contacts as per table below and note
resistance values. Ignition Switch Removal
1. Remove console module, refer to BODYsub-
section.
2. Unhook latch cables (seat and front storage
compartment) and glove box lock cable.
~'E:&; -§‘§_ "',.->\\

v\l_ .TI§r~_,
ilr '
I K
rrrir2D08-02 3-503_a
4
rmr2010-026-D02_b
1. Latch and lock cables
3. Cut locking tie and slide ignition switch protec-

tor downwards.
rmr2011-O75 453
Subsection03 (IGNITION SYSTEM)
9. Turn ignition switch top cover counterclockwise

_ to unlock.
yin Y‘.-1;. 10. Pull out top cover.
_|_ i he
1: q
-"'1 Q.
rrnr2010-UZ6~OO2_C
4. Disconnect ignition switch main connector (at

switch).
5. Disconnect ignition switch antenna D.E.S.S.
COW HSCTO I’.
rmr2OClB-023-O10_a
TYPICAL
Step 1: Raise ignition switch
Step 2: Turn top cover
Step 3: Remove top cover
ll. Remove ignition switch.

Ignition Switch Installation
For installation, reverse removal procedures.
NOTE: Program new keys before completing in-
stallation. Refer to D/G/MLLYENCODED SECU-
R/TY SYSTEM (D.E.S.S.) subsection.
'm'*°'°"°2“"°°3—a Install latch cables and glove box lock cable on
1. D.E.S.S. antenna connector Switch as Show/n_
6. Remove ignition switch retaining screws.
'1! '
1 A
rmr201 U-026-0043
m1r201 04325-002,8
1. RH SIDE: To seat
2. CENTER: to glove box
s. /_.
7- Reta/”"”9 Screws 3. LH S/DE: To front storage compartment
7. Remove ignition key.
8. Raise ignition switch and hold in this position.
454 rmr2011-075
IGNITION COILS
Ignition Coil Access
Remove the following body panels, refer to BODY
subsection:
— LH top side panel
— LH middle side panel.
rmr201 1-02 d-OO6_b
1. Retaining nut
2. Ground cable
Tighten a NEW nut to specified torque.

IGNITION COIL RETAINING NUT
TIGHTENING TORQUE
1ON'm (89lbf'in)
rrni’2010-026001 _fl
TY,>,¢,_,_L V Ignition Coil Test with B.U.D.S.
2.7' 'g””’°”
Oil tank CO” In B.U.D.S., select the Activation and ECM tabs.
Energize the ignition coil for each spark plug alter-
nately by clicking on the coil illustration.
IvuQ I l-an I Mir-lav; >.--~ I inn
7'
m »--
1* * ’
gs" ‘vi Z‘fi\_.‘ #
._ :' 7*.-1-4:$.;“
¢rul'?¢1l1-
1y;""'j" ' '
ri-nr2D'l0-026005_a
1. Front ignition cojl
2. Rear ignition co/I
vmr2D06~D1B-100
TYPICAL NOTE: Ensure each coil spark plug cable is con-
nected to the appropriate cylinder.
gnition Coil Removal
1. Disconnect coil connector.
2. Disconnect spark plug wires.
3. Remove and discard retaining nut.
Ignition Coil Installation
At installation, install the ground cable at the loca-
tion shown.
rmr201 1-075 465

V
._ is +
93
. --IA
rn-K2008-062-O0 I _a
s!HrZO05-U57-01 E_a
1. To front cylinder spark plug
2. To rear cylinder spark plug TYPICAL
You should hear the spark occurring. If in doubt, If battery voltage is read, carry out an /GN/T/ON
use an inductive spark tester. C0/L RES/SMNCE T557?
NOTE: Keep in mind that even if there is a spark If voltage is significantly lower than battery volt-
during this static test, voltage requirement is age, measure voltage at fuse F11 input terminal
higher to produce a spark in the combustion in front fuse box.
chamber when the engine is running. The igni- If voltage reaches fuse F11, check for an open cir-
tion coil may not be working properly in actual cuit between fuse and coil connector.
operation. Replacing the ignition coil may be If voltage does not reach fuse F11, check the fol-
necessary as a test. lowing:
If spark occur, check spark plugs and spark plugs — An open circuit between main relay 1 and
cables. fuse F11.
If there is no spark, carry out /GN/T/ON C0/L IN- - Defective main relay 1 or related circuits, re-
PUT l/0L7ZlGE TESZ fer to POWER D/57'R/BU7'/ON AND GROUNDS
subsection.
Ignition Coil Input Voltage Test
Disconnect the ignition coil input connector.
Turn ignition switch ON.
Using a multimeter set to Vdc, read voltage as fol-
lows.
IGNITION COIL INPUT VOLTAGE TEST
TEST PROBES VOLTAGE
. Close to
Coil connector G d b
roun attery
pm 2 voltage I
rmr201 (J-O26-DO5_a
gnition Coil Control Circuit Continuity

Test
1. Remove key from ignition switch.
2. Remove MF4 fuse.
3. Remove front fascia and the LH headlight.
456 rm F201 1 -O75

4. Disconnect ECM connector "A". For connector

identification, refer to I/I//R/NG HARNESS AND
CONNECTOR subsection.
5. Connect ECM ADAPTER TOOL (P/N 529 O36 166)
on ECM connector
6. Set multimeter to Q.
7. Measure resistance between ignition coil con-
nector and ECM connector as per following ta-
ble.
rmr2008-O23-51B_a
TEST PROBES (IGNITION COIL) gE§é§g’?g3§§)

Pin 2 Pin 1
0.3 to 0.6 Q
Pin 2 Pin 3
If a resistance reading is not as specified, replace

the ignition coil.
lf resistance readings are as specified, carry out an
/GN/T/ON CO/L CONTROL C/RCU/TCON7’/NU/7')’
rmr201Cl-026-0IJ7‘a
TEST
IGNITION COIL GROUND CIRCUIT

Secondary Windings
CONTINUITY TEST Due to the integrated diode, it is not possible to
measure the secondary windings resistance.
Ignition coil ECM connector SPARK PLUG CABLES
connector pin 1 "A" pin M2 Close to O Q
Ignition coil ECM connector U089 to 0 Q Spark Plug Cable Resistance Test
connector pin 3 "A" pin M1 lnspect each spark plug cable condition. If cable
ends, sheath (insulator) or contacts are in poor
If resistance readings are high or infinite, check for condition, replace them.
an open circuit or parasitic resistance. If cables are in good condition, carry out a resis-
If resistance is close to O Q, try a new ECM. tance check as follows.
Disconnect each spark plug wire from the coil as-
Ignition Coil Resistance Test sembly and spark plugs.
An ignition coil with good resistance measure- Measure each cable resistance and compare to
ments can still be faulty. Voltage leak can occur following chart.
at high voltage levels which is not detectable with
an ohmmeter. Replacing the ignition coil may be CABLE POSITION CABLE RESISTANCE
necessary as a test. Front cylinder 5.11 to 8.72 kfl
Primary Windings Rear cylinder 3.24 to 5.53 kfl
Disconnect the ignition coil connector.
Using a multimeter, check resistance in primary If cables do not meet specifications, replace ca-
windings as follows. bles.
SPARK PLUGS
Spark Plug Removal
To access rear cylinder spark plug, remove LH top
side panel, refer to BODYsubsection.
rmr2011-075 457
To access front cylinder spark plug, remove RH SPARK PLUG GAP

top side panel and air filter cover, refer to BODY
and A/R /N7I4KE SYSTEM subsections. SPARK PLUG
MODE L-YEAR TYPE GAP
Disconnect the spark plug cable.
2010 DCPRQE
0.7 mm to 0.8 mm
Unscrew the spark plug one turn. (.028in to .031 inl
Clean the spark plug and cylinder head with pres- 0.8mm to 0.9 mm
surized air, then completely remove spark plug. 2011 DCPR8E
(.031 in to .O35in)
Troubleshooting Fouled Spark Plug Apply HEAT-SINK PASTE P12 (P/N 420 897 186) on
Fouling of the spark plug is indicated by irregular the spark plug threads and gasket to allow proper
running of the engine, decreased engine speed cooling of spark plug.
due to misfiring, reduced performance, and in-
creased fuel consumption. This is due to a loss
of compression. Other possible causes are: pro- -‘>1-
longed idling or low-speed riding, a clogged air
filter, incorrect fuel, defective ignition system, in-
correct spark plug gap, lubricating oil entering the
combustion chamber. The plug face of a fouled
spark plug has either a wet black deposit or a
black carbon fouling. Such coatings form a con-
ductive connection between the center electrode vrnr2008-O24-OD2_a
and ground. 1. Heat-sink paste here
Spark Plug Analysis Hand screw spark plugs into cylinder head and
tighten with a torque wrench and a proper socket.
§ ,
tr-=\ - - ».K.-I
t I I.
\ U K 1 . ‘. T 2
\ .§ \ /. _ 7 .
_'. ~-...-....---- M _. ..... -- ’|
§'| Y|,,“.n ,1’! ‘I-,, an-.-r 1'
\
I’, kr
\- 1 WE 2
ADDEOAA
TYPICAL
I 2 ”at.1’
1. Overheated ll/‘ghtgrey, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, grey, me/ted coating)
i"*r‘1 6”?)
The plug face reveals the condition of the engine, AOOEOBA
operating condition, method of driving and fuel 1. Proper socket

mixture. For this reason it is advisable to inspect 2. improper socket
the spark plug at regular intervals, examining the Torque spark plugs to 19 N'm (168lbf~in).
plug face (i.e. the part of the plug projecting into
the combustion chamber).
Spark Plug Installation
Using a feeler gauge to check electrode gap.
458 rmr20l1-075
Subsection 04 (CHARGING SYSTEM)
CHARGING SYSTEM
SERVICE TOOLS
FLUKE 115 MULTIMETER .......................................... .. .............. .. 529035868
SPANNER TOOL ......................................................... .. .............. .. 529 O36 223

EXTECH AIVIMETER ................................................... .. .............. .. model
380941
NAPA ULTRA PRO BATTERY LOAD TESTER ............. .. .............. .. 95260 ....................................... .. 464
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................. .. .............. .. 293 550 O04
GENERAL
A WARNING -.__ '

. I fir I
Locking devices when removed, must be I 0 ,
replaced (e.g.: locking tabs, elastic stop nuts, r
self-locking fasteners, cotter pins, etc.).

.§' ~
Hoses, cables or locking ties removed during a .*-(“iii
dards.
SYSTEM DESCRIPTION
vmrZOO6-O17-O01
The purpose of the charging system is to keep TYPICAL
the battery at a full state of charge and to provide
the electrical system with the required electrical Voltage Regulator/Rectifier
power for normal vehicle operation. The voltage regulator/rectifier receives AC current
Magneto from the magneto and transforms it into direct cur-
rent (DC).
The magneto is the primary source of electrical
power. It transforms a magnetic field into an al- The direct current is then supplied to the battery
ternating current (AC). for charging and to the vehicles systems through
a 60 A fuse.
The magneto has a 3 phase delta wound stator.
The magneto is capable of 52 amperes. The voltage regulator/rectifier limits voltage to
prevent damage to electrical components.
rmr201 1-076 459

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5. Check static battery voltage. It should be min-

imum 12.6 Vdc.
NOTE: A voltage above 12.6 Vdc indicates a su-
perficial charge. A voltage lower than 12.6 Vdc in-
dicates a bad state of charge. If voltage is lower
I than 12.6 Vdc, completely charge battery before
continuing.
6. Start engine.
#:451- lg;-.
;‘ .<“*- 7. Load the electrical system by turning ON:
— Headlights on high beam
rmr201 0-027-U04
TYPICA L — VOLTA GE REG ULATOR/RECTIFIER

— Front heated grips to high.
NOTE: During the test, do not turn the handlebar
Battery or activate any other accessories. Make sure the
The battery supplies DC power to the electric cooling fan does not turn ON.
starter for cranking the engine. During engine 8. Read voltage.
starting, it also supplies DC power to all the Voltage should be within following specification.
electrical and electronic systems. At low engine
RPM operation and high current load conditions, OUTPUT DC VOLTAGE TEST
it supplements the magnetos output if required, TEST ENGINE SPEED VOLTAGE
and helps to maintain a steady system voltage.
4000 RPM 13.0 - 14 Vdc
INSPECTION If voltage is within specifications, complete in-
spection with the DC CURRENT OUTPUT TEST
CHARGING SYSTEM OUTPUT If voltage is significantly above specification, re-
DC Voltage Output Test place voltage regulator/rectifier.
1. Open seat for access to battery chassis ground NOTE: If voltage exceeds 16 Vdc, the RED bat-
and the battery positive (+) terminal at the tery indicator light will come on in the multifunc-
starter solenoid. tion gauge and the HIGH BATI VOLT fault mes-
sage will be displayed.
2. Remove RED rubber protector from battery (+)
terminal. lf the voltage from the battery does not increase,
or drops, turn engine OFF and check the follow-
868) to Vdc scale. ing:
— Both connectors are properly connected to volt-
4. Connect multimeter between the battery age regulator/rectifier.
ground post and the battery (+) terminal at - 60 amp regulator/rectifier fuse (RFB) near
the starter solenoid. starter solenoid, refer to POWER D/STR/BU-
T/ON AND GROUNDS subsection.
— Connections at RFB fuse, the starter solenoid,
and the magneto output circuit ground to see if
they are loose, corroded or show signs of over-
heating.
NOTE: The magneto output circuit ground is di-
rectly on the negative battery post.
If rectifier fuse, voltage regulator/rectifier connec-
tors, and other connections are in good working
order, carry out a VOLTAGE REGULATOR/RECTI-
F/ER I/I//R/NG TEST (OUTPUT S/DE/.
rrnr200B-024-006_a
TYPICAL — OUTPUT DC VOLTAGE TEST AT BATTERY

DC Current Output Test
This test should be carried out as a complement
to the DC voltage output test.
460 rmr201 I -076
NOTE: Test vehicle under normal operating loads, OUTPUT DC CURRENT TEST
no additional accessories turned on. Do not turn
handlebar, this would significantly increase cur- TEST ENGINE SPEED CURRENT
rent load. If vehicle engine is allowed to get 4000 RPM Minimum 10 A
hot enough, radiator cooling fan will come ON in-
creasing current load by approximately 7 amperes If current reading is significantly below specifica-
above the referenced specification. tion, do the following:
- Check stator wires (YELLOW) and terminals at
Most multimeters have an ammeter
voltage regulator for damage.
function capable of reading only 10 amperes in
series. Normal current load on this magneto - Test stator, refer to MAGNETO AND S7I4RTER
system is above this value and increases with subsection.
additional loads. Use an inductive ammeter — Carry out VOLTAGE REGULA TOR/RECT/F/ER
capable of measuring over 20 amperes of cur- W/R/NG TEST /OUTPUT S/DE) in this subsec-
rent. tion.
NOTE: A current above specification indicates a
1. Remove the following body panels, refer to charging system working harder than expected
BODYsubsection: because of a weak battery or an electric device
— LH mirror turned ON.
- LH wind deflector
- LH middle side panel TROUBLESHOOTING
It is good practice to check for fault codes using
2. On the voltage regulator/rectifier unit, locate the B.U.D.S. software as a first troubleshooting
the connector with the RED/BEIGE wire. step. Refer to D/A GNOST/C AND FAULT CODES
3. Pull back the protective sheath covering the subsection.
wires approximately 3cm (1.25in). Refer to POWER D/S TR/BU T/ONAND GROUNDS
4. Clamp an inductive ammeter such as the EX- for fuses and relays information.
TECH Al\/(METER (P/N MODEL 380941) over the Always refer to the W/R/NG DIAGRAM when
RED/BEIGE Wire of the voltage regulator/recti- troubleshooting an electrical circuit.
fier unit.
Install a battery charger on battery terminals (un-
der seat) for any tests that involve a prolonged
"key ON" period. If battery voltage gets too low,
some accessories are shut off by the ECM and
test results can be altered.
an electrical terminal.
TROUBLESHOOTING
GUIDELINES
Weak or Discharged Battery
If the battery is weak or discharged, check the fol-
rm r2008-024-002 _a lowing:
TYPICAL - OUTPUT DC CURRENT TEST — High key off current draw. Normal current draw
1. Voltage regulator 2 wire connector
2. BLACK wire should be 10 to 20 mA. For 2011 models, a cur-
3. Arnmeter clamp on RED/BE/GE wire rent draw of 350 to 500 mA is normal for the
first 40 minutes after key off.
5. Start engine.
- D.E.S.S. still in programming mode. Complete
6. Read current. key programming, refer to KE)’Sin D/G/TALL)’
ENCODED SECUR/T)’ SYSTEM (D.E.S.S.) sub-
section.
- Check regulator/rectifier fuse (RFB) near starter
I
solenoid.
rmr201 1-076 461
Subsection O4 (CHARGING SYSTEM)
— Check battery and connections. Refer to BAT-

TER)’in this subsection. .-~' I
\
T
.
.
— Check items in LOW OR NO C/-/ARG/NG SYS-

.r rd ‘---\‘i I - . L]
TEM VOLTAGE. / ‘ .'
— Check charging current output, refer to /N- -_ - . . _ I‘ V _ -~
SPECT/ONin this subsection. ‘\__ '

T?
'___/‘ign _ "_j a
T‘ ' L L i ‘-'.\. '
U
I
.,, ‘J _ - , C \
Low or No Charging System Voltage

If charging system voltage is low, the engine may , I‘!
,4- ‘“‘1i .. .44 ' ‘-,5-‘Q
-C»;-1r. .- , I -
\1
be unstable, or stall. :_i2 '
.
\-t4___//;
\'\‘.
Test the following items: . i. II‘ .4-‘. I I ' 7.
rmrZO10-O27-U01_a
- Regulator/rectifier fuse (MF3) in rear fuse box UNDERNEATH LH LATERAL SUPPORT
— Charging system voltage, refer to /NSPECT/ON 1. Regulator/rectifier
in this subsection. 2. 2 wire connector
— Test stator, refer to MAGNETO AND STARTER 3. Set multimeter to Vdc.
subsection. 4. Connect multimeter as per following table to
— Wiring and connections, refer to VOLTAGE test the DC output wire.
REGULATOR/RECT/F/ER in this subsection.
VOLTAGE DC OUTPUT WIRE TEST
Repetitive Blown RFB Fuse PROBES VOLTAGE
The possible causes for a repetitively blown RFB P" 1 .
are: (RE[')nWire) ICIWEISSIS ground Battery voltage
— Voltage regulator/rectifier internal circuit
shorted to ground. If voltage is NOT as specified, repair wire or con-
— DC output (RED) wire shorted to ground. nector.
Refer to VOLTAGE REGULA TOR/RECT/F/ER TEST If voltage is as specified, check ground wire as per
FOR BLOWN RFB FUSEin this subsection. following table.
GROUND WIRE TEST
PROCEDURES
PROBES VOLTAGE
VOLTAGE REGULATOR/ P' P’ 1
RECTIFIER (BLACHKIF/vire)I (REDnwire) Ba“e“"’°"a9e
Static Test If voltage is NOT as specified, repair wire or con-
Due to internal circuitry, there is no static test nector.
available. NOTE: A conventional test light can be used to
check wiring. It should light brightly indicating
Voltage Regulator/Rectifier Wiring Test there is no parasitic resistance in the circuits.
(Output Side)
Voltage Regulator/Rectifier Test for
BODYsubsection:
Blown RFB Fuse
— LH mirror 1.Disconnect the voltage regulator/rectifier
- LH wind deflector 2-wire connector.
— LH middle side panel
2. Disconnect the two wire connector on the volt-
age regulator/rectifier.
462 rmr201‘) 076

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rmr201 0-027-001_c
UNDERNEATH LH LATERAL SUPPORT

m-"2008-024-0D4_a
1. Mounting screws
2. Regu/ator/rectifier
VOLTAGE REGULATOR/RECTIFIER
1. 2-wire connector 4. Install the new regulator in the reverse order of
2. Install a new fuse. removal.
If the fuse still burns, check for a shorted wiring 5. Torque voltage regulator/rectifier mounting
or connector pins. screws to 7 N~m (62 lbf-in).
If fuse does not burn, replace regulator/rectifier. 6. Carry out a voltage regulator/rectifier output
voltage test to confirm proper operation of the
Voltage Regulator/Rectifier new unit.
Replacement 7. Install removed body panels.
The voltage regulator/rectifier is located at front of
the LH lateral support. BATTE RY
1. Remove the following body panels, refer to the Battery Information
BODYsubsection:
These vehicles are equipped with a VRLA battery
- LH mirror
(Valve Regulated Lead Acid).
— LH wind deflector
It is a sealed, maintenance-free, non-spillable
- LH middle side panel type battery that is mounted on its side in the
— LH top side panel. battery rack located behind the LH rear body
2. Disconnect the two connectors attached to the paneL
voltage regulator/rectifier. Refer to the battery manufacturer's instructions
for proper charging procedures.
£. flT/-‘,-/ 1
Battery Voltage Test (No Load Applied)
...">i NOTE: An voltage test is carried out on a battery
\w"/I’; w- ‘ /’ - without discharging current. It is the simplest and
.1.
‘I
2
most commonly used. However, be aware that a
voltage test can indicate that the battery is good
even though the battery does not have enough
power to crank the engine.
A voltage reading provides an instant indication of
the state of charge of the battery, not of it's cur-
rent output capacity. A load test gives a more ac-
rrrir2U1C~027001_b curate indication of the battery's condition.
UNDERNEATH LH LATERAL SUPPORT If the battery has just received a charge, allow it to
1. Regu/ator/rectifier
2. Connectors rest for 1-2 hours before taking a voltage reading.
3. Remove the two mounting screws securing the Set multimeter to Vdc and connect to battery ter-
regulator to the lateral support. minals. Always respect polarity.
rmr201 1-076 463

BATTERY VOLTAGE TEST (NO LOAD) l BATTERY LOAD TEST

FULLY CHARGED BATTERY VOLTAGE TIME TO MEASURE
12.6 Vdc minimum
INTO TEST VOLTAGE
Minimum 10 Vdc
NOTE: A battery that shows a voltage of 12.0 Vdc 5 seconds (load applied)
is considered completely discharged and need to
be recharged. If battery voltage has dropped below 10 Vdc, bat-
tery output capacity has decreased appreciably
Battery Load Test (Engine Cranking) and battery should be replaced.
Battery must be fully charged, refer to BATTERY NOTE: Note, before replacing the battery, make
VOLTAGE TEST /NO LOAD APPL/ED). sure the charging system is in good condition.
1. Set multimeter Vdc and connect it to the bat-
tery.
Battery Removal
2. Measure battery voltage at rest. 1. Open seat, detach gas shock and support seat
slightly higher to allow more room.
3. With the multimeter still connected, crank en-
gine with throttle fully open to initiate "drown 2. Remove the battery access panel. Disconnect
mode" (prevents engine from starting) while pillion rider switch and rear heated grips switch
reading multimeter. if applicable.
A WARNING 1-1
While using drown mode to prevent engine
starting, always release START button before
throttle.
IQ
er. - .__?___':__-T»
rl .
f
Assuming the starting system is in good condi-

tion, a battery voltage that drops below 10 Vdc a
worn—out or defective battery. T '.
NOTE: Note, before replacing the battery, make
sure the charging system is in good condition.
-L . ..,.__ »..,-—
BATTERY LOAD TEST f1T1lZO'ID—O27~OO3_3
BATTERY VOLTAGE WHILE CRANKING 1 - Batte W access Panel

2. Battery access panel retaining screws
10 Vdc minimum 3. Rear heated grips switch
NOTE: Some models are equipped with an audio

Battery Load Test (Using a Battery input jack. To detach it from the cover, un-
Load Tester) screw the retaining ring using the SPANNER TOOL
This is the best test to determine the battery con- IP/N 529 036 223).
dition. Use a load testing device such as the NAPA
ULTRA PRO BATTERY LOAD TESTER (P/N 95260). It
has a 500 Amp carbon pile adjustable load.
Battery must be fully charged.
1. If battery has just been recharged, allow battery
to rest for at least one hour.
2. Follow battery load tester instructions.
3. Apply a load of 150 amperes. At 5 seconds into
the test, check battery voltage.
529036223
464 rmr201 1 O76

7. Lift the leading edge of the battery and carefully

pull it out of the battery rack.
Battery Cleaning
With the battery removed from vehicle, clean the
battery rack, cables, battery casing and posts us-
ing a solution of baking soda and water.
Remove any corrosion from battery cable termi-
nals and battery posts using a firm wire brush.
rsl2U104J94017_a
Rinse with clear water and dry thoroughly using
A UDIO INPUT JACK a clean cloth.
1. Retaining ring
Apply a light coat of DIELECTRIC GREASE (P/N 293
3. Refer to BODYand remove rear side panel. 550 004) on terminals.
4. Disconnect the BLACK (-) negative battery ca-
ble first. Battery Inspection
NUTICE Always disconnect the NEGATIVE (-) Visually inspect battery casing for cracks or any
cable first. other damage. If casing is damaged, replace bat-
tery and thoroughly clean battery rack with a wa-
ter and baking soda solution.
‘H J’
.1-4-6' 2 "__'_
._
lnspect battery posts, connectors, battery rack,
battery holding strap and strap attachment points.
a--""f';»—i
Battery Storage
“'\
It is not necessary to remove the battery during
vehicle storage but is recommended for long term
storage.
-.1
Recharge the battery once a month with an ap-
proved battery charger as per manufacturer's rec-
ommendations.
rrnr2U10-O27-002_a
Clean battery, battery rack and connections as re-
1. Battery
quired, refer to BA77'EHY CLEAN/NG in this sub-
2. Front of vehicle section.
3. Negative battery terminal
For other recommendations during storage, refer
5. Pull back the RED rubber protector on the posi- to the battery manufacturer's instructions.
tive (+) battery post, then disconnect the cable.
6. Remove battery holding strap, then move bat-
Battery Installation
tery towards rear. 1. Insert battery in battery rack.
2. Push battery fully in; leading edge of battery
’___________,_.._. rack will clip over the lower edge of battery.
3. Install battery holding strap.
if-""=-‘"1 NOTICE Always connect RED (+) cable first
then BLACK (-) cable.
—\
4. Connect the RED (+) positive battery cable. Po-
sition the RED protective rubber boot over the
_'_;~* .11
contact.
5. Connect the BLACK (-) negative battery cable.
I at E A
6. Install all removed panels.
‘-11
rrr\r201(}027-002_b
7. Battery holding strap
2. Battery
rmr201 1-076 465

Subsection O4 (CHARGING SYSTEM)
Z
Battery Main Ground Connection

Refer to POWER D/$77?/BUT/ONAND GROUNDS
subsection for vehicle grounds location.
Ensure all ground connections are clean, tight and
free of corrosion.
Battery Positive Connection
A (+) sign can be seen on the LH fuel tank cover.
This identifies the battery terminal (STS3) on the
starter solenoid. This terminal is accessible (along
with the battery ground) primarily for jump start-
ing. A second wire from the battery (+) terminal
is connected to the end of a bus bar in the main
fuse box for power distribution.
Ensure cable connections are clean, tight and free
of corrosion.
466 rmr201 I -O76

Subsection 05 (STARTING SYSTEM)
STARTING SYSTEM
SERVICE TOOLS
FLUKE I15 MULTIMETER .......................................... .. ...... .. 529 O35 868
GENERAL - D.E.S.S. recognizes the key

- Start button pressed in.
SYSTEM DESCRIPTION NOTE: If the transmission was left in reverse
Starting System Operation or any forward gear when the engine was shut
off, the starter will crank the engine when the
SEQUENCE or OPERATION start button is pressed. Commended by the
Start button sends a ground signal to the
TCM (transmission control module), the HCM
I
ECM and pre-starting relay (hydraulic control module) will automatically shift
the transmission to neutral during the engine
Pre-starting relay provides battery voltage start when there is sufficient oil pressure to do
2 to the starter solenoid coil so. Having the parking brake set will not affect
ECM provides ground to the starter solenoid co engine cranking, the normal brake pedal must be
depressed for engine cranking if the transmission
If the start button is activated when engine speed is not in neutral.
is above I400 RPM, engine cranking will not be
allowed. In other words, if the engine is running, TROUBLESHOOTING
no cranking will take place.
If the start switch is activated while the throttle is TROUBLESHOOTING TIPS
opened more than 60°, the engine will not be al-
lowed to start but the starter will crank the engine It is good practice to check for fault codes using
(engine drowned mode). B.U.D.S.as a first troubleshooting step. Refer to
COMMUNICATION TOOLS AND B.U.D.S. sub-
Engine Cranking Conditions section.
Refer to POWER D/STR/BU 7'/ONAND GROUNDS
SM5 Model for fuses and relays information.
The following conditions must be met to allow en- Always refer to the W/R/NG D/AGRAM when
gine cranking: troubleshooting an electrical circuit.
- Transmission in neutral (or in gear with clutch
lever depressed) Install a battery charger on battery terminals (un-
— Ignition switch ON
— Engine stop switch to RUN test results can be altered.
- l\/lode button pressed in once (safety message
acknowledgement) NOTICE Never force a multimeter probe into
- D.E.S.S. recognizes the key an electrical terminal.
- Start button pressed in.
STARTING SYSTEM
SE5 Model TROUBLESHOOTING
The following conditions must be met to allow en-
gine cranking: If the gauge or lights do not come on when igni-
tion switch is ON, refer to TROUBLESHOOT/NG
- Ignition switch ON in /GN/T/ON SYSTEM subsection.
— Engine stop switch to RUN
If gauge and lights come ON with the ignition
— Mode button pressed in once (safety message switch ON and starter does not engage, start
acknowledgement) your testing sequence by carrying out SMRTER
— Transmission in neutral (or in gear with the OPERAT/ON TESTin this subsection.
brake pedal depressed)
rmr201 1-O77 467

Refer to the following list for possible causes: A WARNING

T F12 fuse , While using drown mode to prevent engine
— Battery or connections (refer to CHARGING starting, a|WayS re|ease Start button before
SYSTEM throttle.
— D2 diode
— Start button The starter should rotate smoothly.
— Engine stop switch If the starter does not run smoothly, refer to the
— Starter solenoid MAGNETO AND STARTER subsection.
— Clutch engagement switch (SM5 model) If the starter does not rotate or rotates slowly,
— Gear position sensor (SM5 model) carry out a STARTER INPUT VOLTAGE TEST
— D.E.S.S.
— Brake light switch (SE5 model if transmission Starter Input Voltage Test
in gear) I. Remove the RH top side panel and air filter
— Electrical cables/connections cover, refer to BODYand A/R INTAKE SYSTEM
— ECM. subsections.
If fuse F12 continuously blows, isolate the follow- 2. Set multimeter to Vdc.
ing components to determine the source of the 3. Measure voltage at starter terminal while crank-
short circuit: ing engine with the throttle fully open to initiate
— Pre-starting relay "drown mode" (prevents engine from starting).
— Starter solenoid
— Heated oxygen sensors
A WARNING
— EVAP purge valve While using drown mode to prevent engine
starting, always release Start button before
— Fuel pump throttle.
- D2 diode
— Clutch solenoid valve NOTE: Battery voltage will drop and fluctuate
— Camshaft position sensor. with starter cranking load.
On SM5 model:
— If starter cranks only with the clutch lever de-
pressed, verify the GBPS (gearbox position sen-
sor) and its circuits. Refer to GEARBOX sub-
secflon.
— If starter cranks only in neutral, carry out the
CLUTCH SWITCH CONTINUITY TEST in this
subsection. 4.
PROCEDURES
BAT
ELECTRIC STARTER
Starter Operation Test rm V2008-025-001 _a
Before testing, make sure the battery is in good

condition and fully charged. If there is no voltage at the starter terminal, check
Start button and Stop button using B.U.D.S. See
I. Apply parking brake. procedures in this subsection.
2. Carry out a normal start with throttle fully open If voltage is low, carry out a STARTER CABLE
to initiate "drown mode" (prevents engine from VOLTAGE DROP TES T.
starting).
If battery voltage is good at starter terminal, make
sure engine is not seized. If engine is not seized,
carry out a GROUND C/RCU/T VOLTAGE DROP
TEST
468 rmr2011-O77
Starter Cable Voltage Drop Test STARTER GROUND CIRCUIT VOLTAGE

This test confirms if there is parasitic resistance in DROP TEST
the cable, solenoid or connections. assutt (WHILE
l.To access battery positive terminal, refer to PROBES STARTING)
BODYand remove LH rear side panel. Starter Battery .
2. Set multimeter to Vdc. housing negative post 0'8 Vdc maxmum
3. Connect multimeter probes to the starter termi- If voltage exceeds the specification, ground ca-
nal and battery positive post. bles and connections from battery to RH side of
4. Measure voltage drop as follows while crank- engine.
ing engine with the throttle fully open to initiate If voltage is as per specification, test starter mo-
“drown mode" (prevents engine from starting). tor, refer to MAGNETO AND STARTER subsec-
tion.
A WARNING
While using drown mode to prevent engine Starter Replacement
starting, always release Start button before If the starter has to be replaced, refer to the MAG-
throttle. NETO AND STARTER subsection.
STARTER CABLE VOLTAGE DROP TEST
D2 DIODE (STARTER SOLENOID)
RESULT (WHILE
PROBES STARTING) D2 Diode Troubleshooting
Battery Starter .1 Vdc maximum A defective D2 diode will result in the following
positive post terminal conditions.
If voltage exceeds the specification, test voltage

Shorted Diode
drop between the following points using the same Fuse F12 will blow continually.
method to determine what part of the circuit is at Open Diode
fault:
— Battery positive post and starter solenoid STS3 Diode will not provide protection to the sensitive
electronic components. Malfunction or damage
— Starter solenoid STS3 and STS4 may occur.
— Starter solenoid STS-4 and starter terminal.
Replace cable or solenoid if necessary. D2 Diode Test
Starter Ground Circuit Voltage Drop Diode D2 must be isolated from other parallel cir-
Test cuits for proper testing. Turn ignition switch OFF,
then isolate diode D2 by disconnecting the follow-
This test confirms if there is parasitic resistance in ing:
the ground cables or connections. — ECIVI connector B
1. Set multimeter to Vdc. — Both small connectors on the starter solenoid.
2. Connect multimeter probes to the starter hous- For quick access to the starter solenoid connec-
ing and battery negative post. tions, open vehicle seat. Solenoid connectors can
3. Measure voltage drop as follows while crank- be seen through an opening in the LH fuel tank
ing engine with the throttle fully open to initiate covet
"drown mode" (prevents engine from starting).
A WARNING
While using drown mode to prevent engine
starting, always release Start button before
throttle.
rmr201l-O77 469
SBCIIIOII O5 ELECTRICAL SYSTEM
rmr2008-02 5-004_a
, rrnr2OOB-025—DU5_a
1. Starter solenoid
2. STS? (YELLOW/PINK wire)
3. STS2 IV/OLET/BE/GE wire) D2 DIODE TEST
4. STS3 from battery
5. STS4 to starter SOLENOID STS1 STS2
HARNESS (YELLOWI (VIULETI READING
Set multimeter as shovvn. CONNECTOR PINK) BEIGE)
NOTE: It is important to install the BLACK multi- RED BLACK 05 v
meter probe in the BLACK “com" connector of TEST PHDBES BLACK RED lnfinim UL
the multimeter and the RED probe in the RED con-
nector for proper testing of diode polarity.
If results are not as specified, replace diode.
Diode Replacement
The diode (D2) is located in the rear harness un-
derneath the frame.
1. Refer to BODYand remove the rear cargo mod-
‘(-1.
9,- _ ule.
;¢l..~;.- 2. Remove the wheel well cover by removing the
I L. o_
four reusable plastic rivets, then sliding cover
rearwards.
The diode is located within a 50cm (20in) dis-
tance from the small harness junction.
"6 I
vm r2006-020-005
Ii
Disconnect the two small solenoid connectors.
Diode D2 can then be checked as follows, through
the two small connectors on the solenoid harness.
rrnr2010-D25-Cl01_a
UNDER REAR OF FRAME
1. Harness junction
A. Diode within 50 cm (20in) from this point in the direction of
BITOW
470 rmr201 1-077

3. Open the harness protective sheath to access

the diode.
_sl__e.~l
" ~. 1 .-@<-1""
A
iii)’: »- lT-FT __“:__:f
. - _
NOTICE Be very careful not to damage wire
n_- 1 l-*7,“ I
insulation while opening protective sheath.
I. ."" munldnnnn _ ,_ _ I
Q O F5"—'_i I
I. WI I .
hi“ I, t ink 77‘l
i"'""
¢
.. 2'. ‘
_
W‘_"___A "
, ii, I
°"'""“‘ ,,_.. W"
;'jf""" 11
=i1» (_
A _!L'!!§__ . ..- _
2 aunt. {Ii | . hnnflj
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rmr201 0028-002_b
1. Monitoring page tab

2. ECM tab
rn'ir2008-025-002 3. Stop Button indicator
TYPICAL DIODE WITHIN HARNESS
If the Stop Button indicator in B.U.D.S. comes
NOTE: When replacing the diode, always test the ON when switch is RUN position and OFF when
new diode with the "diode check" on the multime- switch is in STOP position, it indicates that the
ter, before installing it in the circuit. switch and wiring are good and that the D.E.S.S.
4. Replace diode making sure to install it in the module gets the signal. Make sure Start button
right direction. Use the "diode check" function tests good, then carry out a PRE-START/NG RE-
of the multimeter and refer to te W/R/NG D/A- LAY OUICK TEST
GRAII/I If test fails, check for an open circuit or defective
NOTE: If the diode is installed in the reverse switch, refer to W/RING DIAGRAM. Keep in mind
direction, the starter solenoid will not function. that one side of the switch is connected to the
When the ECM completes the circuit to energize D.E.S.S. module and a failure of this circuit will dis-
the starter solenoid coil, the current flow will able starting.
by-pass the coil through the diode. Fuse F12 will
probably blow and open the circuit. START BUTTON
ENGINE STOP SWITCH Start Button Test with B.U.D.S.
1. Connect the vehicle diagnostic connector to a
NOTE: The engine stop switch is located on the computer with the appropriate version of the
RH multifunction switch housing. B.U.D.S. software.
Engine Stop Switch Test with B.U.D.S. 2. Select the Read Data button.
1. Connect the vehicle diagnostic connector to a 3. Select the Monitoring and ECM tabs.
computer with the appropriate version of the 4. Press the vehicles start button and look at the
B.U.D.S. software. Start Button indicator at the bottom of the
2. Select the Read Data button. page.
3. Select the Monitoring and ECM tabs.
4. Place engine stop switch to RUN, then to STOP
and look at the Stop Button indicator at the bot-
tom of the page.
rmr201 ‘I-077 471

22)).-.l'E.=.'l’é' ~ _‘ I <3; I qr; PRE-STARTING RELAY INPUT VOLTAGE test

1“... | Q... j"i;"]"l.;.. '|’T..Z"'lT'T.... |i “T T’ TEST PROBES RESULT
msirt
[- -Y ,,.-' i_ _‘_1_ F2‘ ‘
.,..._....e__,
Front fuse box
i__ _//-' ,;,_ . I pin C3
1 T I -n Ground Batten) voltage
I I
Iarniou
"Z
bin =-,1-:=-:1 '

--
i
.._..L -¢'
‘.
-— L -_ ‘
Front fuse box
6%
.w",,m,,, 1'»_.;" I. ; Q .. . ..
.c_a__~M_'-._-..._- B6" ‘ V, . , pin D3
in-lino;-wmI”_‘ I. , I5‘ _ .,
Imp)
'.. ~ :_
I'__
. _ ,_ _ 1-Q--—-_ . .
H A 'T—'l ll
If there is no voltage on pin C3, D3 or both, check
l
y
2 on-'0
~>v K
Ihfiwfilji/3
s-I\-O
has-nl
’-\0
u.“'.“_n E...
~_‘"’u F-
for an open circuit.
( K»-vi-wj Cwwkunlfl In-M-I inn“ If voltage is as specified, carry out a PRE-START
£J ' /NG RELAYCONTROL CIRCUIT TEST
rrT\r2OI U-Cl2SOD2_a
7. Monitoring page tab Pre-Starting Relay Control Circuit Test

2. ECM tab
3. Start Button Indicator 1. Remove pre-starting relay.
If the Start Button indicator in B.U.D.S. comes 2. Set multimeter to Vdc.
ON while start button is pressed in, it indicates 3. Turn ignition switch (key) ON.
that the starting system input side is functioning
normally (start button, ECM, wiring and connec- 4. Place multimeter RED probe on a positive
tions). Make sure engine stop switch tests good, source such as the starter solenoid batteiy
then carry out a PRE-START/NG RELAY OU/CK input
TEST 5. Place the multimeter BLACK (COM) probe on
If the Start Button indicator does not come ON pin C4 of front fuse box.
in B.U.D.S., check for an open circuit or defective NOTE: Refer to POWER DISTRIBUTION AND
switch, refer to W/RING DIAGRAM GROUNDS for front fuse box pinout.
6. Measure voltage while cranking the engine.
PRE-STARTI N G RE LAY PRE-STARTING RELAY CONTROL CIRCUIT TEST
Pre-Starting Relay Quick Test RESULT
1.Locate pre-starting relay in the front fuse TEST PROBES (WHILE
box, refer to POWER DISTRIBUTION AND STARTING)
GROUNDS. Front fuse box . .
pin C4 Positive source Battery voltage
2. While cariying out a start, touch the relay. You
should feel it "click" when you press start but-
ton. If voltage is as specified, the relay gets a proper
ground signal. Try a known good relay.
If relay does not click when start button is pressed
in, carry out a PRE-STARTING RELAY INPUT If voltage is not as specified, check for an open
VOLTAGE TEST circuit
If relay clicks when start button is pressed in, — Between front fuse box pin C4 and RH multi-
carry out a STARTER SOLENOID INPUT VOLT function switch l\IlSR2~4
AGE TEST - Between ECMB-C4 and RH multifunction
switch MSR2—4.
Pre-Starting Relay Input Voltage Test
1. Remove pre-starting relay. STARTER SOLENOID
2. Set multimeter to Vdc. Starter Solenoid Access
3. Turn ignition switch (key) ON. NOTE: The starter solenoid is mounted on the
4. Measure voltage on pins C3 and D3 of front frame, behind the LH rear panel just ahead of the
fuse box. battery rack.
NOTE: Refer to POWER DISTRIBUTION AND
GROUNDS for front fuse box pinout.
472 rmr2011 O77

To access starter solenoid, remove the following Starter Solenoid Control Circuit Test
body panels, refer to the BODYsubsection: 1. Disconnect connector STSI (YELLOW/PINK
- LH rear panel wire) from solenoid.
— LH fuel tank cover. 2. Set multimeter to Vdc.
3. Place multimeter RED probe on a positive
--1
source such as the starter solenoid battery
input.
4. Place the multimeter BLACK (COM) probe on
YELLOW/PINK wire terminal (wire side).
5. Carry out a normal start and check voltage while
cranking.
STARTER SOLENOID CONTROL CIRCUIT TEST
RESULT (WHILE
TEST PROBES STARTING)
YELLOWPINK
Wire/ I PSgitg/:
" Battery voltage
rmr2DU8025-010
STARTER SOLENOID (RH FUEL TANK COVER REMOVED)
If there is no voltage while starting, check for an
Starter Solenoid Input Voltage Test open circuit.
1.Disconnect connector STS2 (VIOLET/BEIGE If voltage is as specified, the solenoid gets a
wire) from solenoid, and test voltage as fol- proper ground signal. Carry out a STARTER SO-
lows. LENOID ST4 T/C TEST‘ CONTINUI T)/.
2. Turn ignition key ON and carry out a start.
Starter Solenoid Static Test: Continuity
3. Read voltage while start button is pressed in.
Disconnect battery.
STARTER SOLENOID INPUT VOLTAGE TEST
Disconnect small terminals from solenoid.
RESULT
With a multimeter, test the primary winding resis-
TEST PROBES (WHILE
STARTING) tance as follows.
VIOLET/BEIGE B
negajififglgost Battery voltage
SOLENOID WINDING CONTINUITY TEST
MEASUREMENT
SOLENOID
-|'|5RM||\|A|_5 RESISTANCE
@ 20°C l68°F)
STS1 I STS2 ApproximateIy5Q
._ 1+
rmr2008-025-O11_a
If there is no voltage while starting, check for an ff
open circuit including pre-starting relay mechani-

cal contacts. l'I'n r2008-D25-DI I_b
lf voltage is as specified, carry out a STARTER SO-

LENOID CONTROL CIRCUIT TEST Test for a stuck solenoid plunger as follows.
rmr2011-077
413
SOLENOID CONTACTS CONTINUITY TEST CLUTCH SWITCH CONTINUITY TEST

SOLENOID CONNECTOR MEASUREMENT CLUTCH SWITCH RESISTANCE @
Battery Starter - . POSITION 20°C (68°F)
\ terminal I terminal Open C'rCu't Firmly depressed Below 3 Q
Released Infinite (OL)
If switch is defective, replace with a new one.
If switch is good, test related wiring/connectors.
Clutch Switch Removal
Remove clutch lever from handlebar, refer to
CLUTCH subsection.
Push switch towards lever.
rmr2008-O25-012 a
If any measurement is out of specification, re- .4‘ J

place solenoid.
Reconnect battery and starter terminals.
Starter Solenoid Removal
Refer to STARTER SOLENOID ACCESS.
Disconnect the battery. rrnr20DB-028-032_e
Step 1: Push switch
Remove the four electrical connections from the
starter solenoid. Then lift switch to remove it.
Remove the two mounting screws.
Starter Solenoid Installation
Install the new solenoid in the reverse order of the
removal procedure.
Carry out a start of the vehicle to validate that the
new solenoid functions well.
CLUTCH SWITCH
SM5 Model rm r2008-028-O33_a
Step 2: Lift switch
Clutch Switch Continuity Test
Remove console module to access clutch switch Remove the console module, refer to BODYsub-
connector. Refer to BODYsubsection. section.
NOTE: The clutch switch connector is white and Disconnect the clutch switch connector then re-
is located on top of the front heated grips connec- move the connector housing from the connector
tors. suppon.
Disconnect clutch switch connector. Clutch Switch Installation
Using FLUKE 115 MULTIMETER (P/N 529 O35 868), Clutch switch installation is the reverse of the re-
test clutch switch resistance. moval procedure.
474
rmr2011~077
Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))
DIGITALLY ENCODED SECURITY

SYSTEM (D.E.S.S.)
SERVICE TOOLS
MASTER KEY .............................................................. .. ...... .. 529 036106 A78
GENERAL SYSTEM OPERATION

When the ignition switch is turned to the ON posi-
SYSTEM DESCRIPTION tion, a microcircuit inside the key is activated and
The D.E.S.S. system is an electronic anti-start sys- the antenna on the ignition switch transmits by
tem that allows engine starting only with a pro- radio wave a unique binary code to the D.E.S.S.
grammed key. module.
— If the D.E.S.S. module recognizes the ignition
key code, it sends a run signal to the ECM
3i which allows engine cranking to take place.
— If the D.E.S.S. module does not recognize the
code, the cluster will display BAD KEY (it can
take up to 40 seconds before the message dis-
plays).
TROUBLESHOOTING
CLUSTER FLASHES AT SHUTDOWN
1. Only one D.E.S.S. key is programmed. Program
a minimum of 2 keys.
rrrir2008-01 B-0O3_a ENGINE STOPS AFTER 2 MINUTES

1. Ignition switch RUNNING
2. D.E.S.S. module
3. Ignition key with a ROM chip 1'. D.E.S.S module is still in programming mode.
The 2"d key must be programmed within 2 min-
The ignition key contains a ROM chip that includes utes.
a digital type code.
The 2 keys that come with the roadster have been BATTERY COMPLETELY DISCHARGE
programmed at the factory. Up to 4 keys can be WITHIN 1 - 2 WEEKS WHEN VEHICLE IS
programmed on the roadster. NOT USED
1. D.E.S.S module is still in programming mode.
The 2nd key must be programmed within 2 min-
utes when programming keys.
475
rmr20‘l1-07B
Subsection O6 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))
PARTS REPLACEMENT During the programming process, all keys will be

GUIDELINE erased (the first key installed after removal of the
master key will erase the previous keylsl and this
Replace partls) according to situation as per fol- key will be the first newly programmed key).
lowing table.
If you want to reuse previously programmed keys,
SITUATION WHAT TO DO you must reprogram them.
Master key Order a new MASTER KEY (P/N 529 A minimum of 2 keys MUST be programmed.
has been O36 106).
lost The second key must be programmed within
2 minutes. Otherwise, the D.E.S.S. module will
All keys Replace ignition switch. remain in programming mode and the following
have been Replace D.E.S.S. module. conditions will occur:
lost Follow programming procedures
as detailed in PROGRAMMING KEYS
- Engine will start, then stop after 2 minutes.
WITHA NEI/VD.E.S.S. MODULEin — When the ignition is turned OFF, current drain
this subsection. will be higher than usual and the battery will
Ignition
completely discharge within 1 - 2 weeks if the
Replace ignition switch. vehicle is not used.
key broken Follow programming procedures
in ignition as detailed in PROGRAMMING KEYS If key programming was successful, the cluster
switch WITH A NEW /GN/T/ON SWITCH and will display a SUCCESS message. If the cluster
look for ADDITIONAL PROCEDURE does not display this message, the new key pro-
ONLYIF BROKEN KEY OR KEY gramming will not be stored. The entire proce-
CANNOT BE INSERTED IN OLD dure must be repeated from the beginning.
IGNITION SW/TCHin this subsection.
If the programming session is not correctly com-
Defective Replace ignition switch. pleted, no changes are saved in the D.E.S.S. mod-
ignition Follow programming procedures ule.
switch as detailed in PROGRAMMING KEYS
I/I//THA NEW IGNITION SW/TCHin Adding/Reprogramming Keys
this subsection.
The following procedures describe how to pro-
Defective Replace ignition switch. gram keys on a vehicle that has already at least
D.E.S.S. Replace D.E.S.S. module.
module Follow programming procedures
one programmed functional key.
as detailed in PROGRAMMING KEYS NOTE: Additional keys to program must be precut
WITHA NEWD.ES.S. MODL/LEin to the ignition switch.
this subsection. To add or reprogram a key, carry out the following
steps:
D.E.S.S. IVIODULE DIAGNOSIS 1. Insert an already programmed functional key
Use the diagnostic flow chart located in the into the ignition switch.
pocket on the back cover page of the manual. 2. Turn the ignition key to ON.
3. Turn the ignition key to OFF.
PROCEDURES 4. Wait 5 seconds.
5. Remove programmed key.
KEYS
6. Insert MASTER KEY (P/N 529 036 I06).
General Information on Programming NOTE: The master key is purposely "not cut" and
Keys will not turn in the ignition switch.
The D.E.S.S. module is programmed to recognize
the digital code in the key.
A master key is used to program keys.
The cluster will display guiding tips during key pro-
gramming.
47s
rmr201 1-078
After installation of a new D.E.S.S. module (with

or without a new ignition switch), the module will
automatically go into programming mode when
the ignition switch is first turned ON.
NOTE: No master key is required.
To program the ignition keys into the new D.E.S.S.
module, carry out the following steps:
1. Insert 15* key to program into the ignition
switch.
2. Turn the ignition key to ON.
3. Wait until cluster displays NEXT KEY.
ii'1. llZ°i2li'2Ev
No notches 5. Remove key.
2. RED colored 6. Insert the 2"¢I key to program.
7. Wait until the cluster displays MASTER. NOTE:A new D.E.S.S. module will allow
8. Remove the master key. programming of 2 keys initially. If you wish
to program more than 2 keys, refer to
9. Insert a key to program. ADDING/REPROGRAMM/NG KEYS after this
10. Turn ignition switch to ON. procedure is completed.
11. Wait until cluster displays NEXT KEY. 7. Turn ignition switch to ON.
12. Turn ignition switch to OFF. 8. Wait until cluster displays SUCCESS.
13. Remove key. 9. Turn ignition switch to OFF.
14. Insert next key to program. 10. Remove key.
15. Turn ignition switch to ON. Key programming procedure is complete.
16. Wait until cluster displays NEXT KEY. Start engine and let run for more than 2 minutes.
NOTE: If there are at least 2 keys programmed If engine does not stop on its own after 2 minutes,
and you do not wish to program more keys (4 ma- programming mode is complete.
ximum), leave the last programmed key in the ig-
nition switch. If you wish to program another key, Programming Keys with a New
repeat the previous five steps. Ignition Switch
17. Wait until cluster displays SUCCESS. Guidelines
18. Turn ignition switch to OFF. The following procedure describes how to pro-
19. Remove key. gram keys when only the ignition switch has
been replaced.
Key programming procedure is complete.
NOTE: You must have at least the top portion of a
NOTE: When the maximum of 4 keys are pro- key from the old switch containing the electronic
grammed, the cluster will display SUCCESS. chip. Otherwise, both the ignition switch and
Start engine and let run for more than 2 minutes. D.E.S.S. module must be replaced.
If engine does not stop on its own after 2 minutes, Switch Preparation
programming mode is complete.
Connect only the large ignition switch connector
Programming Keys with a New to the NEW ignition switch at this time. The OLD
D.E.S.S. Module ignition switch D.E.S.S. antenna must remain con-
nected to the D.E.S.S. module.
The following procedures describe how to pro-
gram keys on a vehicle when the D.E.S.S. module
has been replaced.
477
rmr201 1-078
Subsection O6 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))
rmr20084)650n2_a
IGNITION SWITCH ASSEMBLY rrnfZOD8~065-004_a

7. D.E.S.S. antenna ring KEY HELD INSIDE ANTENNA RING AS IF IN IGNITION SWITCH
2. D.E.S.S. antenna connector 1. Antenna ring
3. /gnition switch connector 2. Antenna wire connected to D.E. S. 5. module connector
NOTE: The NEW ignition switch will be used to Key Programming Procedure
power ON the vehicle but the OLD ignition key 1. Insert the OLD programmed key into the OLD
and antenna must be used for recognition by the ignition switch (or old antenna).
D.E.S.S. module.
NOTE: If key is broken or if key can not be in-
Additional Procedure Only if Broken Key serted in the old switch, refer to ADDITIONAL
or Key Cannot Be Inserted in OLD Ignition PROCEDURE ONLY /F BROKEN KEY OR KEY
Switch CANNOT BE /NSERTED /N OLD IGNITION
NOTE: Carefully pry off the D.E.S.S. antenna from SW/TCHin this subsection.
the top of the old switch assembly. It will be used 2. Insert a NEW key in the NEW ignition switch.
during the key programming procedure.
3. Turn the NEW ignition key to ON to power the
system.
4. Turn the NEW ignition key to OFF.
5. Wait five (5) seconds.
6. Remove the OLD programmed key and insert
the MASTER KEY (P/N 529 036 106) in its place.
rm Y2 O’O8~OB5~OO3_a
1. Antenna ring
2. Antenna locking pin lone each side)
3. Carefully pry here (each side)
4. Squeeze this clip In to remove from switch assembly
The following illustration shows how to use the

old D.E.S.S. antenna for recognition of the old ig- 1 2
nition key and master key to put the D.E.S.S. mod- rmr2OOB-O01 _a
ule into programming mode. MASTER KEY

7. No notches
2. RED colored
7. Wait until the cluster displays "MASTER" indi-

cating that the module enters the key program-
ming mode.
8. Remove the master key.
478
rmr201 1-O78
1 tf',i-_i';"_‘;»,1‘-‘iyililt \ ,6
'/
9. Quickly disconnect the OLD D.E.S.S. antenna /T
and connect the NEW D.E.S.S. antenna to the “"" _'." .~- I
D.E.S.S. module. ifL 5:,‘-iv-1*‘
2.7!)? " I 2
NOTE: If too much time is used to switch the an- i I ; ._ I ,. 4
tenna connectors, the programming may fail and I)!‘.-/_ .¢
/"I 5-Pr
7“) ‘;I<_I1\!¢_L; '\
the procedure will have to be repeated from the . ,- r-‘.~.._.-.‘.__j'»__
st;
.- a ..,_,_.___......,_,L
.
beginning.
10. Turn NEW ignition switch to ON. ..'~*'»4;- at ‘ ".-» '. - \ ~'n
~
' I S" '‘§T ..‘
=15‘.
11.Wait until cluster displays NEXT KEY. O Y/If

‘fie-=.:.~.\.\ Y - 1931/
- I
~
. ' LET--:1»&~
)
~. Oi-- -7-
~_/
--

‘ . , i <. .& fill,' .4__
.-'=- . T.) L-3.‘1Wg‘ ‘. ’%'I’g-4:1
= ' ‘-""a<3é{f,§i\
V _‘ ' H - .'\§_4_ i
13. Remove key. »'j.S=
- "Hill
\,
I‘ T_-,
_- I
"_l 1 3' ‘I5 {J1
.__ii -5- <1-\._ Jr /
14. Insert next key to program.
15. Turn ignition switch to ON. __‘v~ "as.
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16. Wait until cluster displays NEXT KEY. PARTS REMOVED FOR CLARITY
1. [RH front shock abgorber
NOTE: If there are at least 2 keys programmed 2. ron t rame rnem er
and you do not wish to program more keys (4 ma- 3. D.E.S.S. module
4. Connectors
ximum), leave the last programmed key in the ig-
nition switch. D.E.S.S. Module Replacement
17. Wait until cluster displays SUCCESS. 1. Refer to BODY and remove console module
18. Turn ignition switch to OFF. and service cover.
19. Remove key. Disconnect the D.E.S.S. module connectors.
Complete ignition switch installation. Remove the D.E.S.S. module retaining screws.
Start engine and let run for more than 2 minutes.
If engine does not stop on its own after 2 minutes, i_,__.4i
programming mode is complete.
D.E.S.S. MODULE
rrnr2010-U29-DD2_b I
PARTS REMOVED FOR CLARITY I
1. D.E.S.S. module i
2. Retaining screws
Remove the D.E.S.S. module.

For installation, reverse the removal procedures.
Tighten retaining screws to 7 N¢m (62 lbfeinl.
rmr20OB-O26-DD4
NOTICE Do not apply any dielectric grease in
The D.E.S.S. module is located inside the front the D.E.S.S. module connectors.
frame member under the upper console.
Program a minimum of 2 keys into the new mod-
ule. See PROGRAMMING KEYS WITH A NEW
D.E.S.S. MODULEin this subsection.
I
rmr201 1-078
479
Paperless Manuals
For a Better Tomorrow
wmmmgeon-manuals.com
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)
LIGHTS, GAUGE AND ACCESSORIES

SERVICE TOOLS
ELUKE 115 MULTIMETER .......................................................... .. 529 O35 868 499, 502, 506-507, 509, 511,
513-515, 518-521 , 523-526
SPANNER TOOL ......................................................................... .. 529 O36 223 ....................................... .. 532
SERVICE PRODUCTS
LOCTITE 243 (BLUE) ................................................................... .. 293 800 O60 ....................................... .. 534
GENERAL SYSTEM DESCRIPTION

Refer to W/R/NG D/A GHAM /NFOFr‘/I//A 7'/ON sub- (LIGHTING SYSTEM)
section for diagnostic tips on troubleshooting
electrical problems.
A WARNING
It is recommended to always disconnect the
battery when replacing any electrical compo-
nent. Always disconnect battery as specified,
BLACK (-) cable first. D0 not place tools on
battery. 2\ /2
fer to SELF-L OCK/NG FASTENERS and LOCTITE
APPL/CA7’/ON at the beginning of this manual for
complete procedures.
A WARNING
Torque wrench tightening specifications rmo20l O-O01 »D75_a
must be strictly adhered to. Locking de- NORTH AMERICAN MODELS

vices when removed, must be replaced (e.g.: 1. Hea dI/gh ts
2. Fog lights (not shown)
locking tabs, elastic stop nuts, self-locking 3. Position lights
fasteners, cotter pins, etc.).
rmr2OII O79 481

1 I I _ _ 1

| — i Z — 1 i 1 l
HIGH BEAM is selected, the shutter in both units

“-4
\;{l
l is powered and the top of the light beam is un-
IQ
.
L
-
-3-;
_
Q
blocked.
NOTE: With no power applied to the shutter so-
1L /I lenoid, the shutter is in the closed or low beam
position.
2% /2
European Mode/s
The low beams are located in the front panels on
each side of the vehicle, while the high beams are
located in the console assembly.
Fog Lights
rrnoZO1 U001-304_a
The fog lights are located in the front panels on
EUROPEAN MODELS each side of the vehicle, where the low beams
7. Headlights -— high beam
2. Headlights — low beam take place on European models.
3. Position lights
The fog lights are powered through the LOAD
SHEDDING relay, then through the fog light
switch.
Turn Signal Lights
The signals are conventional bulbs at front and
LEDs at rear.
When the turn signal switch on the left front mul-
tifunction switch is activated, a CAN (Controller
Area Network) protocol signal is generated by the
module in the switch assembly. This CAN signal
is sent to the multifunction gauge.
The multifunction gauge interprets the CAN sig-
nal, then operates the selected turn signal lights.
rn1o201U-O01-047_d
ALL MODELS
The turn signals will turn off automatically in the
1. License plate iighr following conditions:
2. Backup lights
3. Tai//ights/Brake lights 1.After the vehicle has made a turn, the mul-
4. Turn signals tifunction gauge is programmed to turn the
signals off, after a certain amount of degrees
Headlights of steering has been made and then returned
The headlights automatically come ON when the to center. The multifunction gauge receives
engine is started and reaches 800 RPM, and go a CAN signal from the SAS (Steering Angle
OFF automatically 20 seconds after engine shut Sensor) to determine when the turn has been
down. initiated.
The headlight beam selector switch is located in NOTE: The turn signals turn off automatically af-
the left multifunction switch. It is a Hall Effect ter a normal turn, however after a shallow turn or
switch, not a contact switch. The switch cannot lane change they may have to be turned off man-
be checked with an ohmmeter, it must be tested ually.
live, by back-probing. 2. If turn signals are left ON, they will automati-
North American Mode/s cally turn off after 30 seconds while the vehicle
is moving.
The high and low beams are incorporated into a
single unit (one each side) equipped with a shut- NOTE: If the vehicle did not move, they will stay
ter. When LOW beam is selected, the shutter ON until selected OFF, or until the ignition key is
in both units is closed and the top of the light switched OFF.
beam is blocked. When HIGH beam or FLASH
482
rmr2011~O79
The turn signals can be turned off manually at any

time by pressing the turn signal button on the left
multifunction lever.
Hazard Warning Lights Operation
When the hazard switch is pushed, a voltage sig-
nal is sent from the hazard switch to the multifunc-
tion gauge.
The multifunction gauge is programmed to turn on
the lights when it receives this voltage signal. If
the multifunction gauge receives another voltage
signal from the hazard switch, it will turn off the rrnr2Cl10-O30-OOE_a
hazard lights. TYPICAL

7. BLS (brake light switch)
NOTE: The ignition key must be turned on to use
the hazard lights. Position Lights/License Plate Light
Taillight/Brake Light Position Lights
This vehicle is equipped with two taillights that This vehicle is equipped with two marker lights
use LED (Light Emitting Diodes) for illumination. located on top of each front fender.
Nine LED‘s are always lit when the ignition key is The two position lights (or marker lights) come
turned ON and acts as a rear position (or parking) ON when the ignition switch is ON. They receive
light. Those nine LED‘s plus a second set of three power from the ignition switch and will remain on
LED‘s are lit at a higher intensity when used for as long as the ignition switch is left ON.
the brake light function.
License Plate Light
Internal circuitry inside of the taillight housing
causes the intensity to increase when the brakes Receives power from the ignition switch is ON
are applied. and will remain ON as long as the ignition switch
is left ON.
Back Up Lights Operation
When the gearbox is shifted into reverse, a signal
from the GBPS (Gear Box Position Sensor) is sent
to the ECM. A CAN (Controller Area Network) pro-
tocol signal is generated by the ECM. This CAN
signal indicating gearbox is in reverse is sent to
the multifunction gauge.
The multifunction gauge interprets the CAN sig-
nals from the ECM and is programmed to provide
voltage to the back up lights.
rrr\I’ZOI0—03GO05
SYSTEM DESCRIPTION
TAILLIGHT (MULTIFUNCTION GAUGE)
Power for the taillights comes from the ignition Multifunction Gauge Operation
switch. When ignition switch is ON, the following
lights turn on. A WARNING
— Taillights Watching or using the multifunction gauge
- Front position lights or the infotainment center can distract the
— License plate light driver from the operation of the vehicle. Al-
— Front day lights. ways keep on observing the traffic and make
sure the surrounding is clear and safe before
Power for the brake light comes from the BLS doing so.
(Brake Light Switch) located on the brake pedal as-
sembly at the master cylinder.
rmr201)-O79 483
The multifunction gauge includes analog The digital display provides a brief description for
speedometer and tachometer, indicator lamps some of the conditions or problems in conjunction
and an infotainment center with a digital screen. with an indicator lamp.
In addition, the gauge itself is a module. Through The message displayed is large and colored.
CAN (Controller Area Network) it is in constant
communication with the various other on-board
modules. It also directly controls certain functions
of the vehicle such as the following.
— Load shedding relay ground
- Output signal to optional analog temperature
gauge
— Reads the low fuel level of optional analog fuel
gauge
— Reverse actuator ground signal
- Left and right turn signal control
- Back-up lights output
— ACS (Air Controlled Suspension) operation
— Radio, iPod, XM radio and CB control
— Provides power to the left multifunction switch . \ ,.
- Provides power to the radio. 1
For more information on CAN refer to the CON- rmr201 1-O79-DO5_a
TROLLER AREA NETWORK (CAN) subsection. 1. Large colored message
After a moment, the message will stop being dis-

played. An icon will appear in the lower central
portion of the digital display instead.
5)) Qt
rm02010-001-O17‘aen
TYPICAL
1. Analog speedometer :- km/it
2. Analog tachometer (RPM)
3. Indicator /amps
4. Digital display i
1) Analog Speedometer iitt-aaIl§, J-,' l l lififiggi

Displays vehicle speed in kilometers (km/h) or
miles per hour (MPH). To change units, refer to
PREFERENCES SCREEN or use B.U.D.S.
2) Analog Tachometer (RPM) 1
rmdoi 14179006;
Displays engine revolutions per minute (RPM). 1. lcon
Multiply by 1000 to obtain actual revolutions.
The following tables list the indicator lamps during
3) Indicator Lamps and Messages normal operation and for problematic conditions.
Indicator lamps inform of various conditions or
problems.
An indicator lamp can be on or flash alone or in
combination with another lamp.
484
rmr2011 079
Indicator Lamps During Normal Operation

INDICATOR LAMP(S) MESSAGE DESCRIPTION
Temporarily, all indicator lamps are activated
All indicator lamps On None when ignition switch is ON and the engine is
not started
Flashing None Parking brake engaged
if\ ‘i/ ~ + SE5 model: The ignition switch is OFF and the
Flashing None parking brake is not engaged. Always engage
Beeper the parking brake when parking the vehicle
@ On None Gearbox in neutral position
@ Flashing None Gearbox in reverse position
(-)
IE l On None Headlights in the HIGH beam position
Flashing None VSS intervention occurs
Left side turn signal.

@ Flashing None Left and right side indicator lights
flash at the same time: hazard warning lights
Right side turn signal.
@l Flashing None Left and side indicator lights flash at
the same time: hazard warning lights
rmr201!-079 485
/nd/cator Lamps or /con for Problematic Cone’/t/ans

INDICATOR LAMP(S)
OR ICON MESSAGE
E displayed instead of
selected gear None Gearbox posltlon sensor malfunctlon
BAD KEY Wrong or defectlve key
REAR STORAGE
COMPARTMENT OPEN Top or slde storage compartment cover open
COMMUNICATION FAULT CAN (controller area network) communlcatron
@ HI TEMP LIMP HOME Engme IS overheatlng
@
LO BATT VOLT Low battery voltage
HI BATT VOLT Hlgh battery voltage
ABS FAULT ABS malfunctlon No ABS operatlon

VSS FAULT
$9 LIMP HOME
SEAT SWITCH DEFECTIVE
VSS maltunctlon
Defectlve prllton rlder seat swltch
EBD FAULT VSS maltunctlon
(CD) BRAKE FAILURE Low brake flurd level or faulty sensor
CDX®) PARKING BRAKE FAULT Faulty parklng brake or component
CHECK ENGINE Engrne management component maltunctlon

CHECK DPS Dynamlc power steerlng component malfunctlon
C?) CHECK TCM Transmlsslon Control Module component

malfunction
LIMP HOME Important englne management component or VSS
malfunctlon
9 None Low o|l pressure
C9 None Low fuel level
rt
£3
;»—-
CHECK TRANSMISSION
CHECK DPS
MANUAL
T? KEY ERR
4) Digital Display 1) Category Icons

Displays useful real-time information to the rider There are 5 selectable category icons. Each icon
and is used as an interface for the infotainment is linked to a different screen. See table below.
center.
For a complete description of the digital display, CATESSHY CATEGORY ICON SCREEN
refer to D/G/7I4L D/SPLAYDESCR/PT/ON.
Default riding
Important information messages can also be dis-
played, refer to MESSAGES /N /I//ULT/FUNCT/ON
GAUGE I Audio (option package)
Multifunction Gauge Startup (pie) CB (optional)

Information
Trip meter
A self test is initiated every time the ignition key
is turned on. The default riding screen will turn on Preferences (only available
and indicator lights will turn on for a moment. This when vehicle is stopped,
allows the operator to validate that all indicators except for the trailer mode)
are working properly.
Anytime the ignition switch is turned ON after For a complete description, refer to CATEGORY
having been in the OFF position for 5 minutes or /CON SCREEN DESCR/PT/ON
more, the digital display will show the following You can navigate through the category icons to se-
message: lect several functions and to change certain set-
- BEFORE OPERATING READ THE SAFETY tings using the RECC (Roadster Electronic Com-
CARD ABOVE THEN PRESS l\/IODE BUTTON. mand Center).
Press the MODE button to acknowledge this mes- 2) Ambient Temperature
sage to allow engine starting.
The ambient air temperature is displayed in °C
Digital Display Description or °F. To change units, refer to PREFERENCES
SCREEN.
The display is divided in several areas as follows.
3) Clock
1 2 3 The current time is displayed in 24h or am/pm
format. To change the format, refer to PREFER-
‘-
Q >1 n-r - —- -- ——— —-—'—- . _
-aa=@4. .
- _ I rfi
ENCE5 SCREEN
4) Gearbox Position
F _ . _a ' ,
v» -~ ‘,- - Displays the selected gearbox position.
5) Cruise Control Status
Displays ON when the cruise control is turned on
km/h
but not set to any speed.
Displays SET when the cruise control is in opera-
__J jl l laas
__,‘A_,___4_:___5. tion and a speed has been set.
Displays OFF when the cruise control is not in use.
,,_,2g¢_i|,L5,,,\,f(
3:327 6) Trip Meter
4 5 9 6 7 8 Time. distance travelled and average speed since
rmo2010-U0101 5_con the last reset. Two trip meters are available and
. Category icons they are identified as "A and To change units,
. Ambient temperature
. Clock refer to PREFERENCES SCREEN
. Gearbox position
. Cruise control status 7) CB Communication Status (Optional)
, Ir/p meter
CB communication status (optional) Displays wether the CB (citizens' band) is receiv-
Odometer ing (RX) or transmitting (TX).
F0§3O_\lQ)(J'i §-Q)I\~l Main screen
rmr201‘)-079
487
8) Odometer Use the RECC (Roadster Electronic Command

Total distance travelled in kilometers or miles Center) to control the display functions.
since the delivery from the factory. To change
units, refer to PREFERENCES SCREEN
*5‘:-
9) Main Screen
The main screen is the area where the most infor-
mation is displayed. The display will change when
navigating through the available gauge functions.
-4
flu) Q» ta E
90$ rmo20‘I0—0O1-020_a
7. RECC
Pressing the MODE button will move a selection

through the category icons, located at the top left
area of the screen, in this order: Default riding
screen, Audio, CB, Trip meter and Preferences.
Each press of the button will move the selection
-
rrno2DID-001-D15_en
224,.5a -- B27
I
to the next available icon. When an icon is se-
lected, its related screen will appear.
DEFAULT RIDING SCREEN SHOWN NOTE: The audio or CB icons are skipped when
the vehicle is not equipped with these features.
Automatic Digital Display Dimming The Preferences screen is skipped when vehi-
The multifunction gauge contains a photo sensor. cle is above 5 km/h (3 MPH), except for the SE5
In low light conditions the display will automati- model for the towing mode.
cally change to the nighttime viewing screen.
1
I1 E!
2 to (>1 ?
.
-ea=a+ .' ‘=
ififlli
3 = km/h
‘J
__.I
1
l l saa
._,_
‘T-’ T _ RX'_M
[ TRAJET A . 5oN -
B32?
L
rrnr2010~O30—O0'l
_7 _ [T110201 U-001 -01 5_ben
1. Category icons
2. Default riding icon selected
DIMMED DISPLAY FOR LOW LIGHT CONDITIONS
When the selection is on the last icon, it will then
Navigating in the Digital Display move to the first icon when the MODE button will
We recommend you practice selecting some be pressed.
functions on the infotainment center before get- In some screens, vertical or horizontal arrows
ting on the road. You will get used to them and are visible. This indicates that you have to use
they will be easier to use on the road. the LEFT/RIGHT button to change the setting
488
rm r201 1-079
enclosed by the horizontal arrows and to use the Category Icon Screen Description
UP/DOWN button to change the setting enclosed
by the vertical arrows. Default Riding Screen
Pressing an arrow button repeatedly on single or
double arrows will move one selection at a time. 3
Holding an arrow button on a double arrow will
move to the end or beginning of the selection. .<.>>e» :1 sf fie
Holding the DOWN button on the audio volume
lower arrow will mute the audio system. Pressing
the UP arrows brings volume to the last setting.
.__ \ km/h 2
.és g ipllagealflifilsemiel rib_;t cau|§% ssss§;<<!le§i>>
FM "RADIO “I” l l anl
2 PREMIERE _'_“' ' K“ TRIPTA En" I FT
.
103 .5 5 I
- km I
4 5
rrr\o2010~0Ol-401_aen
<< 10? DEFAULT RIDING SCREEN

1. Engine coolant temperature (option package)
2. Fe//ev/(
u e op t‘/on paka
c g e)
T IT TRIPA TOTAL [km] 3. Digital speedometer
4. Engine speed (not factory set)
. 1 OFF, 3...". 8327 5. Radio preset or radio frequency (not factory set)
1. Use the UP/DOWN button to select the vertical arrows 1) Engine Coolant Temperature (except models
2. Use the LEFT/RIGHT button to select the horizontal arrows with Separate Analog Gauges):
When an item is selected, this sets the item to the Bar gauge that continuously indicates the engine
current value. coolant temperature.
After acknowledging the initial safety message at NOTE: On models with a separate analog engine
gauge startup, or after a few seconds elapsed in coolant temperature gauge, the bar gauge is not
any other screen without pressing any RECC but- displayed in the digital display.
ton, the display will automatically return to the de- 2) Fuel Level (except models with Separate Ana-
fault riding screen. log Gauges):
Bar gauge that continuously indicates the amount
of fuel left in the fuel tank.
NOTE: On models with a separate analog fuel
level gauge, the bar gauge is not displayed in the
digital display.
3) Digital Speedometer:
Displays vehicle speed in kilometers (km/h) or
miles per hour (MPH). To change units, refer to
PREFERENCES SCREEN
4) Engine Speed: l
Displays engine speed in revolutions per minute
(RPM).
NOTE: This is not a default setting. To activate
this function, refer to PREFERENCES SCREEN
5) Radio Preset or Radio Frequency:
Displays the selected radio preset or radio fre-
quency.
rmr201 1-O79 489

NOTE: This is not a default function. To activate Radio (FM, AM, WX, XM)
this function, refer to PREFERENCES SCREEN.
Audio Screen (Option) 1 3
This screen is only available when an audio sys- I S S r I T T T " S '1 i‘
The audio screen will appear with its last configu- ‘FIVIIRIADI0
i<'=lTl0n- PREMIERE
1 2\ 'IO3.5 4
smhfleefles 1<..'|Ql?P
FNI RADIO .- r |T‘I.'~ -
1 CRUISE
as -
TRIPA
~ - ‘
Tomi. lkm)
PREMIERE
5 . . ' 4 __. -,.|1
103.5 I rrno201 0-001 -O22_aan
FM RADIO SHOWN
1.
2.
Current selected band
Station number preset
e10» i 3.
4.
Current station
Volume level
TRIPA 1' Li<m Press the LEFT/RIGHT button to select the de-
, 1 ii??? .=z_s_4_i_.5... °“‘5‘3t~7 sired preset radio station.
1m0ZU'ID-GUI-O22_IJBn
1. Current selected audio device

Press and hold the LEFT/RIGHT button for more
than one second to SEEK the next available radio
Repeatedly pressing the SET button will display station. The radio will remain tuned to that station.
the available audio devices in this order: FM, Press the SET button and hold for more than one
AM, WX (weather channel), IPOD or AUX and XM second to enter the setup screen.
(satellite radio).
In the setup screen, press the LEFT/RIGHT button
AUDIO SYSTEM ENABLING to tune the radio frequency in increments of 0.2.
MODE L-YEAR ENABLING NOTE: When a frequency is already recorded in a
201 O Ignition switch ON
preset, its preset number will appear.
To record up to 15 station presets:
Ignition switch ON
Press the DOWN button to record the actual fre-
2911 Press MODE button for 3 quency to the preset number displayed.
seconds immediately after
ignition switch is turned OFF NOTE: While riding, the radio station will be au-
tomatically recorded to the next available preset
AUDIO SYSTEM DISABLING number. If all preset numbers are already used,
the preset number 15 will be over written.
MODEL-YEAR DISABLING
2010 Ignition switch OFF
Ignition switch ON, then OFF
20)) Press MODE button for 10
seconds
NOTE: The FM, AM and WX radio bands will only

appear if a radio is installed. The XM radio will
only appear if a satellite radio is installed. If an
IPOD player is connected, IPOD will be displayed
instead of AUX.
490 rmr201 1-O79

1 email e e
,. _
2 \ PREMIERE
{Q The Scientist
‘ .I
Playlist 1
\;-All 030 CULDPLAY (Rushed of Blood ...]
'l.Ql .
Es:-1-a-~. Li ' ~-'.*i?~ ~
1 CRUISE TRIP A
-- F-~
TOTAL {km}
>4
TR I P A I m
MUTE
OFE - --1.. ~ .
rrno20'l0-ClD'l-027_aer\
8327 .- ..
TYPICAL TYPICAL IPOD SCREEN
1. LEFT/RIGHT button to select the frequency
2. UP button to select the preset number (vehicle stopped)
3. DOWN button to record the radio station Press the LEFT/RIGHT button to change the song
in the current folder.
While riding, the available functions are: Press and hold the LEFT/RIGHT button for more
— Audio volume than one second to change the playlist if the
— Mute and seek (XM radio) functions playlist item is selected, to change the artist if the
— Radio preset functions (selection and storing). artist item is selected and to change the album if
the album item is selected.
/POD or A UX
While riding, the available functions are:
When a MP3 player is connected to the vehicle - Audio volume and mute
audio connector (option package), the AUX screen
will appear. It will play as set at the time of the — Previous or next song selection (iPod)
connection. Only the volume control will be avail- — Artist, album or playlist selection (iPod).
able for this type of player. CB Screen (Optional)
When an IPOD is connected to the vehicle IPOD This screen is only available when a CB is in-
connector (option package) the iPOD screen will stalled.
appean
NOTE: The CB screen will appear whenever the I
PTT (push to talk) button is pressed whatever the
screen that was displayed.
rmr201 1-079 491

1 2 Press the DOWN button to reset the selected trip

__§_ft :1) [Q P 1 meter.
Preferences Screen
CB + 1 2 3
tuaun
\ A I
(mm
<1on@i (H. . V oi-..
Q +> m IE
v
4<new<<+~ ><-I3» <+>(%ls-_,_,._. '.J‘l Y
TRIP A m
rmb2Q10-
1. Current channel _ A
2. CB communication status: RX (receiving), TX (transmitting) and
OFF
3. Squelch adjustment
4. Vo lume a dustment
1 I TRIP A RX
5. Intercom volume adjustment‘!/-com)
6. Voice activation sensitivity 8d]I.lSII'l'IEflI' (vox)
rmr201 IHJ30-U58_aen
Use the LEFT/RIGHT buttons to select the item to 1. 151 column: Main category q
change (channel, squelch, headset volume, inter- 2. 2"Pl column: Secondary category or item
3. 31¢ column: Unit or setting
com volume and voice activation sensitivity).
Use the UP/DOWN buttons to set a value. This screen is only available when vehicle is
stopped.
Press and hold the DOWN button for more than
one second to set the item to its lowest value. NOTE: On SE5 model, the trailer mode in the
PREFERENCES SCREENis available while riding.
Trip Meter Screen
Use the LEFT/RIGHT button to select the desired
column.
1 2 3 Within a column, use the UP/DOWN button to se-
lect the desired item. If more items are available
4.)) Sic‘! E to the next right column, use the RIGHT button to
select the column then use again the UP/DOWN
_¢ AVERAGE SPEED
:.' ‘m button to select the desired item. Continue using
98.3km/h this pattern to reach the desired item.
When an item is selected, this sets the item to the
TRIP A >> current value. You may then go to any screen, the
value will be kept.
W TIME
02.34.00
I I OFF 5?-.§.“"5"
§I. -§.sw .
IIHOZDIO-O01-U24_6Bfi
.
1. Display selection: Trip A, B or Total
2. Pause or resume the selected trip meter
3. Reset the selected trip meter
Press the LEFT/RIGHT button to select the de-

sired trlp meter.
Press the UP button to pause or resume the se-
lected trip meter.
492 n*nr20l1-079
Subsection O7 (LIGHTS, GAUGE AND ACCESSORIES)
,_o,, =1);3In,,l1%
1434 ! - Right compartment opened: 4.2 kQ
— All compartment opened: Less than 0.5 Q (re-
PREFERENCES ‘ ‘/1 sistors bypassed).
The multifunction gauge internal circuitry mon-
itors the voltage drop of the circuit (forced by
the resistors). The gauge is programmed to de-
termine which compartment is open or closed.
Since each compartment resistor has a different
value, the voltage sensed is different for each
compartment cover that is opened.
an 1 V‘ I ‘I
In addition, the multifunction gauge can deter-
mine "on the same wire" if the suspension up or
down switch has been activated. If suspension
UP is activated, the compartment switch resistors
rmr20‘l(}030-Cl57_aen
1. The selected value will be set

are all bypassed and an 825 Tl resistor is used in
their place.
NOTE: When in the 2"¢' or Std column, you can go
back to the column at the left using the LEFT but- SYSTEM DESCRIPTION (REAR
ton. STORAGE COMPARTMENT -
NOTE: When the units are changed they will be 2011 MODELS)
changed on both the analog and the digital dis-
plays. The units will be used for the odometer and The storage compartment storage cover states
both trip meters. (open or closed) are monitored by the multifunc-
tion gauge.
SYSTEM DESCRIPTION (REAR Rear Storage Compartment Switch
STORAGE COMPARTMENTS - Operation
2010 MODELS) If a side or top compartment is left open, a warn-
The storage compartment storage cover states ing will be set on the multifunction gauge indicat-
(open or closed) are monitored by the multifunc- ing a compartment is open.
tion gauge. The storage compartment indicator switches
work through one suspension up/down switch
Rear Storage Compartment Switch circuit.
Operation When the suspension switch is in the FREE (not
If a side or top compartment is left open, a warn- activated) position, the circuit wire is connected
ing will be set on the multifunction gauge indicat- through the switches to the multifunction gauge.
ing which compartment is open. Each compartment has a small micro-switch on
The storage compartment indicator switches the latch mechanism. When a compartment is
work through the same wire as the suspension opened, the micro-switch closes and connects a
up/down switch. gauge pin to the ground through a 1.5 kfi resistor.
There are 3 resistors connected in series between The multifunction gauge internal circuitry mon-
the multifunction gauge and ground. itors the voltage drop forced by either an ACS
Each compartment has a small micro-switch on switch or compartment switch position.
the latch mechanism. When a compartment is
opened, the micro-switch closes and in turn by- SYSTEM DESCRIPTION (LEFT
passes one of the resistors. MULTIFUNCTION SWITCH)
The total resistance of the circuit is as follows ac-
cording to the state of the compartments: Left Multifunction Switch Operation
- All compartments closed: 9.35 kQ The left multifunction switch contains the follow-
— Left compartment opened: 7.8 kQ ing:
— Top compartment opened: 6.6 kQ — MODE button
— SET button
rrnr2011 079 493

— TURN SIGNAL switch The cruise switch, located on the right multi-
— WINDSHIELD UP/DOWN switch function switch, contains momentary contact
— HEADLIGHT beam selector switch switches that are normally open. When activated
— HORN switch the switch contacts close. When closed the
signals from the cruise switch for ON, SET, or RE-
— REVERSE button SUME are sent to the left multifunction switch.
- PTT (Push To Talk) switch (For CB) The left multifunction switch contains a module
— RECC (Roadster Electronic Command Center) that converts the signals into CAN (Controller
— SE5 shift UP/DOWN switch (SE5 models only). Area Network) protocol. The converted CAN in-
The left multifunction switch contains a module formation is then transmitted via the CAN HI and
that converts certain switch inputs to CAN (Con- CAN LO wires to the ECM.
troller Area Network) protocol. The CAN signal Also, the VCM (Vehicle Control Module) wheel
generated by the module in the switch is sent speed sensor information is converted into CAN
via the CAN HI and CAN LO wires to various by the VCM. The ECM uses this information to
modules to perform specific functions. determine vehicle speed.
The MODE and SET CAN signals are received by Given all the input information, the ECM can send
the multifunction gauge. the appropriate electrical signals to the ETC and
The THUMB UP, THUMB DOWN, THUMB RIGHT, accurately control vehicle speed.
THUMB LEFT CAN signals are received by the An electrical signal directly from the BLS (Brake
multifunction gauge and the radio module. Light Switch) to the ECM is one method used to
The REVERSE button signal is received by the disengage the cruise control. Other methods to
TCM (SE5 equipped models) and the multifunc- disengage the cruise control and give back throttle
tion gauge. control to the operator include:
— Squeezing the clutch lever or if a clutch slippage
The PTT (Push To Talk) signals are received by the occurs (SM5 models).
radio and sent to the CB module (option).
— Initiating a gear change (SE5 models).
The WINDSHIELD UP/DOWN signals are re- — Any vehicle stability system intervention.
ceived by the WPM (Windshield and Parking
Brake) module.
The turn signal switch signals are received by the
SYSTEM DESCRIPTION (AUDIO
multifunction gauge. AND COMMUNICATION
In addition, commands from the cruise control SYSTEMS)
switch (part of the RIGHT multifunction switch) Audio and Communication Systems
are sent to the LEFT multifunction switch, con- Operation
verted to CAN and sent to the ECM.
The radio module is located underneath the rear
The only contact switch in the left multifunction right radio control panel. The radio module is in
switch is the HORN switch. It supplies a ground communication via CAN (ControIIerArea Network)
to the horn directly through the switch. protocol with the multifunction gauge. The multi-
The left multifunction switch is powered by the function gauge displays the radio functions. Op-
multifunction gauge. It is powered at the same eration of radio controls is done via CAN with the
time as the radio. RECC (Roadster Electronic Command Center) lo-
cated in the left hand multifunction switch. The
SYSTEM DESCRIPTION (CRUISE radio is equipped with AM, FM and WX (weather
channels). Optionally the radio can be linked with
CONTROL) additional audio equipment such as CB, XM (Satel-
Cruise Control Operation lite radio), i-POD and comes with an auxiliary input
jack to connect an accessory such as a CD player.
The cruise control is operated in conjunction with
the ETC (Electronic Throttle Control). The ECM NOTE: Some infotainment features have prece-
(Engine Control Module) uses various inputs to dence over the others.
calculate the position of the ETC in order to regu-
late the vehicles speed.
494 rmr2011-079
I
Passenger Radio Control Switch MULTIFUNCTION GAUGE

The passenger radio control buttons contains a TROUBLESHOOTING
series of 4 diodes for the volume up and down MULTIFUNCTION GAUGE FLASHES AT
switches, and another 4 diodes for the channel SHUTDOWN
up and down switches.
Each diode (in circuit) drops approximately 0.5 Vdc 1. Only 1 key programmed
when conducting electricity. The combination of - Program a minimum of 2 keys, refer to D/G/TAL
diodes in which the current passes (depending on ENCODED SECURITY SYSTEM (D.E.S.S.) sub-
section.
the what button is depressed) establish different
voltage levels sent to the radio. GAUGE FUNCTIONS INOPERATIVE OR
The radio senses and interprets the different volt- WORKING INTERMITTENTLY
age levels as signals that tell it which switch is ac- 1. Power supply or ground problem
tivated.
- Check power supply and ground circuits.
TROUBLESHOOTING OPTIONS CHANGING ON THEIR OWN OR
RESETTING AFTER SHUTDOWN
DIAGNOSTIC TIPS 1. Software update required
IMPORTANT: When solving an electrical problem, - Check for available software update, refer to
the first thing to do is to check the battery condi- ELECTRONIC MODULES (ECU) UPDATE in
tion as well as its cables and connections. COMMUNICATION TOOLS AND B. U.D.S. sub-
section.
der seat) for any tests that involve a prolonged PROCEDURES
not only test results can be altered, but the vehi-
cle electrical system may not operate normally. HEADLIGHTS
Pay attention to ground wires. They could be- Headlights Aiming Verification
come loose or corroded which causes them to
act as an additional load in a circuit, dropping North Amer/can Models
voltage and reducing current to components. 1. Set the rear suspension air pressure to OkPa
Some components may be grounded through (O PSI) using the schrader valve located under
their outer casing and mounted hardware. This the seat.
should also be considered.
Electrical Connectors
Pay particular attention to ensure that pins are not
out of their connectors, loose, or damaged. The
troubleshooting procedures may not cover prob-
Iems resulting from one of these causes.
Ensure all terminals are properly
crimped on wires and connector housings are
properly fastened. When replacing any electric
or electronic part(s), always check electrical
connections. Make sure that they are clean,
corrosion-free, tight and make good contact.
The voltage and current might be too weak to
go through dirty or corroded connector pins rmo2CI10~OOI -O56j
or terminals. 1. Schrader valve
2. Position the vehicle in front of a test surface as

shown.
rmr201 I-079
495
. V Low Beam
1. Set the rear suspension air pressure to OkPa
A— (O PSI) using the schrader valve located under
_- the seat.
-_
rrr\o201D-OD1-007_b
A. 70 IT? (33 fl“)
7 O Pi 1
.11 Y ‘
__
M»
°
‘ '
r ,‘_- -'7‘
\I f Q! _
d , . rmo201 D-O01-D56_a
1. Schrader valve
rmo201 0-001 ~O0B_a
_ 2. Position the vehicle in front of a test surface as

Trace 2 lines parallel
_ to the ground on the test sur- shown.
face as fOH0Ws' 3. Have a person of at least 91 kg (200lbl taking
LINES ON THE TEST SURFACE place on the driver's seat.
Line A 642 mm (25.3inl above ground
Line B 732 mm (28.8in) above ground
3. l—lave a person of at least 91 kg (200lb) taking A_

place on the driver's seat.
4. Select low beam.
5. Beam aiming is correct when the focus point
(brightest spot) of the headlight reflection is ~'~—
within the marks.
rmo2D10-001-0O7_b
2 A. 10m(33ft)
/
4-\ <—]> (-03
rm02010-001-3U2_b
TYPICAL HEADLIGHT REFLECTION ON TEST SURFACE

1. Ground
2. Focus point
A. 642mm (25.3in) above ground
B. 732mm (28.8in) above ground
rmo2010-001 O0B_a
EUmpea”_ Mode/S _ Trace 2 lines parallel to the ground on the test sur-
NOTE: This verification is valid for either left-hand face as fQ||QW5;
or right-hand traffic regulations.
496 rmr2011-O79
LINES ON THE TEST SURFACE Upper Headlight Units

Line A 415 mm (16.3 in) above ground 2. To adjust headlight beam, turn the adjustment
knob. Adjust both headlights evenly.
Line B 515 mm (20.3 in) above ground
4. Select low beam.

5. Beam aiming is correct when the focus point
(brightest spot) of the headlight reflection is
within the marks.
+-—\ 4-]> <—T
rmu201D-D01-EDZJ:
TYPICAL HEADLIGHT REFLECTION ON TEST SURFACE rmr2011-O79-0013
1. Ground RH SIDE SHOWN
2. Focus point 1. Adjustment knob "HB"
A. 415mm (16.3In) above ground
B. 515mm (20.3inl above ground HEADLIGHT BEAM ADJUSTMENT
High Beam Raise beam Turn knob clockwise
1. Follow steps 1 and 2 of the low beam verifica- Lower beam Turn knob counterclockwise
tion procedure.
2. Trace 2 lines parallel to the ground on the test Lower Headlight Units (European Models Only}
surface as follows: 1. To adjust headlight beam, turn the adjustment
LINES ON THE TEST SURFACE knob. Adjust both headlights evenly.
Line A 800 mm (31.5in) above ground
Line B 850 mm (33.5in) above ground
Select high beam.

Beam aiming is correct when the focus point
(brightest spot) of the headlight reflection is
within the marks.
rmr201 1-079-0023
<——\ -<—1> (—UJ RH SIDE SHOWN

I. Adjustment knob "LB"
rmo20‘lD-U01-301_h
TYPICAL HEADLIGHT REFLECTION ON TEST SURFACE HEADLIGHT BEAM ADJUSTMENT
1. Ground
2. Focus point Raise beam Turn knob clockwise
A. 800mm (31.5inl above ground
B. 850 mm (33.5in) above ground Lower beam Turn knob counterclockwise
Headlights Aiming Adjustment
1. Remove both middle side panels. Refer to
BODYsubsection.
rmr201 1-079 497
I I I
Beam Selector Switch Test with HEADLIGHT HI/LO BEAM RELAY (R8)
B.U.D.S.
FUNCTION PIN COLOR
1. In B.U.D.S., select Monitoring and Cluster
tabs. Relay winding ground (from
beam selector switch) A12 GREEN/RED
2. l\/lonitor the High Beam indicator in the Switch
Inputs field. 12 volt output to HI
beam circuit AID GRAY
12 volt output to LO
Switch inputs Reammei beam Circuit A11 GRAY/BEIGE
I Flasher L1‘ if I 1 HEADLIGHT BEAM SELECTOR SWITCH

FUNCTION PIN COLOR
Flasher R: I * \
From headlights HI/LO
l Hazard: High Beam: if) beam relay (R8) winding MLSZ2 GREEN/RED
Flasher Res: ~
Headlight Circuit Protection
rmr201 1-O79-OO3_a CONDITION CIRCUIT PROTECTION I
7. High Beam Indicator Supplied at all times MF7 of rear fuse box
If the indicator turns ON when high beam is se-
lected, an input signal in sent to the gauge. Headlight Relay Voltage Test
If the indicator does not turn ON when high beam 1. Make sure I\/IF7 of rear fuse box is in good con-
is selected, check switch and wiring continuity. dition and powered.
2. Check for voltage at the front fuse box, head-
Headlight Wire Identification light relay (R6) location using the following ta-
HEADLIGHT RELAY (R6I ble:
FUNCTION PIN COLOR HEADLIGHT RELAY VOLTAGE TEST
12 volt input from fuse TEST PROBES CONDITION V08‘-3Té\)GE
|\/IF7 (headlights power) D“ ORANGE/BLACK
12 volt input from fuse - Close to
MF7 (relay winding input) CU ORANGE/BLACK D41 to CIEIISSIS At all times battery
groun voltage
12 volt output to HI/LO
beam re|ay (R8) D12 BROWN/VIOLET
. Close to
C41 to Chjssls At all times battery
Relay winding ground groun voltage
(from ECMB_F1) C12 BROWN/\/VHITE
. .
C-12 to positive -
Engine Close
ban to
HEADLIGHT HI/LO BEAM RELAY (R8) battery connection running ery
voltage
FUNCTION PIN COLOR
12 volt input from headlight If results are as specified, try a new relay.
relay (R6) (headlights B12 BROWN/\/IOLET If results are not as specified, repair wiring/con-
power) nectors.
12 volt in F3 ut from fuse B10 ORANGE/BLACK NOTE: Note the ground signal to pin C12 is pro-
l\llF7 (relay winding input) vided by the EC|\/I. If circuit is correct and the
ground signal does not reach the relay, try a new
ECM.
HI/LO Headlight Relay Voltage Test
1. Make sure MF7 of rear fuse box is in good con-
dition and powered.
498
rmr201 1-079
2. Check for voltage at the front fuse box, HI/LO HEADLIGHT VOLTAGE TEST
headlight relay (R8) location using the following HEADLIGHT
chart. BEAM
HI/LO HEADLIGHT RELAY VOLTAGE TEST TEST PROBES SELECTOR RESULT
SWITCH
TEST PROBES CONDITION V°('bTé‘)GE POSITION
- Close to 4btO Low beam or Close to

positive attery
Connection . beam
high battery voltage
B-10 to Chdassns At all times battery
groun voltage
Pin 3 to pin 4 High beam bagfysjojfage
B12 to chassis Engine Ctiose
tt to
ground running vgjtsga Pin 3 to chassis H. h beam Close to
ground '9 battery voltage
Engine
A - . Close to
A12 to positive running and bane If there is no voltage at pin 1 in the low beam po-
battery connection High beam Om IV sition, check the headlight and HI/LO headlight re-
selected V ge
lays.
If results are as specified, try a new relay. If there is no voltage at pin 3 in the high beam
If results are not as specified, check headlights reposition, check the HI/LO headlight relay.
lay (R6) repair wiring/connectors. If voltage is within specification from pin 1 to
NOTE: Note the ground signal to pin A12 is pro- pin 4, however the headlight does not illuminate,
vided by the beam selector switch. lf circuit is replace the headlight bulb.
correct and the ground signal does not reach the If voltage is within specification from pin 3 to pin 4,
relay, carry out HEADLIGHT BEA/I/I SELECTOR however the high beam shutter does not function,
SWITCH TEST replace the high beam shutter.
Headlight Voltage Test Headlight Beam Selector Switch Test

1.To test for voltage at the headlight bulb and or NOTE: Due to the electronic circuitry of the head-
shutter solenoid, disconnect the headlight con- light beam selector switch, it must be tested us-
nector, refer to HEADL/GHTHEPL/4CEMENTin ing a voltmeter while headlights are ON.
this subsection. 1. Remove the left side acoustic panel. Refer to
2. Test for power at the headlight connector as per BODYsubsection.
the following chart: 2. Back probe connector terminal with an appro-
3. Start engine. priate tool and test with the FLUKE 115 MULTI-
METER (P/N 529 O35 868) as indicated.
HEADLIGHT VOLTAGE TEST
3. Turn ignition switch ON.
HEADLIGHT
BEAM
TEST PROBES SELECTOR RESULT
SWITCH
POSITION
. 1 to pin
Pin . 4 Low beam CloseVonage
battery to
Pin 1 to chassis LOW beam Close to

ground battery voltage
l
rmr201 1-079
499
Y},
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I“L~_~...?’.'\ I‘.-‘II I
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L/ i......
5!-.4
rrnr2n1003B-O22_a
‘
. ” I
i ,.?’I?%:?.,*(,
1/
<3
I. Upper retaining screw
I'rnr2(IIG030-U02_6
- —*--~ 3. Remove middle retaining screws from front fas-
1. MSL2 connector cia.
2. MSL3 connector
HEADLIGHT BEAM SELECTOR SWITCH TESTING

SWITCH SWITCH
CONNECTOR POSITION RESULT
Connector MSL2 Close to
pin 2 to chassis Low beam battery
ground voltage
Connector MSL2 High beam
pin 2 to chassis or flash high CIOSG to
ground beam Q45 Vdc
If the headlight beam selector switch test is within
specification, however the high beam relay volt- rmr201 D-O38-O23_a
age test failed, test the continuity between left 1. Middle retaining screw
multifunction connector l\/lSL2-2 and relay termi-
nal A-12. 4. Remove lower retaining screws and washers
from front fascia.
If the test is not to specification perform the LEFT
its
MUL TIFU/l/C‘77ON SWITCH VOLTAGE TESTin this
subsection. ll
‘ts " - _. .7
I.. .-
_ -7 ij - IL
Headlight Bulb Replacement
t.
A . 7 ' II E / . '
1. Remove the top side panel. ' I I" Iii‘ ' ‘
2. Remove the upper retaining screws from front
fascia. - ‘ii . ;TF‘7.1"-T-T: II’ ‘ ,
vi 2/
tit. T. ~- .1 r¥i"=*b:»*~'
rmr201 IJ-O3B~lJ24,a
1. Lower retaining screw
5. Remove front fascia.

6. Remove adjustment cable retaining nut.
500
rmr201 1-079
Q.» w
rm0201C¥001-Cl7B_a
Vmrzmwywom 1. Unplug connector

1. Adjustment cable retaining nut 11.Turn the bulb counterclockwise to unlock it.
7. Remove from headlight the 4 retaining screws.
R’
rmo2010-001-07912
rrnc2D1D-CID1-0'I6_a
1. Turn counterclockwise
1. Retaining screws
8. Pull tabs apart the to unlock cover. I2‘ Pu“ bulb out
13. Insert the new bulb into its socket then turn
clockwise to lock it in position.
NOTICE Never put your fingers on a new
halogen bulb. This would shorten its life.
I\J
iii
\
1 Sh».
rmo2010-001-077_a
1. Headlight cover
2. Pull tabs apart
9. Pull cover out.

10. Disconnect the bulb connector.
rrnr2011-O79 501
I I l 1 |
5. Check for voltage at the fog light connector

as per the following chart using the FLUKE 115
MULTIMETER (P/N 529 035 868).
FOG LIGHTS VOLTAGE TEST AT FOG
LIGHT CONNECTOR
FOG LIGHT SWITCH
CONNECTOR POSITION RESULT
Close to
Pin 2 to pin 3 Switch ON battery
voltage
Pin 3 to chassis Close to
ground Switch ON battery
ri-rio2U10-001-i)79_b voltage
7. Turn clockwise
Pin 2 to positive Close to
14. Plug connector to the bulb. battery connection Switch OFF battery
vohage
15. Reinstall headlight cover and remaining parts
in the reverse order of the removal. If the fog light voltage testing is within specifi-
cation, replace the fog light bulb. Refer to FOG
FOG LIGHTS (OPTION PACKAGE) LIGHTBULB HEPL/lCEMENTin this subsection.
If there is no voltage at pin 3 with the headlight
Fog Lights Wire Identification switch ON, perform the FOG LIGHT VOLMGE
FOG LIGHT SWITCH TESTA T SWITCH.
FUNCTION PIN COLOR If result at pin 2 is not as specified, repair ground
circuit.
12 volt input from load
shedding relay 2 GREEN/GRAY Fog Light Voltage Test at Switch
12 volt output to lights 3 GRAY/GREEN 1. Make sure F8 of front fuse box is in good con-
dition and powered.
LIGHTS
2. Remove the central panel to access the back of
FUNCTION PIN COLOR the fog light switch. Refer to BODYsubsection.
12 volt input from fog 3. Perform the test at the back of the fog light
fights Switch 3 GRAY/GREEN
switch with the switch connected.
Ground 2 BLACK 4. Start engine.
5. Perform the test with the FLUKE 115 MULTIME-
Headlight Circuit Protection TER (P/N 529 035 868) using the following illus-
CONDITION CIRCUIT PROTECTION
tration and chart.
F8 of front fuse box
Supplied at all times (through load shedding
relay)
Fog Light Voltage Test at Fog Light

Connector
1. I\/lake sure F8 of front fuse box is in good con-
dition and powered.
2. Remove the middle side panel. Refer to BODY
subsection.
3. Disconnect the fog light connector to be tested.
4. Start engine.
502
rmr2D1‘l-079
l l M 1 j

'1
‘T L
CD-Q-*
rmo201(}O01-071_a
1. Fog light
m1r2010-30-04O_a
2. Access to the fog light bulb
BACK OF FOG LIGHT CONNECTOR (PIN-OUT)
Pull tabs apart to unlock cover.
FOG LIGHTS VOLTAGE TESTING AT SWITCH
FOG LIGHTS
SWITCH P%g’:Ifg"N RESULTS
CONNECTOR
Pin 2 to chassis Any cggftirt/O
ground voltage
PI" 3 ‘° Chassis Switch on Ciigitirllo

ground voltage I."-'
.,2'?’-"Ti 5 '3‘ '1;
If there is voltage at pin 2 to but no voltage at .\""' I I
pin 3 when the switch is ON, replace the fog lights

switch.
If there is no voltage from pin 2 to chassis ground, rmo2CI1t>0O1-O72_a
test load shedding relay. Refer to POWERD/.S‘TF’l- 1. Fog light cover
BUTION AND GROUNDS subsection. 2. Pull tabs apart
If there is voltage at pin 3, check the continuity Pull cover out.

from pin 3 of the fog lights switch and pin 3 of the Disconnect bulb connector.
fog light connector. Repair the wires/connectors
as necessary.
Fog Light Bulb Replacement
Remove the middle side panel.
Clean the back area of fog light. ~o
Insert your hand through the opening above the

upper arm of front suspension.
;/
rmo2010-UB1-O73__a
1. Unplugged connector
Turn bulb counterclockwise to unlock it.
rmr2011-079
503 I
-=2
rmr201D-30-038_
rrno2U10-001-O 74_a
FRONT LEFT BUMPER COVER AIR DUCT
1 . Turn coun terclockwise 1. Screws
2. Plastic rivets
Pull bulb out.
3. Remove the 3 screws at the bottom inside of
IVUTICE Never put your fingers on a new the front panel.
halogen bulb. This would shorten the bulb
life.
Insert the new bulb into its socket then turn clock-
wise to lock it in position.
‘~
rmr201 0-3(H)44_a
INS/DE OF LEFT FRONT PANEL

1. Screws
1?‘
4. Remove the 3 plastic rivets from the top of the
j rmo20l0-001-O74_b front panel.
1. Turn clockwise
Plug connector to the bulb.

Reinstall fog light cover and middle side panel in
the reverse order of the removal.
Fog light Removal
1.Remove the front cargo module. Refer to
BODYsubsection.
2. Remove the 6 plastic rivets and the 2 screws
from the front bumper cover air duct.
504
rmr2011 079
8. Remove the top rear securing screw retaining

the fog light assembly.
Ill I‘. '
rmr2U‘I0-30-O45_a
TOP OF THE LEFT FRONT PANEL

1. Plastic rivets
5. Carefully remove the front panel. ,,.,,,,m,,,,.,,,_.

6. Remove the 2 front screws retaining the fog l~ T°P'@a’s°’@W
“gm aSsembIy' 9. Carefully remove the fog light assembly.
Fog Light Installation
Installation of the fog light is the reverse of re-
moval procedures. Pay specific attention to all
torque values, refer to BODYsubsection.
_ICENSE PLATE LIGHT

License Plate Light Wire Identification
-. IGNITION SWITCH
FUNCTION PIN COLOR
12 Itf F1 f
fr\()(i1t rig: boxo B RED/YELLOW
fog LIGHT
. crews 12 V0 It OU t DU t tO
license plate lights F ORANGE
7. Remove the rear screw retaining the fog light
assembly. |_|G|.|'|'$
FUNCTION PIN COLOR
12 volt input from
ignition switch I ORANGE
Ground 2 BLACK
License Plate Light Circuit Protection

. . F1ff f b
5“f’I°"ed at 8" "mes (throLi>gh iwliéhl
rrnr2010-30-048_a
1. Rear screw
rrnr2011-079 505
Licence Plate Light Test

1. Remove the licence plate light. Refer to Ll-
CE/VCE PLATE L/GHT BULB REPLACEMENT
in this subsection. _§_
/'1'"
2. Perform the test on the licence plate light as per 1
—
‘TI
--P
the following chart with the FLUKE 115 MULTI-
METER (P/N 529 O35 868).
LICENCE PLATE LIGHT TEST
R3
LICENCE IGNITION
PLATE LIGHT SWITCH RESULT
CONNECTOR POSITION
Close to
Pin 1 to pin 2 ON battery rmoZO1D-001-081_a
voltage
7. Pull out
battery 4. Install the new bulb by pushing it in.
ground ON
voltage 5. Reinstall the lens
Pin 2 to positive A Close
batteryto
battery connection W TURN SIGNAL LIGHTS/HAZARD
vohage WARNING LIGHTS
If the test is within specification, replace the Ii- Turn Signal LightslHazard Warning
cence plate light bulb. Refer to LICENCE PLATE Wire Identification
L/GHTBULR REPLACEME/\lTin this subsection.
If results are not as specified, check wiring/con- CLUSTER
nectors. FUNCTION PIN COLOR
CAN HI 24 WHITE/BEIGE
Licence Plate Light Bulb Replacement
1. Remove the lens screws with a Phillips head CAN LO 23 WHITE/BLACK
screwdriver. Output to LH turn
signal/hazard lights 4 GRAY/PINK
Output to RH turn
signal/hazard lights 5 BROWN/YELLOW
HTS
FUNCTION PIN COLOR
LH rear turn
signal/hazard 12 volt 4 GRAY/PINK
input (from cluster)
RH rear turn
signal/hazard 12 volt 4 BROWN/YELLOW
LH rear taillight
assembly ground 5 BLACK
rrno2010-001-OBU_a
1. License plate /ens screws RH rear taillight
2. Pull lens out.
LH front turn
3. Remove the bulb by pulling it off. signal/hazard 12 volt 1 GRAY/PINK
506
rmr201'l-079
LIGHTS 2. Perform the following test at the rear taillight

connector using the FLUKE 115 MULTIMETER
FUNCTION PIN COLOR (P/N 529 O35 868).
RH front turn 3. Turn ignition ON and activate turn signal switch
signal/hazard 12 volt 1 BROWN/YELLOW on vehicle side to be tested.
REAR TURN SIGNAL TEST
LH front turn
signal/hazard ground 2 BLACK PROBE RESULTS
RH front turn Pin 4 Pin 5 Pulsing 8 to 12 Vdc
signal/hazard ground 2 BLACK Pin 4 Chassis ground Pulsing 8 to 12 Vdc
Positive
Turn Signal Lights/Hazard Warning Pin 5 battery Close to battery voltage
Circuit Protection connection
CIRCUIT
CIRCUIT CONDITION PROTECTION If results are as specified, replace turn signal bulb.
If there is no voltage at pin 4, carry out TURN SIG-
Turn signals Supimzgsat an F1 of front fuse box NAL SWITCH TESTW/TH I5’. U.D.S. in this subsec-
IIOFI.
V:/Igrzifiikdg Supimigsat an F5 of front fuse box If result at pin 5 is not as specified, repair ground
circuit.
Front Turn Signal Test Turn Signal Wire Continuity Test
1. Remove the front mirror assembly of the turn 1. Remove the multifunction gauge. Refer to
signal to be tested. Refer to BOD)/. MULTIFUNCTION GAUGEin this subsection.
2. Perform the following test at the front turn sig- 2. Perform the following test between the turn
nal connector using the FLUKE 115 MULTIMETER signal connector and the multifunction gauge
(P/N 529 O35 868). connector using the FLUKE 115 MULTIMETER
3. Turn ignition on and activate turn signal switch (P/N 529 O35 868).
on the vehicle side to be tested. FLASHER WIRE CONTINUITY TEST
FRONT TURN SIGNAL TEST
PROBE RESULTS CONNECTOR S
CONNECTOR
Pin 1 Pin 2 Pulsing 8 to 12 Vdc
Left front turn Close to
Pin 1 Chassis ground Pulsing 8 to 12 Vdc Pin 4
signal pin 1 0.2 Q
Positive Left rear turn Close to
Pin 2 battery Close to battery voltage Pin 4 0.2 Q
signal pin 4
connection
Right front turn Close to
Pin 5
If results are as specified, replace turn signal. signal pin 1 0.2 Q
If there is no voltage at pin 1, carry out TURN SIG- Right rear turn Close to
Pin 5 0.2 Q
NAL SWITCH TEST WITHB.U.D.S. in this subsec- signal pin 4
tion.
If all the turn signal tests and the turn signal
If result at pin 2 is not as specified, repair ground switch test with B.U.D.S. are satisfactory, replace
circuit. the multifunction gauge.
Rear Turn Signal Test If result is not as specified, repair defective circuit.
1. Remove the rear taillight to be tested. Refer Front Turn Signal Replacement
to TAlLLlGH77BRAKE LIGHT REPLACEMENT
in this subsection. Remove mirror, refer to BODYsubsection.
Replace turn signal.
rrnr2011~D79 507
Rear Turn Signal Bulb Replacement

If the rear turn signal bulbs require replacement, Switch inputs Reammei “
refer to 7I4lLLlGH77BR/IKE LIGHT REPLACE-
MENTin this subsection. ; Flasher Lt ~' f 1 Mode Button: -if :1
I Flasher R: Q Set Button: =‘i_'_
TURN SIGNAL SWITCH l .
l Hazard: High Beam C,
Turn Signal Switch Test with B.U.D.S.
I Flasher Rest Park Brake: »
1. In B.U.D.S., select Monitoring and Cluster
tabs.
2. Monitor the Flasher L and Flasher R indicators rmr201 I-030-D01 J2
in the Switch Inputs field. 1. Hazard indicator
If the indicator turns ON when the hazard warning

Switch inputs Rea] Time: 6 lights are on, an input signal is sent to the gauge.
If the indicator does not turn ON, check wiring
Flasher L; '.'~."_}-*7 I continuity and carry out HAZARD WARNING
l
l LIGHTS SWITCH TESTATGA UGE CONNECTOR.
‘ Flasher R: II)
Hazard Warning Lights Switch Test at
j Hazard: {F High Beam: if?» Gauge Connector
1 Flasher Res: :9 Before proceeding with this test, inspect the 10 A
fuse F5 in the front fuse box.
rmr20l I-075-003_b
If the turn signals function, however the hazard
1. Flasher L and Flasher R indicators warning switch does not function, perform the fol-
lowing test.
If the indicator turns ON when the correspond- 1. Remove the multifunction gauge, refer to MUL-
ing turn signal is selected, the switch is good and TIFUNCTION GAUGE in this subsection.
the gauge receives the signal. Carry out the TURN
SIGNAL WIRE CONT/NU/TY TESTin this subsec- 2. Perform the following test at the multifunction
U01"). gauge connector.
If the indicator does not turn ON when the corre- HAZARD WARNING LIGHTS SWITCH TEST
sponding turn signal is selected, replace switch. AT GAUGE CONNECTOR
TEST PROBES SWITCH

CONDITION RESULT
HAZARD WARNING LIGHTS
SWITCH
Pin I0 and Zhassis Activated Clalgftzryo I
Hazard Warning Lights Switch Test groun voltage
with B.U.D.S.
1. In B.U.D.S., select Monitoring and Cluster If test is within specification, replace the multi-
tabs. function gauge.
2. Monitor the Hazard indicator in the Switch ln- If test is not within specification, perform the
puts field. HAZARD WARNING SWITCH TESTATRH MUL-
7'/FUNCT/ON SWITCH CONNECTOR.
Hazard Warning Lights Switch Test at
RH Multifunction Switch Connector
This test is performed at the MSR2 connector.
508
rmr2011-079
If there is voltage at pins 1 and 6 but not at pin 2

when the switch is activated, replace the hazard
switch.
TAILLIGHT/BRAKE LIGHT
Taillight/Brake Light Wire Identification
IGNITION SWITCH
FUNCTION PIN COLOR
12 volt from F1 of B RED/YELLOW
front fuse box
12 volt output to lights F ORANGE
IMIZOIODEU-004 BRAKE SWITCH

MSR2 CONNECTOR
FUNCTION PIN COLOR
1. Remove the left hand acoustic panel, refer to
12 volt input from F5 1
BODYsubsection. of front fuse box
RED/ORANGE
NOTE: The hazard switch is an Hall Effect switch.
It must be tested using a voltmeter while circuit is 12 volt output to lights 2 WHITE
ON. LIGHTS
Back-probe the connector with the appropriate
FUNCTION PIN COLOR
tool using the FLUKE 115 MULTIMETER (P/N 529
035 868). LH taillight 12 volt
2. Turn the ignition switch ON. input (from ignition 2 ORANGE
switch)
3. Perform the test using the following chart:
RH taillight 12 volt
HAZARD WARNING LIGHTS SWITCH TEST AT input (from ignition 2 ORANGE
RH MULTIFUNCTION SWITCH CONNECTOR switch)
TEST PROBES SWHCH
POS|-HON RESULTS LH brake light 12
volt input (from brake 1 WHITE
Close to light switch)
Pin 6 to chassis Any battery
ground RH brake light 12
voltage volt input (from brake 1 WHITE
Close to
light switch)
Pin 1 to chassis Any battery
ground LH rear taillight BLACK
voltage assembly ground 5
Pin 2ground
to chassis RH rear taillight 5
OFF Close to O Vdc BLACK
assembly ground
Pin 2 to chassis ON H to 12 Vdc
ground Taillight/Brake Light Circuit Protection
CIRCUIT
If all tests are within specification, check the con- CIRCUIT CONDITION PROTECTION
tinuity from the l\/lSR2 connector to pin 10 of the
multifunction gauge connector and repair as nec- F1 of front fuse
- -
Taillights Supplied
an timesat box (through
essary.
ignition switch)
If there is no voltage at pin 6, check the continuity
from pin 6 of the MSR2 connector to pin G of the - Supplied at F6 of front fuse
Brake lights an times box
ignition switch and repair as necessary.
If there is no voltage at pin 1, check continuity be-
tween fuse F5 and pin 1. Repair as necessary.
rmr201 I-O79 509

i_ i 1
Taillight/Brake Light Test 2. Open the side storage compartments.

If no lights function check the 30 A fuse F7 in the 3. Remove the 8 retaining screws from the rear
rear fuse box. paneL
1. If taillight, position and licence lights are inop-
erative, check if F1 of front fuse box is in good
condition and powered.
2. Remove taillight to be tested.
3. Perform the following test at the taillight con-
nector using the following illustration and chart.
rmo20104)01-OB2_a
7. Fiear panel
2. Retaining screws
4. Pull out panel.
rmr201 003 U-O07
TAILLIGHT CONNECTOR
TAILLIGHT/BRAKE LIGHT TEST

TAILLIGHT SWITCH if“./‘l
CONNECTOR CONDITIONS RESULTS - V__2;
Pin 2 to chassis Ignition Close to
ground -
switch ON battery
Vonage
. - Close to
Pm I tgu%%aSS'S Brake applied battery
gr voltage
Pin 5 to positive Close to

-
battery connection Any battery
Voltage
rrno201D-U01-DB3
5. Unplug connector.
If there is no voltage at pin 2 of the taillight con- 6. Turn the bulb counterclockwise to unlock it.
nector, check continuity from taillight connector to
pin F of the ignition switch. Repair as necessary.
If there is no voltage at pin 1 of the taillight con-
nector, check for voltage at the brake light switch.
Perform also the 5’/-?A/(E LIGHT SW/TCH TEST
Refer to BRA/(ES subsection.
If result at pin 5 is not as specified, repair ground
circuit.
Taillight/Brake Light Replacement
NOTE: If a LEDs in the taillight or brake light fail,
the entire taillight must be replaced.
1. Open the top storage compartment.
510 rrnr2011-079
LIGHTS
FUNCTION PIN COLOR
LH position 12 volt
input (from ignition 1 ORANGE
switch)
RH position 12 volt
input (from ignition 1 ORANGE
switch)
LH rear position
light ground 2 BLACK
RH rear position
light ground 2 BLACK
rmo2010-001-O84_a
1. Turn counterclockwise Position Lights Circuit Protection
7. Pull bulb out. CONDITION CIRCUIT PROTECTION
8. Insert the new bulb into its socket then turn F1 of front fuse box
clockwise to lock it in position. Supplied at an times (through ignition switch)
Position Lights Test

1. If taillight, position and licence lights are inop-
erative, check if F1 of front fuse box is in good
condition and powered.
2. Remove the position light bulb. Refer to PO-
SITION LIGHTS BULB REPLACE/I/IENTin this
subsection.
3. Perform the test on the position light as per the
following chart using the FLUKE 115 MULTIME-
TER (P/N 529 035 868).
POSITION LIGHTS TEST
IGNITION
rmo20I [I-OOI-D84_b POSITION LIGHT SWWCH RESULTS
1. Turn clockwise CONNECTOR PUSH-ION
9. Plug connector to the bulb. Close to

Pin 1 to pin 2 Switch ON battery
10. Reinstall rear panel in the reverse order of the voltage
removal.
POSITION LIGHTS PI" I ‘° Chassls Switch ON (iigitiryo

ground voltage
Position Lights Wire Identification
Pin 2 to positive Any Cggfitzrso
IGNITION SWITCH ‘ battery connection Vohage
FUNCTION PIN COLOR
12 volt from F1 of If the test is within specification, replace the posi-
front fuse box B RED/YELLOW tion light bulb. Refer to P05/T/ON LIGHTS BULB
HEPL/lCEMENTin this subsection.
12 volt output to lights F ORANGE
If there is no voltage at pin 1, check continuity
from pin F of the ignition switch connectorto pin 1
of the position light connector. Repair wire as nec-
essary.
rmr201 1-079 511

Subsection 07 (LIGHTS GAUGE AND ACCESSORIES)
If result at pin 2 is not as specified repair ground Pull out the bulb from the holder as indicated be-
circuit low.
Position Lights Bulb Replacement . sq...
Push the lens upwards and towards the rear of I

I
rrric2008-001-087_a
1. Pull out bulb
Insert a new bulb in the holder.

Reinstall the parts in the reverse order of their re-
moval.
Test the lights by turning the ignition to ON.
Lift the front portion of lens with your thumb or a BACK UP LIGHTS
small screwdriver to release
Back Up Lights Type
Back up lights are light bulbs located in the rear
taillights.
Back Up Lights Wire Identification
CLUSTER
FUNCTION PIN COLOR
CAN LO 23 WHITE/BLACK
Output to lights 7 PIN K/BEIGE
LIGHTS
rrrio2008—DU3~0D2_a F
UNCTION PIN COLOR

Turn the lens clockwise and remove it from the
bulb holder LH back-up 12 volt
input (from cluster) 3 PINK/BEIGE
RH back-up 12 volt
input (from cluster) 3 PINK/BEIGE
LH rear taillight
RH rear taillight
1 Turn clockwise
rmr201 1-079
Subsection 07 (LIGHTS. GAUGE AND ACCESSORIES)
Back Up Lights Circuit Protection Back Up Lights Bulb Replacement

CONDITION CIRCUIT PROTECTION The procedure to replace the back up lights is al-
most the same as the procedure to replace the
Supplied at all times F1 of front fuse box rear turn signal bulbs or tail light. Refer to 7I4/L-
L/GH77BHAKE L/GHTBEPL/lCEMENTin this sub-
Back Up Lights Test section
1. Remove the rear taillight to be tested. Refer to
774/LLIGH77BHA/(E LIGHTin this subsection. MULTIFUNCTION GAUGE
2. Perform the following test at the rear taillight Multifunction Gauge (Cluster) Wire
connector using the FLUKE 115 MULTIMETER dentification
(PIN 529 035 868).
MULTIFUNCTION GAUGE (CLUSTER)
3. Turn ignition on and put vehicle in reverse.
FUNCTION PIN COLOR
BACK UP LIGHTS TEST
Load shedding relay YELLOW/LT
PROBE RESULTS ground I BLUE
Pin 3 Pin 5 Close to 12 Vdc Analog coolant
Chassis temperature gauge (CTG) 2 BEIGE/BLACK
Pin 3 Close to 12 Vdc signal
ground
Positive Reverse actuator ground 3 LT BLUE/VIOLET
Pin 5 battery Close to 12 Vdc 12 volt output to LH turn
connecflon 4 GRAY/PINK
signal lights
If the test from pin 3 to pin 5 is within specifica- 12 volt output to RH turn 5 BROWN/YELLOW
tion, replace the back up light bulb. signal lights
If the test from pin 3 to chassis ground is not To VlI\/I (D.E.S.S.) 6 YELLOW/BROWN
within specification, perform the BACK UP 2 volt output to back-up
LIGHTS W/BE CONT/NU/TY TEST on defec- 7 PINK/BEIGE
lights
tive circuit.
12 volt input from main 8 ORANGE/RED
If result at pin 5 is not as specified, repair ground relay 2
circuit.
12 volt input from F1 9 RED/YELLOW
Back Up Lights Wire Continuity Test (front fuse box)
1. Remove the multifunction gauge. Refer to 12 volt input from hazard 10 YELLOW/G RAY
/I/IUL T/FUNCT/ON GAUGE in this subsection. switch
2. Perform the following test between the turn Ground g 11 BLACK
signal connector and the multifunction gauge CTG and FG ground 12 BLACK/VIOLET
connector using the FLUKE 115 MULTIMETER
(P/N 529 O35 868). ACS position sensor 13 LT
signal B LU E/YELLOW
BACK UP LIGHTS WIRE CONTINUITY TEST
Analog fuel level gauge 15 BLUE
(FG) signal
TA"-“GHT
CONNECTOR MULEIZIIIEETION RESULT HI beam indicator input 16 GRAY
CONNECTOR
Parking brake switch inpu T 17 GREEN/WHITE
Pin 1 (LH or RH) Pin 7 cg°§eQi°
ACS release solenoid 18 LT BLUE/RED
signal
If all back up lights tests are within specifications,
replace the multifunction gauge. 19 LT
ACS relay ground BLUE/ORANGE
ACS switch supply 20 PINK/GRAY
rmr201 ‘I-079 513 I

MULTIFUNCTION GAUGE (CLUSTER) 2. Perform testing at multifunction gauge connec-

tor as per following illustration and tables.
FUNCTION PIN COLOR
ACS position sensor 21
supply YELLOW/WHITE
Radio and LH
multifunction switch 22 LT GREEN/PINK
(headlights)
CAN LO 23 WHITE/BLACK
Multifunction Gauge Test Using

B.U.D.S. IIHIZUI U-O30-01-La
Connect vehicle to the latest applicable B.U.D.S. MULTIFUNCTION GAUGE CONNECTOR (PIN-OUT)
version. Refer to COMMUNICATION TOOLS
AND B.U.D.S. subsection. 3. Perform the multifunction gauge power tests
With the FLUKE 115 MULTIMETER (P/N 529 O35
In B.U.D.S., select the Activation and Cluster 868) set to Vdc and then with a test light.
tabs.
Click on the WOW Test button. MULTIFUNCTION GAUGE POWER TEST
WITH MULTIMETER
TEST PROBES IGNITION VOLTAGE

iiii§YI2iiiii=
‘~->= I Jfll »..1l.,(~,- ,
is
, _\q'1 I fl?-. I5)-@2151
rI""Il}lQ¢ 1_»:
POSITION DC
f.,.L.t, ......m It 1.]; ‘ ...-_., l .....
A-J 1 l\/lultifunction . Close to
.;.,,,,.. '
connector
pin 9 Chews
ground Any battery
vonage
1 I Multifunction Chassis Close to
connector round ON battery
pin 8 S voltage
.\:|.|qq i
Y\'\)i‘v lifl I MULTIFUNCTION GAUGE POWER TEST
<.~»:u um) 7 I WITH TEST LIGHT
IGNITION TEST
-_j_i- -Wt 1;“ v'<\"V)ll::_‘
rmr201 0-O30-01 3_a

TEST PROBES POSITION LIGHT
ACTIVATION PAGE, CLUSTER TAB Multifunction . -
1. WOW Test button Chassis Bright
Coginnegtor ground Any light
All indications will come and stay ON so that you
can verify each indication. M |'f t' . .
NOTE: The WOW Test only tests the gauge Ana- cuoiinuergiolim Chassg ON Bnght
pm 8 groun light
log displays, LEDs, and LCD. It does not test the
actual circuit functions related to each indication. If there is no power at pin 9, check fuse F1 and
Multifunction Gauge Power Test the related circuit.
If the multifunction gauge is inoperative, first If there is no power at pin 8, check main relay 2
(R3) and the related circuit.
check for fault codes with B.U.D.S., record all
faults then erase them. Reactivate the electrical If the power test is within specification, continue
system and recheck for faults. If any fault code with the MULTIFUNCTION GAUGE GROUND
appears, perform service actions required. Re- TEST.
fer to COMMUNICATION TOOLS AND B.U.D.S.
subsection. Multifunction Gauge Ground Test
1. Remove multifunction gauge. Perform the multifunction gauge ground tests
With the FLUKE 115 MULTIMETER (P/N 529 035 868)
set to OHMS and then with a test light.
514 rmr2011-079
|v|U|_‘|'|FUNc‘|'|QN GAUGE GROUND TEST 2. Remove the 4 gauge trim retaining screws.
WITH MULTIMETER
TEST PROBES OHMS (Q)
Multifunction Chassis
connector pin 11 I ground CIOSS LO '2 Q
MULTIFUNCTION GAUGE GROUND TEST
WITH TEST LIGHT
TEST PROBES TEST LIGHT
. . Positive
Multifunction
. battery .
Bright .
light
connector pin 11 Connection
If the ground at pin 1 1 is not within specification,

check the related circuit. '. S . Si-ii?» V l'_S'.LTS- _ .
If the ground tested to specification, continue r1'r\i'201 O-D30-OO9_a
with the MULTIFUNCTION GAUGE CAN W/BE 1. Gauge trim retaining screws
TEST 3. To release the 2 side retaining tabs on the back
of the gauge trim, insert a screwdriver into
Multifunction Gauge CAN Wire Test the opening at the top of the mirror mounts as
1. Remove the right side service panel. Refer to shown in the illustration. Then slide the screw-
BODYsubsection. driver up the guide ramp and release the tab
2. Perform the multifunction gauge CAN wire test while gently pulling on the side of the gauge
with the FLUKE 115 MULTIMETER (P/N 529 O35 trim.
868) set to the OHMS. Perform the test be-
tween the multifunction gauge connector and
the DLC (Diagnostic Link Connector) located
underneath the right side service panel.
MULTIFUNCTION GAUGE CAN WIRE TEST
Multifunction DLC (Diagnostic Close to ,_-
connector pin 24 Link Connector)
0.2 Q
(CAN HI) connector pin 1
Multifunction DLC (Diagnostic
Close to
connector pin 23 Link Connector) 0.2 Q
(CAN LO) connector pin 2
rrrir2010~O3D-U10_a
If the CAN wire verification test fails, check the RELEASING GAUGE TRIM TAB
1. Opening for guide ramp
related circuit.
If the multifunction gauge functions, however
there is a suspected communication problem with
another component, perform this test between
the multifunction gauge and that component.
If the multifunction gauge power, ground and
CAN verification tests are all to specifications and
the multifunction gauge is inoperative, replace
Multifunction Gauge Removal
1. Remove the left and right side mirrors. Refer to
BODYsubsection.
rmr201 1 -07$) 515

2. Install the gauge by first inserting the bottom

edge, and then gently pressing against the up-
per edge with both hands until both tabs snap
into place.
3. Install gauge trim tab ensuring the 2 side tabs
snap into place.
4. Install the 4 gauge trim screws and torque to
2.5 N~m (22 lbfsin).
5. Install both side mirrors refer to BODYsubsec-
tion.
NOTE: If a new gauge is installed, refer to MUL-
TIFUNCTION GA UGEBEPLACEMENTin this sub-
rrrir2010-030-OI 1_a
section and match the gauge to the ECM.
RELEASING GAUGE TRIM TAB - TOP COVER REMOVED FOR
CLARITY 6. Start vehicle engine and test gauge functions.
1. Guide ramp
2. Gauge trim retai'ni'rig tab
Multifunction Gauge Replacement
4. Steer handlebar completely to the left. NOTE: If the multifunction gauge is replaced, the
5. Remove gauge trim by lifting the lower section engine may not start because of the security ex-
first. change coding. The gauge must be matched to
NOTE: If equipped with the optional analog tem- the ECM for the vehicle to start.
perature and fuel gauges, disconnect the gauge Connect vehicle to B.U.D.S. Refer to COMMUNI-
connectors. CA T/ON TOOLS AND B.U.D.S. subsection.
6. Release the 2 tabs at the top of the multifunc- Once connected, you will see a message similar
tion gauge by pulling down on the tab with a to the following illustration.
screwdriver. Insert a finger at the side of the
multifunction gauge while the tab is down and
pull the gauge out of its mount.
& TI'IB»_CII.I_5I9I‘ codino does not matchlwith
' I the ECM connected. Do youwantto change it?
is I
VrY'\l'ZOU6~O2 U-O5EI_aen
Make sure you have the right type and gauge

model for the vehicle you are working on before
answering Yes, otherwise it will not function
properly. Select Yes to continue.
Once the gauge has been matched to the ECM,
you will need to set the units of measurement,
rmr201 D-03001 2_a miles or kilometers.
RELEASING MULTI FUNCTION GAUGE
1. Multifunction gauge retaining tab In B.U.D.S., select Read Data.
2. Pull down with screwdriver
Select Setting and Cluster tabs and select the de-
7. Disconnect the gauge connector and remove sired unit.
the gauge.
Multifunction Gauge Installation
1. Install connector on multifunction gauge.
516 rmr201 1-O79

v-tron I swim I uuuwiq I Mme» I run I n-in I

ANALOG COOLANT
TEMPERATURE GAUGE
Analog Coolant Temperature Sensor
Wire Identification
‘I ANALOG COOLANT TEMPERATURE GAUGE
FUNCTION PIN COLOR
12 volt input from FGLP ORANGE/RED

Clnflkhli main relay 2 F62 ORANGE/RED
1- mow
rM$¢
To fuel level sensor FG1-S BLUE
19¢;-1l.*;=l‘.§9.2i_I&J Ground FG1-G BLACK/VIOLET
rmr201 1-079-007_a
1. Cluster Units
_EFT MULTIFUNCTION SWITCH
NOTE: The units of measurement may also be
set using the MODE and SET buttons on the Left Multifunction Switch Wire
RECC on the left hand multifunction switch. Re- dentification
fer to the PREFERENCES SCREEN in CATEGORY
LEFT MULTIFUNCTION SWITCH
/CON SCREEN DESCRIPTION located in this
subsecflon. FUNCTION PIN COLOR
The SPS (Suspension Position Sensor) must be re- Hi beam (relay winding GREEN/RED
set with B.U.D.S. Refer to REAR SUSPENSION ground signal) MSLZS2
subsection for the complete reset procedure. 12 volt input MSL2-1 ORANGE/RED
Select the Faults tab and see if there are any
CAN LO MSL3-2 WHITE/BLACK
active fault codes. If the faults have all been
corrected, clear the occurred faults displayed and CAN HI MSL3-3 WHITE/BEIGE
start vehicle. MSL1-2 GREEN
Finally, make sure the multifunction gauge func-
tions properly and that all settings and indications MSL1-3 BROWN
Cruise control switch
are within parameters. IVISLI -4 WHITE
MSL1-1 BROWN/BLACK
ANALOG COOLANT
Ground MSL2-4 BLACK
TEMPERATURE GAUGE
Horn MSL2-6 BROWN/G RAY
Analog Coolant Temperature Sensor
Wire Identification Ground (horn) MSL2-5 BLACK l
ANALOG COOLANT TEMPERATURE GAUGE Left Multifunction Switch Circuit
FUNCTION PIN COLOR Protection
12 volt input from CTGLP ORANGE/RED CONDITION CIRCUIT PROTECTION
ma)" relay 2 ctcz ORANGE/RED Supplied at all times F1 of front fuse box I
Signal from multifunction
gauge CTG1-S BEIGE/BLACK
CAN Communication Test for Left
Ground CTG1-G BLACK/VIOLET Multifunction Switch
1. Ensure the module is powered. Referring to
the W/R/NG DIAGRAM, check the following.
1.1 Power and ground circuits
1.2 Terminals (bad contact, out of shape, bro-
ken)
rmr2011-079 517
1.3 CAN circuits between the querying mod- LEFT MULTIFUNCTION SWITCH VOLTAGE
ule and the missing module (continuity, TEST WITH MULTIMETER
short between CAN LO and HI circuits,
short to power or ground). TEST PROBES VOLTAGE DC
Left Multifunction Switch Test with MSL2 connector Chassis Cggftix/O

B.U.D.S. pin 1 ground Voltage
1. In B.U.D.S., select the Monitoring and ACC
tabs. If voltage is to specification carry out the LEFT
MUL T/FUNCTION SWITCH GROUND TEST
2. Monitor the MSL Group Box of the screen
while activating the following buttons: If voltage is not to specification perform LEFT
/I//UL T/FUNCT/ON SWITCH A CTII44 T/ON W/RE
— Mode CONT/NU/T)’ TEST
— Set
— Thumb Up Left Multifunction Switch Activation
- Thumb Down Wire Continuity Test
- Thumb Right 1. Remove the multifunction gauge.
— Thumb Left 2. Check continuity as follows:
— Push To Talk.
LEFT MULTIFUNCTION SWITCH ACTIVATION
WIRE CONTINUITY TEST
MEI. 510111 I1“-'.\r HIE)? \5f-':'lfI BOY
LEFT TI
X Midi SET/DEC ‘ MULTIFUNCTION MULTIFUNC
GAUGE ON RESULT
GAUGE
Set RCQACGEI. S
connsctoa CONNECTOR
i I\|I’t I IP ('1-ma rm
MSL2 Connector - Close to
(hurt: limm
mn1 Snzz oio
iliuiili I-\qM ‘S
Thu1'I\D L141
lf the continuity test passes and none of the LH
multifunction switch functions operate, replace
F'I2SflTOTflk'
rmr201 I-0751-00-La
If continuity test fails, repair defective circuit.
I. MSL Group Box
Left Multifunction Switch Ground Test
If the indicators turn ON while pressing the but- 1. Check voltage as follows:
tons, the switch is good.
LEFT MULTIFUNCTION SWITCH VOLTAGE
If the indicators do not turn ON in B.U.D.S. con- TEST WITH MULTIMETER
tinue with the left multifunction switch voltage
test. TEST PROBES VOLTAGE DC
MSL2 connector Chassis
Left Multifunction Switch Voltage Test pin 4 I ground Close to .1 Q
This test can be carried out using a test light. A
dim test light indicates a possible parasitic resis- If the test is not to specification repair circuit.
tance in the tested circuit. If the test is to specification continue with LEFT
1. Remove the left acoustic panel, refer to BOD)’ MUL77FUNCT/ON SWITCH CAN WIRE TEST
subsection.
2. Turn ignition switch ON position. Left Multifunction Switch CAN Wire
Test
3. Perform these tests on the left multifunction
switch connector as per following charts using 1. Check continuity as follows:
the FLUKE 115 MULTIMETER (P/N 529 035 868).
518 rmr2011 O79

HEATED GRIPS SWITCH

FUNCTION PIN COLOR
1 LIGHT
To heating element (LO) GREEN/BLUE
12 volt input (from load LIGHT

shedding relay) 2 GREEN/GRAY
LIGHT
To heating element (HI) 3
GREEN/\/\/HITE
Switch illumination ground 7 BEIGE/BROWN
Switch illumination 12 volt 8 ORANGE/RED
input (from main relay 2)
M““K.w,_.
rrrir2I)1(J-030-0O2_a
1. MSL2 connector
Front Heated Grips Circuit Protection
2. MSL3 connector
MULTIFUNCTION SWITCH CAN WIRE TEST
Th'°“9" '°‘-id
shedding relay
F8 of IUS6 front box
DLC
(CAN HI) . . Front Heated Grip Resistance Test
multifunction ID‘afi2iS*'° Close to 0.2 Q 1. Remove the central panel to access the back of
switch connector C onnector )
MSL3 pin 3 pin 1 the heated grip switch. Refer to BODYsubsec-
tion.
DLC 2. Perform the test at the back of the heated grip
(CAN LO) . .
multifunction IDLSSQESIIC switch with the switch disconnected.
Close to 0.2 Q
switch connector
. C 3. Perform the test with the FLUKE 115 MULTIME-
I\/(SL3 pin 2 Og?ne%torI TER (P/N 529 035 868) using the following illus-
tration and chart.
If the CAN wire test fails, repair related circuit.
If the multifunction switch functions, however
mew}, W5. 1i-='~6f_;i9-
there is a suspected communication problem with
another component, perform this test between
the multifunction switch and that component.
If the multifunction switch power, ground and
CAN verification tests all pass and the multifunc-
tion switch is inoperative, replace the multifunc-
tion switch.
FRONT HEATED GRIPS QT“-__.
Front Heated Grips Wire Identification

HEATING ELEMENTS rrnr20'l D030-042_a
FUNCTION PIN COLOR HEATED GRIP SWITCH (PIN-OUT)
. . LIGHT
HI intensity 1 GREEN/WHWE
LO intensity 2 GRFEEI/SJLUE
Ground 3 BLACK
rmr201)-079 519
FRONT HEATED GRIP RESISTANCE TEST PASSENGER HEATED GRIP

(AT SWITCH CONNECTORI SWITCH
TEST PROBES RESULTS
Passenger Heated Grips Wire
Pin 1 to pin 3 Close to 10.9 Q dentification
Pin 1 to chassis ground Close to 6.7 Q SWITCH
Pin 3 to chassis ground Close to 4.5 T2 FUNCTION PIN COLOR
If test is within specification, perform the FRONT 12 volt -input A LIGHT
GREEN/GRAY
HEATED GR/P I/O./.7'AGE TEST
If the test is not within specification, perform test Heating element ground B LIGHT
at front heated grip. Refer to STEER/NG SYSTEM (pulsed) BLUE/PINK
subsection for access to heated grip connectors. Ground C BLACK
NOTE: One open grip heating element will give
an higher ohm reading about double the normal Passenger Heated Grips Switch Circuit
specification. Protection
Front Heated Grip Voltage Test CONDITION CIRCUIT PROTECTION
1. Remove the central panel to access the back of Sllrggigg Ircjigy F8 of fuse front box
the heated grip switch. Refer to BODYsubsec-
tion.
2. Perform the test at the back of the heated grip Passenger Heated Grip Switch Test
switch with the switch connected. 1. Remove the battery panel and switch as-
3. Perform the test with the FLUKE 115 MULTIME- sembly. Refer to PASSENGER HEATED GR/P
TER (P/N 529 035 868) using the following illus- SI/l//TCH REMOVAL in this subsection.
tration and chart. 2. Turn ignition switch to ON position and start en—
4. Turn ignition switch to ON position and start engine.
gine. 3. Perform the test with the FLUKE 115 MULTIME-
FRONT HEATED GRIP VOLTAGE TEST TER (P/N 529 O35 868) using the following table.
IAT SWITCH CONNECTORI PASSENGER HEATED GRIP SWITCH TEST
IAT SWITCH CONNECTORI
TEST PROBES SW'T°H
POSITION RESULTS
TEST PROBES RESULTS
Pin 2 to chassis . Close to CloseVoltage
to battery
ground Switch OFF LT BU/PK to BK wires
battery voltage
Pin 1 to chassis LOW Close to Closevoltage
to battery
ground intensity battery voltage LT GN/GY to BK wires
Pin 3 to chassis HIGH Close to LT GN/GY wire to chassis Close to battery
ground intensity battery voltage ground vohage
If there is no voltage at pin 2, check fuse F8 BK wire to chassis ground Close to 0.2 Q
and load shedding relay operation. Refer to the
POWER D/STR/BUT/ON AND GROUNDS sub- lf test is to specification, proceed with the passen-
section. ger heated grip element resistance test.
lf there is voltage at pin 2 but no voltage at pin ‘I in If there is no voltage from the LT GN/GY wire
the low intensity position, replace the heated grip to chassis ground, check the circuit for fuse F8
switch. and load shedding relay operation. Refer to the
If there is voltage at pin 2 but no voltage at pin 3 section.
in the high intensity position, replace the heated
grip switch. lf there is no voltage from the LT BU/PK wire
to chassis ground, proceed with the passenger
heated grip element resistance test.
520 rrnr201l~079
If there is no continuity from BK wire to chassis

ground, check the ground wire and repair as nec-
essary.
Passenger Heated Grip Element
Resistance Test
1. Remove the right or left rear switch panels to
access the rear grip connector.
2. Perform the test with the FLUKE 115 MULTIME-
TER (P/N 529 O35 868) using the following table.
PASSENGER HEATED GRIP ELEMENT
RESISTANCE TEST
TEST PROBES RESULTS
rmr201 0030-01 6
PIN 1 to PIN 2 of either
grip element 8 to I0 Q 5. Depress the three tabs on the switch and re-
move from battery panel.
If the resistance of either grip element is not
within specification, replace the defective grip.
If the resistance is within specification and the
voltage and ground to the switch are also good,
replace the passenger rear heated grip switch.
Passenger Heated Grip Switch
Removal
1. Refer to BOD)/subsection and remove the fol-
lowing:
— Left middle side panel
- Left top side panel
— Left rear side panel. rmr2010-030-017
2. Remove left screws for battery panel and

switch assembly. Passenger Heated Grip Switch
3. Disconnect PRS (Pillion Rider Switch) connec-
nstallation
tor. Reinstall the passenger heated grip switch in the
reverse order of removal.
rmr201 0-030-O1 5
4. Disconnect passenger heated grip switch con-

nector.
rmr201 I-079 521

RADIO MODULE RA|J|Q MQDULE

Radio Module Wire Identification FUNCTION PIN COLOR
RADIO MODULE RDO2—9 WHITE/BLACK
FUNCTION PIN COLOR RDO2-2 WHITE/BEIGE
LIGHT RDO2-3 GRAY/B LACK
RDO1—6
GREEN/BLACK
RDO2-I BLUE/GRAY
BROWN/LIGHT
RDO1-7 BEIGE/LIGHT
BLUE RDO2—4
GREEN
To GPS RED/LIGHT
RDO1-8 GRAY/LIGHT
connector GREEN RDO2—l1
BLUE
LIGHT To CB connector
RDO1-9 BLUE/LIGHT
GREEN/BEIGE RDO2-5
GREEN
LIGHT RDO2-10
RDOI-34 G RAY/B LAC K
GREEN/YELLOW
RDO2-8 BLUE/G RAY
RDO1-27
12 volt input LIGHT LIGHT
RDO1-28 RDO2-13
from F6 GREEN/RED BLUE/WHITE
RDO1-29
RDO2—6 GRAY/WHITE
CAN HI RDO1-16 WHITE/BEIGE
RDO2-12 BLUE/BROWN
CAN LO RDO'l—17 WHITE/BLACK 12 volt
RDOI-11 ORANGE/GRAY input from LIGHT
RDOI-33
multifunction GREEN/PINK
RDO1-12 BLACK/BLUE gauge
RDOI-I3 BLACK/G RAY WHITE/LIGHT
RDO1-21
RDO1-22 BLACK/VIOLET GREEN
To iPOD
connector LIGHT Passenger radio WHITE/LIGHT
RDO1—23 RDO1-I4
B LU E/B ROWN control BLUE
LIGHT BLUE/LIGHT
RDOl—24 RDOI-15
GREEN/BROWN BLUE
RDO1-25 ORANGE/BROWN RDO1—3O BLACK

Ground RDO1-31 BLACK
RDOI—32 BLACK
Front left RDOI-3 PINK/BLACK

speaker
RDO1-2 PINK
BROWN/LIGHT
Front right RDO1-1O
GREEN
speaker
RDO1-I LIGHT GREEN
Rear right RDO1-26 VIOLET/BLACK
speaker RDO1-18 VIOLET
Rear left RDO1-5 GREEN/BLACK
speaker RDO1—4 GREEN
522 rmr201 1-O79

RADIO MODULE ‘Ea \\\>\/ ‘~ Q

FUNCTION PIN COLOR
RDO2-15 WHITE/GREEN / /ff
RDO2-21 WHITE/BROWN
RDO2—1 6 G RAY/BLACK
RDO2-I 4 B LU E/G RAY
RDO2-23
LIGHT
BLUE/BLUE xii-
_ 4
RDO2-I 7 G RAY/Y E LLOW

XM satellite LIGHT
radio connector RDO2-24 bx
GREEN/GREEN rmr20I CI-030-(J21
RDO2-22 GRAY/B LACK 4. Test the radio voltage power at the at the radio
RDO2-20 BLU E/G RAY connector as per following tables and illustra-
tion using FLUKE 115 MULTIMETER (P/N 529 035
LIGHT 868).
RDO2—1 9 GREEN/LIGHT
BLUE
RDO2—25 GREEN/VIOLET
RDO2-18 GREEN/PINK
®@@§®f5i
Radio Module Circuit Protection QQGQQEI
OOOOQO
Supplied at all times F6 of fuse front box GQOSGGE
Radio Tests Guidelines
Make sure F6 of front fuse box is in good condition
and powered before beginning any voltage test.
The following voltage tests can be carried out us-
rmr20IO-030-O22_a
ing a test light. A dim test light indicates a possi-
RADIO CONNECTOR PIN-OUT
ble parasitic resistance in the tested circuit.
To access the radio connector, refer to RAD/O RE- RADIO CONSTANT POWER CIRCUIT
MOVAL in this subsection. VOLTAGE TEST
TEST PROBES VOLTAGE DC
Radio Constant Power Voltage Test
- 27
Pin ChassisI ground CloseVohage
to battery
lowing:
— Right middle side panel - - Close to battery
Pin 28 Chassis ground Vonage
- Right top side panel
— Right rear side panel. Pin 29 Chassis ground G059 to battery
vohage
2. Remove right radio control panel and switch as-
sembly. If voltage is within specification, carry out RAD/O
3. Disconnect radio connector. AC77V4 T/ON POWER VOLTAGE TEST
If voltage is not within specification, carry out RA-
D/O CONS7I4NT POWER C/RCU/ T CONTINUITY
TEST
rmr201 I -079 523

Radio Activation Power Voltage Test lf the continuity test passes and none of the left
1. Turn ignition switch to the RUN position. hand multifunction switch functions operate, re-
place the multifunction gauge.
2. Perform the following test with the FLUKE 115
MULTIMETER (P/N 529 O35 868) and a test light. If continuity test fails, repair defective circuit.
RADIO ACTIVATION POWER CIRCUIT Radio Ground Circuit Test
VOLTAGE TEST
Verify the radio ground with multimeter between
TEST PROBES VOLTAGE DC the radio connector and chassis ground as per the
. - CloseVohage
to battery following table.
Pin 33 Chassis ground
RADIO GROUND CIRCUIT TEST
If voltage is within specification, carry out RAD/O TEST PROBES RESULT
GROUND C/RCU/T TEST Chassis
Pin 30 Close to 0.1 Q
If voltage is not within specification, perform RA- ground
D/O AC T/ VA T/ON POWER C/RCU/T CONT/NU/ TI’ Chassis
TEST Pin 31 Close to 0.1 Q
ground
Radio Constant Power Circuit Pin 32 Chassis Close to 0.1 Q
Continuity Test ground
Test the radio voltage power continuity with multi- If continuity test fails, repair defective circuit.
meter between the radio connector and the front
fuse block as per the following table. Radio CAN Wire Test
RADIO CONSTANT POWER CIRCUIT If the radio turns on but cannot be controlled by
CONTINUITY TEST the multifunction switch, perform the radio CAN
RADIO FRONT FUSE
wire verification test.
CONNECTOR BOX (FBI) RESULTS 1.To access the radio connector, refer to RAD/O
REMOVAIL in this subsection.
Pin 27 Pin E12 Close to 0.1 Q
2. Remove the right front service panel to access
Pin 28 Pin E12 Close to 0.1 Q the DLC connector. Refer to BOD Ysubsection.
Pin 29 Pin E12 Close to 0.1 Q RADIO CAN WIRE VERIFICATION TEST
If continuity test fails, repair defective circuit. TEST PROBES OHMS (Q)
Radio Activation Power Circuit (CAN HI) radio - DLC

Continuity Test connector Lir§E'gg$ZtCI€0r) Close to 0.2 Q
1. Remove the multifunction gauge. pin I6 connector pin 1
2. Test the radio activation voltage power continu- . DLC
(CAN LO) radio . .
ity with multimeter between the multifunction (Diagnostic
CO'£261(J;0l' Link Connector) Close to 0.2 Q
gauge connector and the radio connector as per
the following table. connector pin 2
RADIO POWER CIRCUIT CONTINUITY TEST If the test is not within specification, check and
(ACTIVATION VOLTAGEI repair the wire as necessary.
MULTIFUNCTION
RADIO GAUGE RESULT Radio Removal
CONNECTOR CONNECTOR 1. Refer to BODYsubsection and remove the fol-
lowing:
Pin 33 Pin 22 C'§§eQ‘° I - Right middle side panel
If the continuity test passes and all the left hand — Right rear side panel.
multifunction switch functions operate beside ra-
dio control, replace the radio.
524 rm r201 1 -O79

Subsection 07 (LIGHTS. GAUGE AND ACCESSORIES)
2. Remove right radio control panel and switch PASSENGER RADIO CONTROL
assembly. Refer to PASSENGER RAD/O CON- SWITCHES
TROL REMOVAL in this subsection.
3. Disconnect antenna connector. Passenger Radio Control Switch Test
1. Remove Passenger Radio Control panel and
switch assembly as detailed in this subsection.
2. Disconnect the radio connector. Refer to RA-
D/O REMOIAAL for access to the connector.
868) to the diode test function.
NOTE: It is important to set the multimeter to the
diode check function when testing the passenger
radio control switch as it contain diodes.
rmr201 D-O30-U19
4. Disconnect radio connector.
,1 . \\\
vri'ii2006-020-005
4. Test the passenger radio control switch at the

radio connector as per following tables.
rmr201 0030021 PASSENGER RADIO CONTROL VOLUME
SWITCH TEST (AT RADIO CONNECTOR)
5. Remove the four screws securing the radio.
SWITCH FLUKE GAUGE
POSITION 115 CONNECTOR VOLTAGE
RED lead Pin 14
Switch Approx.
released BLACK Pin 21 2 Vdc
lead
Volume RED lead Pin 14
Approx.
up BLACK 1 .1 Vdc
depressed Pin 21
lead
Volume BLACK Pin 17

lead Approx.
down 1.6 Vdc
depressed RED lead Pin 18
rrrir2OIO-030-CI2D_B
7. Screws
Radio Installation
Reinstall the radio in the reverse order of removal.
rrnr20'l I-079 525
Section D5 ELECTRICAL SYSTEM
Subsection D7 (LIGHTS, GAUGE AND ACCESSORIES)
PASSENGER RADIO CONTROL CHANNEL If the test is good at the switch but not at the ra-
SWITCH TEST (AT RADIO CONNECTOR) dio connector, check the continuity of the wires
SWITCH FLUKE I
GAUGE between the passenger radio control switch and
POSITION 115 CONNECTOR VOLTAGE the radio connector.
RED lead
If any reading is significantly different than speci-
Pin 15
Switch Approx. fied, carry out the same test at the switch connec-
released BLACK Pin 21 2 Vdc tor, refer to the wiring diagram. If you obtain the
lead same results, replace the switch assembly.
Channe| ‘ RED lead Pin 15 If voltages measured on the switch at the radio
Approx. connector are as specified (or very close to it), the
down BLACK Pin 21 1.1 Vdc switches and the wiring harness are good. The
depressed |ead
fault may be within the radio.
Chennai RED lead Pin 15
Approx. NOTE: The test results given for the diode switch
up BLACK 1.6 Vdc were obtained with a FLUKE 115 MULTIMETER
depressed read Pin 21
(P/N 529 035 868). If a different multimeter is
used, the test result may not be accurate unless
If the test at the radio connector are not within the multimeter has a minimum resistance range
specification, perform the test at the passenger of 12 Mega ohms. Ensure to check the specifica-
radio control switch per following tables tion of the multimeter being used.
PASSENGER RADIO CONTROL VOLUME
SWITCH TEST IAT SWITCH) Passenger Radio Control Switch
Removal
SWITCH FLUKE
POSITION 115 SWITCH PIN VOLTAGE 1. Refer to BODYsubsection and remove the fol-
lowing:
RED lead Pin B
Switch Approx. — Right middle side panel
released BLACK Pin A 2 Vdc — Right top side panel
lead
— Right rear side panel.
vo|ume RED lead Pin B 2. Remove 2 screws for radio control panel and
Approx.
UP BLACK 1.1 Vdc switch assembly.
depressed |ead Pin A
vO|ume RED lead Pin A

Approx.
down BLACK Pin B 1.6 Vdc
depressed |ead
PASSENGER RADIO CONTROL CHANNEL

SWITCH TEST IAT SWITCH)
SWITCH FLUKE
POSITION 115 SWITCH PIN VOLTAGE
RED lead Pin C

Switch Approx.
released BLACK Pin A 2 Vdc
lead rm1Z0‘l003D-l1IB_a
PASSENGER RADIO CONTROL PANEL

Channe| RED ISBCI Pin C 1. Screws
Approx.
dew" BLACK Pin A 1.1 Vdc 3. Disconnect passenger radio control switch con-
depressed |ead nector.
Channel RED IOOO Pin C
Approx.
UP BLACK 1.6 Vdc
depressed mad Pin A
If the test is not within specification at the switch,

replace the switch.
526 rmr201 ‘I-079

, t. *.*§.~\*'
V I I
ff
rmr2O I Cl-03002 1
rmr201 [H330-D16
4. Test the Passenger speaker resistance at the

4. Depress the three tabs on the switch and re- radio connector as per following table:
move from switch panel.
SPEAKER TESTING IAT RADIO CONNECTOR)
SPEAKER GAUGE
CONNECTOR oi-iivis (Q)
Front left Pin 3
speaker Pin 2 3'2 to 4'3 O
Front right Pin 10
Right rear Pin 26
Right left Pin 5
rmr201 D-03001 7
If the resistance values of the speakers is within
specification, perform the SPEAKER /NPUT VOL71
Passenger Radio Control Installation AGE TEST
Reinstall the passenger radio control switch in the
If the resistance of one speaker is bad, check the
reverse order of removal. resistance at the speaker terminals:
- If good, check the continuity of the wires to the
SPEAKERS radio connector and repair as necessary.
Speaker Resistance Test - If bad, replace the speaker.
lowing: Speaker Input Voltage Test
— Right middle side panel 1. Access the correct speaker terminals. Refer to
— Right top side panel the appropriate speaker removal procedure.
— Right rear side panel. 2. Test the speaker with the connectors con-
nected to the speaker with a multimeter set to
2. Remove right radio control panel and switch as- Vac as per the following chart and illustration.
sembly.
NOTE: The voltage reading at half volume should
3. Disconnect radio connector. be pulsing and will vary with the radio station and
volume intensity.
rmr201)-079 527
._!-
r2010-030-043_a rmr2010-030024 _a
TESTING VAC AT THE SPEAKER TERMINALS I. Screws
SPEAKER INPUT VOLTAGE TEST 4. Carefully pull back and upward on rear panel to
TEST ONE HALF remove from vehicle.
PROBES NO VOLUME VOLUME 5. Remove the antenna mast (if necessary).
Speaker .300 Vac to 6. Remove 3 screws inside the top rear storage
Terminals ‘O00 Vac 1.3 Vac compartment securing the speaker and arm
rest assembly.
If the AC voltage test is good at the speaker ter-
minals, replace the speaker.
lf the AC voltage reading at the speaker is not
within specification, replace the radio.
Rear Speaker Removal
1. Open top and both side storage component
covers.
2. Remove 2 screws at the top rear of each side
storage compartment.
. ‘_'=‘;I
_-.”.....E -I
rmr2010-030-O25_a
1. Screws
7. Carefully remove the speaker and arm rest as-

sembly.
NOTE: If the SPEAKER /NPUT VOLTAIGE TESTis
to be performed, proceed with that test now. if
the speaker is to be replaced, continue with this
procedure.
rm r2 010-030-023_é
1. Screws
8. Remove the 3 speaker side cover screws on
the outside of the cover.
3. Remove 4 screws on the rear of top storage
compartment.
528 rmr2011-U79
rmr201 0-O30-O2 5_a

1. Screws
9. Carefully lift the edge of the side cover and slide rmr2010-030-Cl29_a
the 3 hooks on the side speaker cover out of 1. Screw
position.
13. Remove the front speaker cover.
14. Remove the 4 speaker screws.
15. Remove the speaker.
Rear Speaker Installation
Reinstall the rear speaker in the reverse order of
removal, pay attention to the following:
Ensure to engage the groove at the inside edge
of the speaker and arm rest assembly with the lip,
located near the rear of the seat.
NOTICE Failure to engage the groove onto
the lip can result in damage to the speaker and
rmr201D-O30-O27_a arm rest assembly.
10. Remove the speaker front cover screw under
the side the cover.
:'
:2}
rmr201 O-D30-030_a
1. Groove
2. Lip
rmr2010~030-O28_a
1. Screw
Front Speaker Removal
11. Remove the speaker front cover screw under 1_ Remove the mumfunetien gauge Refer to
the side of the cover. MULT/FUNCT/ON GAUGE REMOVAL in this
12. Remove the speaker front cover screw on the subsection.
inside of the speaker assembly.
rri'ir2011-079 529
2. Remove windshield and windshield support to- 11. Remove the 2 screws for the multifunction
gether. Referto W/NDS/-//ELDSUPPORTin the mount under the central panel.
BOD)/subsection.
3. Remove front fascia. Refer to FRONT FASC/A I
Il
in the BODYsubsection.
4. Remove WPM module from it support. Refer
to W/NDSH/ELD MODULE /WPM)in the BODY
subsection.
5. Slightly lift WPM module upwards.
6. Disconnect WPM module connector.
rmr201 D-030-U51 _a
TYPICAL
1. Screw
12. Remove the 2 side multifunction gauge mount

screws.
rmr2010-038-O53_a
7. WPM module connector
7. Disconnect windshield motor wires.

8. Remove WPM module from vehicle.
9. Remove the 2 screws for the multifunction
gauge mount behind the wpm module.
rmr201 0-O30-052_a
1. Screw
13. Slide the multifunction gauge mount up and

remove from the vehicle.
14. Remove the 4 speaker screws.
rmr20104)30-050_a
TYPICAL
1. Screw
10. Remove the central panel. Refer to BOD)’

subsection.
530
rmr2011-079
4. Test the auxiliary audio input jack connector

with a multimeter between the radio connec-
tor and the auxiliary audio input jack as per
following table and illustration.
“T.
i_, ._.
V/Q
AUXILIARY
RADIO AUDIO
CONNECTOR IN JACK RESULTS
CONNECTOR
Pin 11 Pin A Close to 0.1 Q
Pin 12 Pin B Close to 0.1 Q
Pin 13 Pin C Close to 0.1 Q
Pin 22 Pin D Close to 0.1 Q
.s...4e.*. 1/
n'nr2D‘I 0-030-U 53_a Pin 23 Pin E Close to 0.1 Q
1. Screws
Pin 24 Pin F Close to 0.1 Q
15. Disconnect the speaker connector and re- Pin 25 Pin G Close to 0.1 Q
move the speaker from the vehicle.
Front Speaker Installation .; D 3.: \ i
Reinstall the front speaker in the reverse order of
removal.
AUXILIARY AUDIO IN JACK

Auxiliary Audio in Jack Test
lowing:
- Right middle side panel
— Right rear side panel.
2. Remove right radio control panel and switch as-
sembly. rmi2010-U30-D31 _a
3. Disconnect radio connector. A. Contact with radio connector pin 11
B. Contact with radio connector pin 12
C. Contact with radio connector pin 13
Contact with radio connector pin 22
. , .-._\\ Contact with radio connector pin 23
ti \\x\i~.t\ Contact with radio connector pin 24
Q-" !" .U Contact with radio connector pin 25
If continuity test fails, repair defective circuit.

4., V
If continuity is good, test the auxiliary audio input
cable with a multimeter as per following table and
illustration.
AUXILIARY
RADIO
AUDIO INPUT RESULTS
CONNECTOR CABLE
__~ Pin 11 1'ip contact area Close to 0.1 Q

II
1 . 12
Pin Center contact
area Close to 0.1 Q
:rrir2 U1 0-030-02 1
., Rear contact
Pin 13 area Close to 0.1 Q
rrnr2011-079 531
3. Remove 4 screws on the rear of top storage

-15, compartment.
- <-to— <--co
I4-—1 I __;'_'_,:
. if-1.i_-'.,
27""’ .Q .si¢.a _H M___
_ ' - i
I
. iL:l1
rmr2D1D-030-032_a
AUXILIAHYAUDIO INPUT CABLE

1. Contact with radio connector terminal 11
If the continuity is not within specification, replace

the 3.5 mm audio input cable.
Auxiliary Audio in Jack Removal and
installation
Use the SPANNER TOOL (P/N 529 036 223) to re-
move and install auxiliary jack retaining nut. rm 12010030-IJ24_a
1. Screws
4. Carefully pull back and upward on rear panel to

remove from vehicle.
5. Remove the antenna boot and mast.
V -.1‘ .
Jk Q
529036223
ANTENNA
Antenna Removal
1. Open top and both side storage component
covers. rrnr2D1 D-030-U33
2. Remove 2 screws at the top rear of each side ANTENNA BOOT

_o .
1' ,'
r' I '
{I V 1
iv. -—- )
rmr201 D-D3C+023_a "TIYZUI W030-034

1_ Screws ANTENNA MAST
532
rmi'ZO11-079
6. Remove 3 screws inside the top rear storage

compartment securing the speaker and arm
rest assembly.
. =5:
Y-.‘»?».'é
rmr201 O-030132 7_a
10. Remove the antenna signal wire nut from the

stud and remove the signal wire.
_ J
rmr201U<030—D25_a
7. Screws
7. Carefully remove the speaker and arm rest as-

sembly.
8. Remove the 3 speaker side cover screws on
the outside of the cover.
rmr201 O03D—O35_a
1. Antenna mount bolt
2. Ground strap screw
3. Antenna signal wire nut
11. Remove the self threading screw through the

ground strap.
rmK20lfl<03tH128_a
12. Remove the bolt securing the antenna mount.
i. Screws 13. Remove the antenna mount.
9. Carefully lift the edge of the side cover and slide
the 3 hooks on the side speaker cover out of
position.
rmr201 1-O79 533

1 i l i

I Q.
o
rbg2010-0O70U2_a
TYPICAL
1. Drop of LOCTITE 243
2. M6 stainless steel lock washer (if applicable)
NOTICE Apply threadlocker only where

I mr2EJ10—0 3 D-0363
shown.
ANTENNA MOUNT
Antenna Installation HORN

Install the antenna in the reverse order of removal. Horn Test
pay attention to the following: ‘I. Make sure F8 of front fuse box is in good con-
Ensure to engage the groove at the inside edge dition and powered.
of the speaker and arm rest assembly with the lip 2. Remove the front cargo module, refer to BODY
located near the rear of the seat. subsecfion.
NOTICE Failure to engage the groove onto 3. Perform test at the 2 pin horn connector as per
the lip can result in damage to the speaker and the following chart.
arm rest assembly.
E<‘-_.
*3Kg».. .
’
*" “.''Dv?n-v~?_‘
L‘
5;--_
rmrZCl10~030-030_a
rmr2D10-030-U37
7. Groove HORN CONNECTOR
2. Lip
Pass the l\/I6 lock washer (if applicable) on the an-

tenna threads.
Apply a drop pr LOCTITE 243 (BLUE) (P/N 293 soc
060) on the first antenna thread as shown.
534
rmr201 1-O79
I M

Subsection 07 (LIGHTS, GAUGE AND ACCESSORIESI
HORN TEST AT 2 PIN HORN CONNECTOR
TEST PROBES
swnca
POSITION RESULTS
Close to
Pin I Pin 2 ON battery
voltage
Close to
Chassis Any battery
Pin 2 ground voltage
Q
positive Close to
Pin 1 battery ON battery
connection voltage
lf the test is to specification, replace horn. rrnr2010-O30-D44_a
INSIDE OF LEFT FRONT PANEL

If there is no voltage at pin 2, check continuity 1. Screws
from fuse F8 to horn connector and repair as re-
quired_ 4. Remove the 3 plastic rivets from the top of the
left front panel.
l there is no ground to pin 1 with horn switch ac-
tivated, proceed with horn switch testing.
4. Remove left side acoustic panel to access left
multifunction switch connectors, refer to BODY
subsection.
5. Perform the horn switch test.
Horn Removal
1.Remove the front cargo module. Refer to
BOD)/subsection.
2. Remove the 6 plastic rivets and the 2 screws
from the left bumper cover air duct.
rmr201 D—O30—O45_a
TOP OF THE LEFT FRONT PANEL

1. Plastic rivets
5. Carefully remove the fog light fascia.

6. Disconnect the horn connectors.
7. Remove the retaining screw for the horn.
H7‘
rmr2010-030-03B_a
LEFT FRONT BUMPER COVER AIR DUCT
1. Screws
2. Plastic rivets
3. Remove the 3 screws at the bottom inside of

the front panel.
rrn r201 1-079 535

REAR STORAGE COMPARTMENT

SWITCHES (2010 MODELS)
Rear Storage Compartment Switch
Test (at Gauge Connector)
1. Remove the multifunction gauge to access the
gauge connector, refer to MULT/FUNCT/ON
GAUGE RE/V/OIJZIL in this subsection.
2. Set multimeter to S2 and test as follows.
rmr2010-030-048_a
HORN
Horn Installation
Installation of the horn is the reverse of removal
procedures.
HORN SWITCH
Horn Switch Test rrr\r20‘I0—(l30-O14_a
Perform the horn switch test at the MSL2 connec- MULTIFUNCTION GAUGE CONNECTOR (PIN-OUT)
tor as per the following chart.
REAR STORAGE COMPARTMENT SWITCH
TEST (AT GAUGE CONNECTOR)
GAUGE REAR STORAGE
CONNECTOR RESULTS
COM PARTMENTS
ground All closed
9.3 kfl
ground Only TOP opened
6.6 ktz
Pin 20 to chassis Only LEFT side Close to
ground opened 7.8 kQ
Pin 20 to chassis Only RIGHT side Close to
ground opened 4.2 kt)
ground All opened
0.5 Q
rm F2010-03 D—002_a
7. MSL2 connector If the preceding test at the gauge connector

2. MSL3 connector within specification, replace the multifunction
7 HORN SWITCH TEST
gauge.
LEFT MULTIFUNCTION SWITCH
If the reading is OL in all positions:
SWITCH CONNECTOR RESULTS — Check circuit continuity between the ACS
(MSL2) POSITION switch and storage compartment switches.
- Test ACS switch, refer to REAR SUSPENS/ON.
Pin 5 to pin 6 532;“ ot If the reading is 1.5 kfl with all the compartments
. 5 to pin
. 6 Switch Close
open, perform the REAR STORAGE COMPAR71
Pin ON 1 Q to /I//ENTSW/TCH TESTKATSW/TCH CONNECTOR)
at the LEFT switch.
536
rmr201 I-O79
If the reading is 2.7 kfl with all the compartments REAR STORAGE COMPARTMENT SWITCH
opened, perform the REAR STORAGE CO/I//PART- TEST (AT GAUGE CONNECTOR)
MENTSI/V/TCH TESTKATSI/I//TCH CONNECTOR) GAUGE REAR STORAGE
at the TOP switch. coumsctoa COMPARTMENTS RESULTS
If the reading was 5.1 kQ with all the compart- Pin 20ground
to chassis
ments opened, perform the REAR STORAGE All closed OL
COMPARTMENT SW/TCH TEST /AT Sl/I//TCH
CONNECT TOR) at the RIGHT switch. Pin 20 to chassis Any compartment Close to
ground opened 1.5 k.Q
Rear Storage Compartment Switch If the preceding test at the gauge connector is
Test (at Switch Connector) within specification, replace the multifunction
1. Remove the left, right or rear panel as applica- gauge.
ble to access the appropriate switch as deter-
mined in the previous test. Refer to BODYsub- If the reading is OL in all positions:
section. — Check circuit continuity between the ACS
switch and storage compartment switches.
2. Set multimeter to Q and test as follows.
— Test ACS switch, refer to REAR SUSPENS/ON.
REAR STORAGE COMPARTMENT SWITCH If the reading is 1.5 kfl with all the compartments
TEST (AT SWITCH CONNECTOR)
closed, perform the REAR STORAGE CO/I/IPAR71
SWITCH STORAGE STORAGE /l/IENTSW/TCH TEST(ATSW/TCH CONNECTOR)
CONNECTOR COMPARTMENT COMPARTMENT at each switch.
CLOSED OPEN
Pin I to pin 2 OL Close to I Q Rear Storage Compartment Switch

Test (at Switch Connector)
If the test is not within specification, replace the 1. Remove the left, right or rear panel as applica-
switch. ble to access the appropriate switch as deter-
mined in the previous test. Refer to BOD Ysub-
REAR STORAGE COMPARTMENT secuon.
SWITCHES (2011 MODELS) 2. Set multimeter to Q and test as follows.
Rear Storage Compartment Switch REAR STORAGE COMPARTMENT SWITCH
Test (at Gauge Connector) TEST (AT SWITCH CONNECTOR)
l . Remove the multifunction gauge to access the SWITCH STORAGE STORAGE

gauge connector, refer to /I/IL/LT/FUNCT/ON CONNECTOR COMPARTMENT COMPARTMENT
CLOSED OPEN
GAUGE REMOVAL in this subsection.
2. Set multimeter to Q and test as follows. Pin I to pin 2 OL Close to 1 Q
If the test is not within specification, replace the

switch.
FRONT STORAGE
COMPARTMENT LIGHT
Front Storage Compartment Light
Voltage Test
1. Remove the front storage compartment.
2. Set multimeter to Vdc and test as follows.
Frr;20'l 003001 4_a
MULTIFUNCTION GAUGE co/v/vscron (PIN-OUT)
537
rmr201 1-079
l I II I II III I II II II I
FRONT STORAGE COMPARTMENT LIGHT HOOD ACTUATOR

VOLTAGE TEST (2010 MODELS)
Hood Actuator Voltage Test
RESULT
TEST PROBES (ENGINE 1. Open the front storage compartment.
RUNNING) 2. Remove the right front service panel.
L''9 ht ganillec t or .
Chassis Close to battery 3. Disconnect the hood actuator.
(vehicle side) ground Voltage Test condition:
— 2010 models: Engine running
FRONT STORAGE COMPARTMENT LIGHT — 2011 models: Ignition switch ON.
VOLTAGE TEST (Z011 MODELS)
4. Activate the PBS switch.
RESULT 5. Test the voltage with a multimeter on the vehi-
TEST PROBES (IGNITION
cle harness side.
SWITCH ON)
HOOD ACTUATOR VOLTAGE TEST
Light C-Qwector Chassis Close to battery
TEST PROBES RESULT
lvehijclle side) ground Voltage
Pin 1 Chassis Close to battery
If result is not as per specification, check the conti- ground voltage
nuity between pin 1 of the storage light connector
and: If the voltage is to specification, check the conti-
nuity between hood actuator pin 2 and FCS pin 2.
- 2010 models: Load shedding relay If the continuity is good, replace the hood actua-
(front fuse box pin D10) tor. If the continuity is not good, repair the wire as
- 2011 models: l\/lain relay2 necessary.
(front fuse box pin D6).
If there is no voltage to pin I of the hood actuator
If result is as per specification, carry out FRONT connector, continue with the PBS SI/I//TCH FUNC-
STORAGE COMPARTMENT L/GHT GROUND T/ONAL TESTin this subsection.
TEST
Front Storage Compartment Light PBS SWITCH (HOOD ACTUATOR
Ground Test FUNCTION)
1. Remove the front storage compartment. PBS Switch Functional Test
2. Set multimeter to S2 and test as follows. 1. Remove the central panel. Refer to BODYsub-
FRONT STORAGE COMPARTMENT LIGHT
section.
GROUND TEST
P8g|‘T'|5gN TEST PROBES RESULT

Light Close to
Open connector O Q
pin 2 Chassis
(storage ground
Closed compartment OL
side)
If close to O Q regardless of the cover position,

carry out FCS RES/STANCE TEST/FOR STORAGE
COMPARTMENTL/GH77.
If OL regardless of the cover position, check cir-
cuit continuity and carry out FCS RES/STANCE rrrir201D030-O 55_B
PBS CONNECTOR (PIN-OUT)
TEST /FOR STORAGE CO/I//PAR TMENT L/GHT}.
If result is as per specification, replace light.
538
rmr2011 O79
K, WI
Test condition:
— 2010 models: Engine running
- 2011 models: Ignition switch ON.
PBS SWITCH SWITCH FUNCTIONAL TEST
TEST PROBES SWWCH

P05‘-HON RESULTS
PBS connector Close to
pin 5 to Chassis Any battery voltage
ground
PBS connector
pin 4 to Chassis Switch Close to
activated battery voltage
ground
rmr201 O-030-O54_a
If there is voltage at pin 5, check the continuity FCS CONNECTOR
between pin 5 of the PBS connector and: 7. Pin 1
2. Pin 2
- 2010 models: Load shedding relay 3. Pin 3
(front fuse box pin D10)
— 2011 models: l\/lain relay2 FCS RESISTANCE TEST (FOR HOOD ACTUATOR)
(front fuse box pin D6). SWITCH
TEST PROBES PUSH-ION RESULTS
If there is voltage at pin 5 but no voltage to pin 4
with the switch activated, replace the PBS switch.
Pin 1 to pin 2 CESEEEID Close to 0.2 Q
If the test is to specification, check the continuity
from pin 4 of the PBS switch to pin 2 of the FCS
connector and repair the wire as necessary. If result is not as per specification, replace the
front storage compartment switch.
FRONT CASE SWITCH (FCS) If the test is as per specification, carry out the FCS
GROUND TEST
FCS Resistance Test (for Hood If both the FCS RES/STANCE TEST /FOR HOOD
Actuator) ACTUATOR) and the FCS GROUND TESTare as
NOTE: The front storage compartment switch is per specification, check continuity between pin 2
referred to as the front case opening switch in the and hood actuator.
wiring diagram.
1. Open the front storage compartment. FCS Resistance Test (for Storage
Compartment Light)
2. Remove the right front service panel.
1. Open the front storage compartment.
3. Disconnect the FCS connector.
2. Remove the right front service panel.
3. Disconnect the FCS connector.
rmr20‘li-O79
539
rm(ZOl D-030-O54 _a
rmr2010-030-O54_a
FCS CONNECTOR FCS CONNECTOR
1. Pin 1 1. Pin 1
2. Pin 2 2. Pin 2
3. Pin 3 3. Pin 3
FCS RESISTANCE TEST FCS GROUND TEST
(FOR STORAGE COMPARTMENT LIGHT)
TEST PROBES RESULT
TEST PROBES SWITCH
POSITION RESULTS
Pin 1 I Close to 0.1 Q
Pin 1 to pin 3 Cover OPEN Close to 0.2 Q
If the test is not to specification, repair the wire as
If the test is not to specification, replace the front necessary.
storage compartment switch.
If the test is to specification, perform the FCS CRUISE CONTROL SWITCH
GROUND TEST
If both the FCS RES/STANCE TEST (FOR HOOD Cruise Control Switch Test with
ACTUATOR) and the FCS GROUND TES Tare as B.U.D.S.
per specification, check continuity between pin 3 1. Connect B.U.D.S., refer to COMML/N/CAT/ON
and storage compartment light. TOOLSAND B.U.D.S. subsection.
2. In B.U.D.S., select Monitoring and ACC tabs.
FCS Ground Test
1. Open the front storage compartment. Fv—|€\Ibfl5I~$U~
. l .. . I "~ ‘
2. Remove the right front service panel. il|E1~-.»e)-
vmcn -»-.0“
.~@Tu|=>
1*-vs:-_
"so: its-=
(sci
iv: i
3. Disconnect the FCS. vonm I ‘sum; PHWM1 I »'.1»nu- I Fun: I meow I
P€i'5>:A-flwielu M‘..L<.¥l»~n8ih Miilrmnfen
'..;,..,...c. .. .TS....T ""” 6"‘ '
at ax A u
N‘5T‘v:»§rvM~!4f"." "'""‘°\-)"-‘ 5*’
Yinntlfnvm :
rnnnliwi .
nuvoua I
FVJYQIM
AC$P<~0m L»;;n,nuw\:.-E<»
l
‘/"Q1" '5‘ Lwawmtw 1-vz-um Iwtm
':0~trN'>-'vm .- I uj)g1)w U*1t|'$wll\ .
MEET?) Y _iy~:si'T5i§_lrcu_l'}wT-1' ACC ITT” ' ' T ' TTT

a at am Univ mm 5-{Qt-. O
rrr\r20'l0-U30-O39
MONITORING PAGE, ACC TAB
3. Monitor the MSR Group Box while activating

the following buttons:
— SET/DEC
540
rmr201‘l-D79
— RES/ACCEL CRUISE CONTROL SWITCH TEST WITH

— Cruise ON. MULTIMETER
CRUISE SWITCH
MSL I:-row eat MYSI-w'Glt\;t)B\1I
SWITCH POSITION RESULTS
CONNECTOR
mm- ' X SETDEC '\_
Cruise switch
Sor . 1 RESIACCCLK -
OFF - RESUME OL
Pin 1 to pin 3 Switch
mm» (P Cram nu In
Activated
II“-urrb Dom
I iurri; l-bull ‘~ Pin 1 to pin 4 Cruisgrflwitch Close to 0.2 Q

Tltumb LM ~
P\)§nTOTa)t Pin 1 to pin 4 S'UIS§FS'§"’R°R ot

rmr201 1-D79-OO4_b
If the test is to specifications the switch is good.
1. MSR Group Box
If the test is not to specification replace the right
If the indicators turn ON when the corresponding multifunction switch.
switch is depressed, the switch is functional and
sends a message to CAN. CENTRAL PANEL SWITCHES
If the indicators do not turn ON when the corre-
sponding switch is depressed, carry out a CRU/SE Central Panel Switches Illumination
CONTROL SW/TCH TEST Power Test
1. Remove the central panel. Refer to the BODY
Cruise Control Switch Test subsection.
1. Remove the left side acoustic panel. Refer to 2. Turn ignition ON.
BODYsubsection. 3. Probe at the back of the connector for the
2. Perform the following test at the MSR 1 con- switch to be tested and test according to the
nector. following illustration and table using a multime-
NOTE: The MSR1 connector is a 4 pin connector. ter set to Vdc.
It links the right multifunction switch to the left
multifunction switch. The test is performed to the
right multifunction switch side (female connector
with male terminal pins).
CRUISE CONTROL SWITCH TEST WITH
MULTIMETER
CRUISE SWITCH
SWITCH POSITION RESULTS
CONNECTOR
Cruise switch
ON - SET
Pin I to pin 2 Switch Close to 0.2 Q
Activated
l_
Cruise switch rmr201U030-056_a
. . OFF - SET CENTRAL PANEL SWITCH (PIN OUT)
Pin 1 to pin 2 Switch OL
Activated CENTRAL PANEL SWITCHES ILLUMINATION
POWER TEST
Cruise switch
ON - RESUME TEST PROBES RESULT
Pin 1 to pin 3 Switch Close to 0.2 Q
. Chassis Close to battery
Activated Pin 8 ground voltage
rmr2(11l-O79
541
If the test is not within specification, check the

wire continuity between the tested switch main
relay 2 and repair as necessary.
If the test is to specification, continue with the
CENTRAL PANEL SW/ TCHES /LLUM/NA T/ON
GROUND TEST
Central Panel Switches Illumination
Ground Test
1. Turn ignition to OFF position.
2. Probe at the back of the connector for the
switch to be tested and test according to the
following table using a multimeter set to ohms.
CENTRAL PANEL SWITCHES ILLUMINATION
GROUND TEST
PROBES POSITION RESULT
- Chassis Close to
R") 7 I ground 8.25 kn I
If the test is within specification, replace the de-
fective central panel switch. Refer to BODYsub-
section.
lf the test is not within specification, repair ground
circuit as necessary.
542 W201 1 079

I I

Subsection 08 (ELECTRONIC SHIFT SYSTEM (SE5))
ELECTRONIC SHIFT SYSTEM (SE5)

SERVICE TOOLS
FLUKE 115 MULTIMETER .......................................................... .. 529 O35 868 ............................... .. 548-549

FLUKE RIGID BACK PROBES ..................................................... .. TP88 ............................... .. 548-549
GENERAL
SYSTEM DESCRIPTION
The engine features a sequential electronically
controlled mechanical 5-speed gearbox (SE5) with
a hydraulically-actuated type clutch system.
NOTE: The SE5 is an electronically controlled ver-
sion of a sequential manual gearbox.
QL3
<-——1 rmo2010-G01-O36_b
SE5 SWITCHES
1. Upshift
2. Downshift
3. Reverse
4_
rmr201 1-O80-Cl10_a
TYPICAL
1. Transmission control module (TCM)
. Hydraulic control module (HCM)
. snléitches (upshift, downshift, reverse)
I tan
Solenoid valves
mmpmm. Link rod between HCM and shifter
The transmission control module (TCM) manages

4 solenoid valves located on the hydraulic control rrr\1200E-078-U03_a
TYPICAL
module (HCM) that control and activate the gear 1. HCM
shifting process. 2. Clutch servo
. Solenoid valves
-ISBJ. Pressure hose from HCM to clutch servo
The SE5 uses a centrifugal clutch system that en-

gages automatically at approximately 2000 RPM
as the rider increases engine RPM, and disen-
gages when the engine falls below that RPM.
rmr201 1-080 543

I l
Reverse
To shift in reverse gear:
— Engine must be running.
— Vehicle must not be moving.
>__-(“C ' -_:r> E . -..§_q i — Push the reverse button.
I - Pull the gearshift selector (downshift).
If gearbox is in reverse gear and the gearshift se-
_ .__ i_n‘S*i,.l ,-"*1-'-ti:
8 iv -.
lector is pulled (downshift), nothing will happen.
.9.‘
1:‘
::’S3 Double Shift from 18* Gear or Reverse
When the gearshift selector is held for more than
rm r2006-078-005_a 1/3 second, a double shift will take place as fol-
1. Centrifugal clutch lows:
— If gearbox is in 15* gear, the gearbox will shift to
Auto Neutral the reverse gear (reverse button must be held
When engine is started and running, the gearbox also).
is automatically set to the neutral position. - If gearbox is in reverse gear, the gearbox will
The gearbox is not linked with the engine until the shift to the 151 gear.
engine speed is above approximately 2000 RPM
to engage the centrifugal clutch. Auto Downshift
When the following conditions are met, a down-
Shift from Neutral shift will automatically take place:
The following conditions must be met so that a - Throttle is released.
gearshift can take place: — Vehicle decelerates.
— Engine RPM is lower than 1800 RPM. — A predetermined RPM is reached.
— Vehicle speed is lower than 3 km/h (2 MPH). — A predetermined vehicle speed is reached.
Upshift RPM Increase on Downshift
When the gearshift selector is pushed (upshift) When a downshift is commanded, the TCM will
and the vehicle is stopped, the TCM will immedi- transmit a downshift signal through the CAN
ately signal the corresponding solenoid valves on BUS that is used by the engine control module
the HCM to shift the gearbox up one gear if the (ECM) to command the electric throttle actuator
gearbox is in neutral or reverse. (ETA) to momentarily "slightly" open the throttle
When the vehicle is moving and the gearbox is plates to increase engine RPM. This assists the
in 15¢ gear or above, a minimum RPM and speed synchronization of engine RPM and rear wheel
must be met to permit an upshift to take place. speed without any required action by the opera-
Otherwise, no upshift is allowed until the required tor. This also prevents the RPM from dropping
RPM is reached. below centrifugal clutch engagement speed.
If desired, the gearbox can remain in this gear until Vehicle Stop
engine reaches its rev-limited RPM.
When coming to a complete stop, after the gear-
If the gearbox is in 5"‘ gear and the gearshift se- box has shifted into first gear, the centrifugal
lector is pushed (upshift), nothing will happen. clutch will automatically disengage the engine
from the gearbox. This prevents stalling and
Downshift leaves the vehicle ready for its next acceleration
When the gearshift selector is pulled (downshift), event.
the TCM will signal the corresponding solenoid
valves on the HCM to shift the gearbox down TROUBLESHOOTING
one gear as long as it does not cause the engine
RPM to exceed preset parameters. Refer to POWER D/S TR/BUT/ONAND GROUNDS
for fuses and relays information.
544
rmr2011-080
Always refer to the W/R/NG DIAGRAM when Gearbox Does not Shift Into Reverse
troubleshooting an electrical circuit. Refer to REVERSE BUITON TEST WI TH B. U. D. S.
Install a battery charger on battery terminals (un- in the GEARBOXsubsection.
"key ON" period. If battery voltage gets too low, TROUBLESHOOTING WITH
test results can be altered. B.U.D.S.
NOTICE Never force a multimeter probe into B.U.D.S. provides useful features to troubleshoot
an electrical terminal. the gear shift system. Most are obvious. The oth-
ers are described here.
TROUBLESHOOTING NOTE: Some items need the engine to be running
GUIDELINES to be monitored in B.U.D.S. In this case, follow
This troubleshooting guideline should be used the displayed instructions carefully.
jointly with the flow chart available in the pocket
located on the last page of this manual. Monitoring Page in B.U.D.S.
For any problem, start troubleshooting by: Clutch mod (%) is useful to acknowledge the
clutch modulation while shifting.
- Checking fault codes using B.U.D.S.
— Checking oil level and condition. Engine and Outputs Section
HCM share the same oil. Oil type, level and Clutch/Shift Up/Shift Down Sol
condition are very important. — When ON, it indicates that the TCM sent the
NOTE: In doubt of the oil condition or type, command to activate the related solenoid.
change oil and filters before further diagnosis. Check TCM
— When ON, it indicates that a fault relative to the
Gearbox Does not Shift Into Gear (Up TCM is active.
or Down)
— Check battery condition, refer to CHARGING TCM Active
SYSTEM — When ON, it indicates that the TCM is working
— Carry out the TCM STATUS MALIDAT/O/\I. Re- to carry out the gear shifting.
fer to TRANSMISSION CONTROL MODULE — When OFF, it indicates that the TCM is OFF be-
(TCM) in this subsection. cause of a TCM malfunction. No gear shift will
— Using B.U.D.S., check shifting system compo- take place. Refer to TCM STATUS VERIFICA-
nents (shift switches, solenoid valves, TCM, TION in this subsection.
etc.). BLS/Reverse (R)/Neutral (N)
— Carry out HCM oil pressure test, refer to H)’- - They indicate their status as seen by the TCM.
DRAUL/C CONTROL MODULE (SE5) subsec- Switch Inputs Section
tion.
— Check hydraulic and mechanical components. When a LED is ON, it indicates that the switch
— Check if vehicle "creeps" at idle. If so, verify sends the signal.
clutch, refer to CLUTCH (SE5) subsection. Activation Page in B.U.D.S.
- Make sure the shift linkage is in good condition
and adjusted correctly, refer to HYDRAULIC Activation section allows the activation of the dif-
CONTROL MODULE (SE5) subsection. ferent solenoids.
- Check RPM profile in B.U.D.S. (History tab). Routine section allows to force an action such as
Gearbox may not shift every time if a lot of rid- an upshift or downshift. For example, the Shift
ing time is spent at less than 2500 RPM. up button will activate all the necessary solenoids,
- Make sure the ground cable at ignition coil rein the proper sequence, required to carry out an
taining nut is properly installed and in good con- upshift.
dition. Test with B.U.D.S.
Erratic or Harsh Shifting Connect vehicle to B.U.D.S.
Carry out a CLUTCHACT/I447/ON TEST refer to
TEST W/T/-I B.U.D.S. in this subsection.
rmr201‘)-O80 545
NOTE: Make sure you have checked fault codes

and engine oil level prior to carrying the following
tests.
Clutch Activation Test
Refer to BODYand remove RH bottom rear side
panet
Remove clutch cover cap.
rmIQOOB-O78-O51
PISTON — IN
If test is successful, carry out a CLUTCHACT/I/A

T/ON AND MODULATION TEST below.
If test failed, check the HCM oil pressure and
the clutch solenoids operation. Refer to HY-
DRAULIC CONTROL MODULE (SE5I subsection.
If the HCM oil pressure and solenoids test good,
check for clutch mechanical problems. Refer to
CLUTCH (SE5) subsection.
Clutch Activation and Modulation Test
rmr2010-031001 _a In B.U.D.S., click the Clutch activ + mod button.
1. Clutch cover cap Clutch piston should move outwards then return
NOTE: If oil is present when removing cap, check slower than when it moved outwards. Other-
the O-ring on the clutch piston nut and the clutch wise, check the clutch modulation solenoid oper-
piston seal. Replace as required. ation. Refer to HYDRAULIC CONTROL MODULE
(SE5) subsection.
Make sure TCM is operational. Refer to 7'CMSTA-
TUS VERIFICATION in this subsection. Shifting Test
Select the Activation and the TCM tabs. Look at If shift switches DELs turn ON in B.U.D.S. when
the Routine section. switches are pressed in but gearbox does not shift
gears, carry out the following:
Start engine and let run at idle.
Start engine.
In B.U.D.S., click the Clutch activation button.
Go in TCM under Activation. Look at the Routine
Clutch piston should move outwards then return section.
approximately at the same speed.
Click ON the Upshift or Downshift button.
Gearbox should shift into selected gear. If not, try
to manually shift gearbox through all gears as fol-
lows:
Install a 13 mm wrench on the flat edges of the
shift shaft lever and use it to turn shift shaft.
rmr20OBHlI78—05U
PISTON — OUT
546
rmr201 1 O80
Subsection O8 (ELECTRONIC SHIFT SYSTEM (SE5))
Iv"
Switch inputs I
Free Up Button
."' ’E\.
~.-.1 ;, Reverse Button ' Up Button ‘ »
Free Down Button _ .
Down Button f ‘
rmr201 I-D31-O02_a
1. Switch inputs LEDs

rmr2DUB-O78-052_a
1. Shift shaft lever GEAR SHIFTING SWITCH INPUT LED STATUS

CONDITION
If the shift shaft does not turn, disconnect its link- LED
age and try again to turn the shift shaft. IDENTIFICATION SWITCH SWITCH
— If the shift shaft does not turn, proceed with ACTIVATED RELEASED
gearbox repair. Up or Down
— If the shift shaft turns, inspect the shift linkage Button ON OFF
and the HCM hydraulic piston. Free Up or Free
Down Button ORE ON
r~/ If LEDs turn ON as specified, carry out the SH/F71

/NG TEST Refer to TROUBLESHOOTING I/I/ITH
B.U.D.S. in this subsection.
If LEDs do not turn ON as specified, refer to
WIRING DIAGRAM to check wiring and switch
continuity.
REVERSE BUTTON
Reverse Button Test with B.U.D.S.
-4--"PT Connect vehicle to B.U.D.S.
Select the Monitoring and TCM tabs.
W-r2008-078-00 5_a The Reverse Button LED in the Switch Inputs
VIEW FROM BACK SIDE OF HCM section should be OFF when button is free and
1. Shift linkage
2. Hydraulic piston in HCM should turn ON while pressing on it.
PROCEDURES
1 Sir/itch inputs
GEAR SHIFTING SWITCHES Free Up Button I
Gear Shifting Switches Test with Reverse Button Up Button :~
B.U.D.S. I FIQG DOWTI BUIIOFI
Connect vehicle to B.U.D.S. Down Button
Make sure that both clutch and clutch modulation
solenoids and valves work. Refer to CLUTCHAC—
TIVAT/ON TESTin this subsection. rrnQ0‘l 1-031-002_h
Select the Monitoring and TCM tabs. 1. Reverse Button LED

The LED status in the Switch Inputs section If LED turns ON at the appropriate moment,
should be as per following table. carry out the SHIFTING TEST Refer to TROU-
BLESHOOTING VI//TH I5’. U. D. S. in this subsection.
rmr201 ‘I -030 547

If LED do not turn ON when button is pressed in, If TCM module is not visible or active, carry out
refer to the l/l//H/NG D/AGHAM and check wiring TCM /NPUT I/OLMGE T557?
and switch continuity.
TCM Input Voltage Test
TRANSMISSION CONTROL Check fuse MF2 in rear fuse box and fuse F3 in
MODULE (TCM) front fuse box.
TCM Status Validation Refer to BODYand remove:
Turn ignition key to ON.
— LH sen/ice cover.
Ensure that fuel pump turns ON a few seconds.
Otherwise, check ECM power supply. Remove acoustic panel.
Connect vehicle to B.U.D.S.
ln the tool bar at the top of screen, click on Mod-
ule. TCM should be visible in the menu.
I Z M. lylodule
"5!
ECM r
E5,1
E» M l nu-
-9. ops ‘r-1
Realist ... V777 - rmr201 O-O31 —OO2_8
1. Flame
nnr2DDEA)78—O24_a 2. Acoustic panel
1. TCM is visible
Disconnect TCM connector.
If not, the module is either not powered, defective U89 the FLUKE 115 MULTIMETER (P/N 529 O35 868)
or unable to communicate via CAN. and FLUKE RIGID BACK PROBES {P/N TP88).
If TCM module is visible, select Monitoring and Set multimeter t o Vdc.
TCM tabs.
In the Outputs section, check if TCM active LED Read voltage as follows.
is turned ON. Otherwise, turn ignition switch (key) NOTICE To avoid damaging the connector,
OFF, wait 30 seconds, then turn it ON. lf LED still probe only the terminal tip.
does not turn ON, try a new TCM.
TCM
BATTERY VOLTAGE
CONNECTOR
outputs Input volts; rat" 1 Pin 17
L ,___ __.- .. __
l Clutch sol: 45 TCM Active
Ground Battery voltage
Pin 35
1 Sl'liltUpsol: ats c-3»
snm Down sol: ReverselR)! Turn ignition switch (key) ON.
Check rcvr Neutral (N): ~- _ TCM VOLTAGE
CONNECTOR BATTE RY
(KEY ON)
Ecrfliciusmrlvcm ops TCM l Pin 4 Ground Battery voltage
rml’20‘ll-031-O01_a
7. TCM active LED
NOTE: Make sure there is no communication

problem code.
If TCM module is visible and active, carry out
GEAR S/-//F7‘/N6 SW/ TCHE5‘ TEST l/l//TH B. U. D. S.
548 rmr2011-080
rrnr20DB07&026_a rmr20D3-O7 &026_c
If voltage is not as specified, check wiring and lf ground circuits are not as specified, check
connectors between TCM and main relay 2. Re- wiring and connections between TCM and bat-
fer to W/Ff/NG D/AGF’AM. tery ground.
If voltage is good, carry out a TCM GROUND If ground circuits are as specified, try a new TCM.
TESI Clear fault codes.
Clear fault codes.
TCM Test for CAN Communication
TCM Ground Test 1. Check for CAN fault codes using B.U.D.S.
U56 the FLUKE 115 MULTIMETER (P/N 529 O35 868) 2. Carry out TCM 577lT(/5 l/AL/DAT/ON in this
and FLUKE RIGID BACK PROBES (P/N TP88l. subsecflon.
Set multimeter to VDC. If TCM is powered but not visible in B.U.D.S.,
Check ground as follows: carry out the TCM CAN C/RCU/T TEST
1. Connect multimeter RED probe to a positive TCM CAN Circuit Test
source such as the battery terminal of the 1. Refer to BODYand remove:
starter solenoid.
2. Probe TCM connector pins with the BLACK - Service covers.
(COM) probe of the multimeter as follows.
2. Disconnect TCl\/l connector.
NUTICE To avoid damaging the connector,
TCM
BATTERY RESULT
CONNECTOR
Pin 10
_ Positive source Battery voltage
Pin 28
"3=5:" l
l
\
1*‘ » .\._,‘_
n I Ff.’
', 'r‘I‘F
l
l
-..-1 l
vrnr2008r07B~O25_b
1. TCM connector
rmr2U1H)8O 549
3. Locate the diagnostic link connector (DLC).

i
Q.-
i rmr201 O-031 -003_a
7. TCM
2. Frame
rmr201 ‘I-OED-OO'l_a
7. Diagnostic /ink connector (DLC)
Check CAN circuit continuity as per following ta-

ble:
TCM CAN CIRCUIT TEST
TEST PROBES RESULT
TCM
CAN High: etc pin 1 connector c'%Sfl‘°
pin ‘I9
TCM
CAN Low: DLC pin 2 connector mass to
pin 1
lf result is not as specified, repair wiring or con-

rmr2008-0780271
nector.
Pull out TCM.
TCM Replacement
TCM Installation
TCM Removal
Reverse removal procedures.
Refer to BODYand remove LH upper side panel.
Remove acoustic panel.
9.-II""'
rmr2010-lJ31002_a
1. Frame
2. Acoustic panel
Disconnect TCM connector.

Remove TCM retaining screws.
550 rmr201 l-DBO
Section D6 DRIVE SYSTEM
Subsection 01 (DRIVE BELT AND REAR WHEEL)
DRIVE BELT AND REAR WHEEL

SERVICE TOOLS
BELT TENSION METER .............................................................. .. 529 O36 II5 ....................................... .. 554
BLIND HOLE BEARING PULLER SET ......................................... .. 529 O36 II7 ....................... ..560, 562, 565
SOCKET SPANNER ..................................................................... .. 529 O36 I13 ....................................... .. 560

SNAP-ON SEAL PULLER ............................................................ .. YAI O5 ....................................... .. 565
SERVICE PRODUCTS
LOCTITE 243 (BLUE) ................................................................... .. 293 800 O60 ....................................... .. 560
XPS SYNTHETIC GREASE ........................................................... .. 293 550 OIO ....................................... .. 561
rmr201 1 O81 551

Section 06 DRIVE SYSTEM
-r
rant sprocket withwfiyvviieei
'\. 25 N-m
§Ibf°fiII
/_/ / _/$\ *
/
/’/'53‘ 125 N -m
/ \‘@\,,/ (92 lbf-ft)
I I
Iront spiroc-ket_|/vithout
Tl“I1 flywheel
asti
‘\ $ I’ t""‘v.‘ §
$ H ff, '1
110 N-m
'“‘*" '“r-‘*"- —1 (81 lbf~fitl
— — —- —_ -1_. _._._
_FF. Engine
/“~
,/ I. ».\1,<
I" ‘
48 N-m
r, -_' ’.
.. ', (~
_'.' ‘.
(35 lbf-ft)
.\
I ., /L
// V’ L, _,_, H "I;'."(=~
‘\ t\- NEW
\
‘\
\_<€§ lrgffijtl \ NEW
. \ D.
/'/
/ /I.
I
\.
iii‘
‘i
'
1,)‘:s/ 20 N'm
(15 lbf-ft)
OLoctite 243
3 \T’~ /7€//aw/,-, é , ‘NEW

4.
~—-.v “
ca ° /4
‘> XPS Z
\\ /IE
synthetic ,
SR efi
/5/ / /4/0,.
~\grease 0%
130 N-m
(96 lbf-ft) vp. ~. ,3"
/ A
\
\.\ / 1
.» ' I
?';J= >\/
.'-' _ i" I?‘ ’
.\ 7/ ,
\ \/
.7
.»
0
XPS
synthetic grease
= Component must be replaced when removed. _
rm/201 7-D32-001 _b
552 rmr20ll-081
Subsection 01 (DRIVE BELT AND REAR WHEELI
GENERAL WEAR CONDITION

REQUIRED
ACHON
ues and service products as in the exploded Good condition None
views.
Hairline cracks Monitor condition
fer to SELF-L OCK/NG FASTENERS and LOCT/TE Minor chipping Monitor condition
complete procedure. Opened cracks Replace belt
A WARNING Hook wear Replace belt
must be strictly adhered to. Missing teeth Replace belt
tabs, elastic stop nuts, cotter pins, etc.) must Belt fabric worn, Replace belt
be replaced. exposing internal
components
nuuuwnlnxuw
Stone damage Replace belt
During installation, make sure every
part is free from old grease and dirt. This al-
lows for a clean reassembly and will avoid pre- NOTE: Hairline cracks do not require the replace-
mature wear caused by dirt contamination. ment of the belt, but must be monitored closely —
they may lead to opened cracks or missing teeth,
NOTICE Hoses, cables and locking ties re- requiring belt replacement. Damage to the cen-
moved during a procedure must be reinstalled ter of belt will eventually require belt replacement,
as per factory standards. but when cracks extend to the edge of belt, belt
failure is imminent.
Road test vehicle at moderate speeds a few min-
utes to ensure normal operation following mainte- When a drive belt is replaced, also replace the
nance or repair (proper drive belt tension and align- sprockets to increase the longevity of the new
ment, rear brake operates correctly, etc.). drive belt.
Drive Belt Tension Verification
PROCEDURES
NOTICE Always verify drive belt tension
DRIVE BELT with all parts at room temperature and the
rear wheel lifted of the ground.
Drive Belt Inspection
1. Place vehicle on a level surface.
Lift the rear of vehicle and install a jack under the
frame to support the rear of vehicle off the ground. NOTE: The area must be protected against wind
and must have a low background noise.
Remove the belt guard.
2. Set transmission to NEUTRAL.
Inspect the full length of the belt. lnspect for the
following conditions: 3. Lift rear of vehicle by the frame until rear wheel
is off the ground.
NOTICE Do not lift under rear shock ab-
sorber. Always lift by the frame. Refer to
illustration.
rrnr2011-081 553 I
Section O6 DRIVE SYSTEM
rmr20UB-030-008 -_ _ ~@n~__. _- - L.
rm|’ZO0B-031-003
TYPICAL - LIFT BY THE FRAME
TYPICAL - SWING ARM ALIGNS WITH A SPOKE
4. To check the drive belt tension use the BELT
TENSION METER (P/N 529 036115). 7. Position the sensor under the LH passenger
footrest and hold the sonic tension meter sen-
sor approximately 1 cm (1/2in) from belt or
closer without touching the belt.
\ Q
5290361 I5
5. Enter the following specifications to program

the meter.
MASS WIDTH SPAN
8.4 g/m I 28.0 mm/R I 1028 mm HD5201 0005-001
8. Tap the belt to make the belt vibrate and note

the measurement.
9. Repeat step 8.
NOTE: The second value should be within 1 25 N.
If not, repeat measurements until tolerance is
met.
10. Repeat steps 6 to 9 for the 2 remaining wheel
spokes.
rmr200E-031-G02 The average of the 3 obtained values (at the 3
SONIC TENSION METER DISPLAY spokes) must be within the following range:
NOTE: Refer to the manufacturer's instructions
to set the informations into the device.
6. Turn rear wheel to align a wheel spoke with the
swing arm.
554 rmr201 1 {I81

Secti0nO6 DRIVE SYSTEM
Subsection O1 (DRIVE BELT AND REAR WHEEL)
DRIVE BELT TENSION

(PARTS AT ROOM TEMPERATURE AND
REAR WHEEL LlFTED)
45ON:I:15ON
If the tension of drive belt is out of specification,

adjust drive belt as per DH/VE BELT TENS/0NAD-
JUST/WENT
Drive Belt Tension Adjustment
Lift rear of vehicle using a floor jack until rear rrnr2008-031-O06
wheel is off the ground.
Adjust tensioner screws as following:
NOTICE Place floor jack underneath frame — Ttghten screws 1/4 turn to increase belt ten-
only. sion.
— Loosen screws I/4 turn to decrease belt ten-
sion.
NOTE: Always turn both tensioner screws evenly
to keep drive belt aligned.
C
rrnr2008-030-009
TYPICAL
Remove both rear axle caps.

Q-o
From RH side of vehicle, remove and discard cot- imr2008-031-U U7_i
ter pin locking the rear axle nut. 1. Flear axle tensioner
2. Tensioner screw
Tighten rear axle nut enough to avoid rear axle

movement.
Adjust drive belt tension as per specification, refer
to DH/I/E BELT TENS/ON I/ER/F/CA T/ON
When recommended tension is obtained, torque
rear axle nut.
REAR AXLE NUT TIGHTENING TORQUE I
I30 N-m (96 lbf°I’t)
rmr20Cl8-O31 -(}IJ5_i
REAR RH SIDE OF VEHICLE

Install a NEW cotter pin and both axle caps.
1‘. Cotter pin
2. Flear axle nut A WARNING
Using a 36 mm socket, loosen rear axle nut. Always install a NEW cotter pin on rear axle.
Drive Belt Alignment

Drive Belt Alignment Verification
The gap between drive belt and rear sprocket in-
ternal flange should be:
rmr2011-UB1 555
Section06 DRIVE SYSTEM
DRIVE BELT AND REAR SPROCKET

INTERNAL FLANGE GAP
Minimum 1 mm (1/32in)
Maximum 5mm (3/16in)
rrnr20U $030008
TYPICAL
Remove both axle caps.
From RH side of vehicle, remove and discard cot-
ter pin locking the rear axle nut.
.'\ ‘
i<—A
5
_j~=- T I
'fZj"’i'* T _ "*~ ‘
— _ I rrnr2008-031-005_a
' A - -.‘ . 7_
TYPICAL - REAR RH SIDE OF VEHICLE
rmo2 U08-001-O27_a 7. Cotter pin
BELTALIGNMENT 2. Rear axle nut
7- Rear sprocket .
2. Belt Using a 36 mm socket, loosen rear axle nut.
3. Sprocket internal flange _ _
4. Proper belt alignment NOTE: Loosen axle nut just enough to slide wheel
5. Belt exceeding external edge — realign belt
A. M/N. 1mm (1/32in) — MAX 5mm I3/16in)
using axle tensioner screws.
Drive Belt Alignment Procedure

If drive belt needs to be aligned, proceed as fol-
lows.
Lift rear of vehicle using a floor jack until rear
@,
wheel is off the ground.
NOTICE Place the floor jack underneath
frame only.
rl'r\f2008-031-006
Adjust tensioner screws as follows:

— If drive belt is on the outside edge of rear
sprocket, tighten the LH tensioner screw.
— If drive belt is on the rear sprocket flange,
tighten the RH tensioner screw.
Clear rear wheel area.
556 llTl|'2OI1-DB1
Ii’)\f -=~
Ask somebody to start engine.
Select first gear. _ __\
Accelerate engine to turn rear wheel. _,____ /
A WARNING
Keep speed at minimum. Vehicle must be
properly supported and front wheels blocked.
Check drive belt alignment.

Stop rear wheel and repeat in reverse.
Stop engine.
If an adjustment is necessary, tighten the appro- 12 ‘-1-’-/ .-7
priate axle tensioner screw and recheck the align- rr11r20IO-O36-lJ26_6
ment. TYPICAL
1. Belt guard
When alignment is good, check drive belt tension.
Refer to D/-i’/I/E BELT TENS/ON I/EB/F/CAT/0/V. Remove belt tension, refer to DB/I/E BELT TEN-
Torque rear axle nut. S/ON AD./UST/I//ENTand completely loosen ten-
sioner screws to remove belt from rear sprocket.
REAR AXLE NUT TIGHTENING TORQUE Remove shift lever from shift shaft.
130 N'm (96 lbf'ft) Remove LH footrest support from vehicle by un-
screwing retaining screws.
Install a NEW cotter pin and the both axle caps.
A WARNING
Always install a NEW cotter pin on rear axle.
/ 7%: ’
;//' 2',
.1‘ , \ r//
‘I
,-/ Ii _,r~.'
Drive Belt Removal \‘$E*>-_.:-v\'\%
L . ~‘-"V-.I$.\-. . "
.- I‘
W
NOTE: If drive belt is removed but not replaced,
mark the direction of rotation. Drive belt must be
reinstalled in the same direction to obtain the ma-
|i._i
I-__;al
Z; ,'. I‘
I
‘it'll: I'll’
:.’ ‘P *
\
WI; '
’- ' _.;-.
I
z€’?II.r: V:I,
I");
I
A
_ H
- I ". .,\
‘F
ximum drive belt life span.

int ‘I ‘,1?-F’/. I I
4' R --/ r ~' ‘J
T
‘
Lift rear of vehicle by the frame until rear wheel Iii), I,‘ ;5"' I '4’>01 .
Itor-I ~»e
¢z/J:- 1
II‘ "II I 3 . ‘
is off the ground.
I/I
rmr2Dl lP032001_a
7. Footrest support retaining screws.
" - ~, ‘%
.-*
;=-at
-t , . . .. _ j,
--{if-
—I'I
.r :7 ~" /f)‘ _ Iv. +745:-f__ :?' 1,, »
ll-5, ' I’ - 1 (1., ’ __'- ‘
~ -.;._ . . _.» _.» l,
"a \ ‘— F
3
rrnrZOOB-O30-009
1 .~..
..<~
.j --z_
/‘T.,
.,‘ ,
., --
_ {I iF
¢';_
_ T I ll I Ii
TYPICAL \
I ..-I -$1
cIIII
~.
,/ .-'
/" //_ ~ .' O1 - V _ ‘ __.l
Remove body parts as required to access to the 1, / - ~ M.‘ Q, "IL9
I/I‘'I:II\‘ ‘ - ,_...-.-_»-—-
*;-.-
_
front sprocket. Refer to BODYsubsection. _,|-@ I |0 I F)\i"\__

_~.. I I
- - I .......L..c,. - -I ; 7 M»--1,.
. _‘\‘b\‘\_I.f"_
. /a‘ - Q_'\:.
(‘AA
' . .. ' , .‘
rrnr20lCl-D32-0D2_a
Remove belt guard from swing arm. 7. Footrest support retaining screws.
rmr2011-081 557
Unscrew bolt securing LH lateral support to fuel Install the shift lever and align its slot with the dot
tank. on the end of shifter shaft.
Torque Allen screw securing shift lever on shifter
shaft.
SHIFT LEVER SCREW TIGHTENING TORQUE
11 N-m (97Ibf'in)
Make sure that gear shift lever works properly.
REAR WHEEL
Rear Wheel Removal
Place vehicle on a level surface.
rmr2008-031-DlO_a
TYPICAL Remove the following body panels, refer to REAR

1. Lateral support CARGO MODULE D/SASSE/I//BLYin BODYsub-
2. Fuel tank
section.
Lift end of lateral support. - Rear panel
Slide drive belt between lateral support and the — Rear fender.
footrest support bracket. Lift rear of vehicle by the frame until rear wheel
Carefully slide drive belt between sprocket fly- is off the ground.
wheel and shifter shaft.
NOTICE Do not lift under rear shock ab-
r~‘=". ' \ sorber. Always lift by the frame. Refer to
RF
I"-‘Ir’ I‘) U!
-‘-.-'.1.‘
illustration.
, at ‘ ~
-£1
'1:‘
MQ
rmr20U3-OQUFOUB
rrnI'2D‘l D-032-D04
TYPICAL - LIFT BY THE FRAME
NOTICE Do not remove flywheel from front
sprocket for the drive belt removal. Remove both axle caps.
From RH side of vehicle, remove and discard cot-
Drive Belt Installation ter pin locking the rear axle nut.
Installation is the reverse of the removal. How-
ever, pay attention to the following.
When using the same drive belt, reinstall it in the
same direction of rotation. For a new drive belt,
no specific direction is required.
Align drive belt. Refer to DR/VE BELT AL/GN-
MENT
Adjust drive belt tension. Refer to DR/VE BELT
TENS/ON ADJUSTMENT
558 rmr201 1 -081

SectionO6 DRIVE SYSTEM
-— _r_ -
rm F2009-U31-OD5_a
TYPICAL - REAR RH SIDE OF VEHICLE

1. Cotter pin
2. Rear axle nut rmr2010-D36-O31_a
Using a 36 mm socket, loosen rear axle nut. 7. Caliper screws
From the LH side of vehicle, support rear wheel

and remove the rear axle.
; A
(-4-
A,
I
A
m\r2OII8-O31-O06
Loosen rear axle tensioner screws. Be careful not

to unscrew tensioner screws completely.
rmr200B-031-O15_a
\gu> --a
1. Rear axle
fit Remove drive belt from rear sprocket.

Remove wheel from vehicle.
Rear Wheel Disassembly
Remove the external spacer.
rmr20OB-D31-0U7_a
1. Rear axle tensioner
2. Screw ._"~i.
Remove and discard both caliper screws.
rm|2Cl0B~lI31-O20_a
7. External spacer
2. Rear sprocket
rrnr’Z011{)B'I 559
ect|on06 DRIVE SYSTEM
Subsection01 (DRIVE BELT AND REAR WHEEL)
Remove REAR SPROCKET see procedure in this Using the BLIND HOLE BEARING PULLER SET
subsection (P/N 529 036 117), remove and discard wheel bear-
Remove rear sprocket dampers ing.
3/
~ Unb- 529036117
rrnr20D8~031-O1 7_a
7 Rear sprocket dampers
Unscrew wheel hub bolts
rmr2OOB»031-021
Rear Wheel Inspection

Verify condition and wear of the following wheel
components:
- External spacer
Remove wheel hub and spacer — Seals
Using the SOCKET SPANNER (P/N 529 O36 113) un- - O-ring (inside external spacer)
screw the wheel bearing nut — O-ring (around navel
— Rim.
Replace any components as required.
Rear Wheel Assembly
The assembly is the reverse of the disassembly
procedure. However, pay attention to the follow-
ing.
Install a NEW wheel bearing.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) On
threads of wheel bearing nut.
Torque wheel bearing nut.
WHEEL BEARING NUT TIGHTENING TORQUE I
20 Nvm (15 |bf'ftl
Install the rear sprocket and wheel hub on rear

wheel. Refer to REA/-? SPHOC/<’E7'and WHEEL
HUB.
rmr201 1-08‘)
Make sure rear sprocket spokes are aligned along REAR SPROCKET
with rear wheel spokes.
Rear Sprocket Removal
Rear Wheel Installation Remove rear wheel. Refer to HEAR WHEEL in
Install the rear caliper support. Refer to BRAKES this subsection.
subsection. Pull rear sprocket.
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) on
rear axle.
Install the drive belt on rear sprocket.
,»
Align holes of the following components:
— Swing arm
— Rear adjusters
— Caliper support
— Wheel.
Insert the rear axle from the LH side. rrnr200B-031-025_a
‘t fistwl
1. Rear sprocket
On RH side, install a washer and the rear axle nut.
Pull rear wheel backward and tighten rear axle nut Rear Sprocket Inspection
slightly. Verify sprocket as follows:
Using a ruler, measure the distance between — Sprocket teeth for wear.
washer and the swing arm end. — Sprocket bearing turns smoothly and freely.
— Bearing spacer for wear.
\/
4‘)
rrnr20U8-O31-023 rmr2D08-031-026_a
1. Bearing spacer
‘lighten rear adjuster screws to same length on
both sides of swing arm. Replace components as required.
Align drive belt. Refer to DH/I/E BE/.7" AL/GN-
MEN7T Rear Sprocket Disassembly
Remove seal.
A WARNING
Always 'install a NEW cotte r p in on rear axle.
NOTE: The Spyder RT uses a heavy duty rim with

a load rating of 400 kg (882 lb) to match with the
tire. Always check the load rating on rim spoke
to ensure that the rim meets the proper specifica-
tion.
rrnr2011-D81 561
- , -J‘ _~P.‘}- I, 4- d Install the long side of bearing spacer insid e rear
-4"!
sprocket bearing
$4-
rrnr2008-031-U27_a
1. Seal
rm r2 D08-D31 -O26_a
Remove circlip.
7. Long side of bearing spacer
Rear Sprocket Installation

Check the gap between rear sprocket and rear
wheel.
REAR SPROCKET AND REAR WHEEL GAP
_I l_|__-_\$r-...
1.6mm (1/16 in)
'l NOTE: If the gap is higher, remove the rear

‘ A !"- - s p ro c k et and check the condition
" of the nave
rrnr20DB—O31-UZ8_6
1. Circ/ip O-ring.
Make sure rear sprocket spokes are aligned along
Using the BLIND HOLE BEA RING PULLER SET with rear wheel spokes.
(P/N 529 03 6
117), remove and discard
' sprocket
bearing.
FRONT SPROCKET
(WITHOUT FLYWHEEL)
I T I
V _
//\ >_T
""_i*""
i.._........_.._
5290361 17
Rear Sprocket Assembly

procedure . H owever, pay attention to the follow-
ing.
When installing the sprocket bearing, make sure
‘ll
to insert th e b earing
' very straight
' ' damag-
to avoid rmr201 1-D32-OD4
ing sprocket hub and to press the bearing from its

outer race.
562
rmr2011-081
Front 51310Cl<B’¢ Removal , SPROCKET SCREW TIGHTENING TORQUE '

110 N'n1 (81 Ibf'ft)
A CAUTION Apply parking brake before re
moving front sprocket to avoid vehicle move-
ment. FRONT SPROCKET
Remove body parts as required to access to the (WITH FLYWHEEL)
front sprocket. Refer to BODYsubsection.
Loosen drive belt tension. Refer to DB/l/E BELT _c__
.»"%~?_\,_ -I /__.‘ "\\
in this subsection. \ ‘€T\“~/- 4 . ~..
Remove and discard the front sprocket screw. . /

-. ',
‘<1.\\ 1 *=
\
_
3 1 p) ‘ta, 7:5, )
' \\ ix /, I \
f%f,S\
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,/If
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1,‘/_
rmr201 H132-U05
rmr200B-I117-O52_a Front Sprocket Removal

TYPICAL
1. Front sprocket
2. wrecker screw A CAUTION Apply parking brake before re-
3. asher moving front sprocket to avoid vehicle move-
ment.
Remove front sprocket from main shaft.
Remove body parts as required to access to the
Front Sprocket Inspection front sprocket. Refer to BODYsubsection.
lnspect splines of main shaft for wear or other Loosen drive belt tension. Refer to DB/I/E BELT
damages. If necessary replace main shaft (gear- in this subsection.
box disassembly is required). Remove and discard the front sprocket screw.
Check inner splines and teeth of sprocket for wear
or other damages. Replace sprocket as required. NOTICE Do not remove flywheel from front
sprocket for its removal.
Check inner flange of sprocket to ensure it is not
warped or worn out. ".._;~._.__,__
I ~>r~-="-ft?-:-r1*~*=
5. e*<;.~., H as
Front Sprocket Installation
The installation is the reverse of the removal pro- ‘
f i _ whiz
"r-t~)n.."@l.
_ Ar>“.~-')(. Q \ '~ i_
55 .»\ .
cedure. However, pay attention to the following. -

~ ' 1
t 4 .- \ -
.- 1;~-a\-.
* ‘ "* _:_i1
\
Install a NEW front sprocket screw with threads
already coated with a self-locking product. T I »;
_,./-’
ll I )'$§21Ej "1
#--' TT
*' *1c.@>t:'T-ix
'51.
#9’
A WARNING I._ /
.-._ .--.~..¢.~.,-_-»"
J‘*5’mi._4».-7"
‘3vi
r:. —Q;o/
-.;~;_ff»’
Make sure to install a NEW sprocket screw
with threads already coated with a self-lock-
ing product. Screw must be torqued as spec-
ified.
LT%‘ T K.»
_ ~. FJr.
4;:
f-»_)fi_
' “t Z J‘
-.._ -‘*I..:-~-~-----.-.--<.:'-’---
rmr201 1-U32-0O2_a
1. Front sprocket with flywheel

l
) _.4 _ .
‘ '.. lit." st.‘-
j
2. Sprocket screw
3. Washer
Remove front sprocket from main shaft.

rmr2011-081 sea
Front Sprocket Inspection

..-~“.;-Va:
NOT/CE Do not remove flywheel from front ..-S-L - _\\_..¢
t A I —
sprocket for the inspection. E->
1
W
Inspect splines of main shaft for wear or other I
.”
r
-
’_ Beze-
‘-__
damages. If l')9CGSS8l'\,/ replace main shaft (gear- __,
,. -—-_
-_i_
box disassembly is required). l&§£*~+*§=fj?:in?

.rt
l,.l
Check inner splines and teeth of sprocket for wear
or other damages. Replace sprocket as required.
. .
Illlli
IIIII
.Lu.ALL
I
Check inner flange of sprocket to ensure it is not r1rir2UI'I—032003

warped or worn out.
lighten flywheel retaining screws as per the fol-
Front Sprocket Disassembly lowing sequence.
Remove flywheel from front
sprocket only if the sprocket needs to be
A WARNING
changed. If disassembly is required, make Make sure to install NEW flywheel screws
sure to strictly follow assembly procedure. with threads already coated with a self-lock-
ing product. Screw must be torqued as
Unscrew flywheel retaining screws from front specified.
sprocket.
/I :="°'-* E
' 1
1 211.101
-W ,5’.nLj~.;-.» J)‘,-r-‘-._,|,I; (.7! - .l»:..:-.~
i.’ l.‘i'l,..:-1, "31
ND
Ii-9 “r l-Qt.-lA.l@7
3 '.'/
;':l—#_ _
g "..,,_%':=_/3,>-,,;_,i
23,7
‘\._
=~ E » V
rm r201 D-032-0OS_ti
El
rmr2010t)32005_a
1. Flywheel retaining screws
2. Flywheel FLYWHEEL SCREW TIGHTENING TORQUE
3. Frontsprocket
25 NWT) (18 Ibf'ft)
Front Sprocket Assembly
Clean front sprocket threads using a metric tap Front Sprocket Installation
M8 x 1.25. The installation is the reverse of the removal pro-
A WARNING Install a NEW front sprocket screw with threads
To ensure good clamping of flywheel screws, already coated with a self-locking product.
it is imperative to clean front sprocket threads
using a metric tap M8 x 1.25. A WARNING
Install flywheel on front sprocket. Make sure to install a NEW sprocket screw
with threads already coated with a self-lock
Install NEW flywheel retaining screws (with ing product. Screw must be torqued as spec-
threads already coated with a self-locking prod- ified.
uct).
SPROCKET SCREW TIGHTENING TORQUE
I25 N'm (92 Ibfeftl
564 rrnr2011-O81
WHEEL HUB
Wheel Hub Removal
Remove rear wheel. Refer to BEAR WHEEL in
this subsection.
Remove rear sprocket dampers. " DQ
9' “ &
--re rrnr2DO8-O67-DO2_a
_,‘2
1. Inner spacer
2. Wheel hub
1; , Remove the outer spacer.
"T112008-U31 -D1 7_a

*L .¢'='~-£*~:.'
1 ;_.<=.' -.
‘Ki u"f"$£
1. Flear sprocket dampers
Unscrew wheel hub bolts.

'1
I rn'ir2008-U57-0D3__a
1. Outer spacer
2. Wheel hub
_H
Using a seal puller such as the SNAP-ON SEAL
$0311.15. ‘ PULLER (P/N YA105) or a screwdriver, drive the
A seal out of the wheel hub.
Remove wheel hub and spacer.
Wheel Hub Bearing Replacement
Remove the wheel hub inner spacer.
rm 12005-O67-D04_a
1. Seal
2. Wheel hub
Using the BLIND HOLE BEARING PULLER SET

(P/N 529 O36 117), remove and discard sprocket
beanng.
rmr201)-081
565
g -'—r,>-——|—u . Check minimum tread depth by using the tread-

L‘ 'i‘:~VvTwv ' “' L wear indicators. Check in three locations across
I
- _ . —\_
the tire tread:
\_ _ 4:-ma-Q
- Outer edge
‘._.r-"- a _=$ i — Center
- Inside edge.
T2
I-.‘v-——'
The tread-wear indicators will appear across the
__. treads that have been worn down to the minimum
529036117 tread depth. When at least one tread-wear indi-
cator appears across the tread, have the tire re-
placed as soon as possible.
‘I
'11 ‘_ <
,.
I auunuui-um~|uu- -__. §i:u:iB
0: I’
1: - i
I
.\
, .l
I151‘
1_i
1"‘-fZ(108-O67-O05
i..
Clean bearing area.
Install the NEW bearing, make sure to insert the
bearing very straight to avoid damaging wheel hub rmo2D08-001 -O41 _a
1. Tread-wear indicator
and to press bearing from its outer race. A. Appropriate tread depth
Install a NEW seal. B. Minimum tread depth, rep/ace tire
Wheel Hub Installation It is normal to see uneven wear on tire depending

on how the vehicle is driven and road conditions.
The installation is the reverse of the removal pro- The rear tire center tread will wear unevenly de-
cedure. However, pay attention to the following. pending on if the vehicle is driven smoothly or ag-
When installing wheel hub, ensure inner spacer gressively.
is properly seated against both inner races (wheel
bearing and wheel hub bearing). Recommended ‘fire
REAR TIRE
A WARNING
It is imperative to follow the proper MA
Rear 1"ire Inspection LOAD RATING of the tire relating to the
Check tire pressure. Check for air leaks (hissing model of vehicle serviced. Always check on
sound) caused by an ill-fitting rim or a faulty tire the tire sidewall to ensure that the load rating
valve. is in accordance with the following table.
Check tire for:
— Cuts
— Slits
— Cracks.
Check sides of tire for:
- Bumps
— Bulges
— Nails
— Other foreign objects.
566
rmr2011-O81
Section06 DRIVE SYSTEM
REAR TIRE LOAD RATING WHEEL BALANCER

F MAX LOAD \ Motorcycle type Do not remove wheel
MODEL RATWG DESIGNATION balancer hub or wheel bearing
Automotive type Remove wheel hub and
Spyder RT 400 kg (882 lb) MC 2§g(_i|5°Rl5 balancer wheel bearing
NOTE: The Spyder RT uses a heavy duty rim with NOTE: Refer to manufacturer's instructions for
a load rating of 400 kg (882 lb) to match with the wheel balancer operation.
tire. Always check the load rating on rim spoke Install the new balancing masses inside wheel.
to ensure that the rim meets the proper specifica- Position them in the center of the flat inner sur-
'IIlOl'1. face of the rim.
Rear ‘Fire Replacement NOTICE Improperly positioned weights can
cause interference.
A WARNING Install a NEW wheel bearing if it has been re-
The VSS on the vehicle has been calibrated moved.
to perform best with a tire of a specific size,
material, and tread pattern. Replacing the tire Reinstall wheel. Refer to REAR WHEEL in this
with one not approved by BRP can cause the subsection.
VSS to be ineffective. A WARNING
To replace the rear tire, do the following: When installing a new tire, always observe
a break-in period of 300 km (200mi). During
Remove rear wheel from vehicle. Refer to REAR this time, the tire and the VSS will not operate
WHEEL in this subsection. at their maximum efficiency. You could lose
Using an automotive tire changer (rim clamp type), control and crash — use extra caution.
remove the old tire and install the new one.
A WARNING REAR WHEEL TENSIONER
The tire is only designed to rotate in one di- Rear Wheel Tensioner Removal
rection. lf a tire is mounted on the incorrect Remove rear wheel. Refer to REAR WHEEL in
side, you will have less traction and could this subsection.
lose control. Pull tensioner out of swing arm end.
A WARNING
It is imperative to follow the proper MAX
LOAD RAT/NG of the tire relating to the
model of vehicle serviced. Always check on
the tire sidewall to ensure that the load rating
is in accordance with the specification. Refer
to RECOMMENDED T/RE.
NOTE: Refer to manufacturer's instructions for
tire changer operation.
Remove the old balancing masses from rim. rrnr2OOH-030-0 29_a
Clean inner side of wheel with alcohol to remove Separate both sliding blocks.
grease and dust.
Balance wheel using a wheel balancer.
See directive in table below depending which
wheel balancer type is used.
rmr201 1-081 567

Sect|on06 DRIVE SYSTEM
i — i _
*1». -A
H.. ‘. -w- -ea:

—...-‘"ts‘
'__=-.cf'.t_:r:'.‘ ‘:_;*-:1" '‘r'4:
'." .1
i=. .r
/Q. >-9
,1’,-
' /
117112008-030-03°_B
rmr200B-03013333
Unscrew nut completely. 1. Sliding blocks recesses
Insert tensioner into swing arm end.

Install and adjust all other removed paits.
rm r2008-030031 a
Remove tensioner bolt with its washer.
/“I _
./_-
rmr2DD8-03D<U32_a
Rear Wheel Tensioner Installation

Install nut into sliding blocks recesses.
568
rmr201HJ81
Section O7 CHASSIS
Subsection 01 (VEHICLE STABILITY SYSTEM (VSS))
VEHICLE STABILITY SYSTEM (VSS)

SERVICE TOOLS
FLUKE 115 MULTIMETER .......................................................... .. 529 O35 868 ............... .. 575, 577—579, 582

FLUKE RIGID BACK PROBES ....................................... .. ............ .. TP88 579, 582
SERVICE PRODUCTS
BRP HEAVY DUTY CLEANER ..................................................... .. 293110001 ....................................... .. 583
A WARNING SUBSYSTEM FUNCTION

Torque wrench tightening specifications Prevents the loss of steering
must be strictly adhered to. control in normal riding
Locking devices must be replaced with new SCS conditions as well as in
ones when removed (e.g.: locking tabs, elas- (Stability emergency avoidance maneuvers.
tic stop nuts, cotter pins, etc.). Control It applies braking power to the
System) appropriate wheel.
It may also reduce engine torque
as necessary.
moved during the procedure must be rein- Prevents the wheels to lock while
ABS braking.
stalled as per factory standard. (Antilock It reduces braking power to the
Braking
appropriate wheel by modulating
GENERAL System) brake pressure as necessary.
EBD
SYSTEM DESCRIPTION (Electronic
Allows the distribution between
front and rear brakes to be adjuste d
(FEATURES) Brake according to conditions.
Distribution)
The VSS maintains vehicle control in normal riding
conditions as well as in emergency avoidance ma- Optimizes rear wheel traction to
neuvers. TCS
help keeping the vehicle on its
intended trajectory.
The VSS uses the following subsystems to (Traction It reduces engine torque as
achieve its goals. Control necessary.
System) It may also apply brake on rear
wheel if necessary.
The VSS coordinates the SCS, ABS, EBD and TCS

to work together to allow maximum vehicle con-
trol while accelerating, decelerating, turning and
braking.
rm r201 I-O82 569

— I Z i | —
Section 07 CHASSIS
VSS SYSTEM DESCRIPTION

(Vehicle Stability
System) (COMPONENTS)
Vehicle Control Module (VCM)
The Vehicle Control Module (VCM) is the heart
of the vehicle stability system (VSS). It contains
I. + it i 2 microprocessors, 2 hydraulic pumps, sev-
’ SCS ABS EBD TCS
(Stability (Antilock (Electronic (Traction eral solenoids and passageways to the 3 brake
Control Braking Brake Control calipers.
System) System) Distribution) System) I
rrni20084J1 9-OI B_en
Stability Control System (SCS)

The SCS helps to maintain control in normal riding
conditions as well as in emergency avoidance ma-
neuvers by modulating the brake fluid pressure to
the brake calipers. There are several possibilities
for braking modulation. It can, as needed, prevent
a front wheel from lifting by applying the brake on
the opposite wheel and reduce the engine torque
if necessary.
Anti-Lock Braking System (ABS)
The ABS prevents the wheels to lock while brak-
ing. The vehicle configuration allows a single
brake point at the right foot, to provide the op- rrnr20OB-019-019_a
timal amount of hydraulic brake pressure on all 7. Electronic module (2 microprocessors)
three wheel's brake discs, under a multitude of 2 . Hydraulic pump moto r
3. Solenoids and passageways
braking and road conditions. The result is maxi-
mizing vehicle control while allowing the wheels The VCM receives inputs from several sensors
to remain available to generate steering control and performs calculations to cycle the pump and
force in response to the rider's input. solenoids to apply or relieve hydraulic pressure to
or from the vehicle brake calipers. In addition the
Electronic Brake Distribution (EBD) VCM has the ability to send a signal to the ECM
The EBD allows the distribution between front to reduce engine torque if necessary.
and rear brakes to be adjusted according to condi-
tions. Based on inputs from the various sensors, --... 2
I1IIr
it achieves an efficient braking by reacting to ve- vss1 SAS vss 2 I
hicle weigh transfer by reducing the rear braking

pressure as needed. _ 'lg
‘ n
R
.v.¢.u
. W
=%:5 -
Traction Control System (TCS) 1 IQ, ' ’
-ni-av Z I
, LPS
The TCS optimizes rear wheel traction to help
keeping the vehicle on its intended course. It can
13,
E
reduce engine torque if necessary. It may also BLS
apply brake on rear caliper if necessary.
ii-'.a.=
The TCS will limit rear wheel spin only if you turn iiiiiuiiiiii
the handlebars (steer out of straight line) or if ve- <@ ECM
hicle speed exceeds 50 km/h (30 MPH). PRS '""" ' ':
: I BALI. Q
I : A OLS 1
: :% OLS 2
. . . . - - --'\/S5 4
rmr201 1-082-002_a
570
rmr2011-082
Section 07 CHASSIS
VSS Sensors SENSOR

ACRONYM DESCRIPTION FUNCTION
/- ->~ 6 5 Signals the ECM
7 _ ‘Q - that the vehicle
I
,_~-iy__,H has begun braking.
Brake light
\{"'$ BLS switch
The ECM then
broadcasts the
pff_*\ J‘ ‘3 1,
. . ‘
,_ \ \ Q \ .
.32 . A) 5 signal to the VCM
T 1 --I
.-i’ - , .. ;-"/
via CAN bus.
.1-.7 .‘ "*-1*‘ ‘en Signals the VCM
. “ > ‘NU? #1 " 1
' _,;<.\-"-1,1-
'..- :-1. ‘ .. in case of a low
\-- .1 ~ . ’ _'-I Low pressure pressure situation in
LPS switch
.,,;,.f~‘I'§?12!.’ I _lP' the braking hydraulic
8 V ‘-..1\
system.
' 2 3 4 2
ri'1\l’ZO0B~G18-O01 ,a
Signals the VCM in
the event of a low
TYPICAL Brake fluid level brake fluid level in
1. Wheel speed sensor (rear) OLS1 sensor # 1
2. Wheel speed sensors (front) one half of the dual
3. Vehicle control module (VCM) reservoir.
4. Steering angle sensor (SAS)
5. Yaw rate sensor (YRS)
6. Pillion rider sensor (PRS) Will signal the VCM
7. Oil level sensors (OLS) in the event of a low
8. Brake light switch (BLS) and low pressure switch (LPS) Brake fluid level brake fluid level in
OLS2
sensor # 2 one half of the dual
SENSOR
ACRONYM DESCRIPTION FUNCTION reservoir.
Determines the VSS INPUTS!OUTPUTS
Wheel speed speed of the LH
VSS1 sensor # 1 front wheel. INPUT USAGE OUTPUT
Determines the YRS
Wheel speed speed of the RH
.
VSS2 sensor # 2 Longitudinal
front wheel. acceleration
Wheel speed Determines the Lateral
sensor # 4 These sensor
VSS4 speed of the rear acceleration signals (or
(bottom rear wheel.
.
— Modulate
sensod VSS (3) parameters) brake fluid
are used by the pressure to
Determines the Front brake VSS to perform
Steering angle angle of the front pressure proper caliper.
SAS computations
sensor wheels in relation to (inside and to then act — Engine torque
the vehicle. \/CM) by providing the reduction.
Determines lateral SAS proper output(s)
and longitudinal
Yaw rate rates of acceleration PRS
YRS S911 SOT
as well as vehicle BLS thru
rotation. ECM
Signals the VCM LPS These sensors
when a second ‘Z?’ are used to
rider is seated on monitor proper
the rear of the VSS system
seat. The VCM operation. They - Fault codes.
Pillion rider OLS (2)
PRS will make changes are not used
switch to the braking to perform
characteristics computations.
based on the
additional weight
of a rider.
rmr201‘)-082
57')
Section 07 CHASSIS
The YRS and SAS are input sensors that, in addi- Steering Angle Sensor (SAS)
tion to monitoring, broadcast their values to the The SAS is attached to the bottom of the steering
CAN bus to then to be used by other electronic column shaft under the DPS.
modules.
Yaw Rate Sensor (YRS)
The YRS is located under the forward incline of the
frame, just below the glove compartment.
rrrir20D8~O19-02 3_b
1. Steering angle sensor (SAS)
The SAS informs the VCM of the handlebar posi-

rmr20l18019-O20_b tion in relation to the chassis.
TYPICAL NOTE: To test, replace and reset the steering an-
gle sensor (SAS), refer to STEERING (DPS) AND
The YRS measures lateral and longitudinal accel- FRONT WHEELS subsection.
eration as well as vehicle rotation rate. Pillion Rider (Passenger) Switch (PRS)
,---_ Longitudinal ,---,
|
I
|
I
1
Acceleration
X axis W1
---- ----I
Vehicle rutatiuneggx.--' ~-.‘

X35 \ Lateral
t‘ ‘ .' Y . Acceleration
tn /I axis
‘--_..__
pg; ‘T
rmi2008-019-O24_b
TYPICAL - BOTTOM VIEW OF SEAT, REAR LH S/DE

1. Pi//ion rider switch (PRS)
1 I I u I '54
rrnr2ODB-O19-022_aen
The Pillion Rider Switch (PRS), located under the
seat, detects the presence of a passenger and in-
This VCM input helps to determine the direction forms the VCM.
and velocity in which the vehicle mass is actually The center of gravity and weight is much affected
traveling. by the presence of a passenger therefore, the VSS
The VCM calculates the acceleration, deceleration behavior will change based on the addition of the
and rotation of the vehicle. It determines the ve- second rider.
locity and direction, calculates the force (weight)
and adjusts the VCM parameters accordingly.
572
ri'nl‘20'l 'l-O82
Section 07 CHASSIS
Subsection O1 (VEHICLE STABILITY SYSTEM (VSS))
Wheel Speed Sensor (VSS)
/“M- rmr2C)OB-01 9030_a

1. Protrusions on encoder wheel
2. Wheel speed sensor
I'l’I'lr'ZOOB-U19-D7.S_a
FRONT WHEEL SPEED SENSOR The inputs to the VCM from the wheel speed sen-
sors are major inputs to the initiation of ABS, EBD
and TCS.
Brake Fluid Level Sensor (OLS)
i~ _. T
I
ML
rrrir2010-037-001 _b
1. Rear wheel speed sensor
There are 3 wheel speed sensors on the vehicle,

one on each wheel. The wheel speed sensors are
hall effect type sensors that send a digital signal to
the VCM.
As the wheel rotates, the teeth on the encoder rmr2008-D19-O2B_a
wheel pass in front of the sensor. The output fre- 1. Brake fluid reservoir
2. Brake fluid level sensor (front brakes)
quency of the sensor is proportional to the wheel 3. Brake fluid level sensor (rear brakes)
rotation speed.
The brake fluid level in the dual reservoir is mon-
itored on each section individually. The front
switch monitors the rear brake and the rear
switch monitors the front brakes.
The switches inform the VCM in the event of a
low fluid level in any section of the dual reservoir.
Brake Light Switch (BLS)
The brake light switch (B LS) is located close to the
master cylinder. It is activated by the brake pedal.
rmr2011-O82
573
Section 07 CHASSIS
TROUBLESHOOTING
Refer to POWER D/ST/-7/BUT/ONAND GROUNDS
for fuses and relays information.
Always refer to the l/I//H/NG D/AG/RAM when
troubleshooting an electrical circuit.
the VSS shuts off, some accessories are shut off
by the ECM and test results can be altered.
rmr2010-037-0093 an electrical terminal.
7. Brake light switch
2. Low pressure switch
TROUBLESHOOTING TIPS
The BLS turns on the brake lights and supplies If the vehicle is in limp home mode and the appli-
the ECM a signal that the operator is applying the cable indicator lights remain ON in the multifunc-
brakes. The ECl\/l sends the message to the VCM tion gauge, the VSS does not work.
via CAN. This input is used notably to enable the
ABS and deactivate cruise control. Start troubleshooting by checking fault codes us-
ing B.U.D.S. Make sure fuses 6 and 8 in rear fuse
Low Pressure Switch (LPS) box are good; follow the service actions in the
The low pressure switch (LPS) is located close fault codes section. Refer to D/AGNOST/C AND
to the master cylinder (see previous illustration in FAULT CODES.
Brake Light Switch (BLS)). It is also activated by In B.U.D.S., the VCM will not show up in the
the brake pedal. Module menu (top of screen) if the VCM does
Under normal operation during a light to medium not communicate through CAN bus. Refer to
braking, the brake lever does not activate the LPS l/CM CAN RES/ST0/L? TESTin this subsection.
switch. Carry out the tests in this subsection according to
The switch is positioned so that it will be activated the fault codes informations. Refer to D/AGNOS-
only when a predefined stroke is reached. At this 7'/C A/VD FAULT CODES subsection.
point, the VSS checks the pressure in the system
and reacts accordingly. PROCEDURES
lf there is a loss of pressure (leak or air in the sys-
tem), the pedal would travel further than the pre- A WARNING
defined stroke and activate the LPS switch. This The recommended tire pressure is critical
will inform the VCM of the low pressure condition. for optimal VSS operation. Use only recom-
mended tire dimensions and type.
There is also a internal brake pressure sensor for
the front brake circuit in the VCM. Its pressure sig-
nal output can be viewed in B.U.D.S. YAW RATE SENSOR (YRS)
YRS Connector Access
To access the YRS connector, refer to BODYsub-
-50 7000
section and carry out the following;
IE — Open the seat.
|350§l — Remove RH upper side panel.
Brake Pressure ;Sensor(kPa-)‘
imrzooscseoiz
MONITORING TAB, VCM MODULE
574 rmr201 1 DB2

Section 07 CHASSIS
2. Set multimeter to Vdc.

3. Connect multimeter RED probe to a positive
source such as the battery terminal of the
starter solenoid.
4. Probe pin 1 of the YRS connector with the
BLACK (COM) probe of the multimeter.
YRS GROUND CIRCUIT TEST
PROBES RESULT
YRS gicanqector Positive source Battery voltage
rmr2008-019-020,0
TYPICAL <— -
YRS Input Voltage Test

1. Disconnect the YRS connector.
2. Use the FLUKE 115 MULTIMETER IF’/N 529
035 868) and the FLUKE RIGID BACK PROBES
rmr2OOB-O33-O14_c
(P/N TP88).
3. Set multimeter to Vdc. If ground circuit is not good, check wiring from
4. Turn ignition switch to ON. YRS connector to battery ground. Refer to
W/H/NG D/A GRAM.
5. Read voltage as follows.
If continuity is good, check the CAN lines.
YRS INPUT VOLTAGE TEST
PROBES RESULT
YRS CAN Line Test
1. Open front storage compartment cover.
YRS connector
pin 4 Ground Battery voltage 2. Remove service cover.
3. Disconnect diagnostic link connector (DLC).
; 4.
. -=== l’-1 i
: I__..
4. Read wiring resistance between diagnostic link
connector and YRS.
_;;
“FY. f '~
‘ 55
ll
3’
' III |—— '1'"
YRS CAN LINE TEST
I _I§‘,"
‘II ~fl‘A A ul-. f,12 - Lil
CAN* PROBES RESULT
‘ III“ S"-l
YRS Diagnostic
I V V“
‘A , I ‘_ _"; -. by.
‘-4 i
. l' k
I \,.,,=;¢'-" H'gh °°"."e%I°' connrector
'4 I111! §-—. Y2. . -is», 4- '
9'" pin 1 Close
rmr2008‘O33-Ot4_a _ _ to O D
YRS D|ag_nES’EI¢ (continuity)
lf voltage is not good, check wiring and connec-
tors from battery through ignition switch to YRS Low conrinecztor Congwnector
connector. Refer to W//5’/NG D/AGR/I/I//. I‘ pin 2
If voltage is good, carry out the Y/-75 GROUND * CAN: Serial data communication
C/HCU/7' 7'ES7'that follows.
If continuity is not good, check wiring and connec-
YRS Ground Circuit Test tors from diagnostic link connector (DLC) to YRS
I.US6 the FLUKE 115 MULTIMETER (P/N 529 connector. Refer to W/R/NG D/AGHAM.
O35 868) and the FLUKE RIGID BACK PROBES If everything tested good, try a new YRS.
(P/N TP88).
rmr201 1-082 575

Section 07 CHASSIS
Subsection 01 (VEHICLE STABILITY SYST EM (VSS))
YRS Removal it . Yaw Rate Sensor

1. Refer to BODYsubsection and remove the fol- 1‘ ~Longitudinalofiset T 1 I
lowing:
— LH and RH upper side panels
— LH and RH acoustic panels. I Reset Longitudinal Offset
2. Remove LH and RH fuel tank covers. Refer to
I’ __
FUEL 7J4N/(A/VD FUEL PU/I//P subsection. rmr200B-033-01 2_b
3. Remove YRS from frame. SETTING, VCM
1. Reset Longitudinal Offset button
YRS Installation
NOTICE The YRS is very fragile. Do not drop
PILLION RIDER (PASSENGER)
or hit. Handle with care. SWITCH (PRS)
Reverse removal procedure. However, pay atten- PRS Location
tion to the following. The PRS is located under the rear portion of the
Position YRS as illustrated. seat
To access it, open the seat.
l u§"‘
rmr2008-O1 9-024_b
rm r2008-033-047_b
TYPICAL - PRS UNDER SEAT
1. Pi//ion rider switch (PRS)
TYPICAL
1. YRS flange against frame
2. Connector towards rear PRS Connector Access
Reset the YRS. 1. Open seat.
2. Remove battery access panel, refer to CHARG-
YRS Reset /NG SYSTEM subsection.
1. Place vehicle on a flat level surface.
2. Connect vehicle to applicable B.U.D.S. version.
3. ln B.U.D.S., select the following:
— Setting page tab
— VCM page.
4. Have someone sit on the vehicle seat.
5. Click on the Reset Longitudinal Offset button
in the Yaw Rate Sensor field.
576 rmr2011 O82

Section 07 CHASSIS
PRS INPUT VOLTAGE TEST

PROBES RESULT
PRS gfiwngector Ground Battery voltage
_._T:‘_—- .
-1-r __
rmr201 1082-OO2_a
1. PRS connector
2. Battery
3. Seat V
PRS Test with B.U.D.S.

1. Connect vehicle to applicable B.U.D.S. version.
rmr2ODB-033-fl16_a
- VCM page. lf voltage is not good, check wiring and connec-
3. Have someone sit on the rear portion of the tors from battery through ignition switch to PRS
seat (passenger position). connector. Refer to W/R/NG D/AGRAM.
NOTE: The Pillion Rider switch light should If voltage is good, carry out a PRS GROUND C/R-
come ON in B.U.D.S. CU/T TEST
PRS Ground Circuit Test
Low Pressure switch: Q 1. Use the FLUKE 115 MULTIMETER (P/N 529 O35
868) and set it to Vdc.
Brake light switch: Q 2. Connect multimeter RED probe to a positive
Pillion Rider switch: (§<-"*" I source such as the battery terminal of the
starter solenoid.
rrr\r2DO8-O33-D15_b
MONITORING, VCM
3. Probe pin C of the PRS connector with the
T. Pillion Rider switch light BLACK (COM) probe of the multimeter.
If the pillion rider switch light in B.U.D.S. does PRS GROUND CIRCUIT TEST
not come on as specified, carry out a PRS INPUT PROBES RESULT
I/OL7I4GE TEST
PRS pin
connector
C - - source
Positive Battery voltage
4. Have the person leave the seat.
NOTE: The pillion rider switch light should turn
OFF in B.U.D.S.
PRS Input Voltage Test
1. Open seat.
2. Disconnect PRS connector, refer to PRS CON-
NECTOR ACCESS
3. Use the FLUKE 115 MULTIMETER (P/N 529 O35
868) and set it to Vdc.
4. Turn ignition switch to ON.
5. Read voltage as follows.
rmr2011-082 577
Section 07 CHASSIS
MT I
rrnr2011-DB2-0O4_a
rmr2008-033-01 E_cl PRS OUTPUT SIGNAL TEST

1. PRS connector
If ground circuit is not good, check wiring from 2. Back probes
PRS connector to VCM,refer to W/R/NG D/A- If voltage output is not good, replace PRS.
GRA/l//. lf no problem is found, carry out the VCM
GROUND C/RCU/T TEST refer to VEHICLE CON- If voltage output is good, carry out a CONT/NU/TY
TROL MODULE (I/CM} in this subsection. TESTOFPRS S/GNAL W/RESto check wiring and
connectors between PRS sensor and VCM. Refer
If ground circuit is good, carry out the PRS OU71 to W/R/NG D/AGRA/l/7for circuit details.
PUTS/G/VAL TESTthat follows.
PRS Removal
PRS Output Signal Test
1. Open seat.
1. Reconnect PRS connector and rotated it to the
horizontal position. 2. Disconnect the seat stay cylinderfrom the seat.
2. Use the FLUKE 115 MULTIMETER (P/N 529 O35 3. Open seat until a resistance is felt and support
868) and set it to Vdc. in position.
3. Carefully insert the back probes in the PRS con- 4. Disconnect PRS connector. Access connector
nector as specified in the following table. through the hole in the battery cover.
4. Turn ignition key to ON and read voltage as fol- 5. Remove PRS retaining screws.
lows.
PRS OUTPUT SIGNAL TEST
PROBES CONDITION RESULT
No passenger 2 5 to
PRS PRS
seated on rear
position
'
4.14 VCIC
connector connector
- B - C Passenger
pm pm seatedon rear 1%2\%C
position
rmr201 (1033-DO3_a
1. PRS retaining screws
PRS Installation
Reverse removal procedure.
578 rmr201) 082

Section 07 CHASSIS
WHEEL SPEED SENSOR (VSS) 3. Lift each wheel one at a time and manually ro-
tate wheel.
/~1_ 4. Look in B.U.D.S. to see if the corresponding
sensor needle moves.
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rmr201 1-O82-001
Othen/vise, perform the electrical tests.

If one of the sensor gauges does not respond to
wheel rotation, refer to I/SS W/R/NG CONT/NU-
mv2noeo1ec2e_a /T)’ TEST
FRONT WHEEL SPEED SENSOR
VSS Wiring Continuity Test
1. Disconnect the wheel speed sensor connector
to be tested.
2. Disconnect VCM connector, refer to VCM CON-
NECTOR ACCESS in this subsection.
3. Use the FLUKE 115 MULTIMETER (P/N 529
O35 868) and the FLUKE RIGID BACK PROBES
(P/N TP88).
4. Set multimeter to Q.
5. Measure wiring resistance as follows.
rmr20ICHI37-D01_b
NOTICE To avoid damaging the connector,
1. Rear wheel speed sensor probe only the terminal tip.
Make sure that: VCM
— Wheel sensors are securely fastened and un- sensor: T§§m8:L connector: MEASUREMENT
damaged.
PIN
— Rear wheel speed sensor is properly adjusted. I 22
Front LH we
- Front wheel sensor gap is the same (within Z Z1
0.6 mm (.024 in) at 4 different places, 90° 1 6
apart. Othen/vise, inspect components for i__i-—- Close to 0 Q
straightness and ensure wheels are properly From RH 2 13 (continuity)
tightened.
C 1 31
REST iii
VSS Test with B.U.D.S. 2 19
1. Connect vehicle to applicable B.U.D.S. ver-
sion, refer to COMMUN/CAT/ON TOOLS AND
B.U.D.S. subsection.
— Read Data button
- VCM page.
rmr2011-O82 579
Section O7 CHASSIS
NOTE: If gap measurement varies significantly

“Ia with wheel rotation, it may indicate a warped disc
brake or an improperly seated encoder wheel or
disc brake. If measurement is way out of specifi-
cation, it may indicate a bent mounting bracket.
VSS Adjustment Procedure
NOTE: Adjustment is performed by removing or
»eeeeee
Lil. $4;-_’__3V
adding shims between the sensor and mounting
bracket.
rrnr2010-033-0U8_a
1. Remove sensor retaining screw.
2. Remove sensor with spacer and shims.
If continuity test failed, repair wiring or 3. Add or remove shims to obtain gap specifica-
connectors. tion.
If continuity test succeeded, try a new sensor. 4. Reinstall sensor and ensure the spacer is
lf problem persists, try a new VCl\/l. against the sensor followed by the shim(s).
VSS Adjustment (Rear Only) 5. Tighten sensor retaining screw as specified.
1. Lift rear of vehicle and support safely. WHEEL SPEED SENSOR
RETAINING SCREW TORQUE
2. Rotate wheel to align a tooth of the encoder
wheel with the sensor. 10 N'm (89 |bf°in)
3. Use a feeler gauge and measure the gap be- 6. Lower vehicle to the ground.
tween the tooth and sensor.
7. Clear fault codes using B.U.D.S. as necessary.
VEHICLE CONTROL MODULE

(VCIVI)
‘ I
fl,
I "1
rmr201 0-033-0O4_a
Ii '1 vii
A. Gap
ENCODER WHEEL/SENSOR GAR

1.30 — 1.90 mm (.051 - .075 in) rrn!2CIDB4J'| 9-O1 9
TYPICAL
Rotate wheel and repeat measurement at 4 differ-
ent places spaced of approximately 90° apart. VCM Troubleshooting
lf measurement is out of specification, carry out A VCM failure is not likely to occur. These mod-
the VSS ADJUSTMENT PROCEDURE that fol- ules have proven to be very reliable. Prior to re-
lows. placing a suspected VCM, take the following into
account.
580 rmr201 1 -OB2

Section 07 CHASSIS
The problem can be related to a hydraulic function,

— Brake fluid level
— Brake line leaking, bent or pinched
— Brake caliper
— l\/laster cylinder (including piston rod position). I_/
The problem can be related to an electric function,
— Fault codes
- VCIVI electrical connector. Refer to W/R/NG
HARNESS AND CONNECTORS subsection for rm r2010-O33-005_a
detailed information on the VCl\/l connector RH SIDE
- Wiring harness condition. 1. VCM connector
2. RH steering tiered
NOTE: If pins or terminals are not clean, check
VCl\/I harness connector seal condition and ensure Refer to W/R/NG HARNESS AND CONNECTORS
connector mechanism properly locks connector subsection for procedures on how to disconnect
seal against VCM. and reconnect the VCM connector.
Try disconnecting and reconnecting the VCl\/I con- NOTICE Follow procedures to avoid damage
nector to see if it "cures" the problem. to the connector housing and lock lever.
As a final test, try a new VCl\/l without discon-
necting brake lines from the old VCM. Proceed as VCM Power Supply Pinout
follows: VCM CONNECTOR
FUNCTION TERMINAL
IMPORTANT: Disconnecting brake lines would re-
quire the system bleeding. Power from ignition 32
l. Connect VCl\/I connector to a new VCM. switch
2. Turn ignition switch ON. Hydraulic pump power 1
NOTE: It is normal that some fault codes appear Hydraulic valves power 25
at this time.
Grounds 13 and 38
3. If problem persists, the trouble is elsewhere.
Can high 37
4. lf problem is now solved, the VCM in the vehi-
cle is faulty. lnstall the new VCl\/l in the vehicle. Can low 24
A WARNING 13 12uu_ 2 i
Never ride a vehicle with a VCM temporarily
installed. . l....l.-7.-.-nilsi y
VCM Connector Access
A WARNING
.@(.-:1-fie-=1—»1. ea-all ..
The VCM motor and valves are continuously QT “T T“
powered from the battery. Always discon-
nect the battery prior to disconnecting VCM
SI’
connector. 38 37 26 25
rrY\!ZO‘IQ-Q33-0Ul_fl
VCM HARNESS CONNECTOR PINOUT
Connector can be accessed from the front RH
side as illustrated. VCM Input Voltage Test
1. Refer to l/I//R/NG HARNESS AND CONNEC-
TORS subsection and disconnect VCl\/l con-
nector.
2. Disconnect SAS connector.
rmr201 1-O82
581
Section 07 CHASSIS
3. Open the reusable locking tie that secure har- If voltage is good, carry out the VCM GROUND
ness to the chassis. C/RCU/T TESTin this subsection.
4. Gently pull VCM connector out of the chassis to
ease probing. VCM Ground Circuit Test
5. Use the FLUKE 115 MULTIMETER (P/N 529 l.Use the FLUKE 115 MULTIMETER (P/N 529
O35 868) and the FLUKE RIGID BACK PROBES O35 868) and the FLUKE RIGID BACK PROBES
(P/N TP88). (P/N TP88).
6. Set multimeter to Vdc. 2. Set multimeter to Vdc.
7. Turn ignition switch ON. 3. Connect multimeter RED probe to a positive
source such as the battery terminal of the
8. Test for input voltage as follows. starter solenoid.
NOTICE To avoid damaging the connector, 4. Probe pins 13, then 38 VCM connector with the
probe only the tip of the terminal. BLACK (COM) probe of the multimeter.
NOTE: Referto I/CMPOI/I/ERSUPPLYP/NOUTin NOTE: Refer to VCM POWER SUPPL YP/NOUTin
this subsection for pin identification. this subsection for pin identification.
VCM VCM
CONNECTOR BATTERY VOLTAGE CONNECTOR BATTERY VOLTAGE
Pin 32 Ground Battery voltage Pin 13 Positive source

Battery voltage
Pin 38 Positive source
worn!!!
rmr201 O-033-DOZ_a
rmr201 [I-033—UO2_b
If voltage is not good, check wiring/connectors
from battery through ignition switch to VCM har- If ground circuits are not good, check wiring from
ness connector. Refer to W/R/NG DIAGRAM VCM harness connector to chassis ground located
If voltage is good, test for input voltage as follows. on the front part of the frame. Refer to I/I//R/NG
D/AGRA/I//.
NOTE: Ignition switch can be either ON or OFF.
If ground circuits are good, carry out the CAN L/NE
VCM RES/STOR TESTin this subsection.
CONNECTOR BATTERY VOLTAGE
Pin 1 Ground VCM CAN Resistor Test

Battery voltage NOTE: The VCM contains a CAN line termination
Pin 25 Ground
resistor. If the resistor value is not correct, or the
If voltage is not good, check wiring/connectors resistor is open circuit, the VCM will not be able
from battery to VCM harness connector. Refer to to properly communicate with the other modules.
W/R/NG D/A GRAM.
582 rmr201 I 082

Section 07 CHASSIS
Subsection O1 (VEHICLE STABILITY SYSTEM (VSS))
To check the CAN resistor within the VCM, carry VCM Replacement
out the following steps.
When replacing the VCM, the brake
1. Turn off ignition switch. pressure adaptation function in B.U.D.S. must
2. Open front storage compartment and remove be carried out. Refer to BRAKE PRESSURE
RH service cover. ADAPTA77ONin this subsection.
3. Disconnect the ECM-B connector, refer to VCM Removal
ELECTRON/C FUEL /N./ECT/ON (EFI) subsec-
tion. A WARNING
4. Measure VCM CAN resistor by probing at the Cleanliness is critical when working with the
diagnostic link connector (DLC) as follows. VCM and brake lines. All precautions must be
NOTICE To avoid damaging the connector, taken to prevent any foreign particle from en-
probe only the terminal tip. tering the brake system.
VCM CAN RESISTOR TEST NOTE: Before replacing the VCM, make sure
DLC CONNECTOR MEASUREMENT electrical and hydraulic systems are in good
condition, see l/CM REPLACEMENTin this sub-
Pini | Pin2 iio-iaorz section.
If the resistance value is as specified, VCM CAN I. Disconnect batten/. Refer to CHARG/NG S Y5-
resistor and CAN lines are good. Replace VCM. TEM subsection.
If the resistance value is NOT as specified, carry 2. Refer to BOD Ysubsection and remove the bot-
out the I/CM CAN L/NE CONT/NU/Tl’ TESTin this tom rear side panel.
subsection. 3. Disconnect longitudinal engine mount tie-rod at
5. Reconnect ECM connector. both ends, then move it out of the way. Do not
loosen adjuster lock nuts.
VCM CAN Line Continuity Test
Read wiring resistance between diagnostic link
connector and VCM.
NOTE: Refer to VCM POWER SUPPL YP/NOUTin
this subsection for pin identification.
NUTICE To avoid damaging the connector,
VCM CAN LINE TEST
CAN* PROBES RESULT
VCM Diagnostic
High connector Coniénelinor
rmr201 U-006-033_b
Pm 37 pin 1 Close
j _ to O Q 1. Front longitudinal engine mount tie-rod end
YRS Diet-infistlc (continuity) 4. Disconnect both steering inner tie-rod ends.
in
Low connector Connector
pin 24 pin 2 5. Using compressed air, clean:
— The VCM and brake line fittings
* CAN: Serial data communication — The area around the VCM.
6. U86 BRP HEAVY DUTY CLEANER (P/N 293 IIO
If continuity is not good, check wiring and con- 001) to thoroughly clean the parts. Blow com-
nectors from diagnostic link connector (DLC) to
VCM connector. Refer to applicable W/R/NG D/- pressed air again and thoroughly dry the parts.
AGRAM
If everything tested good and VCM does not work,
try a new VCM.
rm r201 1 -O82 583

Section 07 CHASSIS
NOTE: Disconnect brake lines from the old VCM 3 2 1

only just prior to installing the new VCM. The
shorter the time the brake lines are open, the
lesser the possibility of brake system contamina-
tion.
7. Disconnect VCM connector.
'__ ‘,i,-i 'fI‘§=--
~.. Q . I» >‘M
8. Disconnect brake lines.
-Ell!-M/' i “
--_‘. F ,. _ _, .
9. Remove VCM from frame.
It __ I- -
rrri12OOB-033-O44_a
7. To LH front brake caliper

2. To RH front brake caliper
3. To rear brake caliper
3. ‘lighten VCM mounting screws to 7N'm

(62 lbf'in).
4. Tighten longitudinal engine mount tie-rod to
48 N°m (35 Ibf'ftI.
rm r2DClB-(133-D57_a
5. "lighten steering tie-rod ends to 85N'm
TYPICA L
(63 Ibf'ft).
10. Pull out VCM towards the LH side of vehicle. 6. Make sure the VCM connector is properly in-
11. Remove support from VCM. stalled and locked.
7. Reset the YRS. Refer to I¢lW RATE SENSOR
VCM Installation (YRS) in this subsection.
NOTE: Keep the protective plugs on new VCM 8. Bleed the VCM, refer to VCM BLEED/NG pro-
until brake line installation. cedure that follows.
Reverse removal procedure. However, pay atten- 9. Carry out the BRAKE PRESSURE/lDAP7I4 T/ON
tion to the following: procedure in this subsection.
1. Remove protective plugs from VCM brake line
ports. VCM Bleeding
2. Make sure to reinstall brake lines as illustrated. A WARNING
Brake bleeding must be performed to remove
any air trapped in the brake system. Refer to
BRAKES subsection.
After bleeding, refer to D/AGNOS T/C AND FAULT

CODES and do the following:
— Check and clear fault codes.
— Clear LPS fault (if occurred).
584 rmr2011 O82

Section 07 CHASSIS
Brake Pressure Adaptation

NOTICE When carrying out the brake pres-
sure adaptation procedure, ensure the brake
pedal is fully released.
1. Connect vehicle to latest applicable B.U.D.S.
version, refer to COMMUN/CAT/ON TOOLS
AND B.U.D.S. subsection.
2. In B.U.D.S., select the following;
- Setting page tab
— ECM page.
3. In the Brake pressure adaptation field, click on
the Reset button.
The following message will appear in B.U.D.S.
B.U.D.S. MESSAGE
Make sure the brake pedal is released. WHEN YOU
ARE READY, PRESS THE <OK> BUTTON TO START
4. Press OK.
After a few seconds, one of the following
B.U.D.S. confirmation message will appear.
B.U.D.S. CONFIRMATION MESSAGES
Initialization RESET failedl
Initialization RESET succeeded!
If the procedure failed, ensure the following and

repeat procedure:
- NO brake pressure is applied.
— VCM is properly connected.
- ECM is properly connected.
- There are no fault codes in B.U.D.S.
5. Take vehicle out for a test drive. Ensure proper
operation of the VCM and brake system.
rmr201 ‘I-082 585

Section 07 CHASSIS
Subsection 02 (STEERING (DPS) AND WHEELS)
STEERING (DPS) AND WHEELS

SERVICE TOOLS
BALL JOINT INSTALLER ............................................................. .. 529 O35 975 ....................................... .. 624
BEARING PUSHER/REMOVER ................................................... .. 529 O36 O95 ....................................... .. 624
FLUKE 115 MULTIMETER .......................................................... .. 529 O35 868 ....................................... .. 613
MAGNET SOCKET ...................................................................... .. 529 O36 178 ....................... ..614, 618, 621
PITMAN ARM JIG ....................................................................... .. 529 O36 225 ............................... ..618, 620
PITMAN ARM LOCKING TOOL .................................................. .. 529 O36 228 ............................... .. 591, 593
PITMAN ARM PULLER ............................................................... .. 529 O36 227 ....................................... .. 618
PITMAN ARM PUSHER .............................................................. .. 529 O36 226 ....................................... .. 620
SERVICE PRODUCTS
CABLE LUBRICANT .................................................................... .. 293 600 O41 ....................... .. 599—600, 607
LOCTITE 243 (BLUE) ................................................................... .. 293 800 O60 ....................................... .. 614
LOCTITE 767 (ANTISEIZE LUBRICANT) ..................................... .. 293 800 O70 ....................................... .. 620
XPS SYNTHETIC GREASE ........................................................... .. 293 550 O10 ....................... .. 611—612, 617
rmr201l oas 587

Section 07 CHASSIS
65 N-m
s.
g % 7 N-m
(52 Ibf'il1I
(‘I22 lbf-ft)
h\/
~
’//////I7
,
I 1.7 N-in
(15 lbf-in)
ea$3
- ’
/-.
./ Se\' 25N-m
(22 lbf-in)
iQ§_% l
L
7 N-m
T I 105 N-m
_€,//M\0 (62 lbf-in)
(77 Ibf-ft) // /%
- 10 N-m
(89 lbf-in)
XPS synthetic grease 6
E2/Bl. E i ale" _ _ . . _ _ _ _ _ _ L,
-A
§I .3
/ 3.5 N-m
fl la
I.‘
(3 lbf-ft)
25 N'm
(18 lbf-in)
6 XPS synthetic grea S8
T SM5
I______ _.
T
2"'i
,i -
=_~'
23 N. 30 N-m
m
(21 Ibf-ft) _' NEW (22 lbf-ft)
NEW \ 1:?’
Qefi‘.. 4.:
XPS synthetic grease

“-~ ".-":/
“2.-*-‘= ~ 6Loctite 767 (antiseize lubricant)
'2‘ %
(CI: I 34 N-m
(25 Ibf-ft)
itiatii-—/-'n‘\63N.m
as N-m , . I <46 Ibf-ft) ‘\-
(46lbf-ft) /'7 NEW
' - 4s N-m ~‘»’I.‘.. .
Egmm (35'bf'“I lli_(ggl|:f:2tl
rmr201O O34 001 b
588 rmr2D1I~O83
Section 07 CHASSIS
GENERAL The greater the handlebar effort (steering torque),

the greater the assist will be.
During assembly/installation, use the torque val- The slower the vehicle speed, the greater the as-
ues and service products as in the exploded view. sist will be.
Clean threads before applying a threadlocker. Re- When the vehicle is operated in reverse, power
fer to SELF-L OCK/NG FASTENERS and LOCT/TE steering assist will decrease as vehicle speed in-
APPL/CAT/ONat the beginning of this manual for creases.
complete procedure.
NOTE: If available electrical power is limited due
A WARNING to low battery voltage or excessive electrical
Torque wrench tightening specifications system loads that reduce available voltage to the
must be strictly adhered to. DPS, steering assist will be reduced.
Locking devices when removed, must be
replaced (e.g.: locking tabs, elastic stop nuts, SYSTEM DESCRIPTION
cotter pins, etc.). (COMPONENTS)
DPS Unit
NOTICE Hoses, cables, or locking ties re- The DPS unit is a self contained unit that includes
moved during procedure must be reinstalled the steering gear, the DPS module, the DPS mo-
as per factory standards. tor, the steering angle sensor and the torque sen-
sor.
SYSTEM DESCRIPTION X‘ v
(FEATURES)
The Dynamic Power Steering (DPS) provides _ '- \
"4\
.
_. .
a computer controlled, variable power assist,
achieved by an electric motor to optimize the
amount of steering input required by the rider.
“SS--,r-Irfl‘ "*""“‘
I‘-ii-L /\
. v_, 'M
1 U
Q
f'7"/ 1 D .
/’I ii‘/,;:~"l
iilw -$ii3. . .
': Q: I
/ ,
ll :1): 1."
l‘.lr3';-
'»v:':i l ‘*‘~*— -F
' ‘F I A- ' sq
~. -.4.i’»,-'-' Pi
rmr2ClO8-01B~(116_a
W ' I W/i‘-“~""i” TYPICAL - DPS UNIT
. 7. DPS motor
?:,1:-;_-‘-'- ‘ '-.[-_ -1 2. Steering angle sensor
" ' 3. DPS module and torque angle sensor (internal)
rrnfZOIO-D34-0112 _a
1. Dynamic power steering (DPS) The DPS module provides amperage to the motor.
The amount and duration of that amperage is de-
The DPS uses the following parameters: termined by the inputs to the DPS module.
— Battery voltage
The direction in which the motor turns is changed
— Engine RPM by reversing the polarity of the electrical power
- Vehicle speed applied to the motor.
— Torque sensor The DPS motor does not "spin", but rather turns in
- Steering angle. very small increments based on the amount, du-
The amount of steering assist provided is depen- ration, and polarity of the DC power delivered by
dent on the handlebar effort (steering torque), the DPS module.
steering angle and the vehicle speed.
rmr201 1083 589

Section 07 CHASSIS
DPS Unit Protection The torque sensor is very sensitive and can de-
To protect the DPS electronic components, the tect very small changes in the magnetic field.
steering assist behavior will change as follows. The harder the handlebar is turned, the greater
the magnetic deviation, the greater the power
CONDITION DPS BEHAVIOR steering assist.
DPS internal board temperature Steering assist is
is below -10°C (14°F) stopped. Steering Angle Sensor (SAS)
When motor internal
temperature reaches a certain
temperature (DPS continuously Steering assist
estimates it) will gradually
_ decrease.
DPS internal board temperature
is above 75°C (167°F)
DPS internal board temperature Steering assist is
is above 85°C (185°F) stopped.
When the DPS unit temperature is back within

normal operating temperature range:
— Turn ignition key OFF.
- Wait 30 seconds.
— Turn ignition key ON.
Steering assist should resume normal operation.
rmr2OU8-019-O23_a
Steering Torque Sensor TYPICAL - STEERING ANGLE SENSOR
The SAS determines the angle of the front wheels
.,li;\~
in relation to the fore and aft centerline of the ve-
hicle. lt provides a direct reading to the DPS and
VCM of the handlebar position in relation to the
vehicle.
\--1/ SENSOR RESET
5.» ‘ When adjusting or replacing the following parts or

sensors, the steering angle sensor and/or steering
W
torque sensor must be reset (re-zero) for proper
steering and VSS system operation.
‘TX-__
rrnr2OClE-019-U17
TYPICAL ~ STEERING TORQUE SENSOR
The steering column is connected to the shaft on

the DPS unit. A small area of the shaft is magne-
tized. lnside the DPS unit, the sensor surrounds
the magnetized area of the DPS shaft.
When the handlebar is turned, torque is applied
to the shaft which tends to twist the shaft slightly,
deforming the magnetic field. The sensor detects
the torque by measuring the deviation of the mag-
netic field.
590 rmr201‘)-DB3
Section 07 CHASSIS
PART ADJ USTED OR WHAT To DO : Vehicle must be free of passenger or cargo.

REPLACED Suspension spring preload must be set at the
customer's preference and equal on both sides.
- DPS unit
— Steering column Procedure
— Steering column .Place vehicle on a level surface.
support
- Pitman arm 2. Apply the parking brake.
— ‘lie rod 1. Carry out an SAS 3. Lift the front of vehicle.
RESET
— Tie rod end 4. Remove the front wheels.
2. Carry out a TOROUE
— Knuckle SENSOR RESET 5. Make sure brake discs are not warped. Refer
— Wheel bearing to BRAKE D/SC /NSPECT/ON in BRAKES sub-
- Ball joint section.
- Front suspension arm
(lower/upper) 6. Lay the front of the vehicle on wooden blocks
— Steering alignment
as shown.
T Steering Ang)e Sensor Carry out an SAS RESET

(SAS)
ADJUSTMENT
STEERING ALIGNMENT
Required Items
SHOP TOOLS
7 C-clamps (locking pliers can be used as an
alternative at some steps)
_ _
A magnetic laser level 1

.~
A measuring tape rmr201 I-O34-014$
TYPICAL
HARDWARE 1. Ball joint stud
A. Wooden block (approx. 708mm (4-1/4in))
An alignment bar: A 183cm (6ft) (minimum)
carpenters level or equivalent straight edge such as
a 2" x 2" square tubing. The length is important to
I A WARNING
make proper measurements. Make sure the vehicle is securely supported
and stable.
2 spacer bars: flat bars of 127 mm (5 in) x 25mm
(1 in) x 6mm (1/4in)
7. Secure both brake discs to wheel hubs using
2 identical wooden blocks of 108 mm (4-1/4in) x lug nuts and spacers (M18 elastic stop nuts).
30 cm (1 ft) (to rest vehicle on)
6 M18 elastic stop nuts or equivalent spacers
SERVICE TOOLS
The PITMAN ARM LOCKING TOOL (P/N 529 036
228)
A computer with the latest version of the applicable
B.U.D.S. software
Required Conditions for Alignment

To ensure a proper suspension sag:
- Vehicle must be complete.
rmr201 1 -083
591
Section 07 CHASSIS
Subsection O2 (STEERING (DPS) AND WHEELS)
F’ . , --'a"4'j
Q
.< I I .
1 I - u.-
'- I .‘. — _,;-
rmr2008-028-002_a -‘.0:-a
' .. V~4!'V\l 11 I Y» _ <~..., _ ,, _ _ , -v ......M'ifl.»i-Yd?
TYPICAL rmr2OOE-D28-004_a
1. Lug nuts TYPICAL
2. M18 elastic stop nuts (as spacers)
2‘1. Driver
..Y,, - footrest
pipe
8. Using a C-clamp, position a spacer bar at 3. Spacer secured by a C-clamp near rear of frame
100 mm (4 in) from the front end of frame.
10. Mark alignment bar at its center. Align center
mark with an imaginary line through the left
and right front axles.
NOTE: If your bar is longer than 6 feet, mark the
center and 3 feet from center in each direction.
11. Attach the alignment bar to the spacers us-
ing the locking pliers or C-clamps. The align-
ment bar must be centered on an imaginary
line drawn through the front axles with (91 cm
(3 ft) in front of the axles and 91 cm (3 ft) be-
hind them).
. vk. CAL...
rmr20OB-028-OO3_a
I ~...
TYPICAL
1. Spacer bar secured by a C-clamp
2. Frame front and
A. 100mm I4 in)
3 M,‘
I' i I
I} I ‘
NOTE: Ensure spacers are straight (vertical) to it
avoid erroneous measurements. Each spacer ,A|__'i ~ _ _ ‘ fa
must be clamped where the frame is flat. Avoid

clamping on any bracket, plastic or bolt. . . IF.‘ ‘/. I
9. Using a C-clamp, secure the other spacer near
the rear end of the frame.
_.
M
l W; _ M
_
rbsZOID-015-O24_l:|
FRAME TOP VIEW

1. Imaginary line between front axles
2. Edge of frame
3. Alignment bar
12. Ensure alignment bar is parallel with the frame

(left/right) by visually inspecting from the front.
Adjust bar and clamps as required.
13. Position the handlebar so that it is in the
straight ahead position by measuring be-
tween the extremities of the handlebar and a
fixed point at rear.
592
rmr201 H183
Section 07 CHASSIS
-- - SQ
1.
“-2
\3
. , 1%
rmr201 1-0830013 rmr201 1-034-D1G_a
1. Handlebar extremity PARTS REMOVED FOR CLARITY

2. Fixed point at rear 1. DPS unit
2. Pitman arm locking tool
NOTE: The reference points must be the same on 3. Pitman arm
each side.
MAXIMUM DIFFERENCE BETWEEN
MEASUREMENTS
3mm (1/8in)
14. Install the PITMAN ARM LOCKING TOOL

(P/N 529 036 228).
14.1 Place the locking tool over the pitman
arm.
14.2 Finger tighten locking tool screws.
14.3 Secure locking tool on the pitman arm us-
ing a C-clamp or locking pliers.
rmr201 I-034-013_a
1. Pitman arm locking tool

2. Pitman arm
3. C-cIa mp pliers
4. DPS unit
15.hghten the locking tool screws to 1ON'm

(89lbf~in).
NOTICE Do not overtighten. Overtightening
screws can cause damage to the DPS housing.
16. Measure the handlebar position again to make
529035 228 sure it did not move during pitman arm locking
tool installation.
17. Remove each front fender mudguard.
593
rmr201 1-083
Section O7 CHASSIS
l1_
D -~
tilt?
A-
rbs20‘l0-016-004_a
TYPICAL - LH S/DE SHOWN
1. Mudguard
rb52 010-O16-D22_a
18. Hold the tie-rod with an open end wrench (on TYPICAL - FRONT MEASUREMENT SHOWN
1. End of alignment bar
the flat portions of the tie rod) and loosen the 2. Laser level line
lock nut at each tie-rod end. A, Frvnfdisfanfie
19. Install the magnetic laser level on a brake disc. or-E -qfi
rbs2010-O16-O20_a
TYPICAL - REAR MEASUREMENT SHOWN
1. Rear and of alignment bar
rbs2D1 D-O16-O05,a
2. Laser level line
TYPICAL B. Rear distance
1. Magnetic laser level
20. Starting on one side, measure front and rear 21. Refer to the following chart for alignment
distances between alignment bar and laser specification.
levelfine. MEASUREMENT ON ALIGNMENT BAR
IMPORTANT: Measure at the ends of the 183 cm Rear distance (B) - Front distance (A) =
(6 ft) alignment bar. Failure to measure from the 2.5 mm :I: 1.5mm (3/32 in 1: 1/16in) on each
end of the bar will reduce the accuracy of this pro- ede overa 183cnw(6fU span
cedure.
NOTE: Measuring tape must be held perpendicu- NOTE: The wheel alignment must be toe in (pos-
lar to the alignment bar to obtain a precise mea- itive result).
surement. Move the tape end back and forth in 22. To set alignment of each wheel:
the laser light until the shortest distance is read. 22.1 Adjust the tie-rod length by turning it un-
When the shortest distance is read, the tape is til proper alignment speoification is ob-
perpendicular to the bar. tained.
594
rmr201 1-083
Section 07 CHASSIS
22.2Torque tie-rod lock nuts to 34N~m COLD TIRE PRESSURE RECOMMENDATION

(25Ibf'ft). FRONT REAR
103 kPa (15 PSI) 193 kPa (28 PSI)
If steering alignment has just been done, keep the

pitman arm locking tool installed.
If SAS is to be reset without steering alignment:
- Place the handlebar as straight as possible.
— Select a reference point (an object, a line, etc.)
in front of the vehicle.
— By pushing the rear of the vehicle, move the
vehicle forward (approximately 3m to 6 m
rrnr200B-D28-O1 2_a
(10ft to 20ft)) to confirm that wheels are
TYPICAL straight. The vehicle should roll straight with-
1. Tie-rod out veering off to the right or left.
2. Tie-rod lock nut lone per tie-rod end)
- Repeat until wheels are straight ahead.
23. Ensure each tie-rod end is perpendicular (90°)
to its stud after lock nuts are tightened. /" 7 / /
I’) 1
4,. I '4'
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1. Start and stop engine 5 times.

mszmo-oie2s_a ‘
2. Without moving vehicle or handlebar or sitting
1. 77a rod end housing
2. Stud on vehicle, connect vehicle to the appropriate
B.U.D.S. software, refer to COMMUNICATION
24. After lock nuts are tightened, recheck toe in TOOLS AND B. U.D.S. subsection.
on both sides. 3. Select the Setting and VCM tabs.
25. Carry out the following, see procedures in this 4. Click on the Reset Steering Angle button.
subsection:
— SAS RESET
— TOROUE SENSOR RESET
NOTE: Do not remove the PITMAN ARM LOCK-
ING TOOL, it is required for the SAS reset.
SAS RESET
Make sure tire pressure is as specified.
595
rmr2011-083
Section 07 CHASSIS
Wu»
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TROUBLESHOOTING
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F C. Nlifl Luau-mu KPH! F
DPS STRATEGY ACCORDING TO
IIIIQYJ lwl RI —-?-W-W-.w_..-.i..----_.
FAULTS
Blinding R¢!rOi1r:uil mmihw Rm‘ ‘
2»-=w-n--» ii
FAULT DPS BEHAVIOR
mtumqw
SAS (steering
angle sensor)
YRS (yaw rate Limp home mode is set.
sensor)
&1Z'.II¢:1w-l¢P!.‘} ' '7 7 ' ' T ""7 T 7' T’ VSS
rmr2010-03=H)14_a
STEERING ANGLE SENSOR RESET ECM fault
Step 7." Choose Setting tab (GBPS) Limp home mode is set.
Step 2: Select VCM tab
Step 3: Click on Reset Steering Angle button DPS
When battery voltage is lower than
TORQUE SENSOR RESET 11.5 V, steering assist will gradually
Low battery
If steering alignment has just been done, remove voltage decrease. It battery voltage is
below 8 Vdc, no steering assist will
pitman arm locking tool. be available.
1. Place the handlebar as straight as possible.
NOTE: Make sure there is nothing resting on, NOTE: Steering assist will resume on restart if
pulling or touching handlebars. there are no more active fault codes.
2. Connect vehicle to the applicable B.U.D.S. soft-
ware, refer to C0/l///V/UN/CA 7'/ON TOOLSAND FAULT CODE C0051 AFTER DPS
B.U.D.S. subsection. REPLACEMENT OR SAS RESET
3. Select the Setting and DPS tabs.
NOTE: lf the “O torque" is difficult to obtain and re- 1;-rm
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peat, inspect steering system for excessive fric- -. P2515 Occurred ECM 19 0 975! VSS rpman
tion (ball joints and tie-rod ends). KIM?! ouwma an NM um nu vcu COMMUNICATION Mun’
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Fault code C0051 may become active and other
fault codes "occurred" if front wheels were not
straight during SAS reset.
/ - Q. NOTE: Depending on riding conditions, it may
Tmpo Scam (Wu);
take up to 50 km to trip this fault code after a SAS
reset.
rmr201 1-D34~0DE_b
7. 0 Torque Although all the codes relate to the SAS, the
C0051 code has triggered the others.
4. Click on Reset Torque Offset button. The C0051 code is triggered by a discrepancy be-
tween the SAS (steering angle sensor) and the
YRS (yaw rate sensor).
If the vehicle is moving straight ahead and SAS
data shows a steering angle of 1- 2.0° or more
while the YRS shows a O degree (straight) tra-
596
rmr201 1~083
Section O7 CHASSIS
jectory, the VCM will compare these values for a 4. Check for minimum tread depth by using the
short distance then generate several codes and tread-wear indicators. Check in three locations
set the vehicle in limp home mode. across the tire's tread:
To resolve this, the wheels must be positioned ab- - Outer edge
solutely straight while the SAS is reset. Refer to — Center
SAS /?ESE7'in this subsection. — Inside edge.
If fault code C0051 reappears SAS reset proce- The tread-wear indicators will appear across the
dure has been strictly followed, the SAS should treads that have been worn down to the minimum
be replaced. tread depth. When at least one tread-wear indi-
cator appears across the tread, have the tire re-
PROCEDURES placed as soon as possible.
FRONT WHEELS
Front Wheel Removal [IE5
1.Place the vehicle on a level surface.
2.Apply parking brake.
EHIIA
l
3.Loosen wheel lug nuts.
4.Lift the front of vehicle.
5.Secure vehicle on jack stands. Position jack
stands under lower suspension arms.
Remove lug nuts and wheel.
ACAUTION Do not hold the front wheel rmo2008-001-04‘l_a
spoke while attempting to spin the front wheel 1. Tread-wear indicator

as your fingers may be caught between the A. Appropriate tread depth
B. Minimum tread depth, replace tire
wheel and the brake caliper.
lt is normal to see uneven wear on tires depend-
Front Wheel Installation ing on how the vehicle is driven and road condi-
l.The installation is the reverse of the removal tions. The front tires outer or inner tread edges
procedure. will wear unevenly depending on if the vehicle is
driven smoothly or aggressively.
2. Tighten wheel lug nuts to 105 Nvm (77 lbf'ft).
Front ‘Fre Rotation
FRONT TIRES Rotate front tires when tread depth reaches 4 mm
Front 'l'|re Inspection (5/32 in). This will maximize tire life.
1. Check tire pressure. Check for air leaks (hissing A WARNING
sound) caused by a puncture, an ill—fitting rim, or
a faulty tire valve. The tires are designed to rotate only in one
direction. Do not switch the left and right
2. Check tire for: front wheels. The tires must be dismounted
— Cuts from the wheels for tire rotation. If a tire is
— Slits mounted on the incorrect side, you will have
— Cracks. less traction and could lose control.
3. Check sides of tire for:
— Bumps
- Bulges
- Nails
— Other foreign objects.
597
rrnr2011{)83
Section 07 CHASSIS
Front Tire Replacement HANDLEBAR GRIP

A WARNING NOTE: This vehicle uses heated handlebar grips.
The VSS on the vehicle has been calibrated The LH grip may be replaced on its own however,
to perform best with a tire of a specific size, the RH grip must be replaced with the throttle
material, and tread pattern. Replacing a tire handle assembly, that includes the TAS (throttle
with one not approved by BRP can cause the accelerator sensor).
VSS to be ineffective.
LH Handlebar Grip Removal
To replace a front tire, carry out the following ‘l. Remove handlebar end cap retaining screw,
steps: and remove end cap from handlebar.
1. Remove front wheel from the vehicle. Refer to
FRONT l/V/-/EELSin this subsection.
2. Using an automotive tire changer (rim clamp
type), remove the old tire and install the new f T.‘
one.
A WARNING
Tires used on this vehicle are designed to ro-
tate in one direction only. Do not switch the
left and right front wheels or tire direction of
rotation will be reversed.
NOTE: Refer to manufacturer's instructions for HT! V2 Cl ‘I 0-034-003,6
tire changer operation. TYPICAL

1. End cap retaining screw
3. Remove the old balancing weightlsl from the Handlebar end cap
Heated grip
rim. P-.°~1!\> Grip retaining screws (2)
4. Clean the inner side of wheel with alcohol to 2. Slightly pull back the raised shoulder of the rub-
remove grease and dust. ber grip near LH multifunction switch, and re-
5. Balance wheel using a wheel balancer. move the two grip retaining screws.
NOTE: Refer to manufacturer's instructions for
wheel balancer operation. IWGZ:
6. Install new balancing weightlsl inside wheel.

Position them in the center of the flat inner sur- .._ J
face of the rim. _-Y-I
NOTICE Improperly positioned weights can

cause interference with the lower ball joint
stud.
7. Reinstall wheel. Refer to FRONT WHEELS in
this subsection. %._
Ea
mi,
We_,»
A WARNING
When installing new tires, always observe \\_l
a break-in period of 300 km (200mi). During
rrnr2010D34~015_a
this time, the tires and the VSS will not oper-
7. Grip retaining screws (2)
ate at their maximum efficiency. You could
lose control and crash — use extra caution. 3. Remove the lower cover under the LH handle-
bar.
4. Remove the handlebar tube clamp and remove
the tube from the handlebar.
598
rm r20'| ‘l-O83
i I A I
Section O7 CHASSIS
7. Remove the required body parts to access elec-

trical connectors for the heated grip. Refer to
BODYsubsection.
NOTE: The heated grip connectors are located
under the instrument console at the end of the
front frame member. Connectors may be ac-
cessed by removing the LH headlight or the
console assembly.
8. Disconnect the LH heated grip connector.
rrnr201D-O34»-005_a
TYPICAL
7. Handlebar tube
2. Tube retaining clamp
5. Remove the heated grip wire harness from the

retaining clip in the handlebar.
4n
0/
rmr20I0-O34-011_e
1. LH heated grip connector
2. RH heated grip connector
3. Clutch lever switch connector (SM5 only)
9. Cut the locking-tie that secures the wire har-

ness at the front of the upper frame member.
rmi-201 U~O3lHJ04_a
LH HANDLEBAR, LOWER COVER REMOVED 10. Attach a string of approximately 1.25m (4ft)
1. Handlebar to the wire harness to help feed the wires on
2. Multifunction switch
3. Retaining clip the new grip through the upper frame mem-
ber, and rubber seal under handlebar.
6. Remove the handlebar tube from the handlebar 11. Pull the wire harness up to the handlebar.
by removing the screws that secure the tube
retaining clamp. 12. Untie the feed string from the wire harness.
13. Remove the connector housing from the
heated grip wiring.
14. As you pull the grip off the handlebar, feed
an.-i the grip electrical wires through the handlebar
tube.
NOTE: To facilitate removal of the wire harness
from handlebar tube, spray a light coat of CABLE
LUBRICANT (P/N 293 600 O41) in the groove pro-
vided ln the handlebar tube. Align the connector
pins end to end to route them through the multi-
function switch housing and clutch lever housing
(SM5 only). lt is not necessaiy to remove the mul-
l’mr2010-034—OO4_i:l
tifunction switch and clutch lever housings from
1. Handlebar tube the handlebar tube.
2. Tube retaining clamp
3. Handlebar
599
rmr201 ‘I-CIB3
Section 07 CHASSIS
rmr201 O-O34-009_a
SM5 MODEL ILLUSTRATED, CLUTCH LEVER INSTALLED
1. Groove for heater wiring
rrnf201 Cl-034431 3_a

3. Carefully insert the heated grip over the tube
1. Connector pins end to end and simultaneously pull the wire harness
through the groove provided in the tube.
4. Push the heated grip in until the retaining screw
holes in the grip align with the holes in the han-
dlebar tube.
I 1,; 5. lnstall the two grip retaining screws. Torque
v- I. ~
screws to 2.5 Nvm (22 lbf~in).
6. Install the handlebar grip cap and torque retain-
ing screw to 7 Nvm (62 lbf-in).
rrnr2010034—0'l2_a
TYPICAL - LH HEATED GRIP WIRE ROUTING
7. LH multifunction switch (cover removed)
2. Brake lever housing (SM5 only)
LH Handlebar Grip Installation

l. Insert the heated grip wires in the handlebar.
NOTE: To facilitate installation of the wire harness
in the handlebar tube, spray a light coat of CABLE
LUBRICANT (P/N 293 600 041) in the groove pro- rmr2010-034-OOILB
vided in the handlebar tube. Align the connector 1. Cap retaining screw
pins end to end to route them through the multi- 2. Handlebar end cap
3. Heated grip
function switch housing and clutch lever housing 4. Grip retaining screws (2)
(SM5 only).
7. Install the handlebar tube on the handlebar and
2. Position the grip on the handlebar tube with the finger tighten retaining screws at this time.
heater wires properly aligned with the groove in
the handlebar tube. NOTE: A pin inside the tube retaining clamp in-
serts in a hole provided in the handlebar tube for
proper location. The tube clamp is installed with
the notch on its perimeter in line with a pin on the
handlebar.
600
rmr201 1-083
Section 07 CHASSIS
.--
4'-
rrl1l‘2010—D34-0‘l6_a
1 Location pin in retai‘lfl ing clamp

2 Oblong location hole in handlebar tube rmr201 0-034-03 5_a
TYPICAL - HANDLEBAR TUBE CLAMP

1. Torque screws indicated by this arrow first
10. Attach the feed string to the heated grip wire

harness.
11. Using the feed string, pull the wires through
the upper frame member.
‘I2. Install heater wires in the connector housing
as per following table.
LH FRONT HEATED GRIP WIRE CONNECTIONS
flT\l20'lU-034-OO5__b
WIRE PIN NUMBER
1 Notch facing alignment pin Light green/white pin 1 (FLH-1)
8 Push the handlebar tube in until the multifunc- Light green/blue pin 2 (FLH-2)
tion switch makes contact with the handlebar. Black pin 3 (FLH-3)
13. Ensure connector pins are properly locked in,

then reconnect the heated grip connector to
the vehicle harness connector.
14.lnsert the heated grip and multifunction
switch harnesses in the retaining clip pro-
vided in the handlebar.
‘I5. Install the LH handlebar cover. Apply 1 N'm
(9 lbf¢in) to the 4 retaining screws.
16. Install a new locking-tie to secure wire har-
ness at front of upper frame member.
17. Install console, refer to BODYsubsection.
18. Start engine and test heated grip for proper
rrr\r2010-034-O17_a
operation.
1 Multifunction switch to handlebar contact
19. Install all removed body parts, refer to BODY
9 Torque the tube retaining clamp to 10 N-m subsection.
(89 |bf'inl.
NOTE: Torque the clamp retaining screws indi-
cated by an arrow on the clamp first (notch side),
then torque the other screws. See following
illustration.
rmr201 1-O83
601
Section 07 CHASSIS
MULTIFUNCTION SWITCH (LH)

LH Multifunction Switch Removal
1. Remove the screws that secure the multifunc-
tion switch cover.
rmr201 0-034-01 B_a

7. Ink reference line (clutch housing position)
2. Handlebar tube
3. Clutch housing
4. Clutch master cylinder
5. l.H multifunction switch
7. Remove the clutch housing from the handlebar

irrir2D11-DB3-0D3_a
tube.
1. Cover to switch retaining screws _ _
2. Cover to handlebar retaining screw (if applicable)
All Models
2. Separate the cover from the multifunction 8. Remove the multifunction switch housing from
switch housing. the handlebar tube.
3. Remove the lower cover on the LH handlebar. NOTE: If replacing multifunction switch assem-
4. Remove the handlebar tube from the handlebar bly, continue with the following steps.
by removing its retaining clamp. 9. Remove the console assembly for access to
the multifunction switch connectors. Refer to
BODYsubsection.
10. Disconnect the LH multifunction switch con-
nector and cut the locking-tie that secures the
..-
wire harness at the front of the upper frame
member.
rmr20I 0034004-_d
1. Handlebar tube
2. Retaining clamp
3. Handlebar
5. Remove the multifunction switch wire harness

from the retaining clip within the handlebar.
SM5 Model
6. Using an ink marker, draw a reference line on rmr201D~lJ34-01U_a
the handlebar tube to mark the position of the 1. Connector location for LH multifunction switch
clutch lever housing. It will be used to properly
reposition the clutch lever housing on the han- 11.Attach a string of approximately 1.25m (4ftl
dlebar tube for installation. to the wire harness to help feed the new wires
though.
eo2 rm r20 1 1 -OB3

Section 07 CHASSIS
12. Remove the multifunction switch wire har- When installing the multifunction
ness from the upper frame member leaving switch cover, ensure its alignment pin (or
the feed string in its place. screw hole protuberance) is inserted in the
hole provided in the handlebar tube. Ensure
LH Multifunction Switch Installation wire harness exits the switch housing through
The installation is the reverse of the removal pro- the opening provided in the cover.
cedure. However, pay attention to the following 5.Torque retaining screws to 1 Nvm l9lbf'in) in
items. the following sequence:
1. Slide the multifunction switch housing onto the
handlebar tube.
SM5 Model
2. Position clutch lever housing on the handlebar
tube using the reference line, and install its re-
taining clamp.
All Models
3. Align the locating pin (or screw hole protuber-
ance) in the multifunction switch cover with the
hole provided in the handlebar tube.
ms
ti .
rmr201 ‘I-O83-OCl3_b
RETAINING SCREWS TIGHTENING SEQUENCE
6. Attach the feed string to the wire harness and

carefully pull the wires though the upper frame
member.
Ensure proper routing of wire har-
ness through the handlebar and upper frame
member to prevent pinching, chaffing or other
wire damage.
7. Secured harness in the retaining clip within the
rrnr201l}034-D19 _a handlebar.
TYPICAL - LH MULTIFUNCTION SWITCH COVER
1. Alignment pin
1 2/’
rmr2D1D—O34005_c rrrir2010-O34-0 D4_a
1. Handlebar hole 1. Handlebar

2. LH multifunction switch
4. Install the multifunction switch cover. 3. Harness retairiirig clip
rrnr2DI'l'O83 603
Section 07 CHASSIS
8. Secure wiring harness to the front frame mem- 5. Remove the multifunction switch housing from
ber using a locking-tie as per factory specifica- the throttle handle, and its wiring harness from
tion. the retaining clip within the handlebar.
9. Ensure wire harness does not hinder handlebar NOTE: If replacing multifunction switch assem-
movement by turning handlebar in both direc- bly, cariy on with following steps.
tions.
6. Remove the console assembly for access to
10. install console, refer to BOD)’section. the multifunction switch connector. Refer to
11. Test multifunction switch controls for proper BODYsubsection.
operation of applicable systems. 7. Disconnect the RH multifunction switch con-
12. Install all removed body parts, refer to the nector.
BODYsubsection.
MULTIFUNCTION SWITCH (RH) /I I)“ /i._7,. fg\",./ .'_‘>I.|'_‘ ’
RH Multifunction Switch Removal

1. Remove the retaining screws from the RH mul-
tifunction switch cover. _ €~>'.a%%3\ _
. \ , ii
In
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rmrZO'ID-O34-010_a
1. Connector location for RH multifunction switch
8. Cut the locking-tie that secures the wiring har-

9. Attach a string of approximately 1.25 m (4 ft) to
the wire harness to help feed the new wires
though the upper frame member.
rmr201 1-U830D3_a 10. Remove the harness from the frame and han-
1. Cover to switch retaining screws _ dlebar leaving the feed string in its place.
2. Cover to handlebar retaining screw (if applicable)
2. Remove the multifunction switch cover. RH Multifunction Switch Installation

3. Remove the RH handlebar cover. installation is the reverse of the removal proce-
dure. However, pay attention to the following.
4. Remove the 2 screws that secure the multi-
function switch housing to the throttle handle. 1. Position multifunction switch over throttle han-
dle.
NOTE: For proper positioning of the multifunc-
tion switch housing with the throttle handle, a lo-
cation pin is provided on the throttle handle that
must insert in a hole provided in the multifunction
switch housing.
2/
rmr201 04334-02 I _a
1. Throttle handle
2. RH rriultifunction switch housing
3. Retaining screws (2) for the multifunction switch housing
604
iri'\r2011-083
Section O7 CHASSIS
rrnr2D‘lCHJ3H)21_b
rrnr2010-034-O24_a
1. Location hole for multifunction switch in handlebar tube
1. Throttle handle location pin
NOTE: When the multifunction switch housing is
.7 L~§‘# it ., .2
rotated counterclockwise so the location pin (or
screw hole protuberance) inserts in the hole pro-
vided in the handlebar tube, the switch housing
and its cover will properly mate together.
W,,~M_.:-;.m. ‘:'<..,.>_'_
rmr2010-(]34»O27_a
7. Location hole in multifunction switch housing
2. Install the two screws that retain the multi-

function switch housing to the throttle handle.
Torque screws to 1 N~m (9lbf'in).
rmr201 D034-026_a
1. Multifunction switch cover properly closed after switch housing

rotation
5. Install cover retaining screws and torque them

in the following sequence to 1 N~m (9lbf~in)
When installing the multifunction
switch cover, torque the lower retaining screw
first. Ensure wire harness exits the switch
housing through the opening provided.
2/ '
rmr201 0-(134021 _a
1. Throttle handle
2. RH multifunction switch housing
3. Switch housing retaining screws l2)
3. Hold multifunction switch cover over the switch

housing.
4. Rotate the multifunction switch housing coun-
terclockwise (approximately 1/4 turn) until its
location pin (or screw hole protuberance) can be
inserted in the hole in the handlebar tube.
rmrZD11-D83
605
Section 07 CHASSIS
Subsection O2 (STEERING (DPS) AND WHEELS)
14. Install all removed body parts, refer to the

BODYsubsection.
THROTTLE HANDLE
Throttle Handle Removal
1. Remove the RH multifunction switch from the
-, throttle handle. Refer to RH MULT/FUNCT/ON
SW/TCH RE/l/l0lA4L in this subsection.
2. To remove throttle handle, remove the items
listed in the following illustration.
rrnr2U'I1—083-OO3_b
RETAINING SCREWS TIGHTENING SEQUENCE
6. Carefully rotate throttle handle through its full

range of motion, then release to ensure proper
operation.
A WARNING
Always test throttle handle operation. Throt-
tle handle must rotate smoothly and without
restriction through it full range of motion, ri-rir2(J10-O34-02B_a
and return freely to its idle position when RH THROTTLE HANDLE REMOVAL
1. End cap screw
released. . throttle handle return spring
Return spring sleeve
:l=F~)'\> End cap
If throttle does operate smoothly without restric-
tion, or does not return freely to idle position, re- 3. Remove the RH handlebartube retaining clamp
fer to THROYTLE HANDLE /N5774LL/l7'lON in this and remove the tube from the handlebar.
subsection.
NOTE: If replacing multifunction switch assem-
bly, carry on with following steps.
7. Attach the feed string to the wire harness and
carefully pull the harness through.
‘-.-I’
Ensure wiring harness is properly
routed through the handlebar and upper frame
member to prevent pinching, chaffing or other -—¢>'
wire damage.
8. Secure harness in the retaining clip within the
handlebar, and at the front of the upper frame rmr201 0034-0 22_a
'S\%
using a locking-tie. Harness retaining clip
RH multifunction switch
9. Reconnect the multifunction switch connector. RH handlebar tube
5*?-°!\1.‘* Handlebar tube clamp
10. Install the handlebar cover and torque screws
to 1 N'm (9|bf'in). 4. Pull the heated grip wiring from the groove in
11. Ensure wiring harness does not hinder handle- the handlebar tube as you remove the throttle
bar movement by turning handlebar in both di- handle from the handlebar tube.
rections. NOTE: If replacing throttle handle, carry on with
12. Install the console, refer to BOD)/subsection. the following steps.
13. Test multifunction switch controls for proper
operation of applicable systems.
606 rmr201 1-083

Section 07 CHASSIS
5. Remove the console assembly for access to 2. Align the throttle handle and heated grip wire
the heated grip connector and the TAS con- harness with the groove in the handlebar tube.
nector (Throttle Accelerator Sensor). Refer to 3_ As you slide the throme hand|e on the han_
B0Dysubse°I'°n- dlebar tube, carefully pull the wire harness
6. Disconnect the RH heated grip. through the groove in the handlebar tube.
4. Ensure heated grip wiring is properly positioned
3 in line and in the groove provided in the handle-
‘I bar tube.
A WARNING
Ensure heated grip wiring is not wrapped
5 around handlebar tube, or caught on the end
of the tube. Improper routing of heated grip
wires will damage wires and prevent proper
operation of the throttle handle.
IMIQUIO-O34-0'I1_a
..a/
1. LH heated grip connector
2. RH heated grip connector
3. Clutch lever switch connector (SM5 only)
7. Disconnect the TAS connector.
rmI2010-034-0233
IMPROPER INSTALLATION
1. Throttle handle
2. Heated grip wires NOT PROPERLY ROUTED
5. Rotate the throttle handle forward (clockwise)

to align the hole in the throttle handle with the
'"*'*°'°*‘=*~°1°-3 slot at the end of the handlebar tube.
1. TAS connector location
8. Cut the locking-tie that secures the wiring har-

9. Attach a string of approximately 1.25m (4ft) to
the wire harness to help feed the new wires
though.
10. Remove the harness from the handlebar and
frame leaving the feed string in its place.
Throttle Handle Installation
1. Spray a light coat of CABLE LUBRICANT (P/N 293
600 O41) in the groove provided in the handlebar
tube for the heated grip wiring harness.
rmr2011-083 607
Section 07 CHASSIS
2i-I '4
'J€
rml’Z0‘lU4134-029_a rm r20'lO4J34>031_a
1. Hole in throttle handle 1. Pointed end of spring in hole (not visible)
2. Slot in handlebar 2. Folded end of spring in handlebar tube slot
6. Insert the plastic sleeve in the throttle return 7. As you hold the throttle handle steady, install
spring, then insert the spring and sleeve in the the handlebar end cap to hold the assembly
throttle handle. in place. Torque retaining screw to 1N'm
(9lbf~in).
8. Slightly rotate throttle handle to ensure return
spring is properly engaged.
NOTE: If no spring tension is felt, repeat previ-
ous steps to ensure proper engagement of return
spring. If throttle is difficult to turn, the heated
grip wiring may not be properly positioned, or is
wrapped around the handlebar tube.
9. Install multifunction switch over throttle handle
as described in RH MULT/FUNCT/ON SW/TCH
/NS7I4LLATl0Nin this subsection.
10. Carefully rotate the throttle handle a few times
through its full range of motion to ensure it
turns freely.
rmr201 0-034-030_a
1. Plastic sleeve
2. Return spring
A WARNING
Always test throttle handle operation. Throt-
NOTE: A small hole inside the throttle handle is tle handle must rotate smoothly and without
provided for inserting the pointed end of the re- restriction through it full range of motion,
turn spring, and a slot is provided in the handlebar and return freely to its idle position when
tube for anchoring the folded end of the spring. released.
If throttle does not operate smoothly, freely, and

without restriction, ensure heated grip wire har-
ness is properly routed in throttle handle, and en-
sure multifunction switch is properly installed.
If throttle does not return freely to idle position,
also check for proper engagement of throttle han-
dle return spring.
608
rrnr2011-083
Section 07 CHASSIS
NOTE: If replacing throttle handle, also carry out

the following steps.
11.Attach the feed string to the throttle handle
wiring harnesses and carefully route them
through the handlebar and upper front frame
member.
A WARNING
Ensure wiring harness is properly routed
through multifunction switch housing, han-
dlebar, and upper frame member to prevent
pinching, chaffing or other wire damage. r mrZO1 (H734-IJ04_c
TYPICAL - LH SE5 MODEL ILLUSTRATED
12. Secure harness in the retaining clip within the 1. Handlebar tube retaining clamp
2. Wiring harness retaining clip
handlebar, and at the front of the upper frame
using a locking-tie. 3. Remove the ignition switch from the handlebar,
13. Reconnect the heated grip and TAS connec- refer to /GN/T/ON SYSTEM subsection.
tors to the vehicle harness. 4. Remove and discard the 4 handlebar retaining
14. Install the handlebar cover and torque screws SCTSWS.
to 1 Nem (9|bf~in).
15. Ensure wire harness does not hinder handle-
bar movement by turning handlebar in both di-
rections.
16. Install the console, refer to BODYsubsection. """'t
17. Install all removed body parts, refer to the

BODYsubsection.
18. Start vehicle and test for proper operation of
throttle and heated grip.
HAN DLEBAR
Handlebar Removal
1. Remove the LH and RH handlebar covers. rmr201 0-034-007_a
1. Handlebar retaining screws
2. Remove the clamps that secure both LH and
RH handlebar tubes to the handlebar, and re- Handlebar Installation
move the wiring harnesses (LH and RH) from
the retaining clips. Installation is the reverse of the removal proce-
NOTE: This removes all controls from the handle-
bar without disassembling or disconnecting them. 1. Install handlebar using NEW retaining screws.
Torque screws to 38 N'm (28 lbf'ftl.
2. Install ignition switch, refer to /GN/T/ON SYS-
TEM subsection.
3. Torque the screws retaining the central handle-
bar cover to 3.5 N'm (31 lbfein).
4. Install the LH and RH handlebar tubes loosely.
NOTE: A pin in the handlebartube retaining clamp
inserts in an oblong location hole provided in the
handlebar tube. The tube clamp is installed with
the notch on its perimeter in line with a pin on the
handlebar (LH and RH are opposite).
rmr2011-083 609
Section 07 CHASSIS
NOTE: Torque the clamp retaining screws indi-

cated by an arrow on the clamp first (notch side),
then torque the other screws. See following
illustration.
rrrir2l110-O34-O16_a
TYPICAL - LH SIDE ILLUSTRATED

1. Location pin in retaining clamp
2. Oblong location hole in handlebar tube
rmr2D10-034-035_a
TYPICAL - LH HANDLEBAR TUBE CLAMF3 RH SIMILAR BUT

UPSIDE DOWN
1. Torque screws indicated by this arrow first
7. Properly route the wiring harnesses from the

controls on the handlebars and insert them in
the retaining clips provided in the handlebar.
rm r201 U-O34-OO5_b
8. Install the handlebar covers and torque retain-
TYPICAL - LH SIDE ILLUSTRATED ing screws to 1 N~m (9|bfvin).
1. Notch facing alignment pin
9. Install all other removed parts, refer to applica-
5. Push handlebar grip inwards until the multifunc- ble subsection.
tion switch housing touches the handlebar.
STEERING COLUMN
Steering Column Removal
1. Remove handlebar, refer to HANDLEBAR RE-
MOl44L procedure in this subsection.
2. Remove body parts required to access DPS
unit.
3. Remove the pinch bolt that secures the lower
steering column U-joint to the DPS unit shaft,
and discard elastic nut.
rmr2010034017_a
TYPICAL - LH SIDE ILLUSTRATED RH SIMILAR
1. Multifunction switch to handlebar contact
6. Torque the tube retaining clamp screws to

1ON~m (89lbf~in).
610 rmr2011-083
Section 07 CHASSIS
5.AIign the steering column support with the

bracket on the frame. and install its retaining
screws. "Tighten the front screws first, then
tighten the rear screws. Toque screws to
24 Nvm (18lbf-ft).
‘ - NOTE: Ensure the rubber insulator under the
steering support is properly positioned and that
its retaining tabs are inserted in the frame before
torquing support retaining screws.
rmr201 D-0340323
DPS UNIT
1. Lower steering column pinch bolt
4. Remove the 4 screws that secure the steering

column support assembly to the frame.
fmrZ01D-D34-D33_b
1. Rubber steering column support insulator

2. Insulator retaining tabs (each corner)
6. Install all other removed parts, refer to applica-

ble subsection.
STEERING COLUMN BUSHINGS

The steering column bushings and support are re-
placed as an assembly.
rrnQ01D-(134-033_a
Steering Column Support Removal
1. Steering column support 1. Remove the steering column assembly from
2. Screws (4) the vehicle. Refer to STEERING COLUMN
REMOI/54L procedure in this subsection.
5. Pull the steering column out through top of
frame. 2. Push up on the bellows just bellow the steering
column support to expose the upper steering
Steering Column Installation column pinch bolt.
Installation is the reverse of the removal however, 3. Remove the pinch bolt that secures the upper
pay attention to the following. steering column U-joint to the upper steering
I. Apply XPS SYNTHETIC GREASE (P/N 293 550 O10) column shaft.
on steering column splines at lower U-joint. 4. Remove the bellows from the steering column
2. Insert steering column in the frame. support.
3. Index and insert the steering column splines 5. Remove the O-ring from the splines of the up-
onto the DPS shaft splines. per steering column. Discard the O-ring.
4. Install lower U-joint pinch bolt using a NEW 6. Pull the upper steering column shaft out of the
elastic nut. Torque nut to 31 Nem (23 lbf'ft). column support.
rmr2l111-083 611
Section 07 CHASSIS
Steering Column Support Installation I3. Perform the steering angle reset. Refer to
1 Apply XPS SYNTHETIC GREASE (P/N 293 550 O10) STEEH/NG ANGLE SENSOR in this subsec~
to the bushing contact points on the upper tion.
steering column shaft and on the splines of the ‘I4. Perform the torque offset reset. Refer to
lower steering column U-joints. TOHOUE OFFSET/?ESE7'in this subsection.
2. Insert the upper steering column shaft in the
column support. STEERING ANGLE SENSOR
3 Insert a NEW O-ring at the top of the splines on (SAS)
the upper steering column shaft. First, check for fault codes using the latest appli-
4. Insert the bellows over the bottom end of the cable B.U.D.S. software.
steering support. Do not install the locking-tie Before replacing the SAS, check the following.
at this time.
5. Index and push the lower steering column onto SAS Input Voltage and Ground Test
the splines of the upper steering column shaft Disconnect SAS connector.
until the pinch bolt can be inserted through the
grooved portion of the shaft. Turn ignition switch ON.
6 Install a NEW elastic nut on the pinch bolt and
torque nut to 31 N-m (23 lbfsftl. '“m=>»ee \‘ _,/GI
a
7 Position the bellows with the raised shoulder 7
\
on the steering column support inside the '7
~
/
groove provided within the small end of the
bellows. \\\ ‘\
‘__4_ i ‘
/,
0%‘.
I .
IbgZO10-UO60l]1_a
TYPICAL - BOTTOM OF DPS UNIT

1. SAS
2. SAS connector
M ULTIMETER PROBE VOLTAGE

POSITIONS (KEY ON)
SAS connector (pin I) and
2; battery ground
l'l'r1 I2 D10-D34!-O34_a
Upper frame member

Lower steering column shaft ,/ . » - -12
gpper U-joint pinch bolt I\[‘i,§;E§ Q » -
-r/ng
wewwe Raised shoulder on steering column (bellows not illustrated) L53;
8 Install a locking-tie on the grooved portion to

properly secure the bellows. _ Battery voltage
SAS connector (pin 2) and
9 Install the steering column, refer to STEEFI’/N6 battery + terminal
COLUMN /NSMLLAT/ON in this subsection.
IO .lnstall the handlebar and controls, refer to
HANDLE5’Afi’in this subsection.
11 . Install the ignition switch, refer to /GN/7'/O/V
system subsection.
I2 . Install all other removed parts, refer to applica-
ble subsection.
612 rmr201 1-083

Section 07 CHASSIS
No voltage — Check wires and connector pins. SAS Removal

Replace or repair defective parts and reset fault 1_ Remove the from storage Compartment. Refer
codes. to BODYsubsection.
Battery Voltage measured _ Check SAS COmmU' 2. Remove screws retaining the SAS support to
nication link (CAN). DPS.
SAS CAN Communication Link (CAN)
Continuity Test fl
\.
I
K I *
1. Disconnect steering angle sensor connector. -I._i';‘
2. Disconnect the vehicle diagnostic connector.
3. Set a FLUKE 115 MULTIMETER (P/N 529 035 868)
to Q selection and test SAS CAN bus wire con-
tinuity as per following table.
rrnr2008~0Z8-1'1 55_a
“'
5
'
fir
>.
’gt)’
rt’
//————-*“—.
-...;....
I]
-7
'
ml n ' l|
1 .!ol __1
.
TYPICAL
I. RH SAS support screw
3. Disconnect the SAS connector.
“>__V—.v ‘I y/V///;;/1"? ¢..._>‘ ‘E7

579035868
MULTIMETER PROBE
POSITIONS
RESISTANCE @
20°C (68°F)
t - R-.~
4 ,-I /“rig;
'f“)M
I.
SAS connector (pin 3) and l »
ta
diagnostic connector (pin 1) '/ - .
,7 _d"4{.~"‘~j.
-__
flf
rmr200B~028~U 58_a
‘--'““ri“”="F.n It .—_4.R
03 ‘1
:T.—_::1\__ TYPICAL
Tim: I 1. LH SAS support screw
2. SAS connector
Q
Less than 1 Q
SAS connector (pin 4) and 4. Remove SAS from its support.
diagnostic connector (pin 2)
i I
vti
‘ills/5
‘J
Resistance is out of specification — Check wires 'o.. .-1/"2
ls;---s
. "
jfi
-:3.ld.£%\ /if165:1,-~
-1- Ii;
Resistance is good — Replace the steering angle taII9%
sensor and reset fault codes.
rmr200B'D28-O5 7_a
1. SAS
2. SAS support
rm r201 I-O83 613

Section 07 CHASSIS
Remove magnet from the DPS shaft.

%4"‘_ R
MAGNET REMOVAL
R . 0| I MAGNET SOCKET -"
e°l“"ed ‘° (P/N 529 036 178)
529036 I 78
3. Clean the magnet using a clean rag to remove

any metallic particle.
4. Apply LOCTITE 243 (BLUE) (P/N 293 800 O60) on
threads of sensor support screw threads.
529036178 5.lighten SAS support screws to 10N'm
(89lbf'in).
The SAS magnet is a sensitive and
fragile part. Do not to drop it on a hard surface. 6. Install all other parts removed, refer to applica-
Do not place it directly on metallic parts. If the ble subsection.
SAS magnet is dropped, knocked, or place on a Reset SAS, see procedure in this subsection.
metallic surface, replace it with a new one even
if it appears in a good condition. DPS UNIT
5. Remove and discard the seal. DPS Unit Troubleshooting
Check for fault codes using the latest applicable
Q B.U.D.S. software.
J
7A
L DPS Unit Fuse Inspection
Check l\/IF5 (40 A) DPS motor fuse located in the
rear fuse box under seat. Replace as required.
- (Q
I.455
. __ __\_ I 1 ‘C
/I
Ia see» -—
rm r2 U08-O28-056_a
I. Magnet
2. Seal
3. Pitman arm
SAS Inspection
lnspect SAS support for cracks or other damages. \
Replace if necessary. rmo2010-001-10B_a
lnspect the magnet for cracks or other damages. FUSE LOCATIONS, REAR FUSE BOX
DPS motor fuse (MF5)
Replace as required.
The 12 Vdc DPS control power comes from fuse
SAS Installation F3 (25 A) through MAIN Relay 2 (R3), both located
1. Install a NEW seal. in the front fuse box. This fuse supplies power
to several systems including the multifunction
2. Install the magnet and tighten it to 2N'm gauge (cluster). If the cluster is powered, the
(18|bf¢in) using the MAGNET SOCKET (P/N 529 fuse is good.
O36 178).
DPS Unit Circuit Test (Main Power)
1. Disconnect DPS main power connector.
614 rmr201 I-O83

Section 07 CHASSIS
»-Yer, 3}; -c MULTIMETER PROBE

-;*;-
Q\\ La;-.\
.‘
.
-,\.‘
"v .
.
~47, _ ‘. I POSITIONS VOLTAGE
i\' - $5 I *4’ DPS control connector (DPSI
I f < I iiziitifiif pin AI and battery ground
1-?’
or
' I;
| r*r“t@l?m=:r“">.|i",
I \g* D?__1; 1 it 7
. "Q;-)§‘~ ®\—.,;§—jié_-—-J ss_i<'>_§“-'_r-_‘;-‘.'§%' _ _ Battery voltage

.. - . 1..->\:__-:5:-;_ii ., :15 V..__,-_._ ;§:g';5;;_§;.)_., _ ,
I 4 2-»—--‘G ' '7' = -"’».-.'..*:_iE.i ‘
._
rmKZOOB-018-O9(]_a
DPS main power connector If there is no voltage, check wires and connector
DPS control connector pins. Replace or repair defective parts and reset
DPS motor connector
P9Nfi DPS ground fault codes.
If there is voltage. Carry out a CONT//\/U/TY TEST
2. Set multimeter to Vdc. OF DPS UN/T COM/I/IUN/CA T/ON L/NK (CA N).
3. Test for DPS motor circuit as per following ta-
ble. Continuity Test of DPS Unit
MULTIMETER PROBE Communication Link (CAN)
POSITIONS VOLTAGE l\/lake sure DPS is powered by carrying out DPS
UN/T C/RCU/T TEST lCONTFi’OL POWER) in this
DPS power connector (DPS2
pin A) and battery ground subsection.
1. Set multimeter to Q selection.
sf - . 2. Disconnect DPS control connector.

3. Disconnect the vehicle diagnostic connector.
4. Test DPS CAN bus wire continuity as per follow-
-F?
ing table.
Battery voltage MULTIMETER PROBE RESISTANCE @
DPS ground and battery POSITIONS 20°C (68°F)
+ terminal
DPS control connector (pin C)
and diagnostic connector (pin 1)
ti:
No voltage — Check fuse MF5 (40 A). If good, (1

is-t
check wires and connector pins. Replace or repair Below 1 Q
defective parts and reset fault codes. DPS control connector (pin DI
Voltage — Carry out a DPS C/RCU/T TEST (CON- and diagnostic connector (pin 2)
TROL POWEFI’).
DPS Unit Circuit Test (Control Power)

1. Disconnect DPS control power connector and
turn ignition switch ON.
2. Test for DPS control power as per following ta-
ble.
3. Turn ignition switch ON. If resistance is out of specification. Check wires
rmr201H)83 615
Section 07 CHASSIS
If resistance is good. Replace the DPS unit and re- 8. Disconnect the DPS unit control and motor con-
set fault codes using the latest applicable B.U.D.S. IIGCIZOFS.
software.
DPS Unit Removal
1. Open seat and remove 40 A MF5 DPS motor
fuse.
A CAUTION The DPS motor fuse must be

removed to avoid any accidental DPS move-
ment during its installation.
2. Remove the front storage compartment and
console. Refer to the BOD)/subsection.
3. Remove the steering support mounting YFHFZOOB-OZB-(.I63_a
screws. 1. RH speed sensor connector
4. Remove the DPS unit ground wire. 2. DPS unit control connector
3. DPS unit motor connector
9. Remove the pinch bolt securing the lower

steering column U-joint to the DPS input shaft.
rrr\r200B~02B-D61_a
1. Ground wire on DPS unit
5. Remove the LH speed sensor connector. rmr2011063-002_a
6. Disconnect the DPS unit power connector. 1. Lower steering column U-joint
2. Pinch bolt
10. Disconnect the steering angle sensor (SAS)

connector.
11. Remove both tie-rod ends from pitman arm.
Mi ’_-_ ‘
In»;
ll‘!
rmr2OOB-028062_a
1. LH speed sensor connector
2. DPS unit power connector
rmr2OOS-D25-U553
7. Remove the RH speed sensor connector from 1. Steering angle sensor support
its mounting bracket. 2. Pitman arm
3. DPS unit
616 rmr201 H183

Section 07 CHASSIS
12. Pull the steering column up sufficiently to dis- 14 .Pull upwards on the DPS unit to remove it
connect it from the DPS unit shaft. from the frame.
NOTE: Some models may have shims of I5 . If replacing the DPS unit, remove the SAS and
0.25 mm (.01 in) installed between DPS unit magnet from the DPS shaft, refer to SAS HE-
and frame. Note the shims location and quantity MOl44L in this subsection.
at each screw prior to removing DPS unit. These
shims must be reinstalled at the same place. DPS Unit Installation
NOTE: DPS, if replaced, must applicable to the
vehicle model.
1. Install the SAS on its support using NEW nuts.
SAS BOLTS TIGHTENING TORQUE
4.5 N'rn =1; O.5N'rn (4OIbf¢in 1 4Ibf'in) I
2 Install DPS unit on frame.

2.1 Apply XPS SYNTHETIC GREASE (P/N 293 550
O10) on DPS input shaft splines.
' 2.2 Position DPS unit in frame.
2.3 Index and insert steering column splines
.I.,,mam@5_. I on DPS input shaft splines.
MANYPARTS
1 DPS unit
REMOVED F0” CLARITY 2.4 Install all previously removed shims at the
2: gjontrriemberof frame DFODGT IOCBIIOH.
3. " r . .
(ms mm 2.5 Secure DPS units using NEW screws.
DPS RETAINING SCREWS TIGHTENING TORQUE
28 N¢m i 2 Nlrn (21 Ibf¢ft :I: 1 Ibf'ft)
3. Install pinch bolt at lower end of steering col-

umn using a NEW elastic nut.
LOWER STEERING COLUMN NUT
TIGHTENING TORQUE
31 N¢m (23 Ibf¢ft)
4 Install steering column support retaining

maziiigooeoui I screws.
DPS SHIMS STEERING COLUMN SUPPORT RETAINING
SCREWS TIGHTENING TORQUE
13. Remove screws securing DPS unit to frame.
24 Nvm (18 Ibf'ft)
5 Reconnect the DPS unit connectors.

6 Reinstall the DPS ground wire.
GROUND WIRE RETAINING SCREW
TIGHTENING TORQUE
10N'rn :I: 2N~m (89lbf'in 1 18Ibf'in)
7 Install the LH and RH speed sensor connectors

on their mounting brackets.
rmr20OB-O28-OE7_a 8. Install the SAS and magnet, refer to SAS /N-
7. DPS screws S7?4./_LAT/ONin this subsection.
rmr2U110B3 617
Section 07 CHASSIS
9. Reinstall tie-rod ends to pitman arm using NEW The magnet is a sensitive and fragile
nuts. part. Do not drop it on a hard surface and do
TIE-ROD ENDS RETAINING NUTS
not place it directly on metallic parts. If mag-
TIGHTENING TORQUE net is dropped, knocked or place on a metallic
surface, replace it with a new one even if it ap-
62.5 Nsm :I: 7.5N°m (46 |bf'ft :I: 6 |bf'ft) pears in a good condition.
10. Reinstall MF5 40 A DPS motor fuse. Remove and discard the seal.
11 . Install all other removed parts, refer to applica-
ble subsection.
12. Roll vehicle back and forth on a level surface 1
to make sure the wheels are in a straight line.
I3. Carry out TOROUE SENSOR RESET see pro-
cedure in this subsection. "'\\ _ I‘ ._.
2- AH? P . I
PITMAN ARM
Pitman Arm Removal I Ii. Io ~ _
Remove DPS unit. Refer to DPS UN/Tin this sub-
se ct ion. rmr2008r02B-CI S9__a
1. Magnet
Remove the steering angle sensor (SAS) support 2. Seal
from DPS unit.
Unscrew pitman arm nut and washer.
-1
i%~ib.>,.
*i. ll
P-I , 2
S -7‘ .1) i ‘I
L M I , . *\
.,_-
Ll.PiP>»
is ‘i I I Q
rmfl00B-O28-058_a
1. SAS support screws - .
rrnf20DS-028-O7I_a
rt» ~.:'%ac§s-"s......
T‘; -.—....-_ " _'*T\-.Te= '- All
Remove magnet from the DPS shaft. 1. Pitman arm nut

2 . Wsh
Ya er
MAGNET REMOVAL 3. Pitman arm
. MAGNET SOCKET Remove the pitman arm from the DPS shaft.
Re°‘“"ed t°°' l (P/N 529 036 178)
PITMAN ARM REMOVAL
PITMAN ARM JIG
(P/N 529 O36 225)
Required tools
PITMAN ARM PULLER
(P/N 529 O36 227)
5290361 TB
618 rmr2011-083
Section 07 CHASSIS
1 —_~_q.‘
V
I
r. ,
/1
-I"‘“““~
I
*2
I‘
|
.i_. E
-7
5¢;
.
529036225
rrrir20‘l 1-034-00B_a
1. Jig screw tip
2. DPS output shaft
Install the puller over the pitman arm and the jig
thrust bearing.
1\
529036227
Place the jig in a vise.

Position the DPS input shaft in the jig bottom hole.
rrnr2011-O34-009_a
1. Thrust bearing
Z. Pu lle r
3. Pitman arm
Pull pitman arm off the DPS output shaft by turn-

ing the thrust bearing. Hold the jig screw.
rmr201 1-034-DCI7_a
1. DPS input shaft

2. Jig bottom hole
Lean the jig screw tip on the DPS output shaft. “*“"~.
'-11¢
rmr201 1-O34-01 0
rmr201 1-083 619

Section 07 CHASSIS
Pitman Arm Installation

‘Y 1
Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070) on splines of DSP.
Install the pitman arm on the DPS shaft.
PITMAN ARM INSTALLATION
PITMAN ARM JIG
(P/N 529 O36 225)
Required tools
PITMAN ARM PUSHER
(P/N 529 O36 226)
. ~;--.____._...____L _ rmr201 I-034-007_a
I
1. DPS input shaft
2. Jig bottom hole
I
Install the pusher between the jig screw tip and

$1; -e~*é==- pitman arm.
it
_ l ' =
..._L H 1
529036225
<——2
L j i v. ,'__. _ 3
~ _~ yem
. _ .
-:-ii’! ’.'./Q‘. . .~.t
rmr201)-034-011__a
1. Jig screw tip

2. Pusher
3. Pitman arm
Turn the jig screw to push the pitman arm on the

529036226
DPS output shaft until it stops.
Place the jig in a vise.
T, 1
gr
Position the DPS input shaft in the jig bottom hole. NC’ __ M _ __,»’ E
i“ j
I t
' .
l
. 4; '~ _ H H’
"moi isawi 2
Install washer and nut.

hghten nut to 62 Nvm (46 lbf-ft).
620 rmr201 1-083 l

Section 07 CHASSIS
Install a NEW seal.

Install the magnet using the MAGNET SOCKET
(P/N 529 O36 178) and tighten it to 2N¢m
(18lbf~in).
Q .
rrrir2008-028-01 4_a
I
AT PITMAN ARM
1. Cotter pin
2. 77e-rod nut
5296361 78
3. Hardened washers
4. Steering column lever
Clean the magnet using a clean rag to remove any 3. Remove tie-rod from the vehicle.
metallic particle.
Install all other removed parts. Tie-Rod Inspection
Carry out STEERING/IL/GN/I/lEN7I see procedure lnspect tie-rod ends for wear or excessive play. If
in this subsection. excessive, replace tie-rod end.
TIE-ROD "Fe-Rod Installation

1. For the installation, reverse the removal proce-
'I'ie-Rod Removal dure. However, pay attention to the following.
1. Remove wheel, see procedure in this subsec-
tion.
2. At pitman arm and knuckle, remove: I< A
— Cotter pin (discard)
- ‘lie-rod end nut
1*’) _"%¢2
— Hardened washers.
rm r2008-028-OI 5_a
MAXIMUM LENGTH
1. Pitman arm side
,._,4 2. Knuckle side
A. 620mm 1 50mm (24.5in 1- Zln)
TIE-ROD
Maximum length - 620 mm s; 50 mm
dimension “A” l (24.5in =1; 2 in)
I 2
. _ -.. _¢--'~,~ _~;.i~g's5;'T'-yr,-~
. i_r'-;F' H 1_l:ll_. liyir”
t
S. . .l
rrnifl DOPPOZSI-O1 3_a ‘T’ §4
AT KNUCKLE
1. Cotter pin
2. Tie-rod end nut B B ~
3. Hardened washers
4. Knuckle
fmr2OOB-OZSOI 6_a
7. Pitman arm side

2. Knuckle side
B. 12mm (.47in)
rmr2011-083 621
Section 07 CHASSIS
TIE-ROD ° » I
Unengaged threads - - ,r ~33 . —
dimension "B"* l 12mm ('47'"l I ~
* Dimension "B" to be approximately equal upon F
~ _
assembly. 1 I -_
2. 11ghten tie-rod lock nuts finger tight.

;—T‘~.:1
1?“-P-7II", It 1;‘) I_,j
//’‘ I".
E‘ ‘_‘
' -1
g
3. Install tie-rod on steering knuckle. Follow instal- ;:‘T5'.Y _
‘_ I -. 1 _
Iation sequence as depicted in exploded view. rn1r2DOS-028-OIB_a
1. Fender supports
4. Torque tie-rod retaining nut to 63 N'm
(46 lbf~ft). 9. Remove tie-rod end from knuckle, refer to T/E-
5. Install NEW cotter pins. Both ends of cotter HOD)" this Subsection
pins must be folded around nut.
6. Tighten tie-rod end lock nuts to 34N~m
(25Ibf'ft).
7. Carry out STEER/NG ALIGNMENT see proce-
KNUCKLE
Knuckle Removal
1. Place vehicle on a level surface.
2. Apply parking brake.
3. Loosen wheel lug nuts. inrzmmig-P
. . . 1. T - o o
4. Lift the front of vehicle on jack-stands. 2. Kifiurgkleen
5. Remove wheel, see procedure in this subsec- 1O_ Remove upper ban joint Support retaining
non‘ screws.
6. Remove brake disc and encoder wheel. Refer
to BRAKE SYSTEM subsection. ' """“‘*‘
7. Remove wheel speed sensor retaining screw. i
\.
rrnr2008-U28-O2(Il_a
1. Ball joint support screws
2. Knuckle
"“"“°”*”""‘"° 11. Remove cotter pin and lower ball joint nut.
1. Wheel speed sensor
2. Wheel speed sensor screw
8. Unscrew fender supports.
622 rmr201 1-083

Section 07 CHASSIS
rmr2008-028-O21_a
Cotter pin _ _
Lower ball /0/ntnut rmr200E~028-D22_a
Lower suspension arm
.4=$->!\1.* Knuckle WHEEL HUB NUT REMOVAL
1. Prybar
12. Separate lower ball joint from knuckle. 2- 36 mm 5°C/<9‘
2. Using a press, remove wheel hub from knuckle.
Support the knuckle properly to avoid damaging
it.
rmrZO0H~O29-045_a
1. Hit here
13. Remove wheel hub and wheel bearing only if

necessary.
rm r2 D08-028-O23__a
Knuckle Installation Press

Wheel hub
The installation is the reverse of the removal pro- Knuckle
PWNF Blocks to support knuckle
l.l'|ghten upper and lower ball joint nuts to 3.Wheel bearing must be replaced every time
82 Nsm (60 Ibfvftl. wheel hub is removed. Referto WHEEL BEAR-
INGS in this subsection.
2. Install NEW cotter pins. Both ends of cotter
pins must be folded around nut around nut. 4. if the bearing inner race remains on the wheel
hub shaft, use a press and a bearing separator
3. Install tie-rod ends as described in 7'/E-ROD in to remove it.
this subsection.
4. Carry out STEE5’/NG ALIGNMENT, see proce-
WHEEL HUB
Wheel Hub Removal
1. Remove KNUCKLE, see procedure in this sub-
secfion.
rmr2U08-028-O24_a
1. Wheel hub
2. Bearing inner /ace
3. Bear/ng separator
rmr2011-OBS 623
Section 07 CHASSIS
Wheel Hub Installation

1. Press the wheel hub into the bearing using the
BALL JOINT INSTALLER (P/N 529 O35 975) as a
support. This tool will support the bearing inner
race during wheel hub installation.
l,.
rm|Q008-028-02G_a
1. Circl/p
3. Press out the wheel bearing.

REQUIRED TOOL
Wheel bearing BEARING PUSHER/REMOVER
rm r2 008023-025_a
removal i (P/N 529 O36 095)
1. Wheel hub
2. Knuckle
3. Bearing inner race support
2. Before pressing wheel hub, ensure it is per-

fectly aligned.
/VUTICE If the wheel hub is not aligned,
wheel bearing will be damaged and its re-
placement necessary. 52903 5095
3. install the knuckle and all other removed parts. NOTICE Support the knuckle properly to
avoid damaging it.
WHEEL BEARINGS
Wheel Bearing Inspection
1. Lift and support the front of vehicle on jack-
stands. .9!" . f
2. Hold the wheel at the top and bottom and at-

tempt to move it back and forth to check for
looseness and lateral play in the bearing.
3. Rotate wheel and check for smoothness of ro-
tation.
lf there is any play or roughness of rotation, re-
place the wheel bearing. rmr2DOB-02B~0Z7__s
1. Clutch bearing installer

NOTE: First, check if ball joints are loose. If nec- 2. Knuckle
essary repair all defective parts before checking
the wheel bearing condition. Be careful not to Wheel Bearing Installation
mistake play in a ball joint for a bad wheel bearing. 1. Leave the NEW bearing to cool to ease instal-
lation.
Wheel Bearing Removal
1. Remove WHEEL HUB. See procedure in this BEARING COOLING
subsection. In freezer I 30 minutes minimum
2. Remove the circlip retaining the wheel bearing
in the knuckle. 2. Clean all grease from outer and inner surfaces
of knuckle.
3. Heat knuckle in an oven.
624 rmr2011—083
Section 07 CHASSIS
KNUCKLE HEATING
100°C(212°F) | 30 minutes maximum I
4. Install the wheel bearing in the knuckle. Use a
press if necessary.
5. When the knuckle is cold, install the circlip.
6. Install the other removed parts in the reverse
order of removal, refer to applicable procedure
in this subsection.
7. Carry out the steering angle sensor reset. Refer
to SAS HESETin this subsection.
8. Carry out the torque offset reset. Refer to
T0/-?OUE SENSOR /?ESE7'in this subsection.
rmr201 1 osa 625

SectionO7 CHASSIS
Subsection03 (FRONT SUSPENSION)
FRONT SUSPENSION
SERVICE TOOLS
BALL JOINT EXTRACTOR ........................................................... .. 529 O35 827 ....................................... .. 633
BALL JOINT INSTALLER ............................................................. .. 529 O35 975 ............................... .. 633, 636
BALL JOINT REMOVER SUPPORT ............................................ .. 529 O36 121 ............................... .. 633, 636
SPRING REI\/IOVER ..................................................................... .. 529 O36 OO7 ....................................... .. 630
SERVICE PRODUCTS
XPS SYNTHETIC GREASE ........................................................... .. Z93 550 O10 ....................................... .. 630
rrnr201l can 627

Sect|on07 CHASSIS
Subsection 03 (FRONT SUSPENSION)
Upper suspension arm Lower suspension arm
/lie@/
Fr’H Sid8
Q
Ibf-In)
'-
thetic grease (2% Iiiini‘III > Wk 3‘

XPS synthetic grease
G
M ' A .2¢.t;t.
\ " ‘$3 I
\,\
-.. ii‘ \’
‘I’ ‘=9’-‘\§\
‘E
64 N-m
(47 lbf-ft) .. 9F
1.5 N-m
(13lbf-in) Q9
62 N-m
(46lbf-ft) ‘
25 N-m
(18 lbf-ft) %
W . 25 N-m
[(18|bf~1't)
\ lb ,_.
re‘: 0/ ' ,
As.
j ._ Q»
.
’~ 11'
./' ._
$2 /k
if
\
,,;,~ \\_
~
\~ 18lb-ft
MQB]
’@.1
NEW = Component must be replaced when removed.
rmr201 1 -084
Section07 CHASSIS
GENERAL
ues and service products as in the exploded view.
APPL/CA7’/ON at the beginning of this manual for
complete procedure.
A WARNING
Torque wrench tightening specifications 1mr2008-D29-O35
Locking devices when removed (e.g.: locking Turn the adjusting cams clockwise to increase
tabs, elastic stop nuts, cotter pins, etc.) must spring preload.
be replaced. Turn the adjusting cams counterclockwise to de-
crease spring preload.
NOTICE Hoses, cables and locking ties re-
ADJUSTMENT
SPRING PRELOAD ADJUSTMENT
Install a jack under the front portion of frame. rm r2 U08-D3(HJO4_a
Lift the front of vehicle until shock absorbers are 1. Softest adjustment (position 1)
2. Hardest adjustment (position 5)
fully extended.
RECOMMENDED SPRING PRELOAD
A WARNING LOAD CAM POSITION
Adjust both springs to the same load. Un-
even adjustment can cause poor handling 68 kg (150 lb) rider 1, 2
and loss of stability, and/or control, and in- 91 kgg(200 lb) rider 2
crease the risk of an accident.
68 kg (150 lb) rider 3
with cargo
Adjust spring preload by turning adjusting cam
accordingly, with the adjusting wrench in vehicle 91 kg (200 lb) rider 4
tool kit. with cargo
Rider with passenger 5
\,\ ;_:-“r and cargo
\ ~~ r r.
' §/‘T gr ,__' _H (kl...
MAINTENANCE
‘A J?
rl'V1l‘ZQ08*U29'DO2
“M
SUSPENSION LUBRICATION
Apply parking brake.
Loosen wheel lug nuts.
Lift the front of the vehicle.
Secure vehicle on jack stands.
Remove wheel.
rmr201 1-UB4 629

Section07 CHASSIS
Lubricate suspension arms. There are two grease

fittings per arm.
SERVICE PRODUCT
XPS SYNTHETIC GREASE (P/N 293 550 O10)
I 1 Q Q5,» II \_ ‘
-\?T‘"~ 1
3 ' "\\." ' T"T’i-Q;
..:\‘ I } rmr2OClB-O29-0O4_a
FRONT c/moo MODULE REMOVED FOR CLARITY
1. Shock absorber bolts
‘GI » . I Remove shock absorber from vehicle.
II/qfi/Q (51% if) (3 IT
,,——\_ . . .‘
9
\
//3/v"'“‘**-».i\‘"\.
1/ s ‘s Shock Absorber Disassembly
rm F2008-(I70-OCI1 _a
UPPER ARM
Remove spring from the shock absorber.
1. Grease fittings
REQUIRED TOOL
- .. -_
SPRING REMOVER (P/N 529 O36 007)
\¥V kag IV‘

tifésrj
'/1, E 1?
u >31!‘ _ J
_. 2, Q 529036007
4 "\ IF
rmr20Cl8-070-002_a
VI k Q
-~ . '/;)f‘\\:T“‘\‘\§
I Ii \ 9
Place the tool in a vise.
LOWER AFIM
1. Grease fittings
"'=$~*lhr,-_.
PROCEDURES
SHOCK ABSORBER
vmfl D06-025004
Shock Absorber Removal

Position the shock absorber in the tool and install
Remove body parts as required to access to the the spring compressor pins.
shock absorber. Refer to BODYsubsection.
Lift the front of vehicle.
_..
Unscrew shock absorber bolts.
M
> ci
as’,-_...._
rm r2008-O29-005
Tighten the spring compressor tool screw until

the spring is sufficiently compressed to remove
spring locking devices.
Remove spring stopper then release the spring
compressor tool screw.
630 rmr201 1-084
Section07 CHASSIS
Underneath suspension arm, remove air deflector

screws.
vii-1r20D6-026-D1 1
TYPICAL
rm r2008-O29-DOG_a
Shock Absorber Inspection Remove the upper shock absorber bolt.

Examine shock for leaks.
Extend and compress the piston at least 5 com-
plete strokes with its rod upward.
Check that rod moves smoothly and with uniform
resistance over its entire stroke.
NOTE: During compression motion, it is normal to
feel a small resistance only.
Pay attention to the following conditions that will
denote a defective shock:
— A very weak rebound.
— A skip or a hang back when reversing stroke at
mid travel.
rmr200&02S»007_a
- Seizing or binding condition except at extreme 1. Upper shock absorber bolt
end of either stroke.
— Oil leakage. Detach flexible brake hose and speed sensor wire
— A gurgling noise, after completing one full com- from air deflector.
pression and extension stroke. Remove the air deflector.
Check piston rod for excessive wear or pitting.
Air Deflector Installation
lnspect the spring for damage. Replace if neces-
sary. The installation is the reverse of the removal pro-
cedure.
On both ends, check the bushings for excessive
wear or other damages.
UPPER SUSPENSION ARM
Replace shock absorber or spring if any faults are
present. Upper Suspension Arm Inspection
Check upper suspension arms for bending or
Shock Absorber Assembly and other damage. Replace suspension arms if nec-
Installation essary.
For assembly and installation, reverse the disas- l\/love upper suspension arm from side to side and
sembly and removal procedures. up and down. There should be no noticeable play
in bushings.
AIR DEFLECTOR (UPPER ARM) If necessary, remove suspension arm and inspect
Air Deflector Removal pivot bushings and sleeves for wear or damages.
Replace bushings and/or sleeves if necessary.
air deflector. Refer to BODYsubsection.
rmr201 1 -084 631

— M I M i
Section 07 CHASSIS
Upper Suspension Arm Removal

Remove front cargo module. Refer to BODYsub-
section.
Lift the front of the vehicle.
Secure vehicle on jack stands. l
Remove wheel. I
rrnQOI’I8-O29-040_a
Remove brake disc and encoder wheel. Refer to LH SIDE SHOWN
BRAKES subsection. 1. Oil cooler air duct
2. Screw to remove
Remove screws securing the air deflector on up- 3. Upper suspension arm
per suspension arm.
Unscrew upper suspension arm bolts.
"e
. __o ".‘,;uf,/ , _.,.__- -‘
E ' ‘ '\‘-}\I-
.~"',. ‘*1,/y 1.; 9-"
. .-. , ' 3 ‘ _ '- I"INQ‘P
Elli‘ -'+.Ai'."~j'y' --1"n -l_-...
-" I 2
~_, <'w -1' -
-n-
; , ‘@'=IL.-A
" J
‘
. '“* ' ti \'~
---~.~”..~'.
%I \_
v §
. . 1- .
%#\'
ef"r--1'
.“
* :“(_i__|t» H‘ ' I3-",-
tel: I bib
3"‘
'."_-;§-5
P
_."-
:___,_ -
_.._‘ _ ,_ & -_ __‘ ,_,_- _ __
*=-'=‘"*'- ii‘ ‘-1-I¢*<a“>l I - ’=*.-735‘
I- _.I ' ‘ \ .
-::J"_~;;,;_-.1. ‘--
‘V-~_ \_ -‘I
23.; " ' mt ' ' *---
.~ ‘-1_, v- '~' -
rrnr2ODB-029-U383 :.:<. . .. E. ,4
rrnr20(J8-O29-414I_a
Remove screws securing the upper ball joint sup- 1. Upper suspension arm bolts
port. Remove the upper suspension arm without its air
deflector.
Upper Suspension Arm Installation
Position the rounded side of the upper ball joint
support toward knuckle.
rmr2O08-029-0G9_-=1
1. Ball joint support screws
Remove upper screw retaining oil cooler air duct

(LH side) or radiator air duct (RH side).
rmv200B029042_a
1. Ball joint support
2. Rounded side of ball joint support
3. Knuckle
632
rmr201 1-084
SectionO7 CHASSIS
Perform the steering angle reset. Refer to STEER-

ING ANGLE SENSOR in STEERING (DPS) AND
FRONT WHEELS subsection.
Perform the torque offset reset. Refer to
TOROUE OFFSET RESET in STEERING (DP-5‘)
AND FRONT WHEELS subsection.
Lubricate upper suspension arm. Refer to MAIN-
TENANC‘Ein this subsection.
UPPER BALL JOINT

rmfZ008-029015
Upper Ball Joint Inspection
Inspect ball joint end for damage. Ensure it is Press ball joint out of the upper suspension arm.
moving freely without play. Replace ball joints as REQUIRED TOOL
required. BALL JOINT REMOVER SUPPORT
(P/N 529 O36 121)
Upper Ball Joint Removal
Remove the UPPER SUSPENSIONARM, see pro-
cedure in this subsection.
Remove and discard the cotter pin from ball joint.
Unscrew the ball joint nut.
Detach ball joint support from ball joint.
REQUIRED TOOL
BALL JOINT EXTRACTOR (P/N 529 035 827)
rmr200B-O29-U16 a
1. Ball/oint remover
2. Press
Upper Ball Joint Installation

Press ball joint into the suspension arm.
REQUIRED TOOL
529035827
(P/N 529 O36 121)
' s
BALL JOINT INSTALLER (P/N 529 O35 975)
rmrZOOB-029-014
Remove circlip securing ball joint to suspension

arm.
rmr201 1-084
633
i I M M
SectionO7 CHASSIS
1 I l I i 1 i
LOWER SUSPENSION ARM

Lower Suspension Arm Inspection
Check lower suspension arms for bending or
other damage. Replace suspension arms if nec-
essary.
Move lower suspension arm from side to side and
up and down. There should be no noticeable play
in bushings.
If necessary, remove suspension arm and inspect
rmr2008~U25-Oi7_a ,
pivot bushings and sleeves for wear or damages.
1. Ball joint remover Replace bushings and/or sleeves if necessary.
2. Ball joirit installer
3. Steel plate
Lower Suspension Arm Removal
Tighten ball joint nut to specification.
BALL JOINT NUT TORQUE Apply parking brake.
62 Nem (46 Ibfvftl Remove front cargo module. Refer to BODYsub-
section.
Install a NEW cotter pin on ball joint.
/NG ANGLE SENSOR in STEERING IDPSI AND Lift the front of the vehicle.
WHEELS subsection. Remove wheel.
Perform the torque offset reset. Refer to Remove brake disc and encoder wheel. Refer to
TORQUE OFFSET RESET in STEERING IDPSI BRAKES subsection.
AND WHEELS subsection. Remove and discard cotter pin from ball joint.
Unscrew ball joint nut.
AIR DEFLECTOR (LOWER ARM)
Air Deflector Removal
Underneath suspension arm, remove air deflector
screws.
‘I;
rmi2DO8-02 9-043_a
1. Cotter pin
2. Ball joint nut
Remove the lower shock absorber bolt.

rmr2DDB-029411 B_a
UNDERNEATH LH LOWER SUSPENSION ARM
1. Qir gegector screws
2. II’ E €CTOI'
3. Suspension arm
Remove the air deflector.

Air Deflector Installation
cedure.
634
rmr2011 084
SectionO7 CHASSIS
i.(§““'” , 1 1
RAIt -<5‘ I.
5 M. C.
L§"‘?Ii
2) -7.Z;.IE1‘>T’
, ~5'~@
. _
rrrir200B-U29-047,3
1. Lower suspension arm bolts
rmr200&O29-044-_a
1. Lower shock absorber bolt Remove the lower suspension arm with its air de-
Hit the bottom of knuckle to separate ball joint. flector.
Turn suspension arm upside down and remove
the air deflector.
,'; Lower Suspension Arm Installation
* ' -' 7. cedure. However, pay attention to the following.
-i Tighten ball joint nut to specification.
BALL JOINT NUT TORQUE
62 N'm (46 lbfvftl
rmr200B-O29-045,6
1. Hit here Install a NEW cotter pin on ball joint.
Underneath lower suspension arm, remove stabi-
lizer bar bolt. /NG ANGLE SENSOR in STEERING (DPS) AND
X
TOROUE OFFSET RESET in STEERING (DPS)
_ ‘R
Lubricate lower suspension arm. Refer to MAIN-
TENANCE in this subsection.
eraser LOWER BALL JOINT
-\\
_\\
Lower Ball Joint Inspection

lnspect ball joint end for damage. Ensure it is
rrnr20D8029l-046_a moving freely without play. Replace ball joints as
7. Lower suspension arm required.
2. Stabilizer bar
Unscrew lower suspension arm bolts. Lower Ball Joint Removal

Remove the LOWER SUSPENSION ARM see
procedure in this subsection.
Remove circlip securing ball joint to suspension
arm.
rmr20‘I'I-O84 635
Section O7 CHASSIS
. ..:
A_ -A
:7-‘J1-<_-vlhayp
rrnrZOU8-02 9-O2 431
1. Circlip rrnr20Cl8029~D26_a
1. Ball joint remover support

Press ball joint out of the lower suspension arm. 2. Ball joint installer
3. Steelp/are
REQUIRED TOOL
(P/N 529 O36 121) ING ANGLE SENSOR in STEERING (DPS) AND
TOROUE OFFSET RESET in STEERING (DPS)
PIVOT BUSHINGS
NOTE: The following procedure is the same for all
suspension arms.
Pivot Bushings Removal
rrnr2008-029-025_a Remove appropriate suspension arm. Refer to
1. Ball joint remover UPPER SUSPENS/ON ARM or LOWER SUSPEN-
2. Press S/ONARMin this subsection.
Lower Ball Joint Installation Remove sleeve from pivot bushings.
cedure. However, pay attention to the following. is ~.-._____ - .___ _
, - --_.___
Press ball joint into the suspension arm end.
REQUIRED TOOL
(P/N 529 O36 121)
BALL JOINT INSTALLER (P/N 529 O35 975) I rmr20OB-U29-O27_a
1. Sleeve
2. Pivot bushings
Using a punch, remove pivot bushings.
636
rmr2011-084
SectionO7 CHASSIS
,§
Remove stabilizer bar from vehicle.
- Remove oetiker clamps and stabilizer bar stop-
pers.
rmQO0B-0 29-O28_a
1. Pivot bushings 1 2
rrrir2U10~D354J01_a
Pivot Bushings Installation 1. Stopper

2. Oetiker clamp
cedure. Stabilizer Bar Installation
STABILIZER BAR cedure. However, pay attention to the following.
Stabilizer Bar Removal Before installing stabilizer bar, verify if all ball joints
of link rods move smoothly and freely. Replace
Remove front cargo module. Refer to BOD Ysub- link rod if necessary.
section.
Check stabilizer bar bushings for cracks or other
Unscrew stabilizer bar from link rods. damages. Replace if necessary.
§
1". .1
‘E
Install stoppers by aligning stopper with stabilizer
C bar groove.
' ' I II I ' I _ .
T ¢i8__ _ I ___L,.__,;_.-I ‘TV- V-I...‘
1
.___. A;ITTi_(o ;__ _ J
9-E
:-:4-
_ o=)r(l.“I_,- -__.-.e=—._i 1
.2.-;§;~r '0 go -.-. ./ 2
2 2
.__ _ V‘;
-(54
re-?
rrnr2008-029-02 9_a
TYPICAL
1. Stabilizer bar
2. Link rods 3
rmr2010-U35-DCl2_a
Turn stabilizer bar downward. 1. Oe tiker clamp
2. Stabilizer bar stopper
Remove stabilizer bar bushings. 3. Stabilizer bar groove
'* T RI r ‘V ' I,‘ i '“' I “Wt Install all other removed parts.
I vi‘ (1')), I ‘-—-4
_ ' T F F P rlw \ LINK ROD

Link Rod Removal
*‘ <13)"
. 4. Lift the front of vehicle.
‘I —~L.. *t<:-as-=I
L‘. _,.iI ‘KF’
‘
Remove the air deflector from lower suspension

arm.
2 3
rmr200B-U29-O3D_a
TYPICAL
1. Stabilizer bar bushing
2. Remove these bolts
3. Stabilizer bar
rmr201 1-084 637

i
Section 07 CHASSIS
I
-_-
rmr2008-O29033_a
TYPICAL - LH SIDE SHOWN

T. Air deflector
Unscrew the bolts securing link rods.
x\‘€
rmr20OB-029034;
LH SIDE SHOWN
1. Link rod bolts
2. Lower suspension arm
3. Stabilizer bar
Link Rod Installation

cedure.
638 rmr201 1-O84

SectionO7 CHASSIS
Subsection04 (REAR SUSPENSION)
REAR SUSPENSION
SERVICE TOOLS
BLIND HOLE BEARING PULLER SET ............................ .. 529 036117 ....................................... ..661
FLUKE 115 MULTIMETER ............................................. .. 529 O35 868 ....................... ..646, 651, 654
SPRING REI\/IOVER ..................................................................... .. 529 O36 O07 ....................................... .. 657
SERVICE PRODUCTS
LQCTITE 243 (BLUE) ................................................................... .. 293 800 O60 ....................................... .. 662
LOCTITE 592 (PIPE SEALANT) ................................................... .. 293 800 O18 ....................................... .. 654
XPS SYNTHETIC GREASE ........................................................... .. 293 550 010 ....................................... .. 662
rmr201 I-085 639

Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)
KS;compressor
/:S_t'4$;I:IT\;1;l:l:f‘Tt)-I I‘ “““ H Loctisealant
te 592 48 N,
(35 lbffa)
m
(115 Ibf-|n)
We
I I
I
.@ ’1@( <'s
__/
qp
I
- Loctite 592 ‘JR1 '34

» -\
I ‘ |
‘
Z‘
__,_-—'
pipe sealant
% r
_~
: *‘:"»
<§(C @
V
§
I '80
~.
.. (L
%@
~
\ S.
\!
3'
| . _ . . _ . . _ < _ __
---- 5 N-m
<44 lbf-in)
-.
' st,
~.
‘Q5\'J I
7 N'ITI J? sk
(62 Ibf'in) ’ ‘ 7 |\|.m
.-. @ %~\ I62|bf-in)
I}
.1 I B
Rn @~ Q
55 N-m 7 N-m ' Q)

I41 Ibf-ft)
Loctige 243
3‘
(.~ Q
3 N-m @ ‘_
(27 lbf-in)
.0,
90 N-m
(66 lbf-ft)
#9I~./ I
~: 7 N-m
(62 lbf-in)
A XPS snthetic EL
grease
HV2011 O85 10D_a
640
rmr201I O85
Section 07 CHASSIS
GENERAL ACS System with Compressor

(Remote Adjustment)
ues and service products as in the exploded view. This system allows the suspension to be adjusted
electronically using a dedicated button. The sys-
Clean threads before applying a threadlocker. Re- tem can be adjusted on the fly to suit rider prefer-
fer to SELF-LOCK/NG FASTENERS and LOCTITE ences and automatically keeps vehicle level con-
APPL/CAT/0Nat the beginning of this manual for stant with changing rider weight or load applied.
complete procedure.
To achieve this, an air spring is also used but the
A WARNING following components are added compared to the
suspension with manual adjustment:
must be strictly adhered to. — ACS air compressor
Locking devices when removed (e.g.: locking - ACS position sensor
tabs, elastic stop nuts, cotter pins, etc.) must — ACS solenoid valve
be replaced. — ACS relay (R1)
— ACS switch.
A CAUTION The ACS suspension system When the suspension button is pressed, the re-
may be under high pressure (up to 7bar quested setting is sent to the multifunction gauge.
(100 PSl)). Release air pressure prior to work- Depending on the rider adjustment, the multifunc-
ing on the system. Refer to RELEAS/NG A/R tion gauge will request a pressure increase in the
PRESSURE /N SYSTEM FOR SERVICING. air spring using the compressor or a pressure re-
lease using the solenoid valve. The position sen-
A CAUTION Always wear safety goggles sor mounted on the swing arm monitors the vehi-
when working with pressurized air system. cle level to ensure proper ride height.
NUTICE Do not exceed 7bar (100 PSI) in the The highlighted bar on the multifunction gauge in-
system. This might damage the air suspension dicates the actual setting. Pressing the switch will
system. move the bar up or down one at a time.
NOTICE Hoses, cables and locking ties re- The multifunction gauge indicates suspension set-
moved during a procedure must be reinstalled ting as follows.
NOTE: Install a battery charger on battery termi- i;L_j___,,_
. Q;
nals (under seat) for any tests that involve a pro-
longed KEY ON period. If battery voltage gets too
low, some accessories are shut off by the ECM.
SYSTEM DESCRIPTION
T km/I1
ACS System Without Compressor
(Manual Adjustment) <t¥".~'., I'll‘
'‘IQ
The ACS suspension is manually adjustable using
a conventional air compressor and a pressure
tilt- _ - . . . I.
gauge. This system is equipped with an air spring
mounted on the swing arm and located in front rmoZOlU-O01-4UO_ben
OFF i....;2$5..~.-.1._i
of the shock absorber. 1. Actual setting
The air spring is connected directly to an air hose To change the ACS setting, press ACS switch un-
with a pneumatic valve, as a result, adjusting the til the requested setting is displayed in the multi-
air pressure is as easy as inflating a tire. function gauge.
NOTE: When adjusting the pressure, do not put
your weight on the vehicle and do not load cargo
in the storage compartment.
rmr201 I-085 641

Section 07 CHASSIS
3. Wait until the system is completely empty of

air.
NOTE: l\/lake sure to wait enough time in order to
let the system expel the air. (no more pressurized
air sound from the valve).
INSPECTION
ACS SYSTEM LEAK TEST
rmn20I0-001-03B_1 1. Remove the rear side panels. Refer to BOD)’
1. Press here to stiffen subsection.
2. Press here to soften
2. Locate the ACS pneumatic valve.
ACS Suspension Settings
On both systems, the ACS suspension is ad-
justable from 0.7 bar (‘l0PSl) to 7bar (I00 PSI).
Refer to the table below to know the air pressure
setting relating to the recommended loading ca-
pacity of the vehicle.
System Without Compressor
AWARNING
MINIMUM PRESSURE 10 PSI/70 kPa
Do not exceed recommended pressure by I0 PSI/70 kPa
LOAD j PASSENGER+CARGO(lb/kg)
0 100/45 150/10 200/90 I 250/115
Lb/Kg PSI/kPa PSI/kPa PSI/kPa PSI/kPa PSI/kPa
150/10 20/135 40/215 50/345 so/415 10/405 rmo2010-00)-O56_a
_
DFIVER 200/so 30/205 50/345 00/415 10/405 a0/555 TYPICAL
250/115| 40/215 so/415 10/4a5I so/555 90/025 1. Pneumatic valve
704902072
3. Manually adjust air suspension pressure to
System with Compressor specification.
ACS SUSPENSION SETTINGS ACS SYSTEM LEAK TEST PRESSURE
SETTING BAR RIDING POSITION 275 kPa (40 PSI)
l (top) Lowest
4. Spray the following areas with soapy water:
2 Low - Pneumatic valve
3 Factory setting (Middle) — Air spring
4 High — Pneumatic hose fittings
- ACS air compressor output (if applicable)
5 (bottom) Highest
— ACS solenoid valve (if applicable)
Releasing Air Pressure in System for — ACS manifold (if applicable).
Servicing
Before working on the air system, always release
air pressure as follows.
1. Open seat.
2. Push and hold pneumatic valve plunger using a
small screwdriver.
642 rmr201 1 -085

Section 07 CHASSIS
3':1
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rbs20'l0-OI 7~002_a rbsZDlI]-O17-001,21

SYSTEM WITHOUT COMPRESSOR SYSTEM W/TH COMPRESSOR
1. Spray soapy water in these areas 1. Spray soapy water in these areas
NOTE: It may be necessary to wait 5 minutes for

bubbles to appear.
5. Repair any leak.
Pneumatic Fitting Leak
To repair a leak coming from a pneumatic fitting,
proceed as follows:
1. Push the fitting ring away from hose.
2. Hold ring in place.
3. Pull hose out of the fitting.
4. Cut end of hose straight approximately
I mm - 2 mm (.O39in — .O79in).
5. Push the fitting ring in, insert hose and pull ring
back into position.
6. Check for leaks again.
Air Spring Leak
To repair a leak coming from the air spring or its
90° fitting, order the following repair kit.
AIR SUSPENSION REPAIR KIT
(P/N 219 800 175)
rrnr20‘l 1-085 643

SectionO7 CHASSIS
NOTE: This kit includes the air spring and the 90° If the Error Code Appears Momentarily
fitting. If the error code appears momentarily on the mul-
tifunction gauge, it indicates a disparity between
TROUBLESHOOTING the requested and the actual suspension settings.
To deactivate the error code, turn the ignition key
DIAGNOSTIC TIPS to OFF position then wait a few seconds.
Before any troubleshooting operations on ACS NOTE: Ensure that vehicle maximal load capacity
system, it is important to check the fault codes is not exceeded.
using B.U.D.S. to properly diagnose the problem.
Refer to DIAGNOSTIC AND FAULT CODES sub- If the Error Code Remains Active
section. If the error code remains active each time that the
ACS switch is pressed, refer to TROUBLESI-IOO73
ACS Does Not Work and No Fault /NG GUIDELINES
Code Is Set
If the ACS system (system with compressor) is TROUBLESHOOTING
not working, make sure the required option is se- GUIDELINES
lected in B.U.D.S. Otherwise, the ACS system will
not work and no fault code will be set. ERROR CODE "MANUAL" REMAINS
ACTIVE IN GAUGE
1. Connect and start B.U.D.S. to check the Ad-
justable Controlled Suspension option. 1. Leak in the ACS system.
- Check ACS system to detect leak, refer to ACS
SYSTEM LEAK TEST.
Ajustable Controlled %soens1on\
Vehicle Configuration 1 2. Faulty ACS position sensor or wiring. (Refer to
ACS POSITION SENSOR for testing).
1' Willi/Wlll|uul)\_C-S \ - Check ACS position sensor signal circuit continu-
ity.
rrn!Z0'l I -085-00 I _a
- Check ACS position sensor input voltage.
SETTING AND ACC TABS - Check ACS position sensor ground circuit conti-
7. Adjustable Control/ed Suspension nuity.
2. With/Without ACS option
- Perform the ACS position sensor reset with
NOTE: If the option is checked in B.U.D.S. and B.U.D.S.
the vehicle is not equipped with the ACS system, 3. Damaged position sensor.
false fault code(s) will be set. - Check ACS position sensor for damage, refer to
ACS POSITION SENSOR /NSPECT/ON.
Error Code "MANUAL" Displayed in
Gauge REQUESTED SETTING DISPLAY DOES
The error code MANUAL can appear on the mul- NOT CHANGE IN GAUGE
tifunction gauge for different reasons that are not 1. Faulty ACS Switch (CSS) or wiring.
necessarily related to a failure of the ACS system. -Check ACS switch continuity, refer to ACS
SWITCH.
- Check ACS switch control circuit, refer to ACS
SWITCH.
1?
SUSPENSION SETTING CAN NOT BE

CHANGED ON VEHICLE
1. Make sure the following requirements are met:
— Engine is started.
- Parking brake is re/eased.
- Gearbox in gear (first or reverse).
rr11u201‘I£DH3lJ4_a - Rear storage compartments are closed.
TYPICAL
1. Error code MANUAL
644 rmr201 I-O85

Section O7 CHASSIS
2. Damaged fuse. VRMIO E-Pun] f~*’=”~'l¢'"fl I I r- ' v rm.
- Check F8 fuse in front fuse box, refer to POWER ACS P-scrim Sm:-:1 M L rmL
1 ‘GI
_il
3. Damaged relay.
- Check R5 relay (load shedding relay), refer to
POWER DISTRIBUTION AND GROUNDS sub- AC3 POSIIIOI1 SQIISOI
section. 1
- Check R1 relay (ACS relay), refer to ACS RELAY

(R1).
4. Faulty multifunction gauge control circuits.
- Check multifunction gauge control circuit continu-
ity to ACS relay (PIN-19). ACS S/Mlrliliut Lu-/2 > F .1-I
- Check multifunction gauge control circuit continu- ‘€vvllihl'¢-iv!
ity to ACS solenoid valve (PIN-18).
$WIl‘.I’Y Effl -
5. Faulty ACS compressor or wiring.
- Carry out an ACS COMPRESSOR OPERATION ECM jc).1si§(|'\F:Vl_c4*s |TCM lv~¢~1.\ FT
EST. rmr201 1-0B5—DO2_a
Step 7: Select Monitoring
6. Faulty ACS solenoid valve or wiring. Step 2: Select ACC
— Carry out an ACS SOLENOID VALVE OPERATION
TEST. 4. Start engine and release parking brake.
5. Let vehicle run at idle in 151 gear.
TROUBLESHOOTING WITH 6. Press ACS adjustment switch on vehicle.
B.U.D.S.
ACS Position Sensor Monitoring
To monitor the position sensor during trou-
bleshooting operation, proceed as follows:
1. Connect vehicle to B.U.D.S. Referto COMMU-
NICATION TOOLS AND B.U.D.S SOFTWARE
subsection.
2. Select Monitoring page.
3. Select ACC folder.
rrno2Dl D-001-U3B_1
ACS ADJUSTMENT SWITCH
1. Press here to stiffen
2. Press here to soften
7. Check proper operation in B.U.D.S.
PROCEDURES
NOTE: Refer to the exploded view for service
product, torque and assembly details.
ACS POSITION SENSOR

The ACS position sensor is identified SPS in the
W/R/NG DIAGRAM
rmr201 I-O85 645

SectionO7 CHASSIS
ACS Position Sensor Location ACS Position Sensor Input Voltage

The ACS position sensor is located on the Ll—l side Test
of the vehicle near the shock absorber. 1. Remove rear cargo module. Refer to BODY
__ Ni 1'
subsection.
.'T:i?i¢":<-1-1;sl; 2. Disconnect position sensor connector.
_-»' ~\_ 1.
‘J "If-
? " 1:;
‘“*3xKiT‘9
rmiZlJ10-O35-OO4_a
SOME PARTS REMOVED FOR CLARITY PURPOSE

1. ACS position sensor
ACS Position Sensor Signal Circuit rri-\r2OI CHJ36-OO9_a

Continuity Test 1. Position sensor connector
1. Remove rear cargo module. Refer to BODY
subsection.
868) to Vdc.
2. Disconnect position sensor connector.
4. Start engine and release parking brake.
5. Let vehicle run at idle in lat gear.
6. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin 5 (YL/WH)
Battery voltage (1 5 Vdc)
Battery negative (-) Dost
ACS Position Sensor Ground Circuit

Continuity Test
35/
rmr201 U-036009;
1. Remove rear cargo module. Refer to BODY
subsection.
1. Position sensor connector 2. Disconnect position sensor connector.
3. Remove multifunction gauge from vehicle. Re-
fer to LIGHTS GAUGE AND ACCESSORIES
subsection.
868) to Q.
5. Measure resistance as per the following table.
Gauge connector
pin 13 (LT BU/YL)
Position sensor connector
pin 4 (LT BU/YL)
Close to 0 Q
14:5’/'!
rmr20l(}03SO09_a
4_
1. Position sensor connector

868) to Vdc.
646 rmr201 I-085
SectionO7 CHASSIS
4. Start engine and release parking brake. NOTE: Check battery voltage before performing
5. Let vehicle run at idle in 1“ gear. this procedure. Battery must be fully charged or
use a power pack to ensure adequate power for
6. Measure voltage as per the following table. the entire procedure.
TEST PROBES VOLTAGE Resetting Procedure
Pl“ 1 (BK) Battew voltage ‘I. From LH side of vehicle, insert the short block
Battery positive (+) post ii 12 Vdc) in front of the curved portion of frame as
shown.
ACS Position Sensor Reset with NOTE: Make sure block does not touch other
B.U.D.S. parts of vehicle.
Required Tools Z’
REQUIRED TOOLS
2 blocks of wood lfvpically 10 x 10 cm (4 x 4 in))
Short block: 105 mm (4-1/8in)
Long block: 150 mm (5-7/8 in)
Vehicle Preparation
1. Park vehicle on a level surface.
2. Release air pressure, refer to FIELEAS/NG A//-7
PRESSURE /N SYSTEM FOFI SEFIV/C/NG in this
subsection. rbg2U10-0UHJ08_a
LH SIDE OF THE VEHICLE SHOWN

3. lnflate rear tire to 193 kPa (28 PSI). 7. Front of vehicle
2. Catalytic converter
4. Safely lift the vehicle.
5. Turn ignition key to ON. 2. Lower vehicle until it rests on block.
6. Connect vehicle to B.U.D.S. Refer to COMMU- 3. Place approximately 95 kg (2‘l0lb) on passen-
N/CAT/ON TOOLS AND B.U.D.S. SOFTI/I/ARE ger seat.
subsection. 4. Manually lift or push down the rear of vehicle
7. Click the Setting tab. until rear screw of the footrest support is at the
specified distance from the ground.
8. Click the ACC tab at the bottom of the screen.
DISTANCE FROM THE GROUND FOR
NOTE: Ensure the check box With/\Nithout ACS LOW POSITION RESET
is checked.
330mm 1 3mm l13in :1/8in)
l l I l
;!qustab|eCootrolled 5uspe \ - J/_/-s 4" -c_ r_..e--
Vehicle Configuration ~ 1 y -e y . -» L-
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All
AC5 Positlon Sensor Reset ' I l 22-’! ,£ ‘V __7 _..
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ACS Position "- l \.
I 9595/ ._._...¢ -ii yr
I ‘ 1 - ‘A >t+ $~
nos HIGH Positron "» 3°51 . ‘
ACS Low Pusmon ' gm; l
l
rbg2D10-007-O07_c
LOW POSITION FOR SENSOR RESET

1. Short block
A. See tab/e
rbg201 1-D1 ‘l—DU1_a
7. Setting tab 5. Hold vehicle in this position.

2. ACC tab
3. Checked box 6. Click Reset button of ACS LOW Position in
B.U.D.S.
rmr201 1-085 647

SectionO7 CHASSIS
I- _s"""@ I
Ajustable Controlled Suspension
I I I tW I I I I
Alusvable Controlled Suspension
vehicle Conrigureiion . I Vehicle Configuration
I
W WI WW1 thoui ACS II iv VV|lhIWIth0tl ACS
ACS I-“osmon Sensor Reset ACS Pesihnn Sensor Reset

ACS Position ' “Tm ACS Position ‘ » -' 1
M
r-cs war | Positron ~ 83$: I
I ‘ ACS HIGH POSIIIOH 'I ii?‘ J
I 1 I
ACS LOW Position v Bess g/f ACS LOW POSIUOI1 _ ‘U B959! I
Acc I ' _4___g ___ _,_

rbg2011-011-001;: rbg2D11-0114J01_b
1. Click here 1. Click here
NOTICE ALWAYS use provided measure- 11. Save new settings in the vehicle ECU by click-
ments to reset the ACS position sensor. ing the Write Data button in B.U.D.S.
—The ACS position values indicated in
B.U.D.S. are specific to each sensor and
do not match with the suspension height
measurement. [O
— These values must NEVER be used to adjust t
or confirm the position of the ACS position
senson
- Do not try to match these values on other
vehicles. 1I -Writé»Di§t‘é" = I ' ---.\
7. Replace the short block with the long block.

8. Manually lift or push down the rear of vehicle vrnO006-012-I DIJ_ben
until rear screw of the footrest support is at the

specified distance from the ground. 12. Remove weight and wood block from vehicle.
DISTANCE FROM THE GROUND FOR 13. Lower vehicle to the ground.
HIGH POSITION RESET 14. Turn the ignition key to OFF position then wait
385 mm i 3mm (15-5/32in :1/8inl a few seconds.
15. Start engine and release parking brake.
Z’?
16. Let vehicle run at idle in 18* gear.
17. Activate the suspension switch up and down
to ensure the ACS suspension works properly.
ACS Position Sensor Inspection
Check ACS position sensor lever for straightness
or other damage.
Check ACS position sensor lever for proper orien-
rbg201IH?U7-0Cl7_d
tation.
HIGH POSITION FOR SENSOR RESET
1. Long block
A. See table
9. Hold vehicle in this position.

10. Click Reset button of ACS HIGH Position in
B.U.D.S.
648 rmr201 1-085

SectionO7 CHASSIS
4. Detach link rod from position sensor by remov-

ing upper bolt and nut.
rb52flI O-O1 2-001
CORRECT ORIENTATION
rrnr2010-O36-010_a
‘I. Link rod upper bolt
5. Move position sensor arm to access to retain-

ing screws.
6. Remove position sensor retaining screws.
rbs2010-012-002_a
/rvconnecr ORIENTATION
Check ACS link rod for straightness or other dam-
age.
Replace any damaged parts.
ACS Position Sensor Replacement
1. Release air pressure, refer to RELEA5/NG A/R
PRESSURE /N SYSTEM FOR SERV/C‘/NGin this
subsection.
2. Remove body parts as required to access to the rTnr2DlD-03GO1'I_a
position sensor. Refer to BOD)/subsection. 1. Position sensor retaining screws

3. Disconnect position sensor connector. 7. Remove position sensor from vehicle.
8. Install a new position sensor on vehicle as the
reverse of removal.
9. Perform the initialization of the position sensor,
refer to A CS P05/T/ON SENSOR RESETlW/TH
B. U.D.S.).
ACS SOLENOID VALVE

The ACS solenoid valve is identified SRS in the
W/R/NG D/A GRAM.
ti, _ ACS Solenoid Valve Location
rmr201 0036-009_a
The ACS solenoid valve is located on the RH side
1. Position sensor connector of the vehicle near the shock absorber.
rmr201 1-085 649
Section 07 CHASSIS
V
fig
\=?"
rmr2 D10-D36-005_a rmii O10-O36-0D5_b

SOME PARTS REMOVED FOR CLARITY PURPOSE SOME PARTS REMOVED FOR CLARITY PURPOSE
1. ACS solenoid valve 1. Side port
ACS Solenoid Valve Operation Test If air exits from side port:
1.Manually adjust air suspension pressure to - Check input voltage at solenoid valve (PIN-1),
6 bar (87 PSI). refer to the W/R/NG D/A GRA/I//.
2. Remove body parts as required to access to the — Check ground circuit continuity at solenoid
valve (PIN-2), refer to the W/R//\/G DIAGRAM
ACS solenoid valve. Refer to BOD Ysubsection.
- Check connector and terminal condition.
3. Disconnect solenoid valve connector.
If no air exits from side port:
— Replace ACS solenoid valve.
ACS Solenoid Valve Replacement
1. Release air pressure, refer to RELEAS/NGA/R
PRESSURE/N S Y57'/EM FOR SER I//C//I/G I n this
subsection.
2. Remove body parts as required to access to the
ACS solenoid valve. Refer to BOD Ysubsection.
3. Disconnect solenoid valve connector.
rmrZO‘|0-036012_a
1. Solenoid valve connector
NOTICE Be careful not to power the gauge by

the solenoid valve connector in order to avoid
permanent damage to gauge.
4. Connect solenoid valve connector pin 1 (LT
BU/RD wire) to a 20 A suitable fuse jumper and
then directly to the positive battery post.
5. Connect solenoid valve connector pin 2 (BK
wire) directly to the negative battery post. rmr2010-O3&012_a
6. Verify that air exits from side port to confirm 1. Solenoid valve connector
proper solenoid operation. 4. Disconnect pneumatic hoses from air fittings as
follows:
4.1 Push fitting ring toward ACS manifold.
4.2 Hold ring in place.
4.3 Pull air hose.
650 rrnr2011-O85
Section 07 CHASSIS
6 1
1 I _2 3 4 I,/’ "\8 9 10 11 12
gr- I Fttmrtmii
. ta at cm ti rt
II R1 R2 R3] R4 R5 as
IH
is
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2 -R‘
rrnr2D10~O36»013_a
rrnr2010-O36-O03_a
FRONT FUSES BLOCK

I
1. ACS suspension relay (R1)
1. Air fittings
5. Remove ACS manifold retaining screws. ACS Relay Continuity Test

1. Remove relay (R1), refer toACS RELAYLOCA-
T/O/\/.
868) to Q.
Terminal 30
Open (OL)
Terminal 87
4. Apply 12 volts on terminals 86 and 85.

rmr2OID-036-0l4_a
5. Measure resistance again as per the following I
1. ACS manifold retaining screws
table.
6. Remove ACS manifold from vehicle.
Terminal 30 .
7. Unscrew ACS solenoid valve from ACS mani- _ Close to O Q
fold. Terminal 87
I
8. Install a new solenoid valve as the reverse of
removal procedure. If results are not as per the previous tables, re-
place relay.
9. Check the air system for leakage, refer to ACS
SYSTEM LEAK TEST ACS Relay Input Voltage Test
1. Remove relay (R1), refer to ACS RELAYLOCA-
ACS RELAY (R1) 7'/ON.
ACS Relay Location 2. S81 the FLUKE 115 MULTIMETER (P/N 529 035
ACS relay (R1) is located in the front fuse block, 868) to Vdc.
under the front storage compartment cover. 3. Start engine and release parking brake. .
4. Let vehicle run at idle in 15* gear.
5. Measure voltage as per the following tables.
TEST PROBES VOLTAGE
Fuse box pin C1
(LIGHT cu/on Battery voltage \
_ (:1: 12 Vdc) 1
Battery negative (-) post I
rmrZO11-O85 651 I
SectionO7 CHASSIS
Subsection O4 (REAR SUSPENSION)
TEST PROBES VOLTAGE

Fuse box pin D1
(|_|G|-|"|' GN/GY) Battery voltage
_ (1 12 Vdc) 4: *1-’\
Battery negative (-) post

- Check fuse F8, refer to POWER DISTRIBU-
TION AND GROUNDS.
— Check relay R5 (load shedding relay), refer to
POWER D/ST/?/BUT/ON AND GROUNDS.
— Check wiring continuity, refer to the I/I//R/NG
DIAGRAM ri-r|r20I0-036-G15_a
— Check connector and terminal condition. 1. Compressor connector
4. Connect compressor connector pin 2 (ORANGE

ACS COMPRESSOR wire) to a 20 A suitable fuse jumper and then
directly to the positive battery post.
ACS Compressor Location
5. Connect compressor connector pin 1 (BLACK
The ACS compressor is located on the RH side of wire) directly to the negative battery post.
the vehicle near the shock absorber.
6. Verify if compressor works properly.
If compressor does not work:
- Replace compressor.
If compressor works:
.»‘/__
— Check relay R1, refer to ACS RELA)’(R7) in this
subsection.
If the fault is not found after having carried out the
previous tests:
— Check input voltage at compressor (PIN-2), re-
fer to the W/R/NG DIAGRAM
— Check ground circuit continuity at compressor
(PIN-1). refer to the W/R/NG DIAGRAM
— Check connector and terminal condition.
rmr2O ‘I D—D36-DU5_a
SOME PARTS REMOVED FOR CLARITY PURPOSE ACS Compressor Removal

1. ACS compressor
1. Release air pressure, refer to RELEAS/NG A/R
ACS Compressor Operation Test PRESSURE /N S I/STEM FOR SERI//C/NGin this
subsection.
Do not power the compressor di- 2. Remove body parts as required to access to the
rectly with the battery for more than 10 sec- compressor. Refer to BODYsubsection.
onds. Apply voltage quickly to ensure that
the compressor will not over pressurize the 3. Disconnect compressor connector.
ACS system. Respect a 1 minute cool down
between tests.
1. Release air pressure, refer to RELEAS/NG A/R
PRESSURE IN S)/STEM FOR SERV/C/NGin this
subsection.
compressor. Refer to BODYsubsection.
3. Disconnect compressor connector.
652 rrnr2011-085
Section O7 CHASSIS
I...“/\
1mr2010-036-0153
1. Compressor connector ;r;"2oj®3&"°17_a
4. Disconnect compressor pneumatic hose from 2;1 Retaining

Eons collar
manifold as follows:
4.1 Push fitting ring toward ACS manifold. 6. Open retaining collar then remove compressor.
4.2 Hold ring in place. 7. Remove compressor rubber.
4.3 Pull air hose.
rmr2010-036-O'lB_a
-I
\ ~ xx 1. Compressor rubber
\. , . . "I-{)\.
“ ~/‘.11 8. Unscrew check valve and fitting from compres-
-._ IF’ 4'.L
rmr201 0-U36-O I 6_2i
“L! " sor.
1. Compressor pneumatic hose
5. Remove bolts and nuts from compressor retain-

ing collar.
rmr201 1-OH 5-O03_a
1. Check valve
2. Fitting
i'r\‘ir2Cll1-085 653
SectionO7 CHASSIS
ACS Compressor Installation If switch does not work to UP and DWN position,
The installation procedure is the reverse of recheck control circuit continuity as follows.
moval procedure, however pay attention to the ACS SWITCH COMMON CONTROL CIRCUIT
following.
Apply LOCTITE 592 (PIPE SEALANT) (P/N 293 800
O18) on check valve and fitting threads. Multifunction gauge
pin-20 Close to 0 Q
Check the air system for leakage, refer to ACS
S)/STEM LEAK TEST ACS switch pin-6
ACS SWITCH ACS SWITCH COMMON CONTROL CIRCUIT

The ACS switch is identified CSS in the wiring di-
agram. Multifunction gauge
PIn‘20 Close to 0 Q
ACS Switch Access ACS switch pin-2
Remove central panel. Refer to BODY subsec-
tion. If switch does not work to UP position only, check
control circuit continuity as follows.
ACS SWITCH UP POSITION CONTROL CIRCUIT
ACS switch pin-5
d Close to 825 Q
Main groun
If switch does not work to DWN position only,

check control circuit continuity as follows.
ACS SWITCH DOWN POSITION CONTROL
rmr201 O-036-1 02_a CIRCUIT
1. ACS switch TEST PROBES RESISTANCE
2. ACS switch connector
3. Central panel
ACS switch pin-1
Close to 18.2 KS2
ACS Switch Continuity Test Main ground
to Q. ACS Switch Replacement
Check ACS switch continuity as follows. Remove central panel. Refer to BODY subsec-
IIlOl"l.
ACS SWITCH
POSITION PIN RESISTANCE Remove ACS switch from console by pushing re-
taining tabs.
Firmly pushed to UP 2 5
’ C... ... . i L. N .., I2
Released (FREE) 2 3 Close to O Q Q F‘,:.F. . A; ' j
___ i 1 I_ .1 I '_
Firmly pushed to DWN 2 1 J‘. ".‘_.. * ._, . I, I

-C, »-ii. _ . bi fi ~ 1| II.‘-
._'*-.' I '- '—' It ‘
If switch is defective, replace it with a new one. I"-v ‘I I‘ I: ~ I _ ,4:"|

' _ L . 7 - —,;">,_ ~.) I ," 4"
If switch is correct, carry out the ACS SWITCH ll_
"‘.
y
-.¢,---es"
,4
CONTROL C/RCUl T TEST Q. _ g _. ‘
4/ . .,.-4’ if .5
:\. . . .
ACS Switch Control Circuit Test )'
_A‘I
_
,":‘;’L§_ -rt’
to Q.
rrrIr20'lOC36-102_
'T
6*st E’-/‘__\ 1;.
T’ :;';-2
Ia
Check ACS switch control circuits as follows. 1. ACS switch

2. ACS switch connector
3. Central panel
654 rmr201 ‘I-085

Section 07 CHASSIS
Install a NEW switch on console.

Re-install central panel as the reverse of removal
procedure.
ACS AIR SPRING

ACS Air Spring Location
The ACS air spring is located on the swing arm in
front of the shock absorber.
rmr20\O-038—U10_a
1. Link rod upper bolt
4. Disconnect pneumatic hose from air spring as

follows:
4.1 Push fitting ring toward air spring.
4.2 Hold ring in place.
4.3 Pull air hose.
rmr201 0-03641073

1. ACS air spring
ACS Air Spring Removal

NOTICE Always detach link rod from position
sensor before servicing the rear suspension
(on applicable models).
1. Release air pressure, refer to HELEAS/NG A/F’
PRESSURE /N SYSTEM FOR SEHV/C/NG in this
subsection.
2. Remove body parts as required to access to the rmr2U10-D35~O2l_a
ACS air spring. Refer to BOD)/subsection. 1. Air spring hose
3. Detach link rod from position sensor by remov-
ing upper bolt and nut (on applicable models). 5. Install a jack under the rear portion of frame.
6. Slightly lift the vehicle to extend the air spring.
rmr201 1 085 655

Section 07 CHASSIS
rmr2008{l30-O09
TYPICAL
7. From underneath swing arm, remove air spring """°‘°*”""—“

lower retaining screw.
10. Remove the following components from air
_ spring:
— ACS position sensor
— Pneumatic fitting
— Air spring plate retaining nut
- Air spring plate.
rrrir2010-O36-022_a \
8. Remove air spring upper retaining screws on

both side.
rI1'\f'ZD1 O-O3 50253
1. ACS position sensor

2. Pneumatic fitting
3. Air spring plate retaining nut
4. Air spring plate
ACS Air Spring Installation

The installation procedure is the reverse of re-
moval procedure, however pay attention to the
following.
"lighten air spring retaining screws to specifica-
tion.
AIR SPRING SCREWS TORQUE (
rmr20‘llHJ3E~023_a 7 Ngrn
1. Upper retaining screw
9_ Carefuuy push down air Spring then remove it ‘lighten air spring retaining nut to specification.
from vehicle frame. AIR SPRING RETAINING NUT ‘
7 N'n'i (62 lbf¢in)
656 rmr2011-085
SectionO7 CHASSIS
Check the air system for leakage, refer to ACS

SYSTEM LEAK TEST
SHOCK ABSORBER
Shock Absorber Removal
sensor before servicing the rear suspension ,-
(on applicable models).
1. Release air pressure, refer to HELEAS/NG A/F’
PRESSURE /N SYSTEM F05’ SE/?V/C/NGin this rm120OB-030-D10_a
TYPICAL
subsection. 1. Shock absorber
2. Upper bracket
shock absorber. Refer to BODYsubsection. 7. Remove the shock absorber lower bolt.
3. Detach link rod from position sensor by remov- 8. Remove rear shock absorber from vehicle.
ing upper bolt and nut (on applicable models).
Shock Absorber Disassembly
' ‘K 1. Use the SPRING REMOVER (P/N 529 036 007).
529036007
2. Place the tool in a vise.

3. Position the shock absorber in the tool as
shown.
rmr201 U-03501 Cl_a
1. Link rod upper bolt
4. Remove the shock absorber upper bolt.

5. Install a jack under the rear portion of frame.
or ~ rrrii'2OUB4J3CH)I l
TYPICAL
4. lighten the shock spring remover screw until

the spring is sufficiently compressed to remove
spring locking devices.
5. Remove spring stopper and its cap then release
.\ the shock spring remover screw.
rm r2008-D3 D009
TYPICAL
6. Lift the vehicle until the shock absorber can be

removed from upper bracket.
rmr201 1 -O85
657
Section 07 CHASSIS
Shock Absorber Assembly

procedure. However, pay attention to the follow-
ing.
When installing spring stopper and cap, make
sure to install opening at 180°.
rrnr2008-030~01 2_a
TYPICAL
1. Cap 7
2. Spring stopper
6. Remove spring from shock.

Shock Absorber Inspection
Shock Absorber Removed from Vehicle i'n'|r2D08-030-O1-1_a
Examine shock for leaks. TYPICAL

1. Stopper opening
Extend and compress the piston at least 5 com- 2. Cap opening
plete strokes with its rod upward.
Check that rod moves smoothly and with uniform Shock Absorber Installation
resistance over its entire stroke. The installation is the reverse of the removal pro-
NOTE: During compression motion, it is normal to cedure. However, pay attention to the following.
feel a small resistance only. ACS System with Compressor
Pay attention to the following conditions that will In order to avoid damaging ACS po-
denote a defective shock: sition sensor:
- A very weak rebound. — Ensure that the air pressure is released into
— A skip or a hang back when reversing stroke at ACS system.
mid travel. — Do not lift the rear of vehicle too high.
- Seizing or binding condition except at extreme
end of either stroke. Carefully lift the rear of vehicle and monitor the
- Oil leakage. alignment of the bottom of the shock absorber
— A gurgling noise, after completing one full com- (anchoring hole) with the bottom of the lower
pression and extension stroke. brackets.
Replace if any faults are present.
Shock Absorber Installed on Vehicle
Manually adjust air suspension pressure to
2 bar 1 0.2 bar (30 PSI 1 3 PSI).
From the rear, press down the vehicle as much
as possible and release it to let suspension return
upward.
If the suspension bounces freely or returns too
quickly:
- Remove and inspect shock absorber.
rbs20l0~O12»O10_B
1. Lower bracket hole

2. Anchoring no/e
658
rmr201 I-O85
SectionO7 CHASSIS
‘If SHOCK ABSORBER BOLTS TORQUE ‘

-%
‘K mmf 1' 48 N'm (35 |bf'ft)

1;-_4_.
\\
0 SWING ARM
‘ .3
.1
‘ik.IAo»; oi.
,// Swing Arm Removal
I sensor before servicing the rear suspension
\-4/Lt:
\\\ (on applicable models).
rbs20‘lD-012-O04_a
1. Release air pressure, refer to RELEAS/NGA/R
INCORRECT SHOCK ABSORBER ALIGNMENT
1. Lower bracket hole PRESSURE /N SYSTEM FOR SERVICING in this
subsection.
Prior to installing ACS position sensor, ensure that 2. Remove rear cargo module. Refer to BODY
sensor lever orientation is correct. subsection.
3. Remove belt guard from swing arm.
'='.\.
_ K‘
~_ \ \ \
\
.//
//’//I
'1/
rbsZOI(HT|2-Ul]‘l
CORRECT ORIENTATION
12 xj ///
1/ 1’/I-L
rrnr2010-036-026_a
1. Belt guard
4. Remove muffler from swing arm.
1b$20'IU-OI2-OOZ_fl
INCORRECT ORIENTATION
‘lighten link rod on position sensor to specifica-

tion.
LINK ROD RETAINING NUT TOROUE
I I
7 N.rn I rmr20llJ~O36027_a
1. Muffler
Tighten shock absorber retaining bolts to specifi-
cation. 5. Detach ACS position sensor link rod from swing
arm by removing lower bolt and nut (on applica-
ble models).
r|'nr2UI1-O85
659
Section 07 CHASSIS
\_
/*\-_ ‘-._‘
\\ —
rmr2010-038-02B_a
rmr2010-O36-D31_a
1. Link rod lower bolt
1. Caliper screws
6. Remove cables protector and cables fastener
from swing arm. 9. From underneath swing arm, remove air spring
lower retaining screw.
_~2
rmr20I0~03B-029_a
1. Cab/es protector
2. Cables fastener rmr201 0-036-032_a

7. From underneath swing arm, remove parking
brake cable fasteners. IO. Place vehicle on a level surface.
11. Lift the rear of the vehicle.
12. Install a jack stand under frame.
13. Remove rear wheel. Refer to D/-7/VE BELT
14. Unscrew shock absorber lower bolt.
"=1 ---
-u. gr- W-
F-3,‘ I
‘
.
l.‘
' , Ie.
1,~
I,_‘
LI'J‘ --:1
;:.‘
I
V:
0-
I I -'1‘' c..!. '.,_*_.-'
- .L_) . 'I
‘L-1"“..‘ _~.-5
rrm r201 0-036-030_a
1. Parking brake cable fasteners
-f-V
rrnrZUCl8-030-O24_a
._:.
_ _ >r~ ". __\.
g i
/ii
1. Shock absorber lower bolt

8. Remove and discard both caliper screws.
660
rrn r201 1-085
Section 07 CHASSIS
15. Through the RH driver footrest hole, remove:

— Lock nut
— Positioning nut
- Washer
— Spacer
— Swing arm nut and its washer.
rmr2008-030-D28_a
VIEW FROM RIGHT SIDE OF SWING ARM
1. LH inner sleeve
2. RH inner sleeve
3. RH bearing
I
ll
rrnr20OE-030-02 5_a
1. Lock nut
2. Positioning nut l.
3. Washer
4. Spacer
5. Swing arm nut
6. Washer
7. Swing arm bolt
16. Remove swing arm bolt with its washer.
\"'
rmr2OD8-O3002‘!_a
CROSS SECTION OF FRAME AND SWING ARM (LEFT SIDEI
1. [Push inner sleeve here
/I 2. rame
3. Swing arm
4. Swing arm bearings
“'7' 18. Insert a long punch through LH bearing and
push out the RH inner sleeve.
I ‘ \ V I ‘ > 19. Discard inner sleeves.
20. Remove the swing arm.
rmr2(]0S-O30-026_a
1. Swing arm bolt Swing Arm Inspection

2. Washer
Check swing arm for cracks, bending or other
17. Insert a long punch through RH inner sleeve damages.
and push out the LH inner sleeve from swing Check if bearings turn smoothly and freely.
arm.
Replace all damaged parts.
Swing Arm Disassembly
Using the BLIND HOLE BEARING PULLER SET
(P/N 529 036 117), remove swing arm bearings.
rmr201 I-O85
661
Section 07 CHASSIS
i I I I
0
5290361 17
Discard them. rrni?00B-030-035_a

. RH swing arm I
Swing Arm Assembly 2. Swing arm nut
3. Washer
Using a press and an appropriate bearing installer,
install NEW bearings. 8. "lighten swing arm nut to specification.
Swing Arm Installation SWING ARM NUT TOROUE
I . Apply XPS SYNTHETIC GREASE (P/N 293 550 010) 90 N'm (66 Ibf'ft)
on inner sleeves.
9. Move swing arm up and down. The swing arm
2. Insert NEW inner sleeves into bearings, the must move freely and smoothly.
tapered side first. Do not push sleeves com-
pletely. 10. Install the following parts:
3. Align swing arm bores with tapered openings in — Spacer
frame. — Washer '
4. Push inner sleeves completely to retain swing — Positioning nut.
arm to frame.
.ag-- __¢_._1@i
5. From the LH side, insert the swing arm bolt
with its washer.
6. Apply LOCTITE 243 (BLUE) (P/N 293 aoo 060) on
threads of swing arm bolt.
I
_ I
iuunmlani _.2q,,_...,_ ._I
rmr2008-O3CHJ36_a
1. Swing arm nut
2. Spacer
3. Washer
4. Positioning nut
11. Tighten positioning nut to specification.

rmr200B-030-D .,,_, POSITIONING NUT TORQUE
1. Apply threadlocker here (shaded portion) -
2. RH inner sleeve 3 N.m (27 Ibfqn)
7. Install a washer and the swing arm nut. 12- Install The |00|< HUI-
662
rmr201 1-085
i
Section 07 CHASSIS
rmr20DE-O30-D37_a
1. Lock nut
13. Hold positioning nut with a wrench and tighten

lock nut to specification.
’ LOCK NUT TORQUE I
55 Nflm (41 lbf'ft)
14. Install NEW caliper screws.

15. Install all other removed parts.
663
rmr201 1-085
664
Section 07 CHASSIS
Subsection 05 (BRAKES)
BRAKES
SERVICE TOOLS
BLIND HOLE BEARING PULLER SET ......................................... .. 529 036117 ....................................... .. 687
FLUKE I15 MULTIMETER .......................................................... .. 529 O35 868 ....................................... .. 697
MASTER CYLINDER ROD ADJUSTER ....................................... .. 529 O36 II9 ....................................... .. 689
SERVICE PRODUCTS
BRAKE FLUID .............................................................................. .. 293 600 I31 ....................................... .. 669
LOCTITE 243 (BLUE) ................................................................... .. 293 800 O60 ....................................... .. 683
rmr201)-O86 665
Section 07 CHASSIS
Subsection O5 (BRAKES)
FRONT BRAKES
11 N-m
fin
cm I97 Ibf'in)
Front Parking ‘l1N-m
(97 |bf_in)
A,~.-,3
‘,L,;< % Brake Pulley
“F4149 ° _“\ 9 N- "P
(80 Ibf'|n) flu“
7N-m
(62 lbf-in)
16 N-m ‘ I I so N
\§
-.
i\.
.i‘__ (142 lbf-in) e
‘was
-is ‘R
|~\:
»~
\\
V3?"
.\/ iC_§\\/9
\\. Q
\
\
&
)fin?
IIEW I
See vss
@~.Z‘§
i 7 N-m
st
‘\
I I I
/
,g., _. ‘\~
WI
1* . /
\\/ )
. \‘
Bf
IQ
.I‘».
'C) ‘W(62 lbf-in)
_s/
I ):-
\
1""
"i"
16 N-m “\
-E (142 Ibfl-'nl
' =\‘-''11“ <». NEW 48 N-m
4 I35 lbf-ft)
‘x §\n
f/ 28 I\I'I'T1 28 N
‘Z.\'
0 l <21 lbf:I"t)
NE
//1|
V /
\?
$00 ti; Quit; II.}i‘?..i 9
E
ii/0,/5
/'§>.-. \\j:\_l.‘
\ G
ra-
‘@111
fi*;“;'I Z ITI
“ A Ax?
T
rmr201 U O37 12D_a
666 rmr201 1-O86

Section 07 CHASSIS
REAR BRAKE
12 N-m
I106 Ibf'in) <_\>
1,
Q
\ Q
_
it
&
=!:
16 N'|TI
5.5 N-m (142 lbf-in)
(49 lbf-in)
T.
lV>\\
i
1- \ ‘
See VSSAQ
S ee §\ 7 N-m
Installation I (62 lbf-in)
Procedure / 17 I\I'I'T1
(150 lbf-in)
25 N-m
Qu (18 lbf-ft) 16 N,m w E
flag:
f “Q.. (142 lbf-in) / ' I-
.: 64$‘-e\==Q _§Q
Q“
Q
'Q»
% So _, 9 N-in /5
sac”
0
0 % w G K‘ »»
(so lbf ml
c
M/*‘
% .
" ..~_ Qt '\"’"‘ ‘Z ' - " \ r
46 N . m
f\ (34lbf-ft)
.\
29 N-m
(21 I bf~ft)
/
V S
’
\\
E,/S ""5\;?_g
$:7;j\
//-1
W J .
\
—N EW
\
\‘ E
‘
.
rmr201 Q-D37-I 21 _fl
rmr201 1 086 667

Section 07 CHASSIS
GENERAL TASK WHAT TO DO

This subsection covers the maintenance and pro-
reAny brake part
mcement that 1. Check/clear fault codes
cedures related to the braking system mechani- I3
cal components. For ABS related components, re- involved bleeding 2- Clea‘ Lpsfauli
fer to l/EH/CLESIIAB/L/TYSYSTEM (l/SS)subsec-
IIOII.
ADJUSTMENT
ues and service products as in the exploded
VIGWS.
PARKING BRAKE CABLE
ADJUSTMENT
fer to SELF-LOCK/NG FASTENERS and LOCTITE Minor Adjustment
APPL/CAT/0Nat the beginning of this manual for 1. Loosen nuts securing the parking brake cable
complete procedure. adjuster.
A WARNING 2. Turn cable adjuster in order to generate a ten-
sion on the cable.
must be strictly adhered to. NOTE: The parking brake pulley rotates slightly
Locking devices when removed (e.g.: locking clockwise when the proper adjustment is ob-
tabs, elastic stop nuts, cotter pins, etc.) must tained.
be replaced.
Vg s.§;‘>=*
A WARNING . ‘__4 7,”-
Never use thread sealant or Teflon tape on V

it, ,
.
T-: /.
'1-Z~“_.:;:.,_
_\.. ./.._ ~___
. .
brake fittings or bleeders. Brake system dam- i ‘ii’ 1 -.. -
1 . 1
4..
-I
1. pa-1;~."~,i
I _
\~_.
- - -- 4; .
‘
,
-\-. -/I
_
1
'
-~ I»
l
.. I .-
1
age and failure may occurs. 1 i. .‘~~.». ‘l‘ -j V -4»
l
I I\3
A WARNING / .1 ’ V ' V _
Avoid brake system contamination. If re-

‘I\
2 \~» 1' _.»',/ ' -

1~‘-i=-.
_.-<1_;/
~. -3.1.,/./‘P’ . . .-/LT ’ _
quired, clean components prior to removal. .. ~~‘?-*‘
" " . .
.,.-1.:-‘='.<.3*._ .4
». 11- ,.
NOTIGE Avoid spilling brake fluid on plastic, =-<L=-.£=_=+ . =-.-.;:.—;<;€:>5:. * r

rmfZ01 O-O37-I I 7_a
rubber or painted parts. Protect these parts Parking brake cable support
with a rag when servicing brake system. Retaining nuts
Park‘ing bra ke pu lle y
NOTICE Hoses, cables and locking ties re- :l=.W!\>.~* Cable must be under tension
moved during a procedure must be reinstalled 3. iighten retaining nuts on the parking brake ca-
as per factory standards. ble support to 12 N'm (106Ibf'in).
NOTE: Install a battery charger on battery termi- 4. Apply and release the parking brake a few times
nals (under seat) for any tests that involve a pro- to ensure normal operation of the mechanism.
longed /(EYONperiod. If battery voltage gets too If proper adjustment cannot be obtained, refer to
low, some accessories are shut off by the ECM. MA./OR ADJUSTMENT
FAULT CODES Major Adjustment
If any bleeding is performed on the braking sys- NOTE: The major adjustment is used when a
tem, it is important to reset the fault codes. Refer proper parking brake adjustment cannot be ob-
to D/A GNOS T/C AND FA ULTCODES subsection. tained by turning the cable adjuster or when the
caliper is disassembled or replaced.
NOTE: B.U.D.S. software is used to perform the
reset. 1. Remove and reinstall the PARK/NG BRAKE
REAR PULLEY See procedure further in this
subsection.
B68 rrrir2D1 I D86

Section O7 CHASSIS
2. Complete the parking brake cable adjustment

procedure with the M/NOR ADJUSTMENT
MAINTENANCE
BRAKE FLUID
Recommended Brake Fluid
Always use brake fluid meeting the specification
DOT 4 only such as BRAKE FLUID IP/N 293 600131).
A WARNING
To avoid serious damage to the brake system: rmuZOI 0-D01 -OBLB
— Use only DOT 4 brake fluid from a sealed 1. Brake fluid MAX. level mark
2. Brake fluid MIN. level mark
container.
- Use only a clean funnel when filling brake
fluid reservoir.
— Do not use brake fluid taken from old or
already opened containers.
— Do not mix different fluids for topping off.
Brake Fluid Level Verification

Park the vehicle on a firm level surface.
Unlatch and lift seat.
Check brake fluid level in each reservoir, near the
ZI-
rrno2010-001-092,8
A. Operating range
back of the seat. They should both be above the
MIN. mark. Prior to installing brake fluid reservoir caps:
— Check that V slit is in good condition.
— Ensure diaphragm are properly positioned.
W 1
%'._.;., I;
"T102008-O01-Ol10_b
TYPICAL
1. Brake fluid reservoir
A WARNING 5
IbQ20U8'QO3—IJQ2_i
Clean filler caps before removing. TYPICAL
1. V slit
Add fluid as required. Do not overfill.
rmr201 1-O86 669
I
Section 07 CHASSIS
Vehicle Preparation
NOTE: Vehicle battery must be fully charge prior
to bleed brake system.
following components. Refer to BODY subsec-
tion.
vm r2 U08-033-U62_a - Front left and right calipers
TYPICAL — Rear caliper
1. Correct position
2. Wrong position — VCM
Close seat and ensure it is fully latched. — Brake fluid reservoir.
NOTICE Protect plastic, rubber or painted
Brake Fluid Replacement parts with rags when servicing brake system.
To replace brake fluid, perform the complete
brake bleeding sequence. Refer to BRAKEFLU/D I - ~-—~ M---— %»ii.i-W‘
BLEEDING PROCEDURE (COMPLETE S YSTEMI

below.
NOTE: Dispose brake fluid as per your local envi-
ronmental regulations.
Brake Fluid Bleeding Procedure .ea_\i
\’\
(Complete System)
General Guidelines
This procedure is divided in multiple tasks that %\¢\_\
must be completed in a specific order according
to the following table. rbg20flB-O02-104
STEP TASK TYPICAL
1
Perform manual bleeding procedure (left Place vehicle on a level surface.
caliper, right caliper, rear caliper and VCM) Loosen front wheel lug nuts.
2
Perform B.U.D.S. bleeding procedure (front Lift the front of the vehicle.
circuit and rear circuit)
Secure front of vehicle on jack stands.
3 Validate the system pressure
Level the vehicle by using a jack underneath the
Requirements for Task Completion rear shock absorber.
NOTE: To ensure that the vehicle is level, use the
DESCRIPTION QTY bottom vehicle frame as a reference.
RECOMMENDED BRAKE 1.75 L Remove front wheels.
FLU/D I1 .85 qt IU.S. liq.))
Remove clip retaining hose on suspension arm
40 cm (16 in) clear hose (3/16) 3 lone on each side).
80 cm (31 in) Clear hose (3/16) 1
Small locking ties 4
Locking ties 4
Use a computer with the latest version of

B.U.D.S. software, the MPI-2 and a diagnos-
tic cable.
NOTE: Assistance is required to accomplish
some actions.
670 rmr201 I 086

Section 07 CHASSIS
if __ .. _ M
rbg2 U08-00 2-O04_a
TYPICAL
1. Low pressure switch connector and brake light connector
rbg2 008-002-1OS_a
TYPICAL Detach brake fluid reservoir from vehicle.

1. Clip retaining hose Move reservoir down and outside the footrest and
Remove caliper mounting bolts from both front then reinstall at its location as per the following
calipers. picture.
Place brake hoses alongside rear passenger
NOTICE Do not let caliper hang by the hose footrest support.
and do not stretch or twist the hose.
Attach brake hoses to frame using locking tie.
Install each caliper horizontally on the top of its
brake disc with bleeder to the highest point.
Secure caliper with locking tie.
(b92008-00 2-002_a
TYPICAL
1. Rear passenger footrest support
NOTE: The previous steps are required for the

mgzoosaoz-1 U5_a
hoses to run completely down toward the master
TYPICAL cylinder.
1. Brake disc
2. Caliper Replug low pressure switch connector and brake
3. Bleeder to the highest point
light connector.
Open seat. Remove reservoir caps.
Detach lift cylinder from seat. Install a 40 cm (16in) long clear hose onto:
Lift seat and unplug the pillion rider (passenger) — Left caliper bleeder
switch connector. — Right caliper bleeder
Cut locking ties securing brake hoses between - Rear caliper bleeder.
reservoir and master cylinder.
Secure all clear hose with small locking ties.
Unplug low pressure switch connector and brake
light connector. Fill clear hoses with brake fluid using a funnel (ap-
proximately 6O mm (2-1/2 in) long).
rmr201 1-UB6 671

Section 07 CHASSIS
NOTE: Do not release brake pedal until bleeder

has been closed.
4. Pump up system pressure with brake pedal un-
til pedal resistance is felt.
5. Depress and hold brake pedal.
6. Re-open bleeder and then re-close it.
7. Release brake pedal slowly.
8. Repeat manual bleeding procedure for the
other bleeders in this order:
rlJg2OOB-O02~OO‘l_a
— Right front caliper
TYPICAL
1. Brake fluid — Rear caliper
- VCM.
Locate VCl\/l at the front of vehicle.
Install 80 cm (31 in) long clear hose onto VCl\/I B.U.D.S. Bleeding Procedure (Final Bleeding)
bleeder. NOTE: The bleeding procedure is accomplished
FIRST by completing the manual bleeding proce-
dure as explained above.
Brake bleeding is completed using B.U.D.S. soft-
ware. To properly bleed the complete braking sys-
tem, use the bleeding sequence according to this
table.
B.U.D.S. BLEEDING SEQUENCE
OPERATION BLEEDING CIRCUIT
Complete brake system Front circuit and rear
bleeding circuit
rbQ2008-(I02-I l0_a B.U.D.S. BLEEDING
7. VCM bleeder CIRCUIT BLEEDER LOCATION
Secure VCM clear hose with small locking tie. 1: Left front caliper
Front circuit
Fill VCl\/l clear hose with brake fluid using a funnel 2: Right front caliper
(approximately 60 mm (2-1/2 in) long). 3: Rear caliper
Rear circuit
Manual Bleeding Procedure (Preliminary 4: VCM
Bleeding)
NOTE: Brake fluid reservoir must be kept full to NOTE: Each sequence must be carried out with-
prevent airfrom being pumped into the system. If out interruption. Furthermore, brake fluid reser-
a sequence is interrupted or a lack of fluid occurs, voir must be kept full to prevent air from being
start the sequence again. pumped into the system. If a sequence is inter-
1. Start bleeding system with left front caliper. rupted or a lack of fluid occurs, start the sequence
again.
2. Open bleeder and slowly depress then slowly
release brake pedal at least 25 times (full 1. Connect B.U.D.S. Refer to COMM!/N/CA7’/ON
stroke) until fluid freely flows out of the bleeder TOOLS AND B. U. D. 5. SOFTWARE.
without any air bubbles. 2. In B.U.D.S., select Read Data.
NOTE: It may be necessary to pump brake pedal 3. Select Setting folder then the VCM page.
more than 25 times, as a result, it is important 4. Read and understand the procedure on screen
to pump brake pedal until fluid flows out without before beginning it.
any air bubbles.
5. Perform FRONT CIRCUIT BLEEDING and
3. When there is no more air bubbles in clear REAR CIRCUIT BLEEDING inclusively. Follow
hose. close the bleeder while brake pedal is the instruction in B.U.D.S.
depressed.
672 rmr201 1-D86

Section 07 CHASSIS
Reinstall caliper. Refer to CAL/PE/-Tin this subsec- Requirements for Task Completion
tion. Requirements are the same as for bleeding the
Reinstall clip retaining hose on suspension arm complete braking system. Refer to BRAKE FLU/D
(one on each side). BL EED/NG PROCEDURE (COMPLETE S VS TE/l//).
Secure bolt to 11 N'm (97 lbf'in). Vehicle Preparation
—"T _
following components. Refer to BODY subsec-
tion.
- Rear caliper
— VCM
— Brake fluid reservoir.
Level the vehicle.
NOTE: To ensure that the vehicle is level, use the
bottom vehicle frame as a reference.
Open seat.
Detach lift cylinder from seat.
rbg20l)EH)O2-108_a
TYPICAL
Lift seat and unplug the pillion rider (passenger)
7. Clip retaining hose switch connector.
Reinstall wheels on vehicle. Refer to STEER- Cut locking ties securing brake hoses between
/NG/FRONT WHEELS subsection for procedure. reservoir and master cylinder.
Carly out the BRAKE SYSTEM PRESSURE l44L/- Unplug low pressure switch connector and brake
DAT/O/\/as detailed in this subsection. light connector.
NOTICE Do not pump up the brake pedal re-
peatedly before doing the validation. '\
Vehicle Reassembly
s
Reinstall brake fluid reservoir on vehicle with the
hoses at their original location.
Secure brake fluid reservoir to 7 N¢m (62 lbfvinl.
Secure hoses with locking ties.
Install all removed BOD)/parts as the reverse of
the removal procedure. rbg2OIl8-002-OO4_a
TYPICAL
Ride the vehicle and apply the brake a few times 1. Low pressure switch connector and brake light connector
to ensure the normal behavior of the vehicle.
Detach brake fluid reservoir from vehicle.
Brake Fluid Bleeding Procedure Move reservoir down and outside the footrest and
(Rear Brake Only) then reinstall at its location as per the following
picture.
General Guidelines
This procedure is divided in multiple tasks that footrest support.
to the following table. Attach hoses to frame using locking tie.
STEP TASK
Perform manual bleeding procedure
I (rear caliper and VCM)
Perform B.U.D.S. bleeding procedure
2 (rear circuit)
3 Validate the system pressure
rmr201 1-086 673

Section 07 CHASSIS
rbgZOO8-O02-DO2_a
rbg2lJO8-D02-1 IO_£
TYPICAL
7. Rear passenger footrest support 1. VCM bleeder
NOTE: The previous steps are required for the Secure VCM clear hose with small locking tie.
hoses to run completely down toward the master Fill VCM clear hose with brake fluid using a funnel
cylinder. (approximately 60 mm (2-1/2 in) long).
Replug low pressure switch connector and brake Manual Bleeding Procedure (Preliminary
light connector. Bleeding)
Remove reservoir caps. NOTE: Brake fluid reservoir must be kept full to
Install a 40cm (16in) long clear hose onto rear prevent air from being pumped into the system. If
caliper bleeder. a sequence is interrupted or a lack of fluid occurs,
Secure all clear hose with small locking ties. start the sequence again.
Fill clear hoses with brake fluid using a funnel (ap- 1. Start bleeding system with rear caliper.
proximately 6O mm (2-I/2 in) long). 2. Open bleeder and slowly depress then slowly
release brake pedal at least 25 times (full
stroke) until fluid freely flows out of the bleeder
without any air bubbles.
NOTE: lt may be necessary to pump brake pedal
more than 25 times, as a result, it is important
to pump brake pedal until fluid flows out without
any air bubbles.
3. When there is no more air bubbles in clear
hose, close the bleeder while brake pedal is
depressed.
rbg2008-O02-0O1_a has been closed.
TYPICAL
1. Brake fluid 4. Pump up system pressure with brake pedal un-
til pedal resistance ls felt.
Locate VCM at the front of vehicle. 5. Depress and hold brake pedal.
Install 80cm (31 in) long clear hose onto VCM 6. Re-open bleeder and then re-close it.
bleeder.
8. Repeat manual bleeding procedure for VCM
bleeder.
B.U.D.S. Bleeding Procedure (Final Bleeding)
NOTE: The bleeding procedure is accomplished
dure as explained above.
674 rrr\r201 I-UB6

SectionO7 CHASSIS
Brake bleeding is completed using B.U.D.S. soft- STEP TASK

ware. To properly bleed the complete braking sys-
tem, use the bleeding sequence according to this Perform manual bleeding procedure
I
(left caliper and right caliper)
table.
2
Perform B.U.D.S. bleeding procedure
B.U.D.S. BLEEDING SEQUENCE (front circuit)
OPERATION BLEEDING CIRCUIT 3 Validate the system pressure
Rear gggginsgstem Rear circuit Requirements for Task Completion
Requirements are the same as for bleeding the
B.U.D.S. BLEEDING complete braking system. Refer to BRAKEFLU/D
Cmcun. BLEEDER LOCATION
BL EEO/NG‘ PROCEDURE /COMPLETE SYS TEM/.
3: Rear caliper
Rear circuit Vehicle Preparation
4: VCM
NOTE: Each sequence must be carried out with- following components. Refer to BODY subsec-
out interruption. Furthermore, brake fluid reser- tion.
voir must be kept full to prevent air from being — Front left and right calipers
pumped into the system. If a sequence is inter- — Brake fluid reservoir.
rupted or a lack of fluid occurs, start the sequence Place vehicle on a level surface.
again.
1. Connect B.U.D.S. Refer to COMMUN/CAT/ON
TOOLS AND B.U.D.S. SOFTWARE Loosen front wheel lug nuts.
2. In B.U.D.S., select Read Data. Secure front of vehicle on jack stands.
Level the vehicle by using a jack underneath the
3. Select Setting folder then the VCM page.
rear shock absorber.
4. Read and understand the procedure on screen
before beginning it. NOTE: To ensure that the vehicle is level, use the
bottom vehicle frame as a reference.
5. Perform REAR CIRCUIT BLEEDING. Follow
the instruction in B.U.D.S. Remove front wheels.
Carry out the BRAKE SYSTEM PRESSURE l44L/- Never use any type of impact
DA T/ON as detailed in this subsection. wrench for lug nut removal and installation.
The use of impact wrench could damage the
NOTICE Do not pump up the brake pedal re- bolts threads and nuts.
peatedly before doing the validation.
Remove clip retaining hose on suspension arm
Vehicle Reassembly (one on each side).
Reinstall brake fluid reservoir on vehicle with the
hoses at their original location. TM
Secure brake fluid reservoir to 7 Nvm (62 lbf¢in).

Install all removed BODYparts as the reverse of
the removal procedure.
Ride the vehicle and apply the brake a few times
to ensure the normal behavior of the vehicle.
Brake Fluid Bleeding Procedure (Front
Brakes Only)
General Guidelines rbg2 008-002-I 0B_a
This procedure is divided in multiple tasks that TYPICAL

7. Clip retaining hose
to the following table.
rmr2DI1-O86 675
Section 07 CHASSIS
Remove caliper mounting bolts from both front Attach brake hoses to frame using locking tie.
calipers.
NOTICE D0 not let caliper hang by the hose
Install each caliper horizontally on the top of its
brake disc with bleeder to the highest point.
Secure caliper with locking tie.
rbgZD08-U02-0D2_a
TYPICAL
1. Rear passenger footrest support
NOTE: The previous steps are required for the

hoses to run completely down toward the master
cylinder.
Replug low pressure switch connector and brake
light connector.
rbg2008-002-105_a
TYPICAL Remove reservoir caps.

1. Brake disc
2. Caliper Install a 40 cm (‘I6 in) long clear hose onto:
3. B/eeder to the highest point — Left caliper bleeder
Open seat. — Right caliper bleeder.
Detach lift cylinder from seat. Secure all clear hose with small locking ties.
Lift seat and unplug the pillion rider (passenger) Fill clear hoses with brake fluid using a funnel (ap-
switch connector. proximately 60 mm (2-1/2 in) long).
Cut locking ties securing brake hoses between
reservoir and master cylinder.
Unplug low pressure switch connector and brake
light connector.
"-L
IIJQZOOB-(102-DIJ1_6
TYPICAL
7. Brake fluid
rbg2DO8—0O2-O04_a
Manual Bleeding Procedure (Preliminary
TYPICAL _
Bleeding)
1. Low pressure switch connector and brake light connector NOTE: Brake fluid reservoir must be kept full to
Detach brake fluid reservoir from vehicle. prevent air from being pumped into the system. If
a sequence is interrupted or a lack of fluid occurs,
Move reservoir down and outside the footrest and start the sequence again.
then reinstall at its location as per the following
picture. 1. Start bleeding system with:
— Left front caliper
footrest support. - Right front caliper.
676 rmr201 1 -086

Section 07 CHASSIS
2. Open bleeder and slowly depress then slowly 5. Perform FRONT CIRCUIT BLEEDING. Follow
release brake pedal at least 25 times (full the instruction in B.U.D.S.
stroke) until fluid freely flows out of the bleeder Reinstall caliper. Referto CALIPERin this subsec-
without any air bubbles. tion.
NOTE: It may be necessary to pump brake pedal Reinstall clip retaining hose on suspension arm
more than 25 times, as a result, it is important (one on each side).
to pump brake pedal until fluid flows out without
any air bubbles. Secure bolt to 11 N-m (97lbf~in).
3. When there is no more air bubbles in clear ‘A
jr _ EL
hose, close the bleeder while brake pedal is
depressed.
has been closed.
4. Pump up system pressure with brake pedal un-
til pedal resistance is felt.
5. Depress and hold brake pedal.
6. Re-open bleeder and than re-close it.
B.U.D.S. Bleeding Procedure (Final Bleeding) rbg 2008-D02-I U8_a
NOTE: The bleeding procedure is accomplished TYPICAL

I. Clip retaining hose
dure as explained above. Reinstall wheels on vehicle. Refer to STEERING
Brake bleeding is completed using B.U.D.S. soft- (DPS) AND WHEELS for procedure.
ware. To properly bleed the complete braking sys- Carry out the BRAKE SYSTEM PRESSURE VALI-
tem, use the bleeding sequence according to this DATION as detailed in this subsection.
table.
B.U.D.S. BLEEDING SEQUENCE peatedly before doing the validation.
OPERATION BLEEDING CIRCUIT Vehicle Reassembly
Front bleeding
brake system - -
Front circuit Reinstall brake fluid reservoir on vehicle with the
hoses at their original location.
B.U.D.S. BLEEDING Secure brake fluid reservoir to 7 N'm (62 lbf-in).
Cmcul-r BLEEDER LOCATION
_ _ 1: Left front caliper Install all removed BODYparts as the reverse of
Front circuit the removal procedure.
2: Right front caliper
Ride the vehicle and apply the brake a few times
NOTE: Each sequence must be carried out with- to ensure the normal behavior of the vehicle.
out interruption. Futhermore, brake fluid reser-
voir must be kept full to prevent air from being INSPECTION
pumped into the system. If a sequence is inter-
rupted or a lack of fluid occurs, start the sequence
again. BRAKE SYSTEM PRESSURE
l. Connect B.U.D.S. Refer to COMMUN/CA77ON
VALIDATION
TOOLS AND B. L/.D.S. SOFTWARE
2. In B.U.D.S., select Read Data. peatedly before doing the validation.
3. Select Setting folder then the VCM page.
ln B.U.D.S., select Monitoring folder then the
4. Read and understand the procedure on screen VCM page.
before beginning it.
rmr20I1 DB6 677

Section 07 CHASSIS
Slowly depress the brake pedal (only once) until If the average is BELOW 3500 kPa (508 PSI), re-
you reach 3500 kPa (508 PSI) at the brake pres- peat BRAKE FL U/D BLEEDING PROCEDUREwith
sure sensor. the following deviation:
Maintain the brake pedal in position. — Lift the rear of vehicle and adjust master cylin-
Check the Low Pressure Switch button value on der on level.
the computer screen.
TROUBLESHOOTING
ii’:
"II
I we us-r.---I
T la I rm. I mm; I
“IO!
TROUBLESHOOTING
>-“Pt 3--3-: s-ls: ;-—"~~: ;--1'-z
'=. r\ \>
GUIDELINES (PARKING BRAKE)
Rt‘:-
1 -G_‘_/€ 5 ... i_\:___r,;
~\
,'\"I -.~ ‘_ ' .\_1" :_ $1: .¢\.‘\_r/Q \‘..»
I1 I w"__x_4<;
-'
Before any troubleshooting operations on parking
'»—-
L -. vss 1
"‘P—i vss 2
.B_
vss s
.-—. 2
vss -1 z um
I-— brake system, it is important to check the fault
a~I.-.........,.....-....--
A ... ._,, ._i. . _i - ,_i_O,.._ A4 . .__._. _*_.,‘. _ .
W F“,
._ ._-,,'_~t_._i
I-_“. F",
codes using B.U.D.S. to properly diagnose the
in- no sviwqtugasui in-r-I fiv1l4rI'\cr1|r'II :1 taagiw-I Aczronlvlinu an-in; my swiwi om problem. Refer to DIAGNOSTIC AND FAULT
1
kwiiihfiofiiflfl
BmIW¢smul®
I
_
— CODES subsection.
Pi)1\1\-!.k'1' ) '
QITJVAJT WU 5'17’ Ti 77
Bin Pvrwu 9nwrt\?»
7
PARKING BRAKE DOES NOT WORK
rmr200B-032-062_a
1. Faulty WPM module or wiring.
TYPICA L
I. Brake Pressure Sensor (PSI) value - Check if windshield works proper/y.
2. Low Pressure Switch button
- Carry out a WPM MODULE S/GNAL C/RCU/T
If Low Pressure Switch button is still off when CONTINUITY TEST
you reached the required pressure the validation 2. Faulty PBS switch or wiring.
is successful. - Carry out a PARKING BRAKE SWITCH TEST
If Low Pressure Switch button turns on before
3. Faulty HBS switch or wiring.
reaching 3500 kPa (508 PSI), perform the follow-
ing additional steps: - Carry out a PARKING BRAKE LIGHT SWITCH
TEST
Perform equivalent of 3 complete wheels rotation
(for the 3 wheels). 4. Faulty parking brake motor or wiring.
— Carry out a PARKING BRAKE MOTOR OPERA-
Slowly depress the brake pedal until Low Pres- TION TEST
sure Switch button turns on.
Take note of the Brake Pressure Sensor (PSI) 5. Wrong parking brake cable adjustment.
value. - Carry out a PARKING BRAKE CABLE ADJUST-
MENT
Perform equivalent of 3 complete wheels rotation
(for the 3 wheels). PROCEDURES
Slowly depress the brake pedal until Low Pres-
sure Switch button turns on. CALIPER
Take note of the Brake Pressure Sensor (PSI)
value. Caliper Removal
Perform equivalent of 3 complete wheels rotation Front Caliper
(for the 3 wheels). Place the vehicle on a level surface.
Slowly depress the brake pedal until Low Pres- Apply parking brake.
sure Switch button turns on.
Take note of the Brake Pressure Sensor (PSI)
value. Lift the front of vehicle.
Calculate the average of the 3 Brake Pressure Safely support the vehicle on jack stands.
Sensor (PSI) values previously noted.
If the average is EQUAL OR ABOVE 3500 kPa
(508 PSI), the brake system pressure is conform.
Clear fault codes.
678 rmr201 ‘I-086

Section 07 CHASSIS
1 -(‘ii-.L?I’*T$_‘
rrrirl 0084132-01 6
rmI20I 0-036-027_a
TYPICAL I. Muffler
Remove whee)" Remove parking brake cable from parking brake

Remove and discard caliper screws. support.
NOTE: If the caliper is replaced, loosen brake Remove retaining nut from parking brake rearpul-
hose first. See procedure below. Otherwise, ley.
omit the next steps concerning the brake hose. Remove parking brake rear puney and its spring
/ ,.
/-I
/C
'.
$2
Il'1ll'2008-U32-0I7_fl
TYPICAL rrnr20I0-U37-001_B
7' caliper screws 1. Parking brake cable
. 2. P k‘ b k r
NOTICE Do not let caliper hangs by the hose a. PZIIIZZ bigkg ?@”Z”§Zii@y iiui
and do not stretch or twist the hose. 4- "a""'"9 “(<9 ’e‘”P”"eY
Install a drain pan under caliper to catch brake Remove Parking brake support from Caliper
f|uid_ DFHCKBII.
Loosen the Banjo fitting. Disconnect brake hose

and discard sealing washers.
Remove the caliper from the vehicle.
Rear Caliper
Remove muffler from swing arm.
rmr201 0-037#002_a
1. Parking brake support
2. Retaining screws
rm r201 i-ose 679

I
Section 07 CHASSIS
Remove wheel speed sensor from caliper

bracket.
.»
1
r ..»,¢?I/4///A
rmr201 O-03740053
..-"
7. Banjo fitting
rmr2010c370O 3,5
2. Sealing washers
1. Whe_eI_speed sensor
2. Retaining screw Remove caliper.
Remove and discard caliper screws. Caliper Inspection
Check pistonlsl for scratches, rust or other dam-
ages. If so, replace caliper.
Caliper Installation
Install NEW caliper screws.
If hoses were disconnected:
- Install NEW sealing washers.
— Tighten Banjo fitting to specification.
BANJO FITTING TORQUE
rrnr201lH]37-O04_a 29 Nsm (21 lbf'ft)
1. Caliper screws
Front Caliper
NOTE: If the caliper is replaced, loosen brake
hose first. See procedure below. Otherwise, NOTICE To ensure good clamping of calipers
omit the next steps concerning the brake hose. screws, it is imperative to clean knuckle
threads using a metric tap M10 x 1.5.
NOTICE Do not let caliper hangs by the hose
Install a drain pan under caliper to catch brake
fluid.
Loosen the Banjo fitting. Disconnect brake hose
and discard sealing washers.
rbgZDCI8-O02-‘I O7_a
1. Knuckle threads
Tighten caliper screws to specification.
680 rm r201 1 -O86

Section 07 CHASSIS
CALIPER SCREWS TORQUE l-0056" Wheel lug nuts-

48 N.m (35 |bf.ft) the TTOTIL Of VGITICIG.
i Safely support the vehicle on jack stands.

Rear Caliper
‘lighten parking brake cable support screws to
specification. y
PARKING BRAKE CABLE SUPPORT
SCREWS TORQUE
17N'm(150lbf'in)
Tighten parking brake rear pulley nut to specifica-

lOl'I.
PARKING BRAKE REAR PULLEY NUT TORQUE

46 N-m (34 |bf°f’t)
rr‘nr2008032-016
Check wheel speed sensor adjustment. Refer to TYPI¢AL

VEHICLE STAB/L/TY SYSTEM subsection.
_ _ Remove wheel.
Adjust parking brake cable, refer to PARKING R . .
BRAKE CABLEADJUSTMENTin this subsection. e”‘°"e am‘ “Card °a"l°e' “laws-
BRAKE PAD
Brake Pad Inspection
Measure brake pad lining thickness.
BRAKE PAD THICKNESS
I SERVICE LIMIT |
NOTICE Brake pads must always be replaced
in pairs.
1mm(.O4in) I
<
I/"‘l.I‘'*.~-=“L:@../ /
-
Front Brake Pad Replacement T',"l}§‘;:f,f“”""

Place the vehicle on a level surface. 7' Ca/"P9’s"9‘”s
Apply parking brake. Using a flat screwdriver, depress pistons into their
Lift seat. b°"'='$~
Clean and remove the rear reservoir cap.
rrrir2008-O32-0 1 8,a
‘mr20OB-032-003~b Remove brake ads.

TYPICAL p
1. Remove this cap
rmr20l1-086 681
Section 07 CHASSIS
rmr2008~O32-l103_
M12008-U3 2~O19_a TYPICAL

1. Remove this cap
Check the condition of pistons pins. Replace
caliper as required. Remove muffler from swing arm.
Install NEW brake pads with tabs downward.
“.1 I
Ii, I
rrnr200B-D32-020_a
TYPICAL
1. Brake pad tab
rmflm D-O36-027_a
Install caliper. Refer to CALIPER in this subsec- 7. Muffler
tion.
Install wheel. Remove cables protector and cables fastener
from swing arm.
Ride the vehicle a few minutes to make sure the
repair is successful.
A WARNING
When installing new brake pads, always ob-
serve a break-in period of 300 km (200mi).
During this time, the brakes and the VSS
will not operate at their maximum efficiency.
You could lose control and crash - use extra _--1
caution.
Rear Brake Pad Replacement -2

Lift seat.
rmr201 D-03 6-029_a
Clean and remove the front reservoir cap. 1. Cables protector
2. Cables fastener
Remove parking brake rear pulley, refer to PARK-

ING BRAKE REAR PULLEY REMOMAL subsec-
tion.
Remove and discard both caliper screws.
682 rmr20‘I1~D86
Section 07 CHASSIS
rrnr200&0324)14_a
."/-/ /"
/" \ 1. New brake pads
\ \ 2. Wheel speed sensor support
rmr20lO-037-D043
1. Caliper screws Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of brake pad pins.
Remove and discard circlips securing both brake
pad pins. NOTE: If new brake pad pins are used, the
threads are coated with a self-locking product, do
not apply Loctite 243 on threads.
Install brake pad pins. Do not tighten yet.
Install NEW circlips.
Install caliper with NEW screws.
lighten caliper screws to specification
CALIPER SCREWS TORQUE
25N'm (18 Ibf'ft)
lighten brake pad pins to specification.

rmFZOfJB~O3Z-OI Oj BRAKE PAD PINS TORQUE
1. Circlip
2. Brake pad pin 46 N'rn I34 Ibf'ftI
Unscrew and remove brake pad pins. Apply brake a few times.
Check brake pad pins for wear, replace as re- Proceed With PARK/NG BF’/4/(E HEAR PULLEI’//V-
quired. STALL/I7'/O/V. See procedure in this subsection.
Remove wheel speed sensor bracket. Check wheel speed sensor adjustment. Refer to
Use a C-clamp to push the piston into its bore to I/EH/CLE S7148/L/TY SYSTEM subsection.
ease pad installation. Ride the vehicle a few minutes to make sure the
repair is successful.
A WARNING
When installing new brake pads, always ob-
serve a break-in period of 300 km (200mi).
During this time, the brakes and the VSS
will not operate at their maximum efficiency.
You could lose control and crash — use extra
caution.
BRAKE DISC
rmr2008-032-O1 2
Brake Disc Inspection

Remove and discard brake pads.
Measure the brake disc thickness.
Install brake pads with the wheel speed sensor
support.
rmr2011-086 683
Section 07 CHASSIS
_.-‘
.-7
rrnr2008-032-D30 1mr2OD8032~016
FRONT BRAKE DISC TYPICA L
>2 Remove wheel.

Remove caliper screws.
t
tile:
\ , l_
'a-.
I
rmr2OOB-032-O31
REAR BRAKE DISC ' ' ‘ IQ

I 1
rrn!2008-O32-Ol 7_a
MINIMUM BRAKE DISC THICKNESS TYPICAL

7. Caliper screws
FRONT AND REAR | 5.5mm (.22in)
NOTICE Do not let caliper hangs by the hose
Using a dial gauge, verify the brake disc warpage. and d0 fl0t Stretch Or twist the hose.
MAXIMUM BRAKE DISC WARPAGE Remove brake disc.
FRONT AND REAR | 0.12mm (.004in) Rea, Brake Disc
Remove rear wheel. Refer to D/5’/I/E BELTAND
Brake DISC Remm/3I HEAR WHEEL subsection.
Front Brake Disc Remove encoder wheel by unscrewing encoder
\\
Place vehicle on a level surface. WIIGGI screws DISCa'd Screws"
Loosen wheel lug nuts. ~- U \ \
. .
Lift the front of vehicle.
it
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Safely support the vehicle on jack stands. of Q. I . g mo A
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1. Encoder wheel screws
584 rrnr2Dl1-086
Section 07 CHASSIS
Subsection 05 (BRAKESI
..._.,.. U .__ . I.
Remove and discard brake disc screws. /;' ,
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- " B
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_\ / I i TIGHTENING SEQUENCE
\
'”'2°°8*°“‘°”f Install ENCODER WHEEL, see procedure further
I‘ Brake CIISC Screws in this subsection.
R6m0\/9 brake? CIISO Install all other removed parts.
Bl'8I(€ DISC Installation
cedure. However, pay attention to the following. Encoder WheeI Rem9V3I
Position the brake disk so that directional arrow Front Encoder Wheel
poms Iorward" Remove appropriate BRA/(E D/SC, see procedure
in this subsection.
Pull encoder wheel to remove it.
Rear Encoder Wheel
Remove rear wheel. Refer to DH/l/E BELTAND
HEAR WHEEL subsection.
Remove and discard encoder wheel screws.
. ‘£"“:T’j‘ U ms ‘
.. /__d1 Q; Fit». .j° 5
fl'\1f2008-U32-034 ' _ -I./-/'1' i ""“"“""V ‘
Front Brake Disc

- ' I - It I 7 II I 'i
Install the encoder wheel before installing the ; .l 1 w I l
brake disc. 3‘i 1//t
/7
_
_,--
.,
X ‘ _ v_ .._ .-
1 ’
NOTICE Ensure encoder wheel is leaned ;g \I*f_('f/’
_ 4. ”""Y},*" I O. O . Q
against hub.
/Xas\*~- -"‘ 'é
a0_. -e 1‘
-1-I
rmr2 U08-032-032;:
Rear Brake Disc 1. Encoder wheel screws
Install NEW brake disc screws. Encoder whee‘ Inspection
IIghten- brake CIISC Screws to speCIfiCatIOn as per Check if encoder wheel teeth are bent or other-
nghtenmg Sequence‘ wise damaged. Replace encoder wheel if neces-
BRAKE DISC SCREWS TORQUE ‘ sary.
25 l\I'rn ll 8 Ibfvftl
rmr201 1-086 685

Section 07 CHASSIS
Encoder Wheel Installation \ T" S ‘ U "TI. _‘ V

. . . .I._\ *_ 1"» ,9 I i
Front Encoder Wheels 7 If .“ 1'.‘ 9-°- '1
.. . .
Position the encoder wheel so that directional ar-
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ti?‘
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row points forward. I‘ AI QQEI-'i~~tI
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rmrZDU8-O32~032_I::
TIGHTENING SEQUENCE
Install rear wheel.
~’ BRAKE PEDAL
rm'1"°s"W1 Brake Pedal Removal
NOT/CE Ensure encoder wheel is leaned Remove body parts as required to access to the
against hub. following components. Refer to BODY subsec-
tion.
— Brake pedal
Rear Encoder Wheel — Master cylinder.
Position the encoder wheel with the inscription Unhook connecting rod from brake pedal.
SENSOR SIDE facing outward.
/,
-/
/
-_E
1r\'ir2008-032-O41
Install NEW encoder wheel screws. 'm'*°‘°"°""°°~*‘

. . . 1 . cOHHBCIIHQ ' ['0d
lighten encoder wheel screws to specification as 2. Brake pedal
per tghtenmg sequenca From the LH side, underneath vehicle:
ENCODER WHEEL SCREWS TORQUE _ Unfold tab
5 N¢m (44lbf-in) — Remove and discard brake pedal bolt.
686 rmr201 1-use

Section 07 CHASSIS
Subsection 05 (BRAKESI
XvlY'.
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rrnr2010-037-104,6
1. Brake pedal bearings

2. Brake pedal sleeve
2 Brake pedal bolt Brake Pedal Assembly

Assembly is the reverse of the disassembly pro-
Remove brake pedal and both washers cedure.
NOTE: When assembly brake pedal, always use
NEW bearings.
Brake Pedal Installation
Install brake pedal using a NEW brake pedal bolt.
Make sure to install washers as per the following
illustration.
1 Brake pedal
2 Both washers
Brake Pedal Disassembly

Remove and discard brake pedal bearings using 2 /w
the BLIND HOLE BEARING PULLER SET (P/N 529 036
117)
Remove brake pedal sleeve i\‘}\
.3 I
_/1~¢I= \-_
6 »__1,:;®“!.,_-.»;e.,: ‘“:§\
.I .;.=;;.
'-*?\I.I.\'t-“*1-F '
VQWI Si‘
rri-ir2010-D37_400_a
1. Brake pedal
2. Washers
lighten brake pedal bolt to specification.

BRAKE PEDAL BOLT TOROUE
48 N'rn (35 Ibf'ftI
Fold either tabs against a flat side of brake pedal

bolt head.
687
Section 07 CHASSIS
Fill up reservoir with recommended brake fluid

and bleed brake system. Refer to BRAKE FLU/D
in this subsection.
DUAL MASTER CYLINDER

Dual Master Cylinder Removal
following components. Refer to BODYsubsec-
tion.
- Master cylinder
rrnr201U—D37-'lOl_a
— Brake fluid reservoir.
1. Folded tab Cut locking ties securing brake fluid reservoir
2. Brake pedal bolt
hoses to frame.
Each time brake pedal is re-installed, the adjust- Place a container under master cylinder to catch
ment of the master cylinder rod is necessary. Re- brake fluid.
fer to MASTER CYL//\/DER ROD. Loosen Banjo fittings retaining metal brake lines
to master cylinder.
BRAKE FLUID RESERVOIR Apply on brake pedal to empty the brake fluid
Brake Fluid Reservoir Removal reservoir and the dual master cylinder.
Remove body parts as required to access to the Remove Banjo fittings and discard sealing wash-
brake fluid reservoir. Refer to BODYsubsection. ers.
Unplug brake fluid level sensor connectors. Remove and discard master cylinder screws.
Remove reservoir screws.
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rmr20'l0-U37-lD5_a
TYPICAL
1. Sensors connector SOME PARTS REMOVED FOR CLARITY
2. Reservoir screws 7. Banjo fittings
2. Master cylinder screws
Remove reservoir caps.
Unscrew brake fluid reservoir screws.
Empty reservoir as much as possible.
Unplug brake fluid level sensor connectors.
Cut Oetiker clamps and disconnect hoses.
Remove master cylinder by moving it toward the
Brake Fluid Reservoir Installation front.
Connect hoses with NEW Oetiker clamps. Cut Oetiker clamps and remove reservoir hoses
from master cylinder.
Install reservoir on frame.
Plug brake fluid level sensors. Dual Master Cylinder Inspection
Check bellows for cracks or other damages. Re-
place bellows as necessary.
688 rmr201 1-086
Section 07 CHASSIS
Check if the master cylinder plunger is not stuck The adjustment of master cylinder rod must be
by pushing it on. Replace master cylinder if nec- performed when one of the following items is re-
essary. placed or removed:
— Brake pedal
Dual Master Cylinder Installation — Brake pedal stop
NOTICE During installation, ensure all parts — RH footrest support
are cleaned to avoid brake system contamina- — Master cylinder rod
tion. — Hook at the end of master cylinder rod
install reservoir hoses with NEW Oetiker clamps. - Connecting rod.
Remove dual master cylinder. Refer to DUAL
MASTER CYL/NDERin this subsection.
._,_.__y V 1. Unscrew the nut locking the master cylinder rod.
‘_/i) 1
lighten master cylinder rod into hook.
2 1 t .1 . ,
,' ' i ' .3‘
2
W
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ailE '1
i‘
rmr2UO8-032-053_a
1. From the front brake fluid reservoir
2. From the rear brake fluid reservoir
Install dual master cylinder using 2 NEW master

cylinder screws.
Tighten master cylinder screws to specification. rn1r20‘lO-037-'l06_a
MASTER CYLINDER SCREWS TORQUE 1. Locking nut

2. Hook
25 Nvm (18 lbf-ft)
Install the MASTER CYLINDER ROD ADJUSTER
Install metal brake lines on master cylinder with (P/N 529 O36 119) instead of dual master cylinder.
NEW sealing washers. Position the end of rod inside tool.
"lighten Banjo fitting to specification.
BANJO FITTING TORQUE \
28 N'm (21 |bf'ft)
Install brake fluid reservoir.

Plug brake fluid level sensors.
Bleed complete brake system. Refer to BRAKE
FLU/D BLEED/NG PROCEDURE (COMPLETE 5290351 1 8
SYSTEM) at the beginning of this subsection.

MASTER CYLINDER ROD

Master Cylinder Rod Adjustment
A WARNING
This adjustment is necessary to calibrate the
dual master cylinder and avoid braking sys-
tem malfunction.
rmr2011-O86 689
Section 07 CHASSIS
Loosen lock nut.

Remove hook lock.
rmrZOOB-032-054_a
TYPICAL
7. Master cylinder rod adjuster
Ensure brake pedal leans against its rubber stop.

Hold brake pedal in this position. ‘ rmr2010-037~1DE_a
7. Lock nut
Adjust the rod position until it just touches the in- 2. Hook lock
side of the adjuster hole without compressing rub-
ber stop. Remove master cylinder rod from vehicle by mov-
ing it toward the rear.
Unscrew clevis from master cylinder rod.
3 2 1
.- T;_"'.;.'l5 , _
. _. J. _; ;.l
LD
:
l'ml'2008-O32-O_a
1. Master cylinder rod

rmr2008-O32-055 2. Lock nut
TYPICAL 3. Clevis
Hold the master cylinder rod and tighten lock nut. Master Cylinder Rod Installation
Ensure rod does not turn. Completely screw the clevis on master cylinder
rod.
Secure clevis to brake pedal using the clevis lock.
Adjust master cylinder rod, refer to MASTER
CYL /NDER ROD ADJUSTMENT
PARKING BRAKE FRONT PULLEY

Parking Brake Front Pulley Removal
rm r2008-032-O57
TYPICAL
parking brake front pulley. Refer to BODYsubsec-
tion.
Remove tool and install the dual master cylinder. Detach parking brake cable from pulleys as fol-
Refer to DUAL MASTER CYL/NDER in this sub- lows:
secflon. — Ensure parking brake is released.
Attach reservoir hoses with NEW locking ties. — Unscrew nut securing parking brake cable on
parking brake support.
Master Cylinder Rod Removal - Remove cable from parking brake support.
Remove body parts as required to access to the - Unhook cable from rear pulley.
master cylinder. Refer to 5’0Dl/subsection. - Unhook cable from front pulley.
690 rmr201 1-O86

Section O7 CHASSIS
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rmr2010-O37-115_3

2. Nut securing cable to parking brake support rmr201!)-037-1 11_a
3. Rear pulley 1. Front pulley
2. Spacer
Parking Brake Front Pulley Installation

Install spacer on front pulley retaining bolt.
Install front pulley with the lower pulley stopper
positioned toward driver footpeg, refer to illustra-
tion.
—_
-§
rrnf2010-O37-1 O8_a
FRONT PULLEY
1. Parking brake cable
$7.
Remove front pulley retaining nut.
I
rm120'lO-O37-1 ‘|El_a
1. Front pulley
2. Lower pulley stopper
3. Driver footpeg
Install and tighten retaining nut to secure front pul-

ley.
Connect vehicle to B.U.D.S. Refer to COMMUNI-
|'lT\I'2 U10-O37-‘l '|D_5
CATION TOOLS AND B.U.D.S. SOFTWARE sub-
1. Front pulley
section.
Carefully pull front pulley toward the outside then Select Activation page.
remove spacer. Select WPM folder.
Press Park Brake Sequence button to set pulley
at its reference position.
rrnr2Cl11-086 691
Section O7 CHASSIS
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rmr20104)37 115_

2. Nut securing cable to parking brake support
3. Rear pulley
€<iM'lCKé:o?l'fiCM WPM ACCI T"

rmr2011—fJB6-DO1_s
PARK BRAKE SEQUENCE BUTTON
Attach parking brake cable on front pulley.

Attach parking brake cable on rear pulley.
Adjust parking brake cable, refer to PARK/N6‘
BRAKE CABLE AD./USTMENTin this subsection.
Apply and release the parking brake a few times \<.
\_
to ensure normal operation of the mechanism.
PARKING BRAKE REAR PULLEY rmr201 I]-037-1 D8__a

Qt? its
FRONT PULLEY
Parking Brake Rear Pulley Removal 1. Parking brake cable
Detach parking brake cable from pulleys as fol- Remove retaining nut from parking brake rear pul-
lows:
ley.
— Ensure parking brake is released.
— Unscrew nut securing parking brake cable on Remove parking brake rear pulley and its spring.
— Remove cable from parking brake support.
— Unhook cable from rear pulley.
- Unhook cable from front pulley.
rmr2010-D37-O01_a
1. Parking brake cable

3. Parking brake rear pulley nut
4. Parking brake rear pulley
Parking Brake Rear Pulley Installation

Turn caliper actuator clockwise to lean piston
against pad, do not force the actuator.
692 rm r201 1-O86
Section 07 CHASSIS
Install rear pulley retaining nut by hand, do not

torque it for the moment.
Load rear pulley spring in the upper groove of park-
ing brake support.
/‘I
§
rmr2U1Cl037-O02_b
1. Caliper actuator
Install spring in rear pulley groove.

- ta
5.1!r’ -'. - *1
u I
. Q"!-.3,‘
rm|2010-O37_4D3_a
2. Spring
Torque rear pulley retaining nut to specification.

REAR PULLEY RETAINING NUT TORQUE
46 N-m (34 lbf~tt)
Hook cable on rear pulley.
rmr201 D-O37_40l _a
Hook cable on front pulley.
7. Spring installed in groove Attach cable on parking brake support.
Install parking brake rear pulley as follows. Adjust cable retaining nuts in order to generate a
tension on the cable.
PARKING BRAKE REAR PULLEY INSTALLATION
NOTE: The rear pulley rotates slightly clockwise
R As close as possible to support with a when the proper adjustment is obtained.
minimum of 2 mm (.O79in) Torque cable retaining nuts on the parking brake
support to specification.
CABLE RETAINING NUTS TORQUE l
12 Nvm (106Ibf'in)
rmr201 O-037_4D2_a
1. Rear pulley stopper
A. Approximately 2mm (.O79in)
rmr201 1-OB6 693

Section 07 CHASSIS
Is
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rmr2010-037-10B_a
rmr201 Cl-O37-‘I 17_a
. FRONT PULLEY
1. Parking brake support -
2. Cable retaining nuts 1' Parkmg brake cable
3. Rear pulley . .
4. Mustbetensioned From underneath swing arm, remove parking
A WARNING brake cable fasteners.
Ensure parking brake cable is properly ten-

sioned between both pulleys.
Apply and release the parking brake a few times

to ensure normal operation of the mechanism.
PARKING BRAKE CABLE

Parking Brake Cable Removal
parking brake cable. Refer to BODYsubsection.
Detach parking brake cable from pulleys as fol-
lows:
— Ensure parking brake is released. .m@wwi_.
- Unscrew nut securing parking brake cable on SOME PARTS REMOVED F9" CLARITY
- - 1. Parking brake cable fasteners
- Remove cable from parking brake support. From RH side of vehicle, remove cable fastener
_ Unhook Cable from rear pu||ey_ and locking tie securing parking brake cable.
— Unhook cable from front pulley.
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rmr2D1DD37 113_a
SOME mars REMOVED ron CLARITY
=
is
,5;/1
'- ~-.4_A
iC
1. Parking brake support fgglzgjg I;/(ska cab/6 fastener
2. Nut securing cable to parking brake support ' g
3. Rear pulley
694 rmr201 was

SectionO7 CHASSIS
Unscrew nut securing parking brake cable on the

upper support.
Remove cable from the upper support by passing
it through the hole. I
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. rip-up in‘-u-_i| u-sync
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1' {SP3 ' rmr201 O-038-0 59_a
I/(I, TYPICAL
. . ' '-.__ Step 1." Select monitoring
=-s 1 r i‘ =~‘ - r I'* ~ Step 2: Select WPM
:1" . r -
~ .-'1 ‘\ i. -I - 4. Press parking brake switch (PBS) on vehicle.
W .-/ . ,, _ ,
5 vi-IL.’ V X I-.
rrnr2010-037-114__a
1. Nut securing cable to support
2. Hole to remove cable
Remove cable from vehicle.

Parking Brake Cable Installation
Align white lines on the cable with cable fasteners
on swing arm.
rmuzoiouui-oaa_o
Adjust parking brake cable, refer to PARKING PARKING BRAKE SWITCH (PBS)
BRAKE CABLE AD./US TMENTin this subsection.
5. Check proper operation in B.U.D.S.
PARKING BRAKE MOTOR
Parking Brake Motor Operation Test
Parking Brake Operation l. Connect vehicle to B.U.D.S. Refer to COMMU-
To apply parking brake, press parking brake switch NICATION TOOLS AND B.U.D.S. SOFTWARE
(PBS) down. subsection.
To release parking brake, press PBS switch down 2. Select Activation page.
until brake indicator lamp turns OFF. 3. Select WPM folder.
The parking brake cannot be activated while the 4. Press Park Brake Sequence button.
vehicle is moving faster than 1O km/h (6 MPH).
Parking Brake Motor Monitoring (with
B.U.D.S.)
To monitor parking brake motor during trou-
bleshooting operation, proceed as follows:
1. Connect vehicle to B.U.D.S. Refer to COMMU-
N/CAT/ON TOOLS AND B.U.D.S. SOF7i/l/ARE
subsection.
2. Select Monitoring page.
3. Select WPM folder.
rmr201) O86 695

Section 07 CHASSIS
vouch I Swain I Mwtovirq I Aclmlton J Vault I
Aumnm
\MamuaLip
,l~3€1':s‘?i§% ' 'T i T"
Nrmnfl Dam
R31’ _SYfi-R TED
vwmmu Svqnnw I
FIJLSTARYED '
Pausmsumu |-j
l>I:ir'__snmi:_»o" _'
rmr2010-O37-‘l09_e
1. Parking brake motor connectors
Remove retaining bolts and nuts of parking brake

motor.
rmr201 1-O86-OO1_a
PARK BRAKE SEQUENCE BUTTON
5. Verify if parking brake motor works properly to

apply and release parking brake.
If parking brake motor does not work:
- Check input voltage at motor (PIN-1), refer to
the I/I//R/NG DMGRAM
— Check ground circuit continuity at motor (PIN-
2), refer to the W/R/NG D/AGRAM
- Check connector and terminal condition.
previous tests: rmr201 D-O37-1 12_a
— Test motor operation by connecting it directly to 1. Motor retaining bolts
the battery posts.
I If motor works properly, test module, refer Remove motor from vehicle by pulling it upwards.
to PARKlNG BRAKE MODULE (WPM) in this
subsection. Parking Brake Motor Installation
~ If motor does not work properly, replace mo- The installation is the reverse of the removal pro-
tor. cedure. However, pay attention to the following.
Do not power motor directly with the Install parking brake front pulley, refer to PARK-
battery for a long period. Apply voltage quickly /NG BRAKE FRONT PULLEY /NSTALLAT/ON in
to ensure that the motor will not overheat at this subsection.
the end of its stroke. Adjust parking brake cable, refer to PARK/NG
BRAKE CABLE AD./USTMENTin this subsection.
Parking Brake Motor Removal
Remove body parts as required to access to the PARKING BRAKE MODULE
parking brake motor. Refer to BODYsubsection. (WPM I
Remove parking brake front pulley, refer to PARK- NOTE: WPM module has 2 functions, it controls
/NG BRAKE FRONT PULLEY REMOl44L in this windshield and parking brake. The WPM module
subsecfion. is integrated into the windshield base.
Disconnect parking brake motor connectors. For troubleshooting and removal procedures relat-
ing to the WPM module, refer to W/NDSH/ELD
MODULE (WPM) in BODYsubsection.
see |rnr201'l 086

Section O7 CHASSIS

-é".
PBS switch connector
I‘
pin l (GY/OR)
. thy _ >
Cl ose to 0 Q
WPM module connector
. ; _ pin 12 (GY/OR)
!:i'~ ' Ti"-;" If results are not as per the previous tables:
rmi2010-D38-058 i
WPM MODULE AND WINDSHIELD BASE - Repair open circuit in wiring.
WPM Module Signal Circuit Continuity previous operations:
Test - Test PBS switch, refer to PARK/NG BRAKE
1. Remove body parts as required to access to the SI/I/lTCH (PBS) in this subsection.
WPM module. Refer to WPM MODULE RE- — Check input voltage at WPM module (PIN-5),
MOWIL in BODYsubsection. refer to the W/R/NG D/AGRAM.
2. Disconnect WPM module connector. — Check ground circuit continuity at WPM module
(PIN-7), refer to the W/R/NG D/AGRAM.
— Test HBS switch, refer to PARKING BRAKE
LIGHTSW/TCH (HBS) in this subsection.
— Check wiring continuity between HBS switch
/' (PIN-1) and WPM module (PIN-3), refer to the
W/R/NG D/A GRAM
If the fault is still not found:
— Replace WPM module.
PARKING BRAKE SWITCH (PBS)

Parking Brake Switch Test
__,~ Remove central panel. Refer to BODYsubsec-
tion.
rmr201D038—(J53_a
3. Disconnect parking brake switch (PBS) connec- I I

tor. Refer to PARK/NG BRAKE SW/TCH (PBS)
in this subsection.
868) ’tO Q.
5. Measure resistance as per the following tables.
PBS switch connector
pin 2 (YLlLT GNI
Cl ose t o O Q
pin 10 lYL/LT GNI rmr2010-037-DlJE_a
1. Parking brake switch

2. Parking brake switch connector
PBS switch connector Check switch operation as follows.
pin 3 (LT BUIGN)
Cl ose t o 0 Q
pin I (LT BU/GNI
rmr201 ‘I-O85
697
Section 07 CHASSIS
PARKING BRAKE
SWITCH POSITION PIN RESRTANCE
Firmly pushed 2 3 Close to 0 Q
Released (FREE) Infinite (OL)
PARKING BRAKE
SWITCH POSITION P'N RESRTANCE
Firmly pushed 1 2 Infinite (OL)
Released (FREE) Close to O Q
If switch is defective, replace it with a new one.

Parking Brake Switch Replacement i
rmr201 04337-007_a
Remove central panel. Refer to BODYsubsec- 1. Parking brake light switch

2. Parking brake light switch connector
tion.
Remove parking brake switch from central panel Check switch operation as follows.
by pushing tabs. PARKING BRAKE PIN RESISTANCE @
SWITCH POSITION 20°C (68°F)
I ‘ -
I, ---,,'
{Ii i.-;')'i1'
-
I
_ I. .,-
Firmly pushed 1 3 0.2 Q max
-._j *. wt
- _ .._-.-1:5:-:-=¢
:-
. If switch is defective, replace it with a new one.
If the switch tests good, verify wire continuity
- R .' .. - between harness connector and multifunction
‘es. 1 ‘1--r .~1 "‘ ‘ gauge.
MULTIFUNCTION
GAUGE HARNESS RESISTANCE
\\ - I‘
.’>._-Iv \‘,
l>\‘— t, v_‘.. N l\‘ \ CONNECTOR WIRES @ 20°C (68°F)
\._ “V: . \ . PIN
-3‘I‘ILh'jft\"’§'t.1i v ;i
'riirIGlu l].tiuun_li
‘ii. , iti 17 GREEN/WHITE Close to O O
1. Parking brake switch
2. Central panel Parking Brake Light Switch Removal
install a NEW switch on console. Remove body parts as required to access to the
Re-install central panel as the reverse of removal parking brake light switch. Referto BOD Ysubsec-
procedure. tion.
Unplug parking brake light switch connector.
PARKING BRAKE LIGHT SWITCH
(HBS)
Parking Brake Light Switch Test
parking brake light switch. Refer to BODYsubsec-
tion.
Unplug parking brake light switch connector.
698
rmr201)-086
Section 07 CHASSIS
rmr201 U031-O09_a
rmr201 O-037-OO7_a
RH SIDE OF VEHICLE
1. Parking brake light switch 1. Brake light switch
2. Parking brake light switch connector 2. Brake light switch connector
Cut locking ties retaining the switch harness. Check switch operation as follows.
Drill switch rivets. BRAKE LIGHT Pm RESISTANCE @
Firmly pushed 1 2 0.2 S1 max.

lf the switch tests good, verify wire continuity be-
tween harness connector and ECM-B connector.
ECM-B HARNESS RESISTANCE
CONQFNCTOR WIRES @ 2o°c (68°F)
EL- C3 WHITE Close to O S2
rmr2D10~lJ37-00H_a
1. HBS switch rivets
Brake Light Switch Removal
Remove parking brake light switch. brake light switch. Refer to BODYsubsection.
Parking Brake Light Switch Installation Cut locking ties retaining the switch harness.
The installation is the reverse of the removal pro- Drill brake light switch rivets.
cedure.
BRAKE LIGHT SWITCH (BLS)

Brake Light Switch Test
brake light switch. Refer to BODYsubsection.
Unplug brake light switch connector.
699
rrnr201HJ86
Section 07 CHASSIS
LOW PRESSURE PW RESISTANCE @

Firmly pushed 2 3 Infinite (OL)
Released 0.2 Q max.

If the switch tests good, verify wire continuity be-
tween harness connector and VCM.
VCM
HARNESS RESISTANCE
C°N'|§'|'i,CT°R WIRES @ 20°C (68°F)
rmi20‘lO-D37<OClEl_D 8 WHITE/VIOLET Close to 0 Q
RH SIDE OF VEHICLE
1. BLS switch rivers
LPS Removal
Remove switch. Remove body parts as required to access to the
Brake Light Switch Installation
Drill LPS rivets.
cedure. Cut locking ties retaining the switch harness.
LOW PRESSURE SWITCH (LPS)

NOTE: After a low pressure switch (LPS) prob-
l
lem has been solved, it is necessary to clear the
occurred fault in the VCM. Refer to LPS FAULT
(BRAKlNG SYSTEM) below.
Low Pressure Switch Test
Unplug LPS connector.
VFHQOI CI-037<OU9_d
RH SIDE OF VEHICLE
1. LPS switch rivets
Remove switch.
LPS Installation
cedure.
LPS Fault (Braking System)
After a low pressure switch (LPS) problem has
been solved, it is necessary to clear the occurred
rrrir2Dl D037-0D9_c fault in the VCM as follows:
RH SIDE OF VEHICLE
1. LPS switch 1. Turn ignition switch OFF.
2. LPS switch connector
2. Wait 30 seconds.
Check switch operation as follows. 3. Turn ignition switch ON.
700 rmr201 ‘I-O86

Section 07 CHASSIS
4. Firmly press brake pedal until you hear a “click"

from the LPS switch or until braking pressure
reaches 3 500 kPa (508 PSI).
NOTE: The 181 click will come from the brake light
switch. Continue to strongly press pedal to hear
a 2nd click. This one will come from the low pres-
sure switch.
"‘ X.
‘ i .\_..- ~.,t.
;$‘ Y »
lr
. . .
rrnr2008-039-OI 1 _a
TYPICAL
NOTE: Use B.U.D.S. to monitor brake pressure if

desired.
_ . W. ll ......t..,m.. _r,.. . (W,._.~s...i
.‘ E
- ~ — — — — r t
. er .‘ r i ll
K]it
E§
[ Eiiriake PIrejssure;Senset(ekF?e§).» . ‘
rmr2008-039012
MONITORING TAB, VCM MODULE
6. Turn ignition switch OFF.

6. Wait 30 seconds.
7. Turn ignition switch ON.
8. Validate fault was cleared.
rmr2011~0B6
701
Section 07 CHASSIS
Subsection 06 (BODY)
BODY
SERVICE TOOLS
FLUKE 115 MULTIMETER .......................................................... .. 529 035 868 ............................... .. 736-737
SERVICE PRODUCTS
BRP HEAVY DUTY CLEANER ..................................................... .. 293110 OU1 ....................................... ..715
rmr201 1-O87
703
Section 07 CHASSIS
BODY PARTS NOMENCLATURE (VEHICLE FRONT VIEW)
/12
-s
1\
/1
rmI20'lO-O38-001_a
7. Front fascia
2. Front storage compartment cover
3. Bumper cover
4. Front panel
5. Air duct (or light trim)
6. Front fender
7. Passenger handle
8. Rear speaker grille (option package)
.9. Passenger backrest
10. Seat
1 1. Lower wind deflector
72. Upper wind deflector
13. I/\//ndshie/cl
704
rmr201 1-087
Section 07 CHASSIS
BODY PARTS NOMENCLATURE (VEHICLE REAR VIEW)
3\
rmr2D10'038-D02_a
7. Front speaker grille (option package)

2. Mirror
3. Top side panel
4. Middle side panel
5. Bottom front side panel
6. Bottom rear side panel
7. Rear side panel
8. Footrest support
9. Side storage compartment cover
70. Rear fender
77. Flear panel
72. Top storage compartment cover
73. Glove box
T4. Central panel
75. Ignition switch cover
76. Gauge trim
rmr201 1-057 705

Section 0'7 CHASSIS
Subsection06 (BODY)
FRONT CARGO MODULE

Actuato r
IQ
a
/=§~ ((9 '
./e %*~
(5.s"i;if-m) _. ->
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./ I- .»f*‘€?"~- ' ' .'
4.5 N-rn ' '4'//‘/L’ .
(40lbf~in) "ti-.’,._,> / '»/
—%_/ H
/’ . I
_ U ‘S Q,
Q \ Q
,4
_‘
I 7 ' EN.
<§25|br-E21
$7U
I "'1:/._,»; _v
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Q -I T 3.5 ‘I11
‘31'bf""I
s
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»
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4 VX
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ti I /I" 2.5 N-m / 4-5 N-rt»

K: ,4 ’; \_l22lbf-in) (40Ibf-ml
fr \ rt , ~ ta
Is T
LH side shown, RH side identical

“S I i "'\»e_.__,/4
.
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E
ll]
[|
706 rr11r2011-087
Section 07 CHASSIS
CONSOLE MODULE
4.5 N-m 25N-m xg I3

(40 Ibf'inl .1, 1 _
I‘/e\“V R _. lbf'iI;|i_,- ID
% ~ .\ ~ ,\\ '7 Q -'

I3
v’_,___\ Q
, .0 §\‘/ v\?-I II
O. <2» ' I \
2.5 N-m
p V
. (22 Ibf~inI \‘i.
ex
I
4.5 N‘ "
(40 lbf-I?!) w
2.5 N-m
79-‘Q (22 lbf-in) 3.5-m . |;
(31 lbf-in)
':~—!/E/4‘
.. at-*7
3.0%-m Z I.
<27 lbf-in) E»' -
I
E
N-m
, /‘ éiiil-i->_@ 9“\. -rte @\/
3.5-m \ ‘I 1J ‘L T iiéoigrzml
I31lbf-in)
at
; " -'
7 \~
é , I
I Windshield
¥)
iii
, ~
=23!
~1.\2‘.%~"’ L
motor Ia
I
‘\!"
gs
gr-I 3 A
my
Es»‘ 1.9
5
. 0 \ /~'
\‘ V H 3.5 N"lTl
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C1 [Q (31 lb ~in) /1 y Q?
0.
~ A IE \+ O}/f’ IE0‘
Q r_ 6 \ . ,_
XPS.
synthetic
’ -. - ‘/ Q _, r»"»;‘;, i ' ‘ grease
‘ ¢ *‘.%\». .
e
3.5 N-m 4.5 N-m -,_
-I =- =
A
‘1',.~"
(31lbf-in) (40lbf-in)
. .
/
» s. ‘ev_5_»)§ A ,4 e
,»,'- \L/It
§_’$,¢
.3
.__‘ \,;@~
,- . ‘
I
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sequence ,,=w\I 0\ E2}I9‘
\'<E
%\
3%
‘I’-I
é WPM
module
O
XPS
= Component must be replaced when removed synthetic grease
rmr201 1-OB7 707

Section 07 CHASSIS
CONSOLE MODULE
K50 X
§~e~' K5DX
{,:;%t
iill.“
~ 5....
MSX1
M5X25
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.<.t g,‘t *4 ’
§“\,;\V* MW. ,.,.s*_;,ft,*{&%
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/iii! ‘A \'___\_\.-A 4sN-nw\
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£7 T -. likay lag @ _ a°®
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‘.‘ ‘ N3‘ ‘ Q
|-
‘P ex
fl/
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Q
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i_lil*~,",:rI;@‘;'\
7§;\
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vb.
4.5 N-m
(40 lbf'inl Q rI‘J
cl-\~ mi-m
(66|bf-inl ‘ % (40|bf-in)
45Nm I -
‘I
. s”" I
! 9 -7 .*' .:
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= Component must be replaced when removed. ,3
708 rmr201 1-087

SSMWU tm
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Wr 2 O H 0 B7
Section 07 CHASSIS
Subsection O6 (BODY)
_ATERAL BODY PARTS
K50 X
K50 X
M5 X
M5 X
M6 X
_ Tl MGX
M6 X
r ‘w MBX
§EHflHEfiE QM6
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X
%ifI.
741'3;alt
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e
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3.5 N-m
I31 lbf-in)
15.5 N-m 5_5 N.

(22 lbf-in) "13 is ,0 (49 |bf.?:,)
\ W is
/
48 N-m r as‘
(3 5lbf- ft) K’ :' . K ‘r
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(44 |bf'iII)
ii£4
LH side shown, RH side identical §¥
Rim ii
_F
710 rmr201 1 057

Section 07 CHASSIS
REAR CARGO MODULE (REAR VIEW)

2.5 N-m K50 X 16
122 lbf-in) K50 x 20
c M5 x 14
~ D M5 x 25
M6
x 10
,» \_ P\ M6
>< 16
*' ‘M 2.5 N-m M6
x 20
w 9 - (22|bf-in) M§_><_25
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KE E
3.5 N-m
(31 lbf-in)
rmr2011-087 71 1
Section 07 CHASSIS
REAR CARGO MODULE (RH SIDE VIEW)

K50 X
K50 X
M5 X ,
M5 X See tightening " ‘-r’,(\ T5.-‘Q'— g
z '—l3
E.
HEUEE M6 X sequence )¢ 1‘
M6 x 1 4.5 N-m V,/' %\
M5 X (40 lbf-in) \ ,
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I
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(3151:;-in) "
See tightening
sequence
Ein
53
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3'-
. I
712 rmr2011 0237

Section 07 CHASSIS
Subsection06 (BODY)
FRONT FENDER
Q Q
‘Z’
0/ 1/ 4\/;/:
. '1", 1 "J
0
I T‘ »
\/7.0 N-m
(62 lbf-in)
7.0 N-m
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See STEERING
@§\ 3',/. E1
%\/"\ E
MGXZO
LH side shown, RH side identical Nl6X25
rmf201i OB7 7'13

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m r2m O87
Section 07 CHASSIS
GENERAL — While washing the vehicle, check for grease

or oil. You can use BRP HEAVY DUW CLEANER
During assembly/installation, use the torque val- (P/N 293 110 O01) or a mild automotive de-
ues and service products as in the exploded greaser. Thoroughly follow the manufacturer's
\/ISWS. instructions.
Clean threads before applying a threadlocker. Re- — Dry the vehicle with a chamois or a soft towel.
fer to SELF-LOCK//VG FASTENERS and LOCT/TE
APPL/CAT/0Nat the beginning of this manual for Vehicle Waxing
complete procedure. Apply only nonabrasive wax safe for clearcoat
paints on glossy finishes.
A WARNING Avoid applying wax on matte surfaces.
must be strictly adhered to. NOTICE Do not polish windshield with any
Locking devices when removed (e.g.: locking plastic cleaner/polisher.
be replaced. A WARNING
Do not apply a vinyl or plastic protector on
the seat as the surface will become slippery
NOTICE Hoses, cables and locking ties re- and the operator or the passenger may slip
moved during a procedure must be reinstalled off the vehicle.
Be careful when tightening plastic TROUBLESHOOTING
panels. Any deformation on the panel around
the screw is an indication that it is too tight. TROUBLESHOOTING
Do not over torque panels in order to avoid to
damage them. GUIDELINES (WINDSHIELD)
Before any troubleshooting operations on wind-
NOTE: Install a battery charger on battery termi- shield, it is important to check the fault codes
nals (under seat) for any tests that involve a pro- using B.U.D.S. to properly diagnose the problem.
longed /(El/0Nperiod. If battery voltage gets too Refer to D/AG/VOST/C AND FAULT CODES sub-
low, some accessories are shut off by the ECM. section.
VEHICLE CARE WINDSHIELD DOES NOT WORK
Vehicle Cleaning 1. Faulty WPM module or wiring.
To clean the vehicle, do not use high-pressure - Check if parking brake works properly.
washers (like the ones found in car washes) as - Carry out a WPM MODULE SIGNAL C/RCU/T
they may damage certain parts of the vehicle. CONT/NU/TY TEST.
- Carry out a WPM MODULE CAN TEST.
NOTICE Do not clean the windshield with al-
kaline or acid cleaner, gasoline or solvent to 2. Faulty windshield motor or wiring.
avoid windshield damage. - Carry out a W/NDSH/ELD MOTOR OPERATION
TEST.
To clean the vehicle:
- Rinse the vehicle thoroughly with water to re- PROCEDURES
move loose dirt.
— Using a soft, clean cloth, wash the vehicle with DECALS
water mixed with a mild detergent, such as
soap specially formulated for motorcycles or Decal Removal
automobiles. Using a heat gun (low heat setting) warm up one
end of decal for a few seconds until decal can roll
off when rubbing with your finger.
Pull decal slowly and when necessary apply more
heat to ease removal on the area that has to be
peeled off.
rmr201 l~O87 715

Section 07 CHASSIS
if decal tears while pulling off, it has to be heated SERVICE COVERS

for a few seconds longer. lf decal tends to stretch
while pulling off, stop heating and wait a few sec- NOTE: The procedures are the same for LH and
onds to let it cool, then peel it off. RH service covers.
Decal Installation Service Cover Removal

Using isopropyl alcohol, clean the surface and dry 1. Open the front storage compartment cover.
thoroughly. 2. Remove plastic rivet from service cover.
Apply a soapy water solution to new decal
and carefully position it. Using a sponge or a
squeegee, remove the air bubbles and water
working from the center toward the edges. Al-
low to air dry.
e,a.
IVUTICE Do not apply isopropyl alcohol or
solvent directly on decals.
MIRRORS
i‘ i in ‘<§%{"L.€,\\
\_‘ i
NOTE: The procedures are the same for LH and
RH mirrors. I. fijl *‘;‘ ‘T
rmr201 U-038-021 _a
1. F1’Hsen/ice cover
@ ._. '
4'
/i\¢l
Eif;
‘ ~=4 lsifaiit
Mirror Removal 2. Plastic r/vet
1. Hit with a sharp blow lower part of mirror to- 3. Pull down service cover using the recess to re-
ward the rear to unlock it. lease upper tabs from the front fascia.
2. Slide mirror upwards to unhook it from upper
slot.
ya’/1-is rmr2010-O38-061 _a
_ I’
rrnr2011-O87-0fl9_a
4. Lift service cover to remove it.
Step 1: Hit with a sharp blow
Step 2: Slide mirror upwards
NOTICE For the RH service cover, pay at-
tention not to damage the FCS switch (if
3. Disconnect turn signal connector. equipped).
NOTE: Be careful not to let the turn signal wires Service Cover Installation
fall inside body panels.
Mirror Installation cedure.
cedure. However, pay attention to the following. FRONT FASCIA
Hook mirror on the upper slot. Front Fascia Removal
Hit mirror with a sharp blow toward the vehicle to 1. Remove mirrors. Refer to M/HBO/-75 in this
engage lower attachment. subsection.
716 rmr201 ‘l-DB7
Section 07 CHASSIS
2. Remove service covers. Refer to SERVICE

COVERS in this subsection.
-'%_ -I>
3. Remove middle side panels. Refer to M/DDLE -<*~ " 1/;
Q
“/xiii’
'7 3W
.
S/DE PANELSin this subsection.
4. Remove top side panels. Refer to TOP S/DE
PANELS in this subsection.
I 5y
r I I/-1;
i1:-%~ T_‘'fj-
‘.g~I.'‘
5. Remove upper retaining screws and washers
from front fascia.
I. "I- *
I
y/~
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rmr201 U-038-024_a
1‘
8. Remove front fascia from vehicle.

..i/
\l:\ J‘, "1. 1. RV C: 7 . ,
Front Fascia Installation
1» "J+:','I 0
)-(1 '-\_°_‘:, - r 1; I ,_,__
;.\\\\ The installation is the reverse of the removal pro-
' .
L ' 4/
'/ ‘V ‘.3 ‘Y I‘ I “
§~.“T“‘l-*.~'..—--.‘-.-.~-
III,‘
‘»‘ ‘Hi "
“I”? I--‘\-.
» __ = -‘ , .>'- _9 ° g - ‘
*
< :2-»;;,. .-;~.i'i[., .5 ‘° I Torque front fascia retaining screws to 3.5N'm
'- f. . L 4 . .‘“ TE‘; ? l
(31 lbf-in).
. ' l .2. » ' ../ 1 l
rrnr20l0-038-O22_a
MIDDLE SIDE PANELS
6. Remove middle retaining screws and washers RH middle side panels.
from front fascia.
Middle Side Panel Removal
1. Remove middle side panel as follows:
1.1 Pull the rear of panel out of its grommet.
1.2 Slide down the top of the panel to free
panel hook.
1.3 Pull the bottom of the panel out of its
grommet.
1.4 Pull the front of the panel out of its grom-
met.
1.5 Slide the front of the panel to remove it.
rm r2CI'l O-038-O23_a
1. Middle retaining screw .2

.-’
.
7. Remove lower retaining screws and washers ; .»“-we

from front fascia. ._~ .-. £~. ‘¥"_‘_{ ;-2
it I/"\\‘-":‘; '2’
. ---‘ ’/1*“
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V§}";"I.§I
rrI'i020'lU-QUE-OO3_a
REMOVAL SEQUENCE
rmr201 1-087 717

Section O7 CHASSIS
Middle Side Panel Installation 5. Remove mirror. Referto M/R/?OH’Sin this sub-
1. Install middle side panel as follows: Secllo”
1_1 push the {mm of pane; in its grommet 6. Remove upper retaining screws from top side
1.2 Rotate the panel and clip it on the support. panel'
1.3 Push the bottom of the panel in its grom- 1
1/
met. - .-,/"/- ,
1 . 4 Push the rear of the panel in its grommet . " "1/M ir I V _
1.5 Push the top of the panel to fix the plastic . r 43* .-.
,. /4?, 51,;-=\i‘ >,_. . 1* it-
'2 I
hook. "I »- If
as ~ . ._-/t----age
l
S“ -__ 4- . _ .--
-rlrtfi ,¢='<"-1—*
rmr2D1U 038-OD5_a
\ \.i\
_ \ -1 '
. \.\* . \'
\
A-‘
1. Upper retaining screws

.,"
E 7. Remove rear retaining screw from top side

paneL
rrno20'| 0-OU8-003_b
INSTALLATION SEQUENCE ¢ /\ 1
gnij; .. - '
/-°. A ‘\
Q-:_
- C ' ~ {$3
tile
o ,~' _
_ 2»
~‘;‘*u
. -;{"7
" , ~- ‘. . “#21 _
TOP SIDE PANELS in- ---. 1

T§ 9
1I
‘ R’ . \ "\
RH top side panels. it S
“-1
76"”.
i/_
‘ii
.. ‘
\#»<-=---iI
~.3/_I
._
_\
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'
,,’ ii 0
'__,.»»"‘ E
{_,_ __
v_v
Top Side Panel Removal Y
1. Lift seat. /II

/.7'/\/
1'
2. Open front storage compartment.

/_
rmr201 0-O38-U06_a
t :~»/T“Q5._‘- -- ~s-.-. I i . =~..
3. Remove middle side panel. Refer to M/DDLE 1. Rear retaining screw
S/DE P4NELSin this subsection.
4 R . . . 8. Remove LH service cover. Refer to SEHV/CE
emove retaining screws from lower wind de- COVERS m ms Subsecnon
flector.
it
rin X? P ,_ "\
,-
Rt /.
J? ""
.7-:\
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Q
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7. in
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. ..»-K
rrr\r2Ul O-O33-U Dd_E| rm ,2 O1 °_O3fl_uQ7_a
1. Retaining screws of wind deflector 1‘ LH SQMCQ cove;
718
rrnr2011-087
SectionO7 CHASSIS
Subsection06 (BODY)
9. Remove front retaining screw from top side Top Side Panel Installation
panei The installation is the reverse of the removal pro-
v Q//K
Torque top side panel retaining screws to 3.5 N-m
- ,W\fl (31 lbf-in).
l 5 REAR SIDE PANELS

RH rear side panels.
Rear Side Panel Removal
:5
A-
TO!L\I§§§i‘ i,‘.:,-I,"UTA
-,,~ j
"ii _‘,_\‘
. r~ 1. Remove middle side panel. Refer to M/DDLE
I F" I "*l~I
1-P &llI‘I:-I-E5 -i-rl{.‘»~.,{'-_“<‘1§‘ I S/DE PANELSin this subsection.
rrni10'iO-038-00B_a 2. Remove top side panel. Refer to TOP S/DE
1. Front retaining screw PANELS in this subsection.
10. Pull out lower part of top side panel to remove 3. Remove front retaining screw of rear side
it from grommets. paneL
NOTE: Do not remove lower screws from top 4. Remove upper retaining screw and washer
side panel. from rear side panel.
rmr201 0-D38-O1 O_a

1. Front retaining screw
rl:il2010-002-305 2. Upper retaining screw
11. Remove top side panel by lifting it upwards. 5. Remove front plastic rivet from rear side panel.
1 \§1
4: t.‘z
- 1 ll.
'f:"'=-\'_,,.
v.
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L
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.__
rmr201 0-038-O09_a
rmr201 U-038-U1 1_a
1. Top side panel 1. Front plastic rivet
6. Open side storage compartment cover.
rmr2D11-087 719
l Z j j i Z 1 I
SectionO7 CHASSIS
7. Remove rear retaining screws from rear side GLOVE BOX

l.
pane Glove Box Removal
_V Q _ 5_ ‘O: 1. Remove middle side panel. Refer to M/DDLE
.-,5. S/DE PANELS in this subsection.
T7, - ~ » -"T »lL= 2. Remove top side panel. Refer to TOP S/DE
rat ,;=*.~?.§ ” '
'._ \l;L3;’*_; lei V ‘
,1;
3;; r_.“I-*_.-' _
PANELS in this subsection.
_
~-.1-\.Tfi:f_ I _~ _ ,. "3 I! 3. Remove lateral acoustic panels. Refer to
) , =2
-
_._; A
'
g fl ,
rmr201lIH)38-0l2_a
"tr
. \l
-
'_--_;,..§;_»‘;.,:;;v-a __.. ,
.1 E 1
\
Ag‘
.
/‘H1? \_..,;;‘ti.-=4’
, ‘" i “""l"all?3-‘J-ii
~»<._;f_
3:“ -.....
i_
ACOL/ST/C PANELS in this subsection.
4. Disconnect glove
‘ I
box cableI from glove box.
“is; 5. Remove locking ties securing glove box cable.
1. Rear retaining screws
8. Remove top retaining screw of rear side panel.
R1-
_ 4,\;E§¢'%"‘
~‘_
t I 13
rmr201 1-087-005_a
6. Remove locking ties securing central panel

rm1’ZU10~D384Il 3_a switches harness.
i. Top retaining screw 7. Disconnect central panel switches harness con-
nector.
9. Remove rear side panel from vehicle.
NOTICE Be careful not to break lower tabs. ,4 1 1' ~-‘
»'I I I_. ‘*.

-. ; . ‘- ¢- . ,
. _ 5"-ii g __ __
l *‘
' 1 I
\" " tel?

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- I‘ I _ I ‘l __.' f‘jv‘\l-. ' __" ""-1_‘-=l;_'
-.,__ ax M . if-,
-. - . ' _g
.
rbl2010-002-355_a
;.. -»;_
'\\}l~'-l’ '
I
"E
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-
.
O0 ' . 7
I‘
LH REAR SIDE PANEL g ll ‘$3! '1;-' " ' Q

7. Lower tabs \ ' (gift F ‘J.
‘_4.
‘,2i
rmr2011-O87-006_a
Rear Side Panel Installation ' _
The installation is the reverse of the removal pro- 8' llzglove 3 llllasllc llvels llolll glove box on bolll
cedure. However, pay attention to the following. Sl
Torque rear side panel retaining screws to 9' Egtlpii/S62 lelalnlllg screws llom glove box on
3.5 N~m(31|bf~in).
720 l‘|'nf2UI'l-O87
Section 07 CHASSIS
1 V ,4 J"//,-vV0__*:.i‘,:l\'
. it
; _.. 32> - ‘cl-F" 'TQ i —__e»_ '~ \_‘

i§!;t5:.*_\< *1
‘C-\ .
A%//
wiflilit ._,1; \
* ., _ k ' id); I’
4 l A. 37"]-__
" . _ I’ ll
Fl
r 9 i I .; , y- . _ r
R
rrnr2010-038-03U_a
1. Plastic rivets
2. Retaining screws
I
,
IQ.
'-=_—
'7'"
L” '-
-'u I
.‘" 'l ,'
.~.-"‘—~_q-;a ‘
._;
i
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,_
rrnr201D-03Er500_a
TYPICAL - GLOVE BOX UNIT
10. Remove glove box as a unit with central panel 1. Plastic rivets
2. Top acoustic panel
by lifting it upwards. 3. Glove box
11. Remove locking tie securing switches harness 14. Remove plastic rivet securing central panel to
to glove box. glove box.
15. Remove central panel from glove box.
0‘ 1\
llQ.
.\'ifi
‘a
r -
2 \;.-
If»
rmr201 1-087-007_a
rmr2D10-D35-502_a
12. Remove plastic rivets securing acoustic panel 1. Plastic rivet

2. Central panel
to glove box. 3. Glove box
13. Remove acoustic panel from glove box. 16. Remove all the remaining components from
glove box.
Glove Box Installation
cedure.
CENTRAL PANEL
Central Panel Removal
1. Remove glove box as a unit with central panel
from vehicle, refer to GLOVE BOX RE/VIOIAAL
in this subsection.
2. Remove plastic rivet securing central panel to
glove box.
rmr201 1-D87 721

Section 07 CHASSIS
».}m”’ ggl f‘
\g
\
2\*
rrr\r2010-038-016_a
l'“l2°l°'°39“5°l J‘ 1 . Lower plastic rivets
1. Plastic rivet
§: g‘fg”jf,l7gj”e' 5. Remove bottom front side panel from vehicle.
3. Remove central panel from glove box. B0tt0n‘1 Front Side Panel Installation
. Th installation 's the re se of the remo I r -
Central Panel Installation Cegura l Vel Va lo O
Cedurs BOTTOM REAR SIDE PANELS
BOTTOM FRONT S|DE PANELS NOTE: The procedures are the same for LH and
RH bottom rear side panels.
NOTE: The procedures are the same for LH and _
RH bottom front side panels. Bottom Rear Side Panel Removal
. 1. R 'ddl 'd l. R f M/DDLE
Bottom Front Side Panel Removal 5Z;n5O,l§2,\l2_lL5;1ilh£ §jQ§eC,,Oen?l l0
1. Remove middle side panel. Refer to M/DDLE 2 R -d | R f UP 5/ E
SlDEPANELSin this subsection. ' ,j@,‘3{f;,’§,°§h;'si,bi;1';$,5n_ e el t° 7 D
2- Remove Upper letalnlllg Screw from panel- 3. Remove rear side panel. Refer to REAR S/DE
3. Remove upper plastic rivet from panel. PANELS in this subsection.
4. Remove bottom front side panel. Referto BOT-
TOM FRONT s/05 PANELS in this subsection.
5. Remove front plastic rivet from bottom rear
.1-"'
side panel.
/til-ll
rmQUIU-D38-OI 5_a

2. Upper plastic rivet
4. From underneath panel, remove lower plastic

TIVBIS. Ir\'|rZ0‘l U-O38-lJ17_a
1. Front plastic rivet
6. Remove retaining screws from bottom rear

side panel.
722 rrnr20'l'l osv
Section O7 CHASSIS
6. Reinstall all removed panels.

Top
1. Remove glove box as a unit with central panel
!#.~,., g from vehicle. Refer to GLOVE BOXREMOVAL
(Ii in this subsection.
2. Remove plastic rivets securing acoustic panel
to glove box.
‘es
rmr201 U-038-018_a
1. Retaining screws
7. Remove bottom rear side panel from vehicle.

Bottom Rear Side Panel Installation
Torque bottom side panel retaining screws to
2.5 Nvm (22 lbfvinl.
Torque bottom side panel retaining nut (located at
rmr2lJ10-038-50D_a
the rear) to 5.5 N'm (49lbf'in).
TYPICAL
1. Plastic rivets
2. Top acoustic panel
ACO USTIC PAN ELS 3. Glove box
Acoustic Panel Replacement 3. Replace acoustic panel on glove box.
Lateral 4. Reinstall all removed panels and components.
1. Remove middle side panel. Refer to M/DDLE
S/DE PANELSin this subsection. FRONT CARGO MODULE
2. Remove top side panel. Refer to TOP S/DE
PANELSin this subsection. . $9‘
3. Remove retaining screws from acoustic panel. / }‘ -» ._- L...

14'-1. I v~ _,/f’
i9.
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,
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. ~"lll‘P -;;;"—7
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l; ‘ls _,-‘;_T‘;'1;';_:1gE_-‘f ,-\ LL l?" .' l\\ V ll
‘bill;/"
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I I of
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.... FRONT CARGO MODULE
/.4
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1- \ ¢>.r a¢* ~ ~
Q‘\. l 1* ~‘-1:-4.. r 1?‘ ll. .__‘»J' =l-- .1-ill‘ \
“Q-':*.(L:-1;‘//"§‘J-as \'~v‘ i. '
/r‘ ‘-~A‘>_lid;%
# Front Cargo Module Removal
In112CI1CI—D3B4TI9_a
1. Remove mirrors. Refer to M/RRORS in this
1. Retaining screws
2. LH lateral acoustic panel subsection.
2. Remove service covers. Refer to SERV/CE
4. Replace acoustic panel on vehicle. COVE/-?Sin this subsection.
5. Torque acoustic panel retaining screws to 3. Remove middle side panels. Refer to /l/I/DDLE
6 Nem (53 lbf-in). S/DE PANELS in this subsection.
rmr201 1-O87 723
Section 07 CHASSIS
Subsection06 (BODY)
4. Remove top side panels. Refer to TOP S/DE

PANELSin this subsection.
5. Remove front fascia. Refer to FRONTFASC/A
in this subsection.
6. Remove front panel retaining screw on both
side.
ll ‘ti
_ Z
. ‘>4-I / ye I v
A rm I201 O-038-U25_a
. ./"J l I
e=t _. .
,."-tie?!‘ ,'_ ‘ ---
_,-‘Z
_ 7 _- ’ X. I. (‘fl. l _‘. Z 1. Upper retaining screws
> . / I V ‘V _ _ g _‘* .-'Pé...
':I
10. From underneath bumper cover, remove
lower retaining screws from cargo module.
.3. I ~ y _, H
/./I <:f"r-1% * l
‘ll l 7~ ‘?ti’:"’* l“<"1=jo.;€ElT ck} l 1/ I J/_
rrnr201l-lJ870U1_fl
1. Front panel retaining screw s£911.‘

II fink
"Iii>_El -:
7. On applicable models, remove nut securing . _:f;_:;‘h \ ..»~";l ~;'l7;?T!€’..~' \ _
headlight adjustment cable (LB) on both side. IQJPFQJ

II~ I,‘/mlii.- ~‘, -~l
eel
‘ ‘f
. .,.>lrst_*‘_"A;nio?f
~%_,r_
9qr Xi
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39-
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_
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1-‘tail-‘fIl"l
....--4-'~'.";d l / I ‘.-I._--ui ___g_/ /

W“ _ W ‘I _ _:_ IN: l , = - '.-‘;
“J IQ»
: I‘*fi~ _-I: .Ig
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ll I O iito‘
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. ‘Ir? -rlit,.;I’Illl'gil- 1"‘-Ti‘1Ii~i‘;‘ ' y I .",.i.“‘%
",7,
"I £35
“ T1;<_l‘ ‘ I
g rmr2010-lJ38026_a
1. Lower retaining screws
I -."' 4/
.i ;<I.g-» -‘r I a’£%%§\§j
\ ll
_-gl L I ilil;Ili‘;ilIl"‘iI“:I
x7‘ i'-‘Qi-t lllr I-ll _ ,l_
11. Slightly pull cargo module toward front of ve-
s»me.
." t
is_?.-_
.._%,‘\_‘=;, ‘ *. s,_ . celnmmh
all ;I‘¢""i'iIt"iz‘IIi I:4 ‘L
hicle.
. - . 9-. I I>_, ‘ ~ ;_ j .
.-\ -I V.’.-‘»"
ml -,'
3-. V‘) V I.I '.,_‘ I5
I --v-M ‘ I ' I i 12. Disconnect the following components from
F’
Z1? I .Iil . "' “‘ i '1' - r vehicle (if equipped).
.‘ \~-~-I . 0-. l . . — AAPTS sensor connector
rmr201 0-038-027): (
ON APPLICABLE MODELS - Horn connector

I . Headlight adjustrnent cable (LB) — Low beam light connectors (CE)
8. Disconnect the following components from ve- — Fog light connectors
hicle (if equipped). — Storage compartment light.
— B.U.D.S. connector 13. Completely remove cargo module from vehi-
— Storage cover switch (FCS) connector cle.
— Storage cover actuator connector
— Storage cover cable. Front Cargo Module Disassembly
Sequence
9. Remove upper retaining screws from cargo
module. To disassemble the front cargo module, carry out
the following steps in this specific order. Refer to
the exploded view at the beginning of this subsec-
tion for details.
1. Remove front storage compartment cover.
1 .1 Remove 4 screws at the front of cover.
7 24 rmr201 1-O87
Section 07 CHASSIS
2. Remove bumper cover air ducts. 3.l\/love cover upper section backward while
2.1 Remove 2 screws at the rear on both side. pulling lower section forward.
2.2 Remove 4 plastic rivets from inside air 4. Tighten 4 retaining screws at the front of cover.
ducts on both side.
2.3 Remove 2 plastic rivets from underneath
bumper cover on both side.
3. Remove front panels.
3.1 Remove ‘l retaining washer from inside
front panel on both side.
$1
3.2 Remove 3 screws from inside front panel
on both side.
3.3 Remove 3 plastic rivets on the top of front
panel on both side.
rmr201 [H138-5 D3_b
4. Remove front bumper. 7. Upper section backward
2. Lower section forward
Front Cargo Module Assembly and
Installation 5. Loosen 2 retaining screws of cover hinge.
Assemble front cargo module as the reverse of 6. Completely move cover hinge toward the front.
disassembly.
Install front cargo module as the reverse of re-
moval procedure, however, pay attention to the 1‘; - Le X ‘r 4-I i l
following.
Adjust front storage compartment latch, refer to ‘____. L_#_.V — _ _ I
FRONT STORAGE COMPA/?7'MENTin this sub-

section. ___ ._ ~ -_
_." L “i J >-’l i»— ~;,_ l ‘_§\\'
-4 — - L-
Torque storage compartment screws to 4.5 N'm .. ,; 3- 1»-Iii-‘=4? r’

(40lbf'iIll. \;~ Qiw " ;._
513‘ ‘ 1’ ‘\T 31 T
1,."-5',
T /1 ., _ l
‘W x
FRONT STORAGE .. ‘wily Q
COM PARTMENT LATCH ""3>I

l\y/
‘ . .;;::_ *-.II;\<,—
, ,"_ '_ .,,___

i ___. ___
6?A ____ ._"_"'
Front Storage Compartment Latch rbg2 D10-O08-0DB_b
Adjustment 1. Retaining screws of cover hinge

2. Moving cover hinge
2. Loosen 4 retaining screws at the front of cover. 7. Align hinge bracket with housing wall. They
must be parallel.
rbg201O-00841063
1. Retaining screws
rmr201 1-067 725

Section O7 CHASSIS
' T ' . i HAL,’

_3 isj 6. latch
If testasfail, adjust front storage compartment
follows:
6.1 Loosen latch nuts.
‘T; 4 i 6.2 Adjust latch mechanism accordingly.
. . §fig‘ »~—7— 1 ‘T T“‘“—>_— ;;,_.1=_’*k:_€,
L l
l‘ /is l
'.
/=31.
/
C.i‘\;_;,1=
*’*;i
L-r?____;
r___~"-
I, o
ll,
M.. .t*A3'_5‘1‘‘ “fi~ ::‘ A’/" t’ ' ‘fj"_?,*_;‘.|]"'-
;.'__‘<
"-.1T‘ -. .
. ha.. ._..-:.:. 3 - -- ...:.,.-52». Mics.‘-..;.- L......L...".~_....
rbg 2010-U08-OUH_6
7. Retaining screws of cover hinge

2. Hinge housing wall
A. Hinge bracket parallel with housing wall
8. T'ighten 2 retaining screws of cover hinge.

9. Carry out the FRONT STORAGE COMPART-
MENT SEAL VER/F/CAT/O/V. See procedure in rbg2010-ODE-0O7_a
this subsection. T. Latch nuts

2. Latch mechanism
Front Storage Compartment Seal Verification 7. Ensure cover height fits with front panels
NOTICE This test must be performed each height when cover is closed.
time the latch is adjusted in order to avoid
water intrusion into storage compartment. CONSOLE MODULE
. .4‘ - .' . ,' ,r
2. Place a sheet of paper on storage compartment ,1
'
I-' _r
I
seal.
3. Close front storage compartment cover.
1 \‘Q.-\. -. \ » ..~-.c
I,
r ' .\.
\*—~;--a*~¥f_'1j\\‘\'.’.o‘Li>3._‘
.. <-.~->-.253;
,- -iJi'*fi'Pl
T?‘
I
i
\.
“<4
rm r201 (>038-03 2
CONSOLE MODULE
Console Module Removal

rbQ20‘l0-O08-D10_8 1. Lift seat.
4. Check that cover is properly sealed by pulling 2. Open front storage compartment.
on the sheet of paper. 3. Remove mirrors. Refer to M/RRORS in this
5. Repeat the previous steps for the other side. subsection.
4. Remove both service covers. Refer to SER-
FRONT STORAGE COMPARTMENT SEAL I//CE COVER.S‘in this subsection.
VERIFICATION
5. Remove middle side panels. Refer to MIDDLE
PASS Sheet not easily removable S/DE PANELS in this subsection.
FAIL Sheet easily removable
726 rmr201 H387

Section 07 CHASSIS
6. Remove top side panels. Refer to TOP S/DE .- .- I ‘P S .'

PANELSin this subsection. * I‘ " ‘
_
\‘\‘
- P
\_ _
//
- _,z-
510‘;-s‘ _
2'. IQ
';‘
‘,
\l‘ 0 /|,>_5- 1
7. Remove lateral acoustic panels. Refer to ._\.‘.. . A ;_,_.~.~* /...
ACOUSTIC PANELSin this subsection.
8. Remove front fascia. Refer to FRONTFASCIA
in this subsection.
9. Disconnect module harness connectors located
‘tfiII."’< T‘ Q .; >»/-
on the LH side of vehicle.
i ‘ .:.’1/'ii*'~"’5i’ ' A -5~ s
* _ '1Tf'iT
Q?)// , , .V
. TI."§"
-. ~ i- . \, f
V‘ I-— _‘ IT-T rT..- .‘ ' -U
I
T
Rr
.~<:,>ri= .‘.*'f
ir-
T i
. E
/4*
NI _ l.
rmr201 0~D38~03(1__a
-_ _ j "l K
‘TTi
I ‘T 1"
/Q ‘Qeeakfiiw
7. Plasticrivets
.5' \
i=tQ. ;§iT 2. Retaining screws
‘_ <4
14. Slightly lift glove box upwards.
A ._ _. .Th ‘ jT_-_ = ‘» I _ ' T_,\ \_
_ ""~ {V-‘A! .5; T ' 1 ' 4 ,.‘-._ii_\.j.‘ - ':T\ ‘
iii 15. Remove side retaining screws from console
5 “F module.
ii...
/' 1;‘ T1‘
1 ’ i Li
— _4.; r >11
w,i";S_\ L3
‘N'til . ,4 .L T T’'
4:4:“
I-V"! ,7 § Q Eli / ‘"1, 1 .
‘(iii .{ii '9
- '1 E
1 _- _'\l‘i]f
I T1
" \4¢». ‘X - ..\ "' . . ‘T . .l T I '1
rr11f2010-038-029,3

7. Module harness connectors \_\\
\\\
10. Remove nut securing headlight adjustment ca-

ble (HB) on both side.
11. Remove front retaining screws from console
module. \
. *4
1r_.*~'—'r1n"TL—1
rmr20lO-D38—O31_a
7. Side retaining screw

_ pg ’._.\\\§El|,‘ ,i/ 7/ 4|‘
16. Carefully pull console module toward front of
vehicle.
- F" L
7
I = .8.-
W i,?;—- T‘
Console Module Disassembly
'1
/” 51;.
if I55‘
;/.5 \_"\
o “""' /
\ I
Sequence
L J".-‘I To disassemble the console module, carry out the
T, .
rmr201U-035-D2 E_a
r 11- following steps. Refer to the exploded view at the
beginning of this subsection for details.
7. Front retaining screws 1. Remove multifunction gauge.
12. Remove 3 plastic rivets from glove box on 1.1 Remove 4 screws securing gauge trim.
both side. 1.2 Pull down both upper tabs.
13. Remove 2 retaining screws from glove box on 1.3 Move top of gauge toward rear.
both side. 1.4 Disconnect gauge connector.
2. Remove headlights.
2.1 Remove 4 retaining screws from head-
light.
2.2 Disconnect headlight connector.
rmr201 1-087 727

Section 07 CHASSIS
Subsection06 (BODY)
3. Remove windshield. Refer to W/NDSH/ELDin - ~ .\//*

‘,3 \TL xi; \\i"-/.1 ‘I-1 1-4
7- ' TJ
this subsection. T T‘
‘mi ’ ';TT_j'-, >5 “'5' . %.-.f-T;T '"
V ' j ‘\‘,;;,~;"3*;T¢
Console Module Installation ' j
‘
.' _4~' ;~._~ __
T '*v."T
, ‘\ f\
"-~. ‘
T
,4
Assemble console module as the reverse of disas- cf ’T’.‘T’_:.r- ‘-\’ \\,.‘_f_‘=..."‘
sembly, however, pay attention to the following. I .

LII‘.
_./
/ T»~\ere:-= - ~- TZ/~l(
~
\ I
5 "Ii
/II I1} _ » r-'1,‘
, ‘ _;‘;’t V,’ .»<'
Torque gauge trim screws to 2.5 Nem (22 lbf¢in). ,TT_.<1$\-...
4
t ‘--
P".,/-;/’/rTT»'2“‘§-.-
'>7$‘__
> ' 7*“
Install console module as the reverse of removal
>\X:*'—:.'_‘;'_'.:n :7. _‘;>\7%_ .4
J1 T
;f x
3
7- If j
Y
procedure, however, pay attention to the follow-
ing.
Torque console module front retaining screws to I \7I.'T'”:/ 4.
4.5 Nem (40 Ibfvin). rr11rZO I 0O3B~U34_a
7. Seat base retaining bolt

Torque console module side retaining screws to
4.5 Nem (40 lbf~in). 4.4 Remove spacer and caged nuts.
REAR CARGO MODULE E. ~~\

‘ ‘* :_‘:: __P\
:~~\
“"<r'"’;?*, .~’
/‘NT ‘\ J‘ Tl“‘1'rl»T.' .=- __ “ \
if \ 6 Ir-~lL- ’“ * T" v
T . --.~ . ‘*--~_
*— ’ ja . —T_“_§?>-_ ' Q IT " ,_
_' ,,__,
. . +.,_>; /I, 1 --A»
' . 7»
It in \} T‘/"&.T"
- “ T: “S I
5'./_ T L /1
- .- R‘ "‘. V _ T"
"tr 4. ___.__ .’~;5"'. _ “'7. '_.T ‘

1
gT1‘.\;
“IQ
~.T- sT.»-
-_ ~ ~
'ff
‘*i
-1-<13;-;‘5"
_,- , __ (T\
—- . "T.
F‘ \ ~._‘ A J ~
\ \\ :7. f / ,,-<-‘.~‘_‘\_‘
L_:__\;__$:_ ?},.-jaw
;>_ - ‘
,.}",
>2’
, J?» ~‘~ I/,x__i: . _ . . .
'I
_/
,/. ’
‘\-T.
»\ E2‘ _ .
'~
ii .' "j\\
-_
%
/ '37\-1'-4 Ax M> %._ Ii‘-g;.
,\‘K
‘ ;f‘\SQ\ ‘V \l ‘. ‘ii. ‘.;l.~\ 1 \T 2 / - ‘)\
/
1.‘-aw.
3Irr
.'\._ A‘_
ii-.
I
—._ ,, rmr2D10-038-O35_a
|I!.é Q1
‘T T -\'”’f_*_a Y
*4 =l 2.7. Spacer
Caged nut
'm'=°‘°*’“*°°3 5. Remove rear retaining screw from battery ac-

REAR CARGO MODULE
cess panel (LH side).
Rear Cargo |\/|Odu|e |={emOVa| 6. Disconnect passenger heated grip switch.
1. Remove middle side panel. Refer to MIDDLE 7. Remove battery access panel from vehicle.
S/DE PANELS in this subsection. ..,‘)__ , -. _ \ .
2. Remove top side panel. Refer to TOP S/DE
PANELSin this subsection. 1 T .» i _;-~\‘_ ~_ _ -55;!‘
3. Remove rear side panel. Refer to REAR SIDE
PANELS in this subsection. I ”‘" i.TI,i*’ .:—~--_ l l 7 ’ ./ \
,7/T” " /T ~ ' /»’ ‘I T ,/V I
4. Remove seat from vehicle as follows: -_’ '* I - 2 .
4.1 Disconnect shock absorber from seat :l_ _\\'_‘ j.v\" ~___ I
base.
4.2 Unplug pillion rider (passenger) switch.
4.3 Remove seat base retaining bolts. .-.i»iIT.\asr-1s~ -
,
'~<,
rmr2D‘l O-035-O36_a
-
r
~/
,’
;§*‘*“§~
T ,__._ll' “ '
—"'
1
l
7. Battery access panel

2. Rear retaining screw
8. Remove rear retaining screw from audio player

access panel (RH side).
9. Disconnect passenger audio control switch (op-
tion package).
728 rrnr2011-087
Section 07 CHASSIS
y*=-1‘ ".-—_T--_;
10. Remove audio player access panel from vehi- »/ _;.=.=" _.i—,l-1L~.1—_~1 _ 1
Ti ~ is T
cle.
'
9‘) -~ Z. ~‘-' ‘Q.-i “A _
T§t?.l.l7*"ffr;
,__‘ \\
‘\‘
Tr I” "i’*” *\
~.TI/..~ Qtf,
, .. . . ,_ 3 Q ,
T ._r€/-Ey‘_;+
/' /T /
T’ .,.; "is
‘f"%3lll7§i*
_.
Y’! l
1 T /§\
T
YT.
I
.-,- _ /'/
rmr2D‘IO~03B-O4fl_a
*'
I
T jg’
.~
y
'
Ti vi
g ya la i
t,T\.
/’
..
-'.-"-T:TY
I
‘ //ll‘
-
""'
l _\
5g_§_
/
I
7. Cargo harness connectors
rmr2010-038-037_a
13. Remove lateral retaining screws and washers
1. Audio player access panel lon both side) of rear cargo module.
2. Rear retaining screw
11. Disconnect LH ground strap by unscrewing I
each retaining screw.

A
rrnr20l D4)3B~U4l_a
7. Lateral retaining screw
_\
14. Remove top retaining screws of rear cargo
module.
rm r201 0-D38-03E_a
7. LH ground strap retaining screw . ~__§L'v;
12. On the LH side of the vehicle near passenger //I /"ll E _ Ii; " ' T .
grab handle.
- Disconnect both cargo harness connectors.
- Disconnect accessories connector (if appli-
cable). i.._,..!Il ..ir
1..atI
e . , .(, - T fir»,
1>25-‘L
T“ ‘M’ " T I
ta» T,i».-- .»_-
-"1" .T~ I»//IT J
\
‘\<ii3l/$1 Tr’/=Il¥"'T 7
rrnr2010-O38-O42_a
P— j ‘fill‘_’ a ‘ /"Lg!
1. Top retaining screws
NOTICE To avoid damaging the rear cargo

module:
— Never lift rear cargo module by the passen-
ger grab handle.
- Always install rear cargo module on an ap-
propriate support.
rm|QO‘l H187 729
Section 07 CHASSIS
15. With the assistance of a coworker, carefully 4.2 Disconnect taillight connector.
pull rear cargo module toward rear.
16. Install rear cargo module on an appropriate Rear Cargo Module Installation
support. Assemble cargo module as the reverse of disas-
sembly, however, pay attention to the following.
Torque taillight screws to 2.5 N'm (22 Ibf'in).
Torque passenger backrest screws to 4.5N'm
(40lbfvin) for the ones inside storage compart-
ment and to 2.5 N'm (22 lbf¢in) for upper screws.
Torque rear fender screws to 3.5 N'm (31 lbf'in)
as per the following sequence.
JLl—! '
., -
TmT»2n11-cs7-one
TYPICAL — REAR CARGO MODULE SUPPORT
Rear Cargo Module Disassembly

Sequence
To disassemble the rear cargo module, carry out
the following steps in this specific order. Refer to rmr201 H187-OD4_a
the exploded view at the beginning of this subsec- TIGHTENING SEQUENCE
tion for details.
Torque rear panel screws to 3.5 Nvm (31 lbf-in).
1. Remove rear panel.
Install cargo module as the reverse of removal
1.1 Open top and side storage compartment procedure, however, pay attention to the follow-
covers. ing.
1.2 Remove 2 screws on the top of each side Torque rear cargo top retaining screws to 9 Nem
storage compartment. (80Ibf~in).
1.3 Remove 4 screws on the rear of top stor- Torque rear cargo lateral retaining screws to
age compartment. 4.5 Nem (40 Ibf'in).
2. Remove rear fender. Torque battery and audio player access panels re-
2.1 Remove 3 screws on the upper portion of taining screws to 3.5 Nvm (31 lbf~in).
rear fender. Torque seat base retaining bolts to 4.5 N'm
2.2 Remove 2 screws on the rear of each side (40lbf'in).
2.3 Remove 1 screw on the back of each side WINDSHIELD
Windshield Removal
2.4 Disconnect licence plate connector.
1. From inside windshield, remove retaining
3. Remove passenger backrest. screws from windshield trim panels.
3.1 Remove 3 screws inside top storage com-
partment.
3.2 Remove 2 screws on the top of passenger
backrest.
4. Remove taillight.
4.1 Remove 3 screws on the taillight housing.
730 rmr2011-O87
Section 07 CHASSIS
4. Remove windshield retaining screws and

sleeves from support.
T
'44‘ I 1
£2
-*:‘;
l/// ?_ _ .,_ \_;.
‘_
I/4
‘" g
?;nm=§"P /J-1'1",‘-" 1-‘ _k ‘\\__ ‘pi
‘ct:
I "Z-,1»-*4-" \-_
*
, 5-:5? I .~rTT'§'i...-.~!'_'_T a __:*-l5 \,
...\ l»
irni’Z07U03B-O43_a
7 Windshield trim panels retaining screws
2 Place a sheet of paper on windshield to protect

it refer to illustration
TICE If this precaution is not taken rri1r2O'lD4338-O45_a
scratch on the windshield may occur 1. Windshield retaining screws
5. Carefully remove windshield from vehicle.

Windshield Installation
NOTICE Prior to installing windshield trim
panel, place a sheet of paper on windshield to
protect it.
I“
xv
2?‘ \
3 Remove windshield trim panels from vehicle 17' T‘-
_ .- ‘is
rb|201 0-O02-O28
SHEET OF PAPER POSITIONING

A T
Torque windshield retaining screws to 4.5 Nvm
i[4O lbf'in).
Torque windshield trim panels retaining screws to
2.5 N~m (22 lbf'in).
7 Windshield trim panels
731
SectionO7 CHASSIS
Subsection06 (BODY)
WINDSHIELD SUPPORT Windshield Support Installation

Windshield Support Removal The installation is the reverse of the removal pro-
NOTE: To access directly to windshield motor, it
is not necessary to remove windshield from wind- Make sure that arm bushings are installed as per
shield support (step 1). the following illustration.
1. Remove windshield. Refer to W/NDSH/ELDin _
this subsection. ,
2. Remove C-clips from side arm pins.
’,r'
rmr201 04138-O4E_a
1. Bushings
Install NEW C-clip on arm pins.
WINDSHIELD MOTOR
Do not remove windshield motor
mumamsa from windshield_base._ Both are calibrated at
1' Side arm‘ the factory. If windshield motor needs to be
2. C-clip changed, replace windshield base with WPM
module and windshield motor as an assembly.
3. Remove side arm pins.
4. Rotate windshield support toward front.
5. Remove C-clip from center arm pin.
T:
l
rrnr201D-038-O47_a
7. Center arm
2. C-clip
6. Remove center arm pin.

7. Remove windshield support from vehicle.
732 rmr2011-087
Section 07 CHASSIS
Windshield Wiring Diagram /1155*
MULTIFUNCTION MAIN RELAY 2

SWITCH (LEFT) lFl3l
6
L0PN UFI
RD
CAN CAEN~HPN‘*0 T_T.;

Q\()
"Iv-"1
K-20 E-20
\ \
WHB
44¢/a\/§\/A\
WHB 0RlHD~6
\1
is to 3: Q .\ 5»
$<$ st“ \‘§‘§ §z\§'\ ~‘$‘& \.§"§ rmDZO‘lD-IJO1-0ZO_|'i
WPM WINDSHIELD a PARKING BRAKE MODULE 1' Wm/5h'e"d adjustment swnch
DWN UP j _
W 9, , _ 9 9, 3 5. Check proper operation in B.U.D.S.
§¢ gs 45+ ~t\.5» ‘gs gs
I I I‘ V V V
\/ \/ \/ ‘D Va» I 30-: ""**¢ I lama : I-at I in-< l
— __
N-8 U-8
-\ BK-
\ GYR
GVLTG
1% ck,
UH-20 UR-20
GN
B+U
‘T. minima-
WINDSHIELD MOTOR 9.“; 5",,’ p_;.,,,;
rmr201 ‘I-0B7~2D0_a ""“' ' NM"
Windshield Motor Monitoring s 1 ~ ---

(with e.u.o.s.i TYPICAL
To monitor windshield motor during troubleshoot- 7. Windshield operation monitoring lights
ing operation, proceed as follows: _ _ _
1. Connect vehicle to B.U.D.S. Refer to COMMU- Wlndshleld Motor Operatlon Test
/\//5,47‘/O/V TOOLS A/VD B_U_D_5‘_ SO/-'7')/|/A/?E 1. Connect vehicle to B.U.D.S. Refer to COMMU-
subsection. NICATION TOOLS AND B.U.D.S. SOFTWARE
2. Select Monitoring page. subsection: _
3_ Se|eC.[ WPM tab 2. Select Activation page.
3. Select WPM tab.
Tu» I tau Wow»: I MDOI I I-0| I won |
mining“
i-ma I-o-Iva Int-nd
I-no.--Q vi-ulwni 81-}-‘BI
vntrvté
is-'-‘7-1-I-"'-"f‘.'=*-l'.1"l__-l-J"“*‘1 * 7 7 f.
irnr2010-038-05El_a
TYPICAL
Step 7: Select monitoring
Step 2: Select WPM
4. Press windshield adjustment switch on vehicle.

rn1r20‘l1-O87 733
Section 07 CHASSIS
yum. j use I mum; Ar:-new I Fol; I new I vamn I 5-um I Muww nmcoi | Pu; I Haw; '
AA.'|‘i1 ~=
Wu-am: Lb
\Vrr.l'|d.l Evin
Pat film 4.‘!-

l
‘
l Wltlldd DM1
Put hum m I
1
Pnrfl Dido FREE I Pn Ba FREE I
El 1
'F("v Tm-.,=2 tr; Joli} is-an om-i rm LE1]

ri'ni2010-O38-060_a rmr201 U-03B-O60__b
TYPICAL TYPICAL
Step 7 : Activation page 7. Windshield Up and Down button
Step 2: WPM folder
7. Verify if windshield motor works to lower wind-
4. Press Windshield Up button. shield.
v-“Ta. I .;.iT=-Ta I w-ma 1==~Ior~ I rm I mu, I
lf windshield motor does not work:
cw...“ — Check input voltage at motor (PIN-2), refer to
the W/R/NG DIAGRAM
I'l"\¢l4"lUDt|III 1
— Check ground circuit continuity at motor (PIN-
F;rf\F|3l\ Eli
1l, refer to the WIRING DIAGRAM.
. 1-. Bren ms: l
previous tests:
— Test motor operation by connecting it directly to
the battery posts.
- If motor works properly, test module, refer to
W/NDSH/ELD MODULE (WPM) in this sub-
7:-in jnnr} vcm" Q“--4 I7 7’
section.
imiZD1 O-O38-U50_b ‘ If motor does not work properly, replace
TYPICAL windshield base with WPl\/I module and
7. Windshield Up and Down button windshield motor as an assembly.
5. Verify if windshield motor works to raise wind- Do not power motor directly with the
shield. battery for a long period. Apply voltage quickly
If windshield motor does not work: to ensure that the motor will not overheat at
— Check input voltage at motor (PIN-1), refer to the end of its stroke.
the W/R/NG DIAGRAM
— Check ground circuit continuity at motor (PIN- Windshield Motor Removal
2), refer to the WIRING DIAGRAM 1. Remove windshield and windshield support
— Check connector and terminal condition. together. Refer to W/NDSH/ELD SUPPORTin
this subsection.
6. Press Windshield Down button.
2. Remove front fascia. Refer to FRONTFASC/A
in this subsection.
3. Remove retaining screws of upper wind deflec-
tors.
4. Remove upper wind deflectors from vehicle.
734 rmr2011-D87
Section 07 CHASSIS
7. Remove console panel by lifting it toward front.

8. Remove retaining screws from WPM module.
\
rmrZ010-038-O49,_a
7. Upper wind deflector

2. Retaining screws
5. Remove lower retaining screws from console

panel rrnr2U1G03B—052_a
1. WPM module
2. Retaining screws
,,
9. Slightly lift WPM module upwards.

10. Disconnect WPM module connector.
rmr201 0-038—050_a
1. Console panel
2. Lower retaining screws
6. Remove upper retaining screws from console

panel rmr201!)-D35-053_a
11. Disconnect windshield motor wires.

12. Remove windshield base (WPM module) from
vehicle.
13. Remove both side arms as follows:
13.1 Remove retaining nut and washer.
13.2 Remove retaining bolt and washer.
13.3 Remove sleeve.
13.4 Remove side arm.
rmr201 O-03 8-O51 _a
rmr2011-087 735
Section 07 CHASSIS
D0 not remove windshield motor WINDSHIELD MODULE (WPM)

from windshield base. Both are calibrated at
the factory. If windshield motor needs to be NOTE: WPM module has 2 functions, it controls
changed, replace windshield base with WPM windshield and parking brake. The WPM module
module and windshield motor as an assembly. is integrated into the windshield base.
Windshield Motor Installation

1'"
' >-.
cedure. However, pay attention to the following. *1:
Torque WPM module retaining screws to 4.5 Nvm
1140 lbf'in) as per the following sequence.
i f -S5-1
E
\._ _" g r_
‘_ _-~
_._- 1: '3 ' T“ -:-'i'
\_
E‘
~ I
_._
i —-_ r
e.=... 1-r_-_.
_i ’
=
Vi
.
-_ / .‘4I O,
5 7-» 7‘E§"EJ '4 rmr201EH)3&05B
WPM MODULE AND WINDSHIELD BASE
i- ' . .1 -Ml‘ L“ WPM Module CAN Wire Test
E
-tt»i-1.1...
‘Q’
_*
5.. r
0
IE.
Es .
1. Check WPM module power and ground cir-
cuits. refer to W/NDSH/ELD W/Ff/NG D/A-
GRAM in this subsection.
868) YO Q.
rm|201 1-087-0lJ3_a
TIGHTENING SEQUENCE 3. Measure resistance as per the following table.

Torque console panel retaining screws to specifi- WPM MODULE CAN WIRE TEST
cation as per the following sequence. TEST PROBES OHMS (S2)
CONSOLE PANEL RETAINING SCREWS TORQUE
WPM module DLC (Diagnostic
Link Connector) Close to
Upper retaining screws 2.5 N'm (22 lbfIin) pin 6 (CAN HI) 0.2 Q
connector pin 1
Lower retaining screws 3.0 N'm (27 lbfvin)
WPM module DLC (Diagnostic
Link Connector) Close to
pin 8 (CAN LO) 0.2 Q
connector pin 2
NOTE: The DLC (Diagnostic Link Connector) is lo-
cated underneath the right side service panel.
If the CAN wire verification test fails, repair related
circuit.
If the WPM module power, ground and CAN veri-
fication tests are all pass and the WPM module is
inoperative, replace the WPM module.
WPM Module Signal Circuit Continuity
Test
’rmr201 1-O87-002,3
WPM module. Refer to WPM MODULE HE-
TIGHTENING SEQUENCE
/l//Ol44L in this subsection.
Torque upper wind deflector retaining screws to 2. Disconnect WPM module connector.
4.5 N'm (40 lbf'in).
736 rmr2D11-087
Section 07 CHASSIS
Do not remove windshield motor

from windshield base. Both are calibrated
at the factory. If WPM module needs to be
changed, replace windshield base with WPM
module and windshield motor as an assembly.
rmr20‘l0-O3B—OS3_a
3. Disconnect LH multi-switch (MSL) connector.

Refer to LIGHTS} GAUGE ANDACCESSOR/E5
subsecflon.
868) to Q.
MSL switch connector
pin 2 (WH/BK)
Close to 0 Q
pin 8 (WH/BK)

MSL switch connector
pin 3 (WH/BE)
A Close to O Q
pin 6 lWH/BE)
lf results are not as per the previous tables:

- Test MSL switch, refer to L/GHTS GAUGE
AND ACCESSORIES.
— Repair open circuit in wiring.
previous operations:
— Check input voltage at WPM module (PIN-5),
refer to the W/R//VG DIAGRAM
- Check ground circuit continuity at WPM module
(PIN-7), refer to the W/R/NG DIAGRAM
If the fault is still not found:
— Replace WPM module.
WPM Module Replacement
To replace WPM module, refer to W/NDSH/ELD
MOTOR in this subsection.
rmr201 1 -O87 737
7
Section 07 CHASSIS
Subsection 07 (FRAME)
FRAME
24 N-m
(17 lbf-ft)
w__D._ . I ,
/@_5q»
15 N-m (1%? /
(133 |bf'il'I)
¢ 9’ _. _. " (\§' / NE
./I
T
firsIQ‘5 A
if/:~ ,_
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g
lg;\\
24 N-m
(17 lbf-ft)
1 Tl 4%
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~ C‘ 6 I 5";
\\\-
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. \./~§q; _ .
_
/ #9
/1 ' ' °\ 0
_ l= ;
\r2' at (133 lbf-in)
=\ (6; ma) 9"j‘e

\
\
is
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,t
15 N-m
f
(133 lbf-in)
IE3!

rrm1D1H'J8&001_a
rmr2011-088 739
Section 07 CHASSIS
GENERAL - ~ /’£.‘i>"‘i"'i““* '* I 1';//1

W *’ ~l3
~ iiitl i ,) .1
tfiia _ ;.‘t';:;¥
ues and service products as in the exploded view. .(» _,_
.\ "l.
L:Q
fer to SELF-LOCK//VG FASTENERS and LOCTITE
';‘”"“"“ .- ' __._3R fir»/--"
‘ /;/‘vi‘\‘ l t?'I?§?’
>7 _ g _, ‘y “—;..- _m_;- .,
complete procedure.
lull - _ ~ @i “ gt”) 1
g%
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A WARNING :1;
iv
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‘ .' '. 7 a 35”’
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J
r§~_,_
1
3
rrnr2010-O39-003_a
til): .
Locking devices when removed (e.g.: locking l. Cut locking ties
2. LH lateral frame support
be replaced. Remove the top screw on the oil cooler air duct.
Remove the two mounting screws on the voltage
NOTICE Hoses, cables or locking ties re- regulator.
moved during a procedure must be reinstalled Remove the two front mounting screws on the LH
as per factory standards. lateral support.
PROCEDURES "‘ ' t " -;-I WA _'_ _ :1 I,‘
; lg? . ‘l
LATERAL S U PPORTS
at1irtlli\.’"’
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LH Lateral Support Removal
Remove the following LH body panels:
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fi g
I
I.
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- Q,-* __,.._._._..._‘ <2’
_ _ /,- _V
rmr2010-03EHJ04_a
7. Oil cooler air duct upper screw
2. Voltage regulator screw (the second screw is not shown)
3. Front mounting screws
Remove screws securing the top of the lateral

panel support.
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ra >3’5l§“**t\~ ..¢ \ /it/-

rrnr20ID039002_a
1. Top side panel
2. Front panel
3. Rear side panel
T“
"1* ‘Tr’'»--
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I f __ "~#_.
1* ‘W £-
4. Middle side panel

5. Bottom rear side panel ~r1 _‘so-4
it-»~'t>»1'~_~ is ‘ Vi__ y
Cut locking ties securing wires to the lateral frame 5"‘
‘P 1x‘_
‘Z
'2/C"
-5 ~‘ J\“‘l'- “
suppon. .;~ L » n,‘;g¢—~s*1]

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/!‘....‘..,
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7. Lateral panel support

Remove top mounting nut on the ignition coil

bracket.
740
rmr2011-088
Section O7 CHASSIS
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rmr201 D039-UO9_a
4
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1. Top nut on ignition coil bracket

2. Ignition coil 1. Top side panel
2. Front panel
3. Rear side panel
Remove bolt and nut securing lateral support to 4. Mddl
I e SI‘de panel
fuel tank. 5. Bottom rear side panel
Cut locking ties securing the engine coolant tank

and the seat latch cable, to the RH lateral frame
support.
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1. Retaining bolt
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1.
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‘ 1"‘ _. \\\ ,~,¢"'E§’-‘T-T»

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2. Fuel tank rrnr2010—039-D1D_a
1. Cut these locking ties
Remove the two rear mounting screws.
Remove the two front mounting screws.
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1. Rear mounting screws
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it'll
rmr2D10-D35-01\_a
Remove the LH lateral support. 1. Front mounting bolts
RH Lateral Support Removal Remove screws securing the top of the lateral
Remove the following RH body panels: panel support.
rmr201 1-088 741

Section 07 CHASSIS
I
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1. Cut this locking tie
2. Locking nut
-,_ 'T_',.- \\\.— t---" In r .
‘ ‘K 1
4-4:
aE:‘%::?&
1. Lateral panel support 3. Cable and in parking brake pulley

2. Retaining screws
Remove bolt retaining the top of coolant radiator. Remove bolt and nut securing lateral support to
fuel tank.
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rmr201 U-039-01 5_a
1. Coolant radiator
2. Upper retaining bolt 1. Retaining bolt
Disconnect parking brake motor connectors. Remove the two rear mounting screws on the Rl-l
lateral support.
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rmr201 H388-OD 23 rrnr201D-035-t!16_a
1. Parking brake motor connectors 1. Rear mounting bolts
Cut locking tie securing the reverse cable to lateral Lateral Support Installation
support.
Install lateral support, components, fasteners and
Unscrew locking nut retaining parking brake cable. panels in the reverse order of removal.
Remove the cable end from parking brake pulley.
FRAME
Frame Inspection
lnspect the frame and subassemblies for:
— Cracks
— Bends
742
rmr201 1 -088
Section 07 CHASSIS
— Twisting
— Buckling
— Paint condition
- Any other damages.
Repair or replace as required.
Arc Welding on Frame
A WARNING
Welding should be performed by a profes-
sional welder and limited to areas that are rmr2008-()35~013
not safety related.
NOTICE Make sure wires are completely iso-
Before any arc welding is carried out anywhere on lated from the frame. Apply a piece of electri-
the vehicle, disconnect the following: cal tape over each terminal if necessary.
— Battery (refer to CHARG/NG SYSTEM subsec- Fuel Tank Static Ground Removal
tion)
— Dynamic Power Steering (DPS) unit (refer to Remove the following RH body panels, refer to
STEER/NG /DPS) AND WHEELS subsection) BODYsubsection:
— Front chassis ground (see procedure below) - Top side panel
- Fuel tank grounding cable (see procedure be- — Rear panel.
low). Locate fuel tank static ground on the RH rear cor-
ner of the fuel tank.
This will protect the components
against damage caused by the high current
flowing in the frame during the welding. If
welding is to be carried out near plastic ma-
terials, it is recommended to either remove
the part from the area or to protect it with
aluminum foil to prevent damage.
A WARNING
If welding is to be carried out near the fuel
tank, the fuel tank should be removed.
Front Chassis Ground Removal
Remove LH upper side panel, referto BODYsub-
secfion.
Unscrew nut enough to remove torque, then un- rrnr200B-035-O14_a
screw ground post bolt. 1. Fuel tank grounding cable

2. Fuel tank mounting bolt
NOTE: Note position of wires and star washer for
reinstallation. While holding bolt, remove elastic nut.
NOTE: Note position of star washer for reinstalla-
'[lOl1.
NOTICE Make sure fuel tank grounding cable

is completely isolated from the frame. Apply a
piece of electrical tape over terminal if neces-
sary.
rmr201 l-O88
743
_ | 1 I 1 I M I M
Section 07 CHASSIS
Subsection O7 (FRAME)
Arc Welding Specifications

When arc welding, use the following specifica-
tlons:
- Amperage: 70 -110 A
— Voltage: 20 - 24 V
- Rod: E-7014 (3/32 in).
NOTE: Install the welder ground as close as pos-
sible to the area to be repaired.
Frame Care
Clean the frame with appropriate cleaners and
rinse thoroughly.
Touch up all areas where paint has been scratched
or chipped off.
Spray all bare metal parts of vehicle with metal
protector.
For frame welding, see ARC WELD/NG ON
FRAMEin this subsection.
744
rmr201 1 O88
Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM5/SE5))
SPYDER RT (SM5/SE5)
SPYDER RT
MODEL
SM5 | SE5
ENGINE
ROTAX® 991, 4-stroke, 60° V-tvvin,
Engine type Dual Over Head Camshaft IDOHC), liquid cooled
Number of cylinders 2
Number of valves 8
Bore 97 mm (3.82 in)
Stroke 67.5 mm (2.66 in)
Displacement 998 cm3 (60.9 in3)
Compression ratio 12.221
Type Dry sump with separate oil reservoir and oil cooler
Oil filter (engine and BRP Flotax paper type, replaceable
transmission)
Engine oil Minimum 350 kPa (51 PSI) @ 5000 RPM / 80°C (l76°F) oil temperature
pressure
Capacity
(oil change 3.9 L (4.1 qt (U.S. liq.)) 4.2L (4.4 qt [U.S. liq.))
with engine
Lubrication filter)
Capacity
Engine oil
(oil change
with engine — 4.3L (4.5 qt (U.S. liq.))
and HCM
filters)
XPS synthetic blend oil (summer grade) [P/N Z93 600 121) or a
Recommended 5W40 motorcycle oil (semi-synthetic (minimum) or synthetic) meeting
the requirements for API service SL, SJ, SH or SG classification
Exhaust system 2 into 1 with catalytic converter
Air filter Paper element
Intake valve opening 20° BTDC @ 1 mm (.04in)
Intake valve closing 40° ABDC @ 1 mm (.04in)
Exhaust valve opening 45° BBDC @ 1 mm (.04 in)
Exhaust valve closing 5° ATDC @ 1mm (.04 in)
Intake 0.11 mm to 0.l8mm (.0043 in to .0071 in)
Valve clearance
Exhaust 0.22 mm to 0.29 mm (.0087 in to .0li4in)
New 5.961 mm to 5.975 mm (.2347 in to .2352inl
Intake
Sen/ice limit 5.950 mm (.2343 in)
Valve stem diameter
New 5.946 mm to 5.960 mm (.2341 in to .2346 in)
Exhaust
Service limit 5.935 mm (.2337 in)
Intake and New 0.005 mm (.0002 in)
Valve out of round exhaust 0.06 mm (.0024in)
Service limit
New 6.006 mm to B.0lBmm (.2365 in to .2369in)
Valve guide diameter 6.050 mm (.2382 in)
Service limit
rmr2010-040 745
SPYD ER RT
MODEL
SM5 | see
ENGINE (cont'd)
I New 1.00 mm to 1.40 mm (.0394in to .0551 in)
Intake _ _ ,
Sen/ice limit 1.60 mm (.063 in)
Valve seat contact width
Exhaust _ _ _
New 33.459 mm to 33.475rnm (13173 in to l.3l79in)
Valve lifter bucket diameter _ _ _
Service limit 33.440 mm (13165 in)
Valve lifter bucket radial clearance Service limit 0.08 mm (.0031 in)
New 39.24 mm (1.5449 in)
lnnerspring _ __
Valve springs free length
New 41.97 mm (1.6524inl
D te '
U Ispnng Service limit 40.50 mm (l.5945in)
New 96.940 mm to 96.950 mm (3.8165 in to 3.8169 in)
S‘ A
me I / Service limit 96.920 mm (38157 in)
Piston measurement
New 96.950 mm to 96.960 mm (38169 in to 3.8173 in)
Size 2 / B _ _ ,
Piston/cylinder clearance _ __
1st Upper compression ring, bsection
Piston ring type 2'") Lower compression ring, taper-face
3rd
Oil scraper ring
All New 0.15 mm to 0.35 mm (.0059 in to .0138 Ill)
Fl" d
mg en gap All Service limit I mm (.0394in)
Upper
compression Service limit 0.120 mm (.0047 in)
ring
Ring/piston groove clearance Lower
compression Service limit 0.120 mm (.0047 in)
ring
Oil scraper ring Service limit 0.100 mm (.0039 in)
Size 1 /A New 97.000 mm to 97.012 mm (36189 in to 3.8194 in)
Cylinder bore
Size 2 / B New 97.012 mm to 97.025 mm (3.8194 in to 3.8199 in)
Camshaft bearing journal _ ,,
Camshaft bearing journal bore _ _ _
Camshaft radial clearance Service limit 0.060 mm (.0024 in)
Crankshaft deflection MAG 5'"ii B Service limit 0.070 mm (.0028 in)
Clutch side Service limit 0.040 mm (.0016 in)
New 41.979 mm to 42.010mm (16527 in to 1.6539 in)
Crankshaft pin diameter . _ _ _
Service limit 41.960 mm (1.652 in)
Connecting rod big end diameter
(with plain bearings) Service limit 42.080 mm (1.6567ii1l
745
Subsection O1 (SPYDER RT (SM5/SE5))
SPYDER RT
MODEL
SM5 I see
ENGINE (cont'd)
New 0.020 mm to 0.045 mm (.0008 in to .0018 inl
Connecting rod big end radial play 0.070 mm (.0028 in)
Service limit
New 22.010mm to 22.020 mm (.8665 in to .8669 in)
Connecting rod small end diameter
Service limit 22.030 mm (.8673 ifll
Piston pin diameter 21.990 mm (.8657 in)
Service limit
CLUTCH
te Centrifugal clutch +
Wet clutch, multi~pla ' wet multi-plate clutch,
Type hydraulic operation automatically controlled by
(pneumatic assist) the TCl\/l
Flecommended Brake fluid 001 4
Clutch fluid 60 ml (2 U5. OZ) Use engine oil for lubrication
Capacity
Clutch spring free length Service limit 58.00 mm (2.283 inl
Clutch plate assembly
(friction and steel driven plates] Service limit 43.00mm (1.693in) 41.00mm (1.614in)
thickness
Friction and steel driven plate warpage Sen/ice limit 0.15rnm (.0059in)
Engagement — 2000 1» 200 HPl\/l
Centrifugal clutch speed
Stall — 3200 r 200 HPIVI
GEARBOX
Sequential manual 5-speed Sequential electronic 5-speed
Type (SM5) with reverse (SE5) with reverse
Primary reduction gear ratio 60/31
1st 32/14
2nd 29/17
3rd 26/19
Gear ratio 4m 26/23
5th 24/25
Reverse 36/14
Shift fork claw thickness Service limit 3.90 mm (.1535 in)
Width of shift fork engagement groove Service limit 4.50 mm (.1772in)
15!’ 2|'1Cl and 3fCl Sen/ice limit 29.035 mm (1.143 in)
4111 Service limit 29.125 mm (1.1467in]
Free pinion bore diameter 5111 26.025 mm (1.0246 inl
Service limit
Reverse Service limit 40.040 mm (15764 in)
MAG side 34.975 mm (1.377 inl
Free pinion Service limit 24.970 mm (.9831 in)
Main shaft journal diameter bearing
Clutch side 19.970 mm (.7862 in)
rmr20l0-040 747
Section O8 TECHNICAL SPECIFICATIONS
SPYDER RT
MODEL
SM5 | ses
ee/ineox (C0n’['d)
MAG side Service limit 19.970 mm (.7862 in)
Free pinion
bearing 4", Service limit 29.030 mm (1 .1429 in)
Clutch shaft journal diameter
Free pinion
bearing 5th Sen/ice limit 21.970 mm (.865 in)
Clutch side Sen/ice limit 29.965 mm (1.1797ln)
COOLING SYSTEM
Type Liquid cooled, single radiator with cooling fan
Ethyl glycol/water mix (50% coolant, 50% water).
Type Use premixed coolant sold by BRP (P/N 219 700 362) or
Coolant
coolant specifically designed for aluminum engines
Capacity 3.2 L (3.4 qt (U.S. liq.))
Thermostat Opening temperature 75°C (167°F)
Radiator fan 102°C (216°F)
Radiator cap opening pressure 90 kPa (13 PSI)
ELECTRICAL SYSTEM
Magneto generator output 650 W @ 6000 RPM
Ignition system type Electronic ignition with dual output coil
Ignition timing Electronically controlled, not adjustable
Quantity 2
2010 NGK DCPHQE
(apply heat-sink paste P12 (P/N 420 897 186) on spark plug thread)
Type
Spark plug NGK DCPR8E
2011
(apply heat-sink paste P12 (P/N 420 897 186) on spark plug thread)
DCPRBE 0.8 mm - 0.9mm (.031 in - .035 in)
e an DCPRQE 0.7 mm - 0.8 mm (.028in ~ .031 in)
Engine RPM limiter setting Fon/va rd 10 000 HPM
Type Maintenance free
Model Yuasa YTX24HL-BS
Battery
Voltage 12V
Nominal rating 21A'h
Headlight Halogen, 2 x 65 W (type: H9).
CE models: halogen, 4 x 65 W (type: H9)
Fog light (Spyder FlT-S/LTD) Halogen, 2 x 35 W
Taillight/brake light LED, 3.1 W total
Front LEO, 4.5 W each side
Turn signal lights
Rear 2x21W
Position lights 2x5W
License plate light 5W
Backup light 2x21W
Day light (Spyder FlT—S/LTD) 0.5 W
Front storage compartment light (Spyder HT-S/LTD) 0.2 W
748 rmr2010 O40

srvnen at
MODEL
srvrs ( srzs
ELECTRICAL SYSTEM (0ont'dl
Accessories 40A
TCM valves — | 20A
B0 A (model year 2010),
Rectifier spare (model year 2011)
Fuses Main fuse 40A
(Under S981) Dynamic Power Steering (DPS) 40A
TDOTOI’
VSS pump 40A
Headlights 30A
VSS valves 25A
Lights: tail, position,
plate and day. 15A
Vbat: cluster, VlM and DLC
Vbat control: main relays.
Vkey: SAS, YRS. VCM. ECM. 10A
D.E.S.S., PRS and MSR
Vbat: main relay.
Vrelayed: WPM, CL, F6, 25A
CTG, PBS pilot light, TCM and
DPS
Vbat: cooling fan relay 15A
Vbat: hazard and brake light 10A
switch
Fuses Vb: d‘ X ,CB,6PS d
(under the sen/ice center behind iPOD)
at Ia ml M an 15A
the front storage compartment) Wat, backup actuator and
10A
trailer module
Vbat: horn, shedding relay.
Vrelayed: suspension relay, 20A
heated grips, HA and LED.
Pilot lights: CSS, FHS and FGS
Vbat: accessory plugs 10A
Vrelayed: ECM 5A
Vrelayed: injectors and ignition 15A
coils
Vrelayed: H0281 and 2, EVAP.
CAPS, fuel pump motor, CSV 15A
and pre-starting relay
FUEL SYSTEM
Multi-point Electronic Fuel injection (EFI)
T with ETC (Electronic Throttle Control),
Fuel delivery system Ype dual throttle body (51 mm) with an actuator
Operating pressure 330 kPa (48 PSI)
Fuel pump Type Electrical module in fuel tank
Idle speed 1400 RPM 1 100 (not adjustable)
rmr2010-040 749
SPYDER RT
MODEL
I srvrs | see
FUEL SYSTEM (cont'd)
MINIMUM OCTANE RATING
Type REGULAR unleaded gasoline
Inside North
America 87 (R+M)/2
0°ta"e ‘mg Outside North 92 RON
Fuel
America
OCTANE RATING (OPTIMUM PERFORMANCE)
Type PREMIUM unleaded gasoline
Inside North
America 91 (R+M)/2
0 ' .
mane mung Outside North
America 95 RON
Fuel tank capacity 25L (6.6 U.S. gal.)
DRIVE SYSTEM
Type Drive belt
Final drive
Ratio 28/79
Material Carbon reinforced
Drive belt
Tension (with rear wheel lifted) 450N1150N
Final drive ratio 2.811
STEERING
Turning radius 4.73 m (15.5 ft)
Total toe-in (vehicle on ground) -10 mm 1 0.5 mm (-.394 in 1 .02 in)
Camber angle 0° 1 0.5°
Tie-rod maximum length unengaged threads 12mm (.4724 in) maximum
Tie-rod maximum length 620mm (24.41 in)
SUSPENSION
FRONT
Suspension type Double suspension arm with anti-roll bar
Suspension travel 151 mm (5.9 in)
Shock absorber 911/ 2

Type Oil damper
Spring free length 250.5 mm 1 3mm (9.9 in 1.1 in)
Spring preload adjustment 5 position cam adjustment
HEAR
Suspension type Air pressure, swing arm with single shock
Spyder RT/audio and
convenience/techno package Adjustable air pressure: 69 kPa to 689 kPa (10 PSI to 100 PSI)
Preload adjustment
Air Controlled Suspension (ACS),
Spyder HIS/LTD compressor-controlled air suspension with 5 customized positions
Suspension travel 145 mm (5.7 in)
O 1
Shock absorber “I r
Type Oil damper
Spring free length 303.5 mm 1 3mm (11.9 in 1.1 in)
Spring color code Part number indicated on spring, no color code available
750 rmr2010»040
Subsection O1 (SPYDER RT (SM5/SE5))
SPYDER RT
MODEL
SM5 1 see
BRAKES
Foot-actuated. Fully integrated hydraulic 3-wheel braking
Type system with ABS and EBD
Front brake Dual discs of 250mm (9.8in) with 4 piston calipers
Rear brake Single disc of 250mm (9.8 in) with 1 piston caliper
Capacity 530 ml (17.9 U.S. oz)
Brake fluid
Type DOT 4
Parking brake Mechanical, electrically actuated to the rear caliper
Front 4 pistons caliper
Caliper
Rear Single piston. Sliding pins caliper
Front Organic
Brake pad material
Rear Organic
Minimum brake pad thickness 1 mm (.04in)
Minimum brake disc thickness Front/rear 5.33 mm (.21 in)
Maximum brake disc warpage 0.12 mm (.005 in)
TIRES AND WHEELS
T/RES
Type (use BRP recommended Front MC 165/65R14 47H (special motorcycle type)
tires) Rear MC 225/50R15 76H (special motorcycle type)
Minimum: 89 kPa (13PS|) (0.89 bar).
Front Maximum: 117 kPa (17 PSI) (1.17 bar)
Pressure
Minimum: 179 kPa (26 PSI) (1.79 bar).
Rear
Maximum: 207 kPa (30 PSI) (2.07 bar)
Front 2.5 mm (3/32 in)
Minimum tire thread depth
Rear 4.0 mm (5/32 in)
WHEELS
Front 14in><5in
Size
Rear 15inx7in
Front wheel nuts torque 105 N'm (77 lbf°ft)
Rear drive axle nut torque 130 N'm (96 lbf¢ft)
DIMENSION
Overall length 2 667mm (105in)
Overall width 1 572 mm (62 in)
Windshield in upper position 1 600mm (63 in)
Overall height
Windshield in lower position 1 473 mm (58 in)
Seat height 772 mm (30.4 in)
Wheel base 1 708 mm (67 in)
Front wheel track 1 384 mm (54.5in)
Ground clearance (front and under engine) 115mm (4.5in)
rmr2010-040
SPYDER RT
MODEL
M5 | SE5
WEIGHT AND LOADING CAPACITY
Dry weight 421 kg (928 lb)
Capacity 55L (14.5 U.S. gal.)
Front stora e com artment _
g p Maximum load 16 kg (35 lb)
C .
1.8L (.5 U.S. gal.)
Glove box apaclty
Maximum load 2kg (4lb)
Capacity 23.5 L (6.2 U.S. gal.)
Side storage compartment _
Maximum load 7kg (15lb)
Capacity 40.5L (10.7 U.S. gal.)
Rear stora e com artment ,
Q p Maximum load 9kg (20lb]
Total vehicle load allowed (including operator, passenger, cargo
and added accessories) 240 kg (525 lb)
Gross vehicle weight rating (GVWR) ass kg (1 ,4e2 lb)
Maximum weight on trailer tongue 18kg (40Ib)
Maximum towed weight (trailer and cargo) 180 kg (400 lb)
752 rrnr2010-040
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-2863(9'8-32
TYPICAL PAGE
Section 02 CHASSIS Page heading

Subsection 01 (WHEELS AND WHEEL HUBSI (i indicates section
and subsection.
Subsection title 1) WHEELS AND WHEEL HUBS
Exploded view assists Drop represents a

HI-TEMP
you in identifying parts A) GREASE » service product
and their related NLGI-2 to be applied.
positions. 64'
NEW indicates that the

part must be replaced
*3 V with a new one.
\‘T
See /_
§
eQ3
PROCEDUFIE l / T
INSIDE I 1
, /,4\
\
s
Specific torque
Q applicable to this
installation.
1 05 N-m
.
(77 lbf ft) (—i— CAUTION: Pay attention
to torque specifications
Some of these are in
Ibfvin instead of lbf~ft.
Use appropriate
torque wrench.
Illustration number
for publishing process. 4' ><><><uiwo
Document number for fi rml'ZO'lD—DDO 55 (i Page number

publishing process.
VQVCEIR
VQV :
-2863(9'8-32
TYPICAL PAGE
Section 01 CHASSIS
Subsection O1 (WHEELS AND TIRES)
"little in bold indicates

category of information ———> GENERAL NOTICE Make sure lo place the jack under
fr ame and not under trailer shell. Severe dam-
to be carried out. During assembly/installation, use the tordue val- age will occur if the trailer is raised by its shell.
ues and service products as in me explO09L‘I vie-.-ii
Clean threads before applying a threadlocker. Re- P U sh arid pull
. the wheel from the UDDer edge to
Reference to a specific WSELF-LOCK/NG FA57'ENER$ and LOCTITE feel the play.
section or subsection. APPi£.i'CA.f'i'0Nat the beginning of this manual for If any Dlav I5 fell, replace wheel hub bearings. See
complete procedure B‘EAHING REPLACEMENT
C heck if the wheel turns freely II wheel is hard
A WARNING io turn. lubricate or replace wheel bearrngs.
must be strictly adhered to. Wheel Bearing Seal Inspection
Locking davices when removed (e.g.: locking C heck if the seal leaksexcessively or is damaged.
tabs. elastic 5IOp nuts. cotter pins. elc.l i-mist A shgnt lirm ol grease around the seal is normal.
be replaced with new ones.
A doing a lot cl grease under normal operation, |fl-
clicates a detective seal ihat needs to be renlaceo.
PROCEDURES
Indicates component Wheel Bearing Lubrication
procedures apply to. Z» WHEELS t. Install a jack under traitor lrarno.
Wheel Inspection NOTICE Make sure lo_ place the jack under
Check wheel for cracks, humus or other damages f ra me
and not under trailer shall . Severe dam-
Indicates specific Replace wheel as required age will occur if the trailer is raised by its shell.
procedure to be W) Wheel Removal 2. Remove ihe appropriate wheei See WHEEL
carried out. REMOVAL
‘I Park the vel'i=cle and trailer ori a firrn_ level arid
l'IO|'\'SIlpQQ|'\|' ground 3. Remove the protective cal?
Leave the trailer coupled to the V'EI'ltClE. aoolv 4 Remove and discard me cotter pin
parking brake and stop the engine 5. Remove the wheel hub nut and its washer
2. Loosen each wheel lug nuts 172 rum. Illustration always
3. Install a jack under trailer frarne, near the sus-
pension attacnmeiir point.
F?
.,1 ,.
\
,-- -- “-
(W follows te><t to which
it applies.
NOTICE Make Sure to place the jack under X {B _..__‘a.L ’d/_.\\
r
frame and not under trailer shell. Severe dam-
age will occur if the trailer is raised by its shell. TYPICAL
4. Remove wheel lug nuts indicates a general view
5. Remove the wheel from the trailer. which may not represent
Wheel Installation exact details.
1. Using a clean rag, clean the mounting surface t‘YPN1'»\l ( I
of ii-ie hub I Prtstr-.'f .i- i..,ei |
r\|1|ArA|r JMI
2. Install the wheel and all wheel lug nuIS
3. Tigl-ileri wheel lug nuts enough to secure tarn-
Wild‘ I’ JP iilif
$5 is.i .. I
poraritv the wheel in place. 6.Clean the deteriorated grease from the hear- Call-outs pertaining
4. Lower trarlar completely arid apply tho final ings and inside the hub to above illustration.
iorciie Tighten lug nuts to 105 N-m (77'lDflI1i 7. Check seal conchtion Reolace if necessarv.
8. Grease the bearing cavity wirn ni-temp bearing
WHEEL BEARINGS grease NLGI-2 or an equivalent
Wheel Bearing Inspection NOTICE Do not fill up more than 20% of the
Install a |acl< under trailer frame cavity between the bearings.
2
VQVCEIR
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The illustrations figuring in this parts catalog show typical construction of the different assemblies 2
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Les illustrations contenues dans ce catalogue indiquent la disposition des pieces les unes par rapt
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2010-2011 CanAm UNLOCKED Spyder RT-RTS-Service & Parts PDF

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Please note that some of the models indicated may need supplemental manuals which

Thank you for buying this product from Labanda22.

SAFETY NOTICE ............................................................... .. .................................... .. XII

INTRODUCTION ..................................................................................................... .. XIII

03 ELECTRONIC MANAGEMENT SYSTEMS

03 ELECTRONIC MANAGEMENT SYSTEMS (cont‘d)

O5 ELECTRICAL SYSTEM (COI'It'd)

05 ELECTRICAL SYSTEM (cont'd)

O5 ELECTRICAL SYSTEM (COnt'd)

A CAUTION Indicates a hazardous situation

imizoi 1-051 Xlll

_rmo2008-0O14)91_a 1. Engine Identification Number (E. LN.) location

7. EPA exhaust emission label located under seat

MANUAL INFORMATION parts used in a particular model vehicle. However,

Many of the procedures in this manual are inter-

A number of procedures throughout the book re-

This manual uses technical terms which may be

Section 06 ENGINE A Page

Loctite 243 Drop represents a

Bold face number

Document number for

Specific torque applicable to this installation.

Bold face number followingpart

4.8 8.8 9.8 10.9 12.9

FASTENER FASTENER GRADE/TORQUE

5'25 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade

FASTENER INFORMATION Threadlocker Application for

SELF-LOCKING FASTENERS lllll 555‘

1. Clean threads (bolt and hole) with solvent.

3. On retaining nut threads

1. Adjust screw to proper setting.

NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application

3. Apply a strip of proper strength Loctite on lead-

1. Proper strength Loctite

1. Clean inner housing diameter and outer gasket

XXII rmr201 1-051

ADAPTER HOSE BEARING PUSHER/REMOVER CLUTCH ASSEMBLY HOLDER

#3; Page: 186, 211, 624

Page: 186, 211

Page: 148 BELT TENSION METER Page: 207

Page: 554 Page: 257

BLIND HOLE BEARING PULLER SET CRANKSHAFT PLAIN BEARING TOOL

CRIMPING TOOL (KOSTAL)

ECM ADAPTER TOOL ENGINE LIFTING TOOL KOSTAL DIE

Page: 55, 173, 254, 351, 353, 359,

FUEL HOSE ADAPTER

ENGINE LEAK DOWN TEST KIT

Page: 84, 256-257

Page: 106 Page: 256, 268

PISTON CIRCLIP INSTALLER 991

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PITMAN ARM ..IlG

OIL SEAL INSTALLER

OIL SEAL INSTALLER

PITMAN ARM PUSHER SOCKET SPANNER TEST CAP

Page: 560 I‘?

Page: 464, 532

Page: 53, 394

~\K . Page: 37, 40

PULLER/LOCKING TOOL VALVE GUIDE REMOVER (6 MM)

SEAL PUSHER VALVE SPRING COMPRESSOR CUP

Page: 81 Page: 121

VALVE SPRING COMPRESSOR

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