2013

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SPYDER™ RS
SPYDER™ ST
SPYDER™ RT
 TABLE OF CONTENTS

SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIV
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIV
VEHICLE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XV
MANUAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XVI
FASTENER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XX

01 MAINTENANCE
01 – MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
02 – STORAGE PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CLUTCH SYSTEM (SM5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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

02 ENGINE
01 – ENGINE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
02 – AIR INTAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
RESONATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
AIR FILTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
03 – EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
EXHAUST SYSTEM INSTALLATION SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CATALYTIC CONVERTER FRONT GASKET REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
MUFFLER HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
HEAD PIPE (FRONT CYLINDER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
HEAD PIPE (REAR CYLINDER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
04 – LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

I
TABLE OF CONTENTS

02 ENGINE (cont’d)
04 – LUBRICATION SYSTEM (cont’d)
MAINTENANCE (cont’d)
ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
OIL PRESSURE SWITCH (OPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
OIL TANK STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
OIL HOSE CONNECTOR TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
OIL NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
OIL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
ENGINE OIL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
OIL DUCT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
OIL TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
05 – COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
ENGINE COOLANT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
COOLING SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
COOLANT TANK CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
COOLANT TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
COOLANT TEMPERATURE SENSOR (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
WATER PUMP HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
WATER PUMP IMPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
WATER PUMP SHAFT AND SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
06 – MAGNETO AND STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
MAGNETO COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
SPRAG CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
SPRAG CLUTCH GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
STARTER DRIVE GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
ELECTRIC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
07 – CYLINDER HEAD AND CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
CYLINDER LEAK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
BALANCE SHAFT DRIVE GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
CAMSHAFT TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

II
 TABLE OF CONTENTS

02 ENGINE (cont’d)
07 – CYLINDER HEAD AND CYLINDER (cont’d)
PROCEDURES (cont’d)
BALANCE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
VALVE LIFTER BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
PISTON RINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
08 – CRANKCASE AND CRANKSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
ENGINE REASSEMBLY SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
DRIVE GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
TIMING CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
CRANKSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
BALANCE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
09 – CLUTCH (SM5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
CLUTCH FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
CLUTCH OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
CLUTCH LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
MASTER-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
CLUTCH SOLENOID VALVE (CSV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
CHECK VALVE (CLUTCH SOLENOID VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
HYDRAULIC PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
CLUTCH DIAPHRAGM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
PRESSURE PLATE AND CLUTCH SPRINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
CLUTCH HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
CLUTCH DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
10 – CLUTCH (SE5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
HYDRAULIC PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
PRESSURE RETAINING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

III
TABLE OF CONTENTS

02 ENGINE (cont’d)
10 – CLUTCH (SE5) (cont’d)
PROCEDURES (cont’d)
PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
CLUTCH HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
CENTRIFUGAL CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
CLUTCH DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
11 – HYDRAULIC CONTROL MODULE (SE5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
SYSTEM DESCRIPTION (COMPONENTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
SYSTEM DESCRIPTION (PRINCIPLE OF OPERATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
HCM OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
HCM OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
SHIFT AND CLUTCH SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
OIL HOSE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
HCM OIL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
HYDRAULIC CONTROL MODULE (HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
INTERMEDIATE OIL PUMP GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
HYDRAULIC PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
12 – GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
REVERSE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
GEARBOX POSITION SENSOR (GBPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
REVERSE ACTUATOR (SM5 MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
SHIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

03 ELECTRONIC MANAGEMENT SYSTEMS

01 – OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
ENGINE MANAGEMENT SYSTEM (EMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
VEHICLE STABILITY SYSTEM (VSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
DYNAMIC POWER STEERING (DPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
ELECTRONIC SHIFT SYSTEM (SE5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
02 – CONTROLLER AREA NETWORK (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
03 – COMMUNICATION TOOLS AND B.U.D.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
MULTI-PURPOSE INTERFACE-2 (MPI-2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
B.U.D.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

IV
 TABLE OF CONTENTS

03 ELECTRONIC MANAGEMENT SYSTEMS (cont’d)

04 – DIAGNOSTIC AND FAULT CODES (RS SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
FAULT CODE DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
SPECIFIC FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
05 – DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
FAULT CODE DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
SPECIFIC FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

04 FUEL SYSTEM
01 – ELECTRONIC FUEL INJECTION (EFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
THROTTLE POSITION SENSOR RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
FUEL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
CAMSHAFT POSITION SENSOR (CAPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
AMBIENT AIR PRESSURE AND TEMPERATURE SENSOR (AAPTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
COOLANT TEMPERATURE SENSOR (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
HEATED OXYGEN SENSOR (HO2S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
KNOCK SENSOR (KS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
THROTTLE ACCELERATOR SENSOR (TAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
ELECTRIC THROTTLE ACTUATOR (ETA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
ENGINE CONTROL MODULE (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
02 – FUEL TANK AND FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
FUEL SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
FUEL SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
TROUBLESHOOTING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
DIAGNOSTIC FLOW CHART (FUEL PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
EVAP PURGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377

V
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05 ELECTRICAL SYSTEM
01 – POWER DISTRIBUTION AND GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
POWER DISTRIBUTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
POWER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
FUSES AND RELAYS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
LEFT FUSE BOX (LFB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
RIGHT FUSE BOX (RFB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
FUSE BOX PIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
GROUND CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
02 – WIRING HARNESS AND CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
CONNECTOR ABBREVIATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
DEUTSCH CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
MOLEX CONNECTOR (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
PACKARD CONNECTOR (TCM AND GAUGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
DELPHI CONNECTORS (DPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
AMP MULTILOCK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
AMP CONNECTOR (8-CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
DELPHI CONNECTOR (VCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
BATTERY CABLE TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
03 – IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
04 – CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
CHARGING SYSTEM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
VOLTAGE REGULATOR/ RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
05 – STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
TROUBLESHOOTING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
STARTING SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
ELECTRIC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
D2 DIODE (STARTER SOLENOID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
ENGINE STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425

VI
 TABLE OF CONTENTS

05 ELECTRICAL SYSTEM (cont’d)

05 – STARTING SYSTEM (cont’d)
PROCEDURES (cont’d)
START BUTTON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
PRE-STARTING RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
STARTER SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
06 – DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
PARTS REPLACEMENT GUIDELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
D.E.S.S. MODULE DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
D.E.S.S. MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
07 – LIGHTS, GAUGE AND ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
SYSTEM DESCRIPTION (LIGHTING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
MULTIFUNCTION GAUGE CLUSTER (RS BASE MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
MULTIFUNCTION GAUGE (RS-S MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
MULTIFUNCTION GAUGE (ST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
SYSTEM DESCRIPTION (MULTIFUNCTION GAUGE) (RT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
SYSTEM DESCRIPTION (REAR STORAGE COMPARTMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
SYSTEM DESCRIPTION (LEFT MULTIFUNCTION SWITCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
SYSTEM DESCRIPTION (CRUISE CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
SYSTEM DESCRIPTION (AUDIO AND COMMUNICATION SYSTEMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
MULTIFUNCTION GAUGE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
TURN SIGNAL LIGHT TROUBLESHOOTING TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
AUXILIARY LIGHTS (OPTION PACKAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
LICENSE PLATE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
TURN SIGNAL LIGHTS/HAZARD WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
TURN SIGNAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
HAZARD WARNING LIGHTS SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
TAILLIGHT/BRAKE LIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
POSITION LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
BACK UP LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
MULTIFUNCTION GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
ANALOG COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
ANALOG FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
LEFT MULTIFUNCTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
FRONT HEATED GRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
PASSENGER HEATED GRIP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
RADIO MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
PASSENGER RADIO CONTROL SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
AUXILIARY AUDIO IN JACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502

VII
TABLE OF CONTENTS

05 ELECTRICAL SYSTEM (cont’d)

07 – LIGHTS, GAUGE AND ACCESSORIES (cont’d)
PROCEDURES (cont’d)
REAR STORAGE COMPARTMENT SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
FRONT STORAGE COMPARTMENT LIGHT (RT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
HOOD ACTUATOR (RT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
PBS SWITCH (HOOD ACTUATOR FUNCTION) (RT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
FRONT STORAGE SWITCH (FSS) (RT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
CRUISE CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
CENTRAL PANEL SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
08 – ELECTRONIC SHIFT SYSTEM (SE5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
TROUBLESHOOTING WITH B.U.D.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
GEAR SHIFTING SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
REVERSE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
TRANSMISSION CONTROL MODULE (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514

06 DRIVE SYSTEM
01 – DRIVE BELT AND REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
REAR SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
FRONT SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
REAR TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
REAR WHEEL TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535

07 CHASSIS
01 – VEHICLE STABILITY SYSTEM (VSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
SYSTEM DESCRIPTION (FEATURES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
SYSTEM DESCRIPTION (COMPONENTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
TROUBLESHOOTING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
YAW RATE SENSOR (YRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
PILLION RIDER (PASSENGER) SWITCH (PRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
WHEEL SPEED SENSOR (VSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
VEHICLE CONTROL MODULE (VCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
02 – STEERING (DPS) AND FRONT WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
SYSTEM DESCRIPTION (FEATURES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
SYSTEM DESCRIPTION (COMPONENTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
SENSOR RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
STEERING ALIGNMENT VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
STEERING ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
SAS RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
TORQUE SENSOR RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567

VIII
 TABLE OF CONTENTS

07 CHASSIS (cont’d)
02 – STEERING (DPS) AND FRONT WHEELS (cont’d)
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
DPS STRATEGY ACCORDING TO FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
FAULT CODE C0051 AFTER DPS REPLACEMENT OR SAS RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
FAULT CODE P0551 FOLLOWING NEW DPS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
FRONT WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
FRONT TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
HANDLEBAR GRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
MULTIFUNCTION SWITCH (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
MULTIFUNCTION SWITCH (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
THROTTLE HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
STEERING COLUMN BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
STEERING ANGLE SENSOR (SAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
DPS UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
TIE-ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
WHEEL BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595
03 – FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
SPRING PRELOAD ADJUSTMENT (RS-S MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
SUSPENSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
AIR DEFLECTOR (UPPER ARM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
UPPER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
AIR DEFLECTOR (LOWER ARM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
PIVOT BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
LINK ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
04 – REAR SUSPENSION (RS AND ST SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
SWING ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
05 – REAR SUSPENSION (RT SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
ACS SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
TROUBLESHOOTING WITH B.U.D.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623

IX
TABLE OF CONTENTS

07 CHASSIS (cont’d)
05 – REAR SUSPENSION (RT SERIES) (cont’d)
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
ACS POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
ACS SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
ACS RELAY (R4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
ACS COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
ACS SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
ACS AIR SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
SWING ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
06 – BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
BRAKE SYSTEM PRESSURE VALIDATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
TROUBLESHOOTING GUIDELINES (PARKING BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
ENCODER WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661
FOOTREST RELEASE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662
BRAKE FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664
DUAL MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664
MASTER CYLINDER ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
PARKING BRAKE FRONT PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666
PARKING BRAKE CABLE TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668
PARKING BRAKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669
PARKING BRAKE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671
PARKING BRAKE MODULE (PBM) (ST MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673
WINDSHIELD AND PARKING BRAKE MODULE (WPM) (RT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673
PARKING BRAKE SWITCH (PBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
PARKING BRAKE LIGHT SWITCH (HBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
BRAKE LIGHT SWITCH (BLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676
LOW PRESSURE SWITCH (LPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
07 – BODY (RS AND ST SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
VEHICLE CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
MIDDLE SIDE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
UPPER SIDE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
CENTRAL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
FRONT FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
REAR FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706
REAR FENDER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
REAR BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709
REAR PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
UPPER TAIL COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711

X
 TABLE OF CONTENTS

07 CHASSIS (cont’d)
07 – BODY (RS AND ST SERIES) (cont’d)
PROCEDURES (cont’d)
LOWER TAIL COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
LOWER SIDE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
REAR SADDLEBAGS SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714
CONSOLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
UPPER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718
LOWER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719
SERVICE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720
FRONT FASCIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
STORAGE COMPARTMENT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
STORAGE COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722
STORAGE COMPARTMENT COVER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
BUMPER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724
SKID PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725
SEAT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725
BOTTOM PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726
OIL COOLER AIR DUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727
RADIATOR AIR DUCT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727
DRIVER FOOTPEG SUPPORT AND FOOTPEG (RS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727
PASSENGER FOOTPEG SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728
FOOTREST SUPPORT AND FOOTPEG (ST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729
08 – BODY (RT SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745
VEHICLE CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745
TROUBLESHOOTING GUIDELINES (WINDSHIELD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745
MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746
SERVICE COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746
FRONT FASCIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746
MIDDLE SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 747
TOP SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 748
REAR SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749
GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750
CENTRAL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751
BOTTOM FRONT SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752
BOTTOM REAR SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752
ACOUSTIC PANELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753
FRONT CARGO MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
FRONT STORAGE COMPARTMENT LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755
CONSOLE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 757
REAR CARGO MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758
FOOTREST SUPPORT AND FOOTREST REMOVAL (ALL RT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764
WINDSHIELD SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765
WINDSHIELD MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765
WINDSHIELD MODULE (WPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 769

XI
TABLE OF CONTENTS

07 CHASSIS (cont’d)
09 – FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 771
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773
FRONT FRAME (RS AND ST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773
LATERAL SUPPORTS (RS AND ST MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773
LATERAL SUPPORTS (RT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778

08 TECHNICAL SPECIFICATIONS
01 – SPYDER RS (SM5/SE5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 781
02 – SPYDER ST (SM5/SE5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 789
03 – SPYDER RT (SM5/SE5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 797

09 WIRING DIAGRAM
01 – WIRING DIAGRAM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
WIRING DIAGRAM LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
WIRING DIAGRAM CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806

XII
 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 2013 Can-Am™ roadsters followed, could result in severe damage to ve-
described in the list in the INTRODUCTION. hicle components or other property.
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
Products Inc. (BRP) products. Mechanical tech- Although the mere reading of such information
nicians should attend continuous training courses does not eliminate the hazard, your understand-
given by B.R.P.T.I. ing of the information will promote its correct
use. Always use common shop safety practice.
Please note that the instructions will apply only
if proper hand tools and special service tools are It is understood that this manual may be trans-
used. lated into another language. In the event of any
discrepancy, the English version shall prevail.
The content depicts parts and procedures appli-
cable to the particular product at time of writing. BRP disclaims liability for all damages and/or in-
SERVICE and WARRANTY BULLETINS may be juries resulting from the improper use of the con-
published to update the content of this manual. tents. We strongly recommend that any services
Make sure to read and understand them. Dealer be carried out and/or verified by a highly skilled
modifications that were carried out after manufac- professional mechanic.
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 product(s) other than those mentioned in this
document.
It 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:

WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.

CAUTION Indicates a hazardous situation

which, if not avoided, could result in minor or
moderate injury.

rmr2013-002 XIII
INTRODUCTION

INTRODUCTION
GENERAL INFORMATION
This Shop Manual covers the following BRP made 2013 Can-Am Roadsters.
YEAR MODEL COLOR MODEL NUMBER
SM5 A1DB, A1DC, A1DD, A1DE, A1DF
RS Magnesium
SE5 A2DB, A2DC, A2DD, A2DE
Alloy Orange B6DB, B6DE
SM5 Magnesium B6DC, B6DG
Neutron Green B6DD, B6DH
RS-S
Alloy Orange B1DE, B1DF, B1DH, B1DL, B1DM

SE5 Magnesium B1DB, B1DG, B1DN

Neutron Green B1DC, B1DD, B1DJ0, B1DK

2013
SM5 B7DB, B7DC, B7DD, B7DE
ST Magnesium
SE5 B8DB, B8DC
Magnesium C1DD, C1DG
SM5
Circuit Yellow C1DB, C1DC
ST-S
Magnesium C2DE, C2DG
SE5
Circuit Yellow C2DB, C2DC, C2DD, C2DH

Black Current D4DA D4DB, D4DH

ST Limited SE5
White Pearl D4DC, D4DD, D4DF, D4DG
Magnesium A3DB, A3DD, A3DE, A3DG
SM5
Quantum Blue A3DC, A3DF
RT
Magnesium B2DB, B2DE, B2DG
SE5
Quantum Blue B2DC, B2DD, B2DF
Circuit Yellow B5DB, B5DG
Magnesium B5DC, B5DH
SM5
Quantum Blue B5DD, B5DJ
2013 Viper Red B5DK, B5DL
RT-S
Circuit Yellow A4DB, A4DC, A4DD, A4DL, A4DM
Magnesium A4DE, A4DF, A4DN
SE5
Quantum Blue A4DG, A4DK, A4DP
Viper Red A4DR, A4DS, A4DT
Black Current B9DE, B9DF, B9DK, B9DL, B9DM
RT Limited SE5 Lava Bronze B9DB, B9DG, B9DJ, B9DP, B9DR
White Pearl B9DC, B9DD, B9DN

XIV rmr2013-002
 INTRODUCTION

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.

VEHICLE INFORMATION
VEHICLE IDENTIFICATION
NUMBER (V.I.N.)

rmo2008-001-111_a
1 2 1. Engine Identification Number (EIN) location
rmo2008-001-091_a

TYPICAL — VEHICLE SERIAL NUMBER LABEL

1. VIN (Vehicle Identification Number) EPA COMPLIANCE LABEL
2. Model number

rmo2008-001-094

rmo2013-003-037_a

TYPICAL
LOCATION OF VIN
1. Swing arm (VIN label)
2. Lower frame (VIN stamped on left side)

ENGINE IDENTIFICATION
NUMBER (EIN)
The engine identification number is located near
the left rear engine mount, under exhaust pipe.

rmo2008-001-044_b

TYPICAL
1. EPA exhaust emission label located under seat

rmr2013-002 XV
INTRODUCTION

MANUAL INFORMATION parts used in a particular model vehicle. However,

they represent parts which have the same or a
MANUAL 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.

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).

rmr2008-002-004_a

TYPICAL
1. Left
2. Right

This manual uses technical terms which may be

different from the ones of the PARTS CATALOGS.
When ordering parts always refer to the specific
model PARTS 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
XVI rmr2013-002
 INTRODUCTION

TYPICAL PAGE

Section 06 ENGINE Page heading

Subsection 01 (MAGNETO) indicates section
and subsection.

Subsection title MAGNETO

Indicates applicable Models
models.

Loctite 243 Drop represents a

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

Bold face number

1 is used to identify
a part referred to
the text.
NEW indicates that the
part must be replaced NEW
with a new one.

5 N•m
(44 lbf•in)

Illustration number
for publishing process. XXX0000

Document number for 55 Page number

publishing process.
mmr2008-001

NOTICE Pay attention to torque specifications.

Some of these are in lbf in instead of lbf ft.
Use appropriate torque wrench.
Typical_iso_2008_en

rmr2013-002 XVII
INTRODUCTION

TYPICAL PAGE

Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEM)
Tittle in bold
indicates category
of information to be GENERAL
carried out. NOTE: The following procedures can be done
without removing the engine.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Reference to a Clean threads before applying a threadlocker. Re-
specific section fer to the SELF-LOCKING FASTENERS and LOC-
or subsection. TITE APPLICATION sections at the beginning of
this manual for complete procedure. “TYPICAL”
WARNING indicates a general
Torque wrench tightening specifications
view which may
must be strictly adhered to. not represent exact
Locking devices (e.g.: locking tabs, elastic 1 details.
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones. TYPICAL
1. Starting pulley

PROCEDURES NOTE: To remove starting pulley bolts, hold mag- Call-outs pertaining
Indicates component neto flywheel with a socket as shown. to above illustration.
procedures apply to. MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
Indicates specific a clean cloth. Illustration always
procedure to be Magneto Flywheel Removal follows text to which
carried out. Remove muffler, refer to the EXHAUST SYSTEM it applies.
section.
Remove acoustic panel.
Remove rewind starter. mmr2007-016-002

Remove starting pulley no. 2. TYPICAL Italic bold face type-

Models
setting indicates a
Remove the connecting flange retaining the
procedure applicable
rewind starter to the engine housing. to a specific
model(s).

mmr2008-001 57

Bold face number following part

name refers to exploded view
at beginning of subsection.
typical_txt_2008_en

XVIII rmr2013-002
 INTRODUCTION

TIGHTENING TORQUES
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When
a torque is not specified, refer to the following table.

WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices when removed (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter
pins, etc.) must be replaced.

In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following proce-
dure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
3. Tighten fastener to the recommended torque value.
NOTICE Be sure to use the recommended tightening torque for the specified fastener used.
NOTE: When possible, always apply torque on the nut.
NOTE: Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are
used to secure a part (eg. a cylinder head). Some parts must be torqued according to a specific sequence
and torque pattern as detailed in the installation procedure.

4.8 8.8 9.8 10.9 12.9

Property
class and
head 4.8 8.8 9.8 10.9 12.9
markings
4.8 8.8 9.8 10.9 12.9 12.9

5 8 10 12
Property
class and

12
10

nut
5

markings
A00A8BS

FASTENER FASTENER GRADE/TORQUE

SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5 – 2 N•m 2.5 – 3 N•m 3.5 – 4 N•m 4 – 5 N•m
M4
(13 – 18 lbf•in) (22 – 27 lbf•in) (31 – 35 lbf•ft) (35 – 44 lbf•ft)
3 – 3.5 N•m 4.5 – 5.5 N•m 7 – 8.5 N•m 8 – 10 N•m
M5
(27 – 31 lbf•ft) (40 – 47 lbf•ft) (62 – 75 lbf•ft) (71 – 89 lbf•ft)
6.5 – 8.5 N•m 8 – 12 N•m 10.5 – 15 N•m
M6 16 N•m (142 lbf•in)
(58 – 75 lbf•ft) (71 – 106 lbf•ft) (93 – 133 lbf•in)
M8 15 N•m (133 lbf•in) 25 N•m (18 lbf•ft) 32 N•m (24 lbf•ft) 40 N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 73 N•m (54 lbf•ft)
M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 128 N•m (94 lbf•ft)
M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)

rmr2013-002 XIX
INTRODUCTION
FASTENER INFORMATION
NOTICE Most components in the vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners
could cause damage to the vehicle or possible
personal injury.
SELF-LOCKING FASTENERS
PROCEDURE
A00A6LA
TYPICAL — SELF-LOCKING FASTENER
The following describes common procedures
used when working with self-locking fasteners.
Use a metal brush or a tap to properly clean a
threaded hole, then use a solvent. Allow the sol-
vent time to act, approximately 30 minutes, then
wipe off. Solvent utilization is to ensure proper
adhesion of the product used for locking the fas-
tener.
LOCTITE® APPLICATION
PROCEDURE
The following describes common procedures
used when working with Loctite products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.
XX
Threadlocker Application for
Uncovered Holes (Bolts and Nuts)
1
2
A00A3LA
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.
2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
threads and allow to dry.
3. Choose proper strength Loctite threadlocker.
4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.
Threadlocker Application for Blind
Holes
1
2
lmr2007-040-004_a
1. On fastener threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.
2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
rmr2013-002
 INTRODUCTION

4. Apply several drops along the threaded hole Threadlocker Application for
and at the bottom of the hole. Pre-Assembled Parts
5. Apply several drops on bolt threads.
6. Tighten as required.

Threadlocker Application for Stud

Installation in Blind Holes 1

1 3

2
A00A3OA

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

A00A3PA

1. Apply here
2. Plunger

1. Adjust screw to proper setting.

2. Apply a few drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.

rmr2013-002 XXI
INTRODUCTION

NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application

a soldering iron (232°C (450°F)).

Application for Stripped Thread Repair 1 2

5
1
6
8
2
1

A00A3QA 4 7
1. Release agent
2. Stripped threads 1 3
3. Form-A-Thread
lmr2007-040-006_a
4. Tapes
5. Cleaned bolt 1. Proper strength Loctite
6. Plate 2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
7. New threads (P/N 293 800 038) on both sides of gasket
8. Threadlocker 3. Loctite Primer N only

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

XXII rmr2013-002
 INTRODUCTION

3. Apply a strip of proper strength Loctite on lead-

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

Threadlocker Application for Case-In

Components (Metallic Gaskets)

A00A3VA 1
1. Proper strength Loctite

1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with LOCTITE PRIMER
N (P/N 293 800 041).

rmr2013-002 XXIII
XXIV rmr2013-002
 SERVICE TOOLS INDEX

ADAPTER HOSE BALL JOINT REMOVER SUPPORT CLUTCH ASSEMBLY HOLDER

(P/N 529 035 652) (P/N 529 036 121) (P/N 529 035 618)

Page: 603, 605

BEARING PUSHER/REMOVER
(P/N 529 036 095)
Page: 55

ALIGNMENT BAR Page: 191

(P/N 529 036 265)
CLUTCH ASSEMBLY HOLDER
(P/N 529 036 133)
Page: 190, 216, 596

BEARING PUSHER
(P/N 529 036 096)

Page: 218
Page: 560
CLUTCH PACK COMPRESSION TOOL
Page: 190, 217
(P/N 529 036 144)
ALIGNMENT BAR
(P/N 529 036 266) BELT TENSION METER
(P/N 529 036 115)

Page: 213

CRANKCASE SEAL PUSHER

Page: 522 (P/N 529 036 092)

Page: 560
BLIND HOLE BEARING PULLER SET
(P/N 529 036 117)
BALANCE SHAFT PLAIN BEARING
REM/INST
(P/N 529 036 094)
Page: 262

CRANKSHAFT PLAIN BEARING TOOL

(P/N 529 036 093)

Page: 150
BALL JOINT INSTALLER
(P/N 529 035 975)
Page: 27, 117, 149, 189, 216, 528,
530, 533, 615, 639, 661
Page: 150

Page: 595, 605

1
SERVICE TOOLS INDEX

CRIMPING TOOL (HEAVY GAUGE ENGINE LEAK DOWN TEST KIT HANDLE
WIRE) (P/N 529 035 661) (P/N 420 877 650)
(P/N 529 035 730)

Page: 401

CRIMPING TOOL (KOSTAL) Page: 87, 262

(P/N 529 035 909)
Page: 108
KOSTAL DIE
(P/N 529 035 906)
ENGINE LIFTING TOOL
(P/N 529 036 181)

Page: 398

ECM ADAPTER TOOL

(P/N 529 036 166)

Page: 22, 24, 26 Page: 398

FLUKE 115 MULTIMETER LARGE HOSE PINCHER

(P/N 529 035 868) (P/N 529 032 500)

Page: 57, 175, 260, 316, 318, 324,

327, 331, 334, 337, 339, 343, 345,
347–349, 374, 380, 395, 404, 410

ECM TERMINAL REMOVER 2.25 Page: 84

(P/N 529 036 175)
Page: 57, 93–94, 174–175, 241, MAGNET SOCKET
263–264, 316–317, 324, 328, 330–331, (P/N 529 036 178)
336, 375, 380, 414, 428, 461, 466–467,
470–473, 477–478, 480, 483, 485–486,
488–491, 515, 543, 545–546, 548, 550,
584, 624, 629, 632, 673–674, 769–770

Page: 395 FUEL HOSE ADAPTER

Page: 585, 590, 592
(P/N 529 036 023)
ECM TERMINAL REMOVER 3.36
MAGNETO PULLER
(P/N 529 036 174)
(P/N 529 036 097)

Page: 365 Page: 96

Page: 395

2

MAIN SHAFT PROTECTOR
(P/N 529 036 123)
Page: 262, 273
MAIN SHAFT SEAL INSTALLER
(P/N 529 036 088)
Page: 262
MAIN SHAFT SEAL PUSHER
(P/N 529 036 124)
Page: 262
MASTER CYLINDER ROD ADJUSTER
(P/N 529 036 119)
Page: 665
MASTER KEY
(P/N 529 036 106)
Page: 430, 432
SERVICE TOOLS INDEX
MPI-2 DIAGNOSTIC CABLE OIL SEAL INSTALLER
(P/N 710 000 851) (P/N 529 036 070)
Page: 262
OIL SEAL PUSHER
Page: 283 (P/N 529 035 757)
MPI-2 INTERFACE CARD
(P/N 529 036 018)
Page: 87
PISTON CIRCLIP INSTALLER 991
Page: 283 (P/N 529 036 072)
OETIKER PLIERS
(P/N 295 000 070)
Page: 131
PITMAN ARM JIG
(P/N 529 036 225)
Page: 59–61, 82–85, 363, 367–368,
370, 381
OIL PRESSURE GAUGE
(P/N 529 036 142)
Page: 590–591
PITMAN ARM LOCKING TOOL
(P/N 529 036 228)
Page: 239
OIL SEAL INSTALLER
(P/N 529 036 069) Page: 560, 563
Page: 117
3
SERVICE TOOLS INDEX

PITMAN ARM PULLER REAR WHEEL BEARING PUSHER SPANNER TOOL

(P/N 529 036 227) (P/N 529 036 246) (P/N 529 036 223)

Page: 605

SEAL PUSHER
Page: 497
Page: 590 (P/N 529 035 766)
SPRING COMPRESSOR
PITMAN ARM PUSHER
(P/N 529 036 184)
(P/N 529 036 226)

Page: 88 Page: 600, 611, 635

SM5 CLUTCH PISTON TOOL SPRING INSTALLER/REMOVER

(P/N 529 036 258) (P/N 529 035 983)
Page: 591

PRESSURE GAUGE
(P/N 529 035 709)
Page: 39, 42

SUCTION PUMP
(P/N 529 035 880)

Page: 178

Page: 55, 365 SOCKET SPANNER

(P/N 529 036 113)
PROTECTION SLEEVE
(P/N 529 036 071) Page: 84

TEST CAP
(P/N 529 035 991)
Page: 528

Page: 262

PULLER/LOCKING TOOL
(P/N 529 036 098)

Page: 79

Page: 96, 138–139, 154

4
 SERVICE TOOLS INDEX

VACUUM/PRESSURE PUMP
(P/N 529 021 800)

Page: 79, 167–168, 171, 176, 363,

378, 381

VALVE GUIDE INSTALLER (6 MM)

(P/N 529 036 075)

Page: 127

VALVE GUIDE REMOVER (6 MM)

(P/N 529 036 074)

Page: 127

VALVE SPRING COMPRESSOR CUP

(P/N 529 036 073)

Page: 123

VALVE SPRING COMPRESSOR

(P/N 529 035 724)

Page: 123

5
 Subsection XX (MAINTENANCE SCHEDULE)

MAINTENANCE SCHEDULE
TWN: INGÉNIERIE: Provient du guide du conducteur 2013

TWN: ref rmo2013–003

Maintenance is very important for keeping your vehicle in safe operating condition. Proper maintenance
is the owner's responsibility. Perform periodic checks and follow the maintenance schedule. The main-
tenance schedule does not exempt the pre-ride inspection.

WARNING
Failure to properly maintain the vehicle according to the maintenance schedule and procedures
can make it unsafe to operate.

BREAK-IN INSPECTION - 1 000 KM (600 MI)

Replace engine oil and oil filter.
Inspect and clean the oil tank strainer.
Replace the Hydraulic Control Module (HCM) oil filter (SE5 model only).
Check engine coolant level.

Using BRP Utility and Diagnostic Software (B.U.D.S.), check fault codes and install required updates.

Inspect throttle twist grip operation.

Check lighting system (brake light, hazard warning light, turn signal lights, position lights, license plate light).
Check operation of control switches.
Inspect the drive belt condition and its tension. Adjust if required.
Check tightening torque of the rear wheel axle nut.
Check steering for abnormal play.
Lubricate front suspension arms.
Check parking brake operation. Clean and adjust as required.
Check body panels looseness.
Check operation of storage compartment latches, hinges and key barrels.

MINIMUM MAINTENANCE - (IF DRIVING LESS THAN 7 500 KM (4,600 MI)ANNUALLY)

Replace engine oil and oil filter.
Replace the Hydraulic Control Module (HCM) oil filter (SE5 model only).
Check clutch fluid level (SM5 model only) (1).

Check radiator, hoses and water pump.

Check engine coolant level (1).

Perform a pressure test of cooling system.

Check reverse mechanism operation. Adjust as required (SM5 model only).
Using BRP Utility and Diagnostic Software (B.U.D.S.), check fault codes and install required updates.

rmr2013-003 1
Subsection XX (MAINTENANCE SCHEDULE)

MINIMUM MAINTENANCE - (IF DRIVING LESS THAN 7 500 KM (4,600 MI)ANNUALLY)

Clean the rear wheel speed sensor. Check the sensor gap. Adjust as required (2)

Using BRP Utility and Diagnostic Software (B.U.D.S.), check pillion rider switch operation.
Inspect throttle twist grip operation.
Replace the fuel filter (every 5 years).
Check battery connection tightening. Clean them if necessary.
Check lighting system (brake light, hazard warning light, turn signal lights, position lights, license plate light).
Check operation of control switches.
Inspect the drive belt condition and its tension. Adjust if required.
Check bearing condition of rear sprocket and rear wheel.
Check front wheel bearings condition.
Check tightening torque of front wheel lug nuts.
Check tightening torque of the rear wheel axle nut.
Check steering for abnormal play.
Check tie-rods condition.
Check shock absorbers for leak or other damages.
Lubricate front suspension arms.
Check ball joint condition.
Check Air Controlled Suspension (ACS) for leak or other damages (if so equipped)
Check and/or replace brake fluid (1).

Check brake pads and discs condition.

Check and adjust parking brake.
Check tightening of passenger handles.
Lubricate footrest hinges.
Check body panels looseness.
Check operation of storage compartment latches, hinges and key barrels and/or lubricate.
Check operation of brake pedal and footrest mechanism (models with a flat footrest).
(1) Replace every 2 years.
(2) Check the gap each time the rear wheel is loosened.

EVERY 500 KM (300 MI)

Check engine oil level.

EVERY 7 500 KM (4,600 MI)

Replace engine oil and oil filter.
Replace the Hydraulic Control Module (HCM) oil filter (SE5 model only).
Check clutch fluid level (SM5 model only).
Check engine coolant level.
Using BRP Utility and Diagnostic Software (B.U.D.S.), check fault codes and install required updates.
Inspect throttle twist grip operation.

2 rmr2013-003
 Subsection XX (MAINTENANCE SCHEDULE)

EVERY 7 500 KM (4,600 MI)

Check lighting system (brake light, hazard warning light, turn signal lights, position lights, license plate light).
Check operation of control switches.
Inspect the drive belt condition and its tension. Adjust if required.
Check tightening torque of front wheel lug nuts.
Check tightening torque of the rear wheel axle nut.
Check steering for abnormal play.
Check tie-rods condition.
Check brake fluid level.
Check brake pads and discs condition.
Check parking brake operation. Clean and adjust as required.
Check tightening of passenger handles.
Check body panels looseness.
Check operation of brake pedal and footrest mechanism (models with a flat footrest).

EVERY 15 000 KM (9,300 MI)

Check reverse mechanism operation. Adjust as required (SM5 model only).
Clean the rear wheel speed sensor. Check the sensor gap. Adjust as required (1).

Using BRP Utility and Diagnostic Software (B.U.D.S.), check pillion rider switch operation.
Check battery connection tightening. Clean them if necessary.
Check shock absorbers for leak or other damages.
Check operation of electric windshield (if so equipped)
Lubricate front suspension arms.
Check brake hoses for cracks or other damages.
Check Air Controlled Suspension (ACS) for leak or other damages (if so equipped)
Check operation of storage compartment latches, hinges and key barrels.
(1) Check the gap each time the rear wheel is loosened.

EVERY 22 500 KM (14,000 MI)OR 2 YEARS (WHICHEVER COMES FIRST)

Inspect and clean the oil tank strainer.
Check and adjust valves clearance (1).

Replace air filter and clean air filter housing (2).

Replace clutch fluid (SM5 model only).

Replace engine coolant.
Check cooling system cleanliness, general condition and leaks.
Perform a pressure test of cooling system.
Inspect and clean the throttle body.
Check condition of fuel hoses. Replace as required.
Spark plugs replacement.
Check bearing condition of rear sprocket and rear wheel.

rmr2013-003 3
Subsection XX (MAINTENANCE SCHEDULE)

EVERY 22 500 KM (14,000 MI)OR 2 YEARS (WHICHEVER COMES FIRST)

Replace bearing seals and wear sleeves of rear axle.
Check front wheel bearings condition.
Perform steering alignment.
Check ball joint condition.
Replace brake fluid.
(1) Valve adjustment must be performed more frequently if driving often at high RPM.
(2) Inspection and replacement more frequent when using in dusty or wet areas.

EVERY 30 000 KM (19,000 MI)OR 5 YEARS (WHICHEVER COMES FIRST)

Replace the fuel filter.

EVERY 46 000 KM (28,500 MI)

Replace the rear sprocket bearing.

TWN: finref

4 rmr2013-003
 Subsection XX (STORAGE PROCEDURE)

STORAGE PROCEDURE
SERVICE PRODUCTS
Description Part Number Page
BRP PREMIXED COOLANT .......................................................... 219 700 362 ........................................... 1
XPS FUEL STABILIZER.................................................................. 413 408 601 ........................................... 1
XPS ROADSTER WASH ................................................................ 219 701 703 ........................................... 2
XPS STORAGE OIL (EXCEPT U.S. COUNTRY) ............................. 413 711 600 ........................................... 1
XPS STORAGE OIL (U.S. COUNTRY ONLY) ................................. 413 711 900 ........................................... 1

GENERAL 2. Spray XPS STORAGE OIL (EXCEPT U.S. COUN-

If the vehicle is not ridden for at least 4 months,
such as during the winter, proper storage is nec-
essary to keep the vehicle in good condition.
PROCEDURES
FUEL SYSTEM
TRY) (P/N 413 711 600) or XPS STORAGE OIL (U.S.
COUNTRY ONLY) (P/N 413 711 900) into throttle
body (5 seconds in each openings) while crank-
ing in drowned mode (throttle wide open and
depress start button).
3. Reinstall air filter housing cover.
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
XPS FUEL STABILIZER (P/N 413 408 601) or an equiv-
alent to prevent fuel deterioration and fuel system
gumming. Follow the manufacturer's instructions
for proper use.
Pour fuel stabilizer in fuel tank. Fill up fuel tank.
NOTICE Engine should be run after fuel sta-
bilizer is added to ensure fuel system compo-
nents protection against varnish deposits.
Do not drain fuel system.
ENGINE
Engine Oil and Filter Replacement
Change engine oil and filter. Refer to LUBRICA-
TION SYSTEM subsection.
HCM Oil Filter Replacement (SE5)
Change HCM oil filter. Refer to HYDRAULIC CON-
TROL MODULE (SE5) subsection.
Engine Internal Lubrication
Engine internal parts should be lubricated to pro-
tect them from rust formation during the storage
period.
Proceed as follows:
1. Remove air filter housing cover. Refer to AIR
INTAKE SYSTEM subsection.
Clutch Fluid Level Inspection
Check clutch fluid level. Refill if necessary.
COOLING SYSTEM
Coolant Inspection
Check coolant level.
Test coolant density using an antifreeze hydrome-
ter.
NOTE: Follow manufacturer's instructions for
proper use.
Use BRP PREMIXED COOLANT (P/N 219 700 362) or
a blend of 50% antifreeze with 50% distilled wa-
ter to provide the optimum cooling, corrosion pro-
tection and antifreeze protection.
NOTICE Do not use tap water, straight an-
tifreeze or straight water in the system. Tap
water contains minerals and impurities which
build up in the system. Straight water will
cause the system to freeze while straight an-
tifreeze will cause system temperature prob-
lems.
Change coolant if necessary. Refer to COOLING
SYSTEM subsection.

rmr2013-004 1
Subsection XX (STORAGE PROCEDURE)

ELECTRICAL SYSTEM Vehicle Waxing

Battery Charging SURFACE PRODUCT/PRECAUTION
Slow charge the battery once a month at the rec- Apply only non-abrasive wax,
Glossy finishes
ommended charging rate of 2 A. It is not neces- safe for clear coat paints
sary to remove the battery. Mat surfaces Avoid applying wax

WHEELS AND TIRES NOTICE Do not polish windshield with any

plastic cleaner/polisher.
Tire Pressure
Inflate all tires to their recommended pressure. 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 FRONT 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.

2 rmr2013-004
 Subsection XX (PRESEASON PREPARATION)

PRESEASON PREPARATION
Prior to use the vehicle, proper preparation is re-
quired after the storage period.
Any worn, broken or damaged parts found during
the storage procedure should have been replaced.
If not, proceed with the replacement.
PROCEDURES
5. Check that the engine stop button is working
properly.
6. Start engine, release parking brake and ensure
parking brake indicator is off on the multifunc-
tion gauge cluster.
7. Drive forward slowly a few feet then apply
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. HICLES PREPARED AS PER STORAGE PROCE-
Charge battery as required. Refer to CHARGING DURE above.
SYSTEM. Carry out these additional steps:
Check the following items: – Check the level of engine coolant. Refer to
– Tires: Look for damage, incorrect inflation and COOLING SYSTEM subsection.
excessive tread wear. – Check the brake fluid level. Refer to BRAKES
– Wheels and lug nuts: Look for damage. subsection.
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 SUSPENSION subsection.
cotter pin are in place. – Replace engine oil and filter. Refer to LUBRICA-
– Drive belt: Look for fraying, cuts, punctures TION SYSTEM subsection.
and missing teeth. Verify alignment. For addi- – Replace HCM oil filter (SE5 model). Refer to
tional information, refer to DRIVE BELT AND HYDRAULIC CONTROL MODULE (SE5) sub-
REAR WHEEL subsection. section.
– Leaks: Look under the vehicle for any leaks. – Models with a flat footrest: Release the latch
– Brake pedal: Press and make sure you feel underneath footrest. Pivot footrest by pushing
firm resistance. Pedal must fully return when down its front part. Flip back the footrest until
released. it latches. The mechanism must work freely.
– 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:
1. 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.

rmr2013-005 1
 Subsection XX (ENGINE REMOVAL AND INSTALLATION)

ENGINE REMOVAL AND INSTALLATION

SERVICE TOOLS
Description Part Number Page
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ........................................... 13
ENGINE LIFTING TOOL ................................................................ 529 036 181 ................................. 8, 10, 12

48 N•m
(35 lbf•ft)
10 N•m
(89 lbf•in)
24 N•m
(17 lbf•ft)

61 N•m
24 N•m (45 lbf•ft)
(17 lbf•ft)

10 N•m
(89 lbf•in)

61 N•m
48 N•m 30 N•m (45 lbf•ft)
(35 lbf•ft) (22 lbf•ft)

48 N•m
(35 lbf•ft)

24 N•m
(17 lbf•ft) 33 N•m
(24 lbf•ft)
rmr2013-006-100_a

rmr2013-006 1
Subsection XX (ENGINE REMOVAL AND INSTALLATION)

GENERAL For RT models, refer to BODY subsection to re-

CAUTION To avoid potential burns, let en-
gine and exhaust system cool down.
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
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
move the following:
– Both mirrors
– Both middle side panels
– Both top side panels
– 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 LUBRICA-
TION SYSTEM subsection.
Drain engine coolant. Refer to COOLING SYS-
TEM subsection.
Remove muffler and catalytic converter. Refer to
EXHAUST SYSTEM subsection.
Remove both lateral supports. Refer to FRAME
subsection.
Remove the air filter housing and the resonator.
Refer to AIR INTAKE SYSTEM subsection.
Release drive belt tension. Refer to DRIVE BELT
AND REAR WHEEL subsection.

ENGINE On Right Side of Vehicle:

1. Disconnect parking brake.
Preparation for Engine Removal
2. Disconnect the coolant hoses from cylinder
Place vehicle on a workstation that will have ac- heads.
cess to an engine-lifting hoist.
Disconnect the BLACK (-) cable from battery, then
the RED (+) cable.

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.

For RS and ST models, refer to BODY subsec-

tion to remove the following:
– Both mirrors rmr2010-006-002_a
– Both middle side panels 1. Coolant hoses
– Both top side panels
3. Remove screws retaining water pump cover.
– Rear body assembly
– Both heat shields
– Both bottom side panels
– Both lateral console panels (ST Models)
– Front storage compartment
– Central panel.

2 rmr2013-006
 Subsection XX (ENGINE REMOVAL AND INSTALLATION)

rmr2010-006-005_a

1. ETA connector

rmr2013-006-002_a
8. Cut locking tie attaching spark plug cable and
1. Water pump cover retaining screw clutch actuation valve hose.

4. On SM5 models, unplug the clutch actuation

valve connector.
5. Remove the starter cable from the starter.

rmr2010-006-006_a

1. Cut this locking tie

2. Clutch activation valve hose
3. Spark plug cable

9. On SM5 models, disconnect the clutch actua-

rmr2010-006-003_a tion valve hose from throttle body.
1. Clutch actuation valve connector
2. Starter cable

6. Unplug spark plug cable from the front cylinder

head.

rmr2010-006-007_a

TYPICAL
1. Cut this Oetiker clamp

rmr2010-006-004_a
10. Remove ground wire from engine.
1. Spark plug cable

7. Unplug the electric throttle actuator (ETA) con-

nector.

rmr2013-006 3
Subsection XX (ENGINE REMOVAL AND INSTALLATION)

rmr2013-006-003_a rmr2013-006-004_a

VIEWED FROM UNDER THE VEHICLE 1. EVAP canister support screw

1. Ground wire screw
13. Loosen clamps securing throttle body to in-
11. On SM5 models, disconnect clutch hose and take adapters.
discard sealing washers.
NOTE: Place a container under clutch hose to re-
cover the clutch fluid.

rmr2010-006-012_a

1. Retaining clamps

14. Lift throttle body and attach it against the top

rmr2010-006-009_a
frame member.
SM5 MODEL SHOWN NOTE: Place clean rags inside intake adapters to
1. Clutch hose
avoid debris in engine.
12. Remove screws retaining the EVAP canister to On Left Side of Vehicle:
cylinder.
1. On SE5 models, detach the clutch servo hose
from the bottom of oil tank.

4 rmr2013-006
 Subsection XX (ENGINE REMOVAL AND INSTALLATION)

5. Remove the front sprocket and move drive belt

rearward. Refer to DRIVE BELT AND REAR
WHEEL subsection for procedure.

rmr2013-016-022_a

SE5 MODEL SHOWN

1. Oil tank
rmr2010-006-015_a
2. Clutch servo hose
TYPICAL
2. Cut locking tie retaining ignition coil wire and 1. Oil tank vent
2. Front sprocket screw
unplug ignition coil connector.
6. Remove both oil hose connectors from
crankcase.

rmr2010-006-013_a

TYPICAL
1. Cut this locking tie
2. Ignition coil connector
rmr2010-006-016_a

3. Unplug spark plug cable from the rear cylinder 1. Oil hoses
head.
7. Remove the oil tank and oil cooler with the ig-
nition coil.
8. Remove the LH footrest.
8.1 Remove bolt retaining shifting link to shift-
ing block.

rmr2010-006-014_a

TYPICAL
1. Spark plug cable

4. Disconnect the oil tank vent from crankcase.

rmr2013-006 5
Subsection XX (ENGINE REMOVAL AND INSTALLATION)

rmr2010-006-020_a
rmr2010-006-017_a
1. Reverse cable support
TYPICAL – SM5 ENGINE SHOWN 2. Retaining screws
1. Shifting block 3. Reverse lever
2. Shifting link
10. On SM5 models, unplug the reverse actuator.
8.2 Remove screw securing the middle of the
footrest to frame.

rmr2010-006-028_a

1. Reverse actuator connector

11. On SM5 models, remove screws retaining

rmr2010-006-018_a
the reverse actuator to frame.
1. Retaining screw

8.3 Remove both screws securing the rear of

footrest to footrest support.

rmr2010-006-021_a

1. Reverse actuator screws

12. Disconnect stator connector from regulator,

refer to STATOR CONNECTOR ACCESS in
rmr2011-055-001_a
MAGNETO AND STARTER subsection.
VIEW FROM THE REAR OF VEHICLE
1. Rear retaining screws 13. Disconnect injector connectors at throttle
body.
9. On SM5 models, remove screws retaining re-
verse cable support to engine and detach the
end of the cable from the reverse lever.

6 rmr2013-006
 Subsection XX (ENGINE REMOVAL AND INSTALLATION)

rmr2013-006-301_a rmr2013-006-300_a

TYPICAL - PARTS REMOVED FOR CLARITY TYPICAL - PARTS REMOVED FOR CLARITY
1. Injector connectors 1. Both knock sensors connectors (KS)

14. On SE5 models, disconnect solenoid connec-

tor at HCM
15. Unplug the following sensors.

rmr2010-006-025_a

1. Coolant temperature sensor (CTS)

rmr2010-006-022_a

1. Gearbox position sensor (GBPS)

rmr2010-006-023_a rmr2013-006-300_b

1. Camshaft position sensor (CAPS) TYPICAL - PARTS REMOVED FOR CLARITY

1. Crankshaft position sensor (CPS)

rmr2013-006 7
Subsection XX (ENGINE REMOVAL AND INSTALLATION)

Lifting Engine
All Models
1. Install the lifting tool.
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 cylinder
heads.

rmr2013-006-205_e

1. Pivot retaining bolt

4. On the LH side of engine, remove engine

mount bolt.
529036181

1.3 Lift hoist until there is no slack in the chain

but do not apply tension on the chain.
2. Loosen rear RH engine support bolts.

rmr2013-006-202_c

1. Engine mount bolt

rmr2010-006-031_a

1. Upper engine support bolt

5. Loosen the rear LH support bolts.
2. Lower engine support bolt

3. On the LH side of engine, remove pivot retain-

ing bolt.

8 rmr2013-006
 Subsection XX (ENGINE REMOVAL AND INSTALLATION)

rmr2013-006-205_g rmr2013-006-202_g

1. Rear LH support bolts

Remove bolt securing the engine stabilizer rod
from the front engine support.
NOTICE Never unscrew stabilizer rod jam
nuts unless the rod needs to be changed.
NOTE: Do not loosen jam nuts to preserve align-
ment.
rmr2013-006-001_a
7. Remove support assembly retaining bolt.
8. Loosen the rear RH support bolts.
9. Lift engine slowly and remove it from vehicle on
the LH side.
Engine Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
NOTE: Prior to installing engine, inspect condition
of engine mounts (front and rear pads).
Position engine in chassis.
Align stabilizer rods and engine mounts, lean en-
gine as needed.
NOTE: Unless link rods dimensions were
changed, or link rods replaced, no engine align-
ment is necessary. Otherwise proceed with
engine alignment. Refer to ENGINE ALIGNMENT
in this subsection.
Install all mounting bolts and mounting nuts.
Torque bolts to specifications.
Install all other removed parts.

TYPICAL Engine Alignment

1. Retaining bolt
Install an alignment pin (homemade tool) through
6. Remove stabilizer rod retaining bolt. engine supports and chassis to align the engine.

rmr2008-008-026_a

ALIGNMENT PIN — HOMEMADE TOOL

A. Approximately 400 mm (16 in)
B. 19 mm (3/4 in)

rmr2013-006 9
Subsection XX (ENGINE REMOVAL AND INSTALLATION)

– Both top side panels

– Rear body assembly
– Both heat shields
– Both bottom side panels
– Both lateral console panels (ST Models)
– Front storage compartment
– Central panel.
For RT Models, refer to BODY subsection to re-
move the following parts:
– Both mirrors
rmr2008-008-025_a

TYPICAL
– Both top side panels
1. Engine mounts shield – Both middle side panels
2. Alignment pin
– Both bottom side panels (rear and front)
Lean engine against alignment pin. – Glove box
Install all mounting bolts and mounting nuts. – Central panel.
Torque mounting bolts and mounting nuts to Release drive belt tension. Refer to DRIVE BELT
48 N•m (35 lbf•ft). AND REAR WHEEL subsection.
Remove alignment pin. Move oil tank and oil cooler (for LH side) or radiator
(for RH side) aside to make room.
Final Assembly Remove the air filter housing cover.
Make sure coolant and oil drain plugs are rein- On left side, remove retaining bolt securing res-
stalled and tight. onator.
Fill cooling system. Refer to COOLING SYSTEM
subsection.
Fill engine with the recommended oil and re-
quired quantity. Refer to LUBRICATION SYSTEM
subsection.
Reconnect battery.

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.
rmr2013-007-302_a

Align and adjust tension of drive belt. Refer to 1. Resonator

DRIVE BELT AND REAR WHEEL subsection. 2. Resonator retaining bolt

Test drive vehicle to confirm proper operation. Install the ENGINE LIFTING TOOL (P/N 529 036 181).

ENGINE MOUNTS
Engine Mounts Removal
Front Rubber Mounts
For RS and ST Models, refer to BODY subsection
to remove the following parts:
– Both mirrors
– Both middle side panels

10 rmr2013-006
 Subsection XX (ENGINE REMOVAL AND INSTALLATION)

Remove longitudinal link (retaining bolts on stabi-

lizer rod).
Remove longitudinal stabilizer rod.

529036181

Remove bolt securing the engine longitudinal sta-

bilizer rod from the front engine support.
NOTICE Never unscrew stabilizer rod jam
nuts unless the rod needs to be changed.
NOTE: Do not loosen jam nuts.

rmr2013-006-204_b

TYPICAL - VIEWED FROM TOP

1. Front engine support
2. Longitudinal stabilizer rod retaining bolt
3. Longitudinal stabilizer rod retaining bolt

Remove nuts securing the front engine support.

rmr2013-006-001_a

TYPICAL
1. Retaining bolt

rmr2013-006-006_b

TYPICAL - RH SIDE SHOWN

1. RH front engine support bolt

rmr2013-006-202_g

TYPICAL
1. Longitudinal stabilizer rod retaining bolt

rmr2013-006 11
Subsection XX (ENGINE REMOVAL AND INSTALLATION)

– Front storage compartment

– Central panel.
For RT Models, refer to BODY subsection to re-
move the following parts:
– Both mirrors
– Both top side panels
– Both middle side panels
– Rear body assembly
– Both bottom side panels
– Front storage compartment
– Central panel.
Release drive belt tension. Refer to DRIVE BELT
AND REAR WHEEL subsection.
rmr2013-006-202_c

TYPICAL - LH SIDE SHOWN

Install the ENGINE LIFTING TOOL (P/N 529 036 181).
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.
NOTICE Limit movement to avoid damage to
cylindrical exhaust pipe slip joints and support
engine weight.
529036181

Lift hoist until there is no slack in the chain but do

not apply tension on the chain.
Remove rear engine support bolts, both rear en-
gine support and pivot retaining bolt.

rmr2013-006-202_f

TYPICAL - LH SIDE SHOWN

1. Front rubber mount
2. Remove these nuts
rmr2010-006-031_a

Rear Rubber Mounts TYPICAL - RH SIDE

1. Rear RH upper engine support bolt
For RS and ST Models, refer to BODY subsection 2. Rear RH lower engine support bolt
to remove the following parts:
– Both mirrors
– Both top side panels
– Both middle side panels
– Lateral console panels (ST Models)
– Rear body assembly
– Both bottom side panels
12 rmr2013-006
 Subsection XX (ENGINE REMOVAL AND INSTALLATION)

Engine Mounts Installation

rmr2013-006-205_f
TYPICAL – LH REAR ENGINE SUPPORT
1. Rear LH engine support nuts
2. Rear left engine mount deflector bolt
3. Pivot retaining bolt
Front Rubber Mounts
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install rubber mount to frame.
Secure rubber mount to frame and engine support
Reinstall untouched link rods.
NOTE: Unless link rods dimensions were
changed, or link rods replaced, no engine align-
ment is necessary. Otherwise proceed with
engine alignment. Refer to ENGINE ALIGNMENT
in this subsection.
Tighten rubber mount nuts to specification.
RUBBER MOUNT NUT TORQUE
24 N•m (18 lbf•ft)

Using the BLIND HOLE BEARING PULLER SET Tighten all engine bolts.
(P/N 529 036 117), remove rear rubber mounts.
Adjust drive belt tension. Refer to DRIVE BELT
AND REAR WHEEL subsection.
Rear Rubber Mounts
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Insert rubber mount into tube and align the tab
with the recess on tube.
Using a plastic hammer, insert rubber mount into
tube.
529036117 Tighten nuts to specification.
TIGHTENING TORQUE
Engine support retaining
24 N•m (18 lbf•ft)
screws
Rubber mount retaining
61 N•m (45 lbf•ft)
screw

Adjust drive belt tension. Refer to DRIVE BELT

AND REAR WHEEL subsection.

rmr2013-006-005_a

TYPICAL - BLIND HOLE BEARING PULLER INSTALLATION

POSITION

rmr2013-006 13
 Subsection XX (AIR INTAKE SYSTEM)

AIR INTAKE SYSTEM

2.3 N•m (20 lbf•in)

6 N•m
(53 lbf•in)

NEW

7 N•m
(62 lbf•in) 2.3 N•m
(20 lbf•in)

NEW

3 N•m 7 N•m
(27 lbf•in) (62 lbf•in)

NEW = Component must be replaced when removed.

rmr2013-007-100_a

rmr2013-007 1
Subsection XX (AIR INTAKE SYSTEM)

GENERAL
During assembly/installation, use the torque val-
ues and service products as specified in the ex-
ploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed must be re-
placed with new ones (e.g.: locking tabs, rmr2013-007-300_a
elastic stop nuts, cotter pin, etc.). RIGHT SIDE SHOWN
1. Retaining clips
2. Air filter cover
NOTICE Hoses, cables and locking ties re-
moved during procedures must be reinstalled 4. Push air filter cover forward to expose air filter.
as per factory standards. 5. Pull out filter.

PROCEDURES
AIR FILTER
Air Filter Removal
NOTICE 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 rmr2013-007-301_a
degradation or damage can occur. RIGHT SIDE SHOWN
1. Air filter
1. For RT Models, refer to BODY subsection and
remove the following parts: NOTE: A small amount of oil in the air filter area
– Right middle side panel is normal. Clean as necessary.
– Right top side panel Air Filter Inspection
– Right acoustic panel.
Inspect air filter for cleanliness and damage.
2. For RS and ST Models, refer to BODY subsec-
tion and remove the following parts: NOTICE It is NOT recommended to blow
– Console assembly compressed air on the paper filter. This could
– Lateral console panels damage the paper fibers and reduce its filtra-
tion ability when used in dusty environments.
– Upper side panels.
– Central panel NOTICE Do not wash the paper filter with any
3. Release the 3 retaining clips from the air filter cleaning solution.
cover. Replace air filter as necessary.

Air Filter Installation

Carefully install air filter in its cover.
Properly position air filter cover then secure with
all clips.
2 rmr2013-007
 Subsection XX (AIR INTAKE SYSTEM)

Reinstall parts in the reverse order of their re-

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.
rmr2011-079-002_b

1. Headlight adjuster
2. Side panel support

6. Remove the resonator retaining bolt.

rmr2013-007-204_b

1. Resonator hose
2. Air filter cover

4. On left side of vehicle, disconnect the wire har-

ness connectors (3) to the console module and rmr2013-007-302_a

move them aside. 1. Resonator

2. Resonator retaining bolt

7. Pull the resonator up off it's front mounting

bracket, then out to the side of the vehicle.

Resonator Inspection
Inspect resonator and hose condition paying at-
tention for deformation, cracks or other damage.
Replace any defective part.

Resonator Installation
Installation is the reverse of the removal proce-
dure however, pay attention to the following.
rmr2010-038-029_a

SOME PARTS REMOVED FOR CLARITY

Ensure the 2 rubber cushions are installed in the
1. Console module harness connectors resonator mounting bracket.
5. For RT models, remove the nut that retains the
headlight adjuster cable (high beam on CE mod-
els) to the RH side panel support and move the
cable aside.
rmr2013-007 3
Subsection XX (AIR INTAKE SYSTEM)

– Lateral console panels

– Upper side panels.
– Central panel
3. Remove locking ties securing wiring harness to
air filter housing.

rmr2013-007-303_a

1. Rubber cushions
2. Resonator mounting bracket

Ensure the resonator mounting pins on the inlet

tube properly engage and are fully seated in the
rubber cushions when installed.
rmr2013-007-304_a

TYPICAL
1. Cut these locking ties

rmr2013-007-206_a

1. Resonator mounting pins

Move assembly forward to torque rear supporting

screws. rmr2013-007-305_a

TYPICAL
1. Cut these locking ties
AIR FILTER HOUSING
4. Unplug the breather hose from the bottom
Air Filter Housing Removal of the air filter housing. Discard the Oetiker
1. For RT Models, refer to BODY subsection and clamp.
remove the following parts:
– Console module
– Middle side panel
– Top side panel
– Acoustic panel.
2. For RS and ST Models, refer to BODY subsec-
tion and remove the following parts:
– Console assembly

4 rmr2013-007
 Subsection XX (AIR INTAKE SYSTEM)

rmr2010-007-005_a

TYPICAL
1. Air filter housing
2. Breather hose
rmr2013-007-204_b

5. Release the 4 clips retaining the the LH side of 1. Resonator hose

2. Air filter cover
the air filter housing cover.
8. Release the 4 clips retaining the RH side of the
air filter housing cover.

rmr2013-007-201_a

1. Locking clips

6. Remove the RH lateral support, refer to FRAME rmr2013-007-203_a

subsection. 1. Locking clips

7. On right side of vehicle, loosen clamp securing 9. Remove air filter housing cover.
resonator hose to air filter cover and push hose 10. Remove air filter housing retaining screws.
off of air filter cover.

rmr2013-007 5
Subsection XX (AIR INTAKE SYSTEM)

rmr2010-007-010_a

rmr2013-007-307_a

FROM LH OF VEHICLE
1. Retaining screws

rmr2013-007-306_a

FROM RH OF VEHICLE
1. Retaining screws

11. Pull air filter housing out of vehicle.

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
6 N•m (53 lbf•in)

6 rmr2013-007
 Subsection XX (EXHAUST SYSTEM)

EXHAUST SYSTEM
SERVICE TOOLS
Description Part Number Page
SPRING INSTALLER/REMOVER ................................................... 529 035 983 ......................................... 5, 8

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 6–7

rmr2013-008 1
Subsection XX (EXHAUST SYSTEM)

See ELECTRONIC FUEL

INJECTION (EFI) 13 N•m
43 N•m (115 lbf•in)
(38 lbf•ft) NEW
NEW
43 N•m
(38 lbf•ft)
NEW See ELECTRONIC FUEL
INJECTION (EFI)

7 N•m NEW
(62 lbf•in) 13 N•m
(115 lbf•in)
20 N•m
20 N•m (15 lbf•ft)
(15 lbf•ft) 7 N•m
(62 lbf•in) NEW
7 N•m NEW
(62 lbf•in)
20 N•m
(15 lbf•ft) 5 N•m
RS Loctite 243 NEW (49 lbf•in)

11 N•m
18 N•m (97 lbf•in)
(159 lbf•in) NEW
RT

NEW
5 N•m
20 N•m (49 lbf•in)
NEW (15 lbf•ft) Loctite
ST NEW 11 N•m 243
(97 lbf•in)

Loctite 243

NEW = Component must be replaced

5 N•m
when removed. (49 lbf•in)
rmr2013-008-100_a

2 rmr2013-008
 Subsection XX (EXHAUST SYSTEM)

GENERAL
WARNING
To avoid potential burns, never touch ex-
haust system components immediately after
the engine has been run as these compo-
nents are very hot. Let engine and exhaust
system cool down before performing any
servicing.

WARNING
Torque wrench tightening specifications
must be strictly adhered to. Locking de-
rmr2010-008-002_a
vices must be replaced when removed (e.g.:
TYPICAL
locking tabs, elastic stop nuts, self-locking 1. Head pipe to drive belt clearance
fasteners, cotter pins, etc.).
3.2 Ensure clearance between the LH inlet
Hoses, cables or locking ties removed during a pipe on the catalytic converter and drive
procedure must be reinstalled as per factory stan- belt is at least 8 mm (5/16 in).
dards.

EXHAUST SYSTEM
INSTALLATION SEQUENCE
NOTE: When installing exhaust system compo-
nents, use new gaskets and new hardware as
applicable. Apply specified torques. Refer to the
exploded view.
1. Install all exhaust system components loosely
to ease adjustment of components.
2. Torque exhaust system components in the fol-
lowing order. Adjust sequence as required ac-
cording to parts removal and installation to en- rmr2010-008-003_a
sure proper clearances are obtained. TYPICAL
1. Catalytic converter inlet pipe to drive belt clearance
EXHAUST SYSTEM TORQUE SEQUENCE
3.3 Ensure clearance between the LH inlet
1. Rear head pipe (RH) to cylinder head
pipe on the catalytic converter and the
2. Front head pipe (LH) to cylinder head frame is at least 3 mm (1/8 in).
3. Catalytic converter support bracket to frame
mount
4. Rear head pipe to catalytic converter (clamp)
5. Front head pipe to catalytic converter (clamp)
6. Muffler mounting bolt
7. Muffler to catalytic converter flange bolts

3. Check exhaust system clearance gaps as com-

ponent fasteners are torqued:
3.1 Ensure clearance between the LH front
head pipe and the drive belt is at least
8 mm (5/16 in).

rmr2013-008 3
Subsection XX (EXHAUST SYSTEM)

rmr2010-008-004_a

TYPICAL
1. Catalytic converter inlet pipe to frame clearance

3.4 Ensure clearance between the flange on

the catalytic converter outlet pipe and the
swing arm is at least 4 mm (5/32 in).
NOTE: This measurement is taken at a slight
angle with the suspension fully extended. rmr2013-008-202_a

TYPICAL
1. Park brake mechanism to muffler clearance

4. Recheck clearances when all components are

torqued. Adjust as required.

MAINTENANCE
CATALYTIC CONVERTER FRONT
GASKET REPLACEMENT
NOTE: When replacing the front catalytic con-
verter gasket, the catalytic converter and muffler
can be removed as a unit.
1. Open the seat.
rmr2013-008-201_a
2. For ST and RT models, remove both mirrors,
TYPICAL
refer to BODY subsection.
1. Converter flange to swing arm clearance 3. Remove the following body panels, refer to
3.5 Ensure clearance between the park brake BODY subsection:
mechanism on the rear wheel and the – LH and RH middle side panels
muffler is at least 10 mm (13/32 in). – LH and RH wind deflectors
– LH and RH top side panels
– Central panels
– Rear body module.
4. Remove clamp retaining catalytic converter
pipe to front head pipe.

4 rmr2013-008
 Subsection XX (EXHAUST SYSTEM)

rmr2011-057-001_a

TYPICAL - FRONT HEAD PIPE TO CATALYTIC CONVERTER rmr2013-008-204_b

1. Exhaust clamp to remove
1. Frame
2. Catalytic converter
5. Remove spring and clamp retaining catalytic 3. Front support bracket
converter to rear head pipe. 4. Screws to remove (2) LH side
5. Screw to remove (1) RH side
REQUIRED TOOL
7. With the assistance of a coworker, support the
SPRING INSTALLER/REMOVER (P/N 529 035 983) muffler and remove the muffler retaining bolt.

rmr2013-008-205_b

1. Muffler
2. Muffler retaining bolt to remove

NOTICE Insert padding between muffler and

rmr2013-008-203_b
TYPICAL - REAR HEAD PIPE TO CATALYTIC CONVERTER
1. Exhaust clamp to remove
2. Exhaust spring to remove
6. Remove the screws that secure to the frame
the front support bracket for the catalytic con-
verter.
park brake mechanism on rear wheel axel to
prevent contact between parts and damage to
the muffler.
8. As you support the catalytic converter, unhook
the aft rubber support from the catalytic con-
verter.

rmr2013-008 5
Subsection XX (EXHAUST SYSTEM)

PROCEDURES
MUFFLER HEAT SHIELDS
Heat Shields Removal
Remove the three screws mounting the rear heat
shield to the front end of the muffler.

rmr2013-008-204_c

TYPICAL
1. Aft rubber support to remove (catalytic converter)

9. Carefully pull the catalytic converter off both

head pipes.
NOTICE 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. rmr2013-008-206_a
Wrap the muffler with a thick cloth or blanket 1. Muffler
to protect it during removal, installation. 2. Rear muffler shield
3. Front muffler shield
10. Remove exhaust gasket from each head pipe.
11. Install a NEW exhaust gasket on each pipe.
12. Install the muffler and catalytic converter in
the reverse order of the removal however, pay
attention to the following:
– Clean muffler retaining bolt threads and ap-
ply LOCTITE 243 (BLUE) (P/N 293 800 060), or
install a new bolt.
– Apply torques as specified.
MUFFLER RETAINING CONVERTER SUPPORT
BOLT BRACKET
18 N•m (159 lbf•in) 7 N•m (62 lbf•in)

INSPECTION rmr2013-008-211_a

Always inspect exhaust system parts for the fol- 1. Rear muffler shield
2. Rear muffler shield mounting screw
lowing defects or damages:
– Cracks Remove the three screws mounting the front heat
– Tearing shield to the front section of the muffler.
– Bending
– Dents
– Corrosion
– Leaks
– And any other damage or defect which could
affect system performance.
Replace as required.

6 rmr2013-008
 Subsection XX (EXHAUST SYSTEM)

rmr2013-008-212_a rmr2013-008-207_a

1. Front muffler shield 1. Muffler flange

2. Front muffler shield mounting screw 2. Catalytic converter flange
3. Nuts to remove
4. Springs to remove
Heat Shield Installation
1. Clean muffler retaining bolt threads and apply 3. While supporting muffler, remove the muffler
LOCTITE 243 (BLUE) (P/N 293 800 060) to the mounting hexagonal screw, seal, rubber seal
threads of the mounting screws. and washer from the muffler support.
2. Position rear heat shield on muffler, install and
torque the three mounting screws.
3. Position front heat shield on muffler, install and
torque the two mounting screws.
MUFFLER SHIELD SCREW TORQUE
5.5 N•m (49 lbf•ft)

MUFFLER
Muffler Removal
1. Position vehicle for ease of access to muffler
retaining bolt and muffler flange screws under
the vehicle.
2. Remove the nuts and springs that secure the
muffler flange to the catalytic converter flange. rmr2013-008-205_b

NOTE: The socket head screws may be left in the
flanges at this time.
1. Muffler
2. Muffler retaining bolt to remove
NOTICE Insert padding between muffler and
park brake mechanism on rear wheel axel to
prevent contact between parts and damage to
the muffler.
4. Remove the two socket head screws from the
muffler flange and carefully remove the muffler
from the catalytic converter.
5. Discard old muffler gasket.

Muffler Installation
1. Install a NEW muffler gasket on the muffler end
of the catalytic converter exhaust pipe.

rmr2013-008 7
Subsection XX (EXHAUST SYSTEM)

NOTICE Insert padding between muffler and 2. For ST and RT models, remove both mirrors,
park brake mechanism on rear wheel axel to refer to BODY subsection.
prevent contact between parts and damage to 3. Remove the following body panels, refer to
the muffler. BODY subsection:
2. Insert muffler pipe over catalytic converter pipe – LH and RH middle side panels
and insert the two socket head screws through – LH and RH wind deflectors
the flanges. – LH and RH top side panels
3. Install muffler retaining bolt on muffler support – Central panels
and tighten nut until it bottoms out loosely. – Rear body module.
NOTE: Push muffler in its spherical joint when 4. Remove the MUFFLER, see procedure in this
tightening muffler support retaining bolt. subsection.
4. Install springs and retaining nuts on the muffler 5. Remove the spring retaining the catalytic con-
flange screws and tighten nuts slightly. Do not verter to the rear head pipe (RH side).
torque them at this time.
REQUIRED TOOL
5. Torque the muffler retaining nut first, then
torque the flange nuts as specified in the fol- SPRING INSTALLER/REMOVER (P/N 529 035 983)
lowing table.
MUFFLER TORQUE SEQUENCE
18 N•m
STEP 1 Muffler retaining nut
(159 lbf•in)
STEP 2 Inner muffler flange nut 6. Loosen the exhaust clamps securing the cat-
11 N•m
(97 lbf•in)
alytic converter to both head pipes sufficiently
STEP 3 Outer muffler flange nut to slide the clamps down the pipes.
NOTE: Ensure clearance between the flange on NOTE: Note the position of each clamp for instal-
the catalytic converter exit pipe and the swing lation.
arm is as specified with full swing arm extension.
Refer to EXHAUST SYSTEM INSTALLATION SE-
QUENCE for illustration.
CATALYTIC CONVERTER FLANGE TO
SWING ARM CLEARANCE
At least 4 mm (5/32 in)
(with full swing arm extension)

NOTICE When compressing the rear suspen-

sion, ensure the muffler clears the park brake
pulley on the rear caliper by at least 10 mm
(13/32 in). To help respect the distance, insert
a wooden block of 85 mm (3-11/32 in) between
muffler and left side of swing arm. If clearance
rmr2011-057-001_a
is not obtained, loosen then re-torque the
TYPICAL - FRONT HEAD PIPE TO CATALYTIC CONVERTER
flange nuts until proper clearance is obtained. 1. Exhaust clamp to remove
Refer to EXHAUST SYSTEM INSTALLATION
SEQUENCE for illustration.
6. Start engine and ensure the muffler gasket ring
is not leaking.

CATALYTIC CONVERTER
Catalytic Converter Removal
1. Open the seat.

8 rmr2013-008
 Subsection XX (EXHAUST SYSTEM)

rmr2013-008-203_b rmr2013-008-204_c

TYPICAL - REAR HEAD PIPE TO CATALYTIC CONVERTER TYPICAL

1. Exhaust spring to remove 1. Aft rubber support to remove (catalytic converter)
2. Exhaust clamp to remove
9. Carefully pull down on catalytic converter ex-
7. Remove the screws that secure the front sup- haust pipes to disconnect them from the head
port bracket for the catalytic converter to the pipes.
frame.
Catalytic Converter Installation
1. Install NEW gaskets on the head pipes.
2. Ensure both exhaust clamps are positioned
loosely on catalytic converter pipes prior to
insertion on front head pipes.
3. Insert the catalytic converter support bracket
onto the converter support hooks. Ensure the
grommets are in good condition.
4. Insert the catalytic converter pipes over the
head pipes.
5. Insert the support hook above the catalytic con-
verter into its rubber support.
6. Slide exhaust clamps over each converter to
head pipe joint and tighten them just enough for
rmr2013-008-204_b
them to remain in position.
1. Frame
2. Catalytic converter 7. Install the RH head pipe spring using same tool
3. Front support bracket
4. Screws to remove (2) LH side as removal.
5. Screw to remove (1) RH side
NOTE: Make sure pipe joints are bottomed out to
8. As you support the catalytic converter, unhook prevent leakage which could affect system effi-
the rubber support above the converter. ciency.
8. Install screws that secure the front converter
support bracket and torque as specified.
9. Properly position exhaust clamps at converter
to head pipe joints and torque as specified.

rmr2013-008 9
Subsection XX (EXHAUST SYSTEM)

CONVERTER TORQUE SEQUENCE

Front converter support 7 N•m
STEP 1
bracket (62 lbf•in)
Rear head pipe to
STEP 2
converter 20 N•m
Front head pipe to (15 lbf•ft)
STEP 3
converter

10. Ensure proper exhaust system clearance gaps

are obtained. Refer to EXHAUST SYSTEM IN-
STALLATION SEQUENCE at the beginning of
this subsection.
11. Install muffler, refer to MUFFLER INSTALLA-
TION. rmr2013-008-208_a

1. Front oxygen sensor (LH side)

12. Install all remaining removed parts and panels. 2. Front head pipe

HEAD PIPE (FRONT CYLINDER) 9. Remove and discard the four nuts retaining
head pipe to front cylinder head.
Head Pipe Removal (Front Cylinder)
1. Open the seat and both rear side cargo com-
partments.
2. For ST and RT models, remove both mirrors,
refer to BODY subsection.
3. Remove the following body panels, refer to
BODY subsection:
– LH and RH middle side panels
– LH and RH wind deflectors
– LH and RH top side panels
– Rear body module
– LH middle side panel
– LH bottom front side panel rmr2008-010-014_a
– Oil cooler air duct. TYPICAL
1. Front cylinder head
4. Remove LH lateral support, refer to FRAME 2. Nut locations (one is not visible)
subsection. 3. Gasket, head pipe to cylinder head

5. Remove air intake system resonator, refer to
AIR INTAKE SYSTEM subsection.
6. Remove the muffler. Refer to MUFFLER RE-
MOVAL in this subsection.
7. Remove the catalytic converter. Refer to CAT-
ALYTIC CONVERTER REMOVAL in this subsec-
tion.
8. Remove the oxygen sensor from the head pipe,
refer to HEATED OXYGEN SENSOR (HO2S) in
the ELECTRONIC FUEL INJECTION (EFI) sub-
section.
10. Remove head pipe by carefully moving the
pipe forward off the mounting studs, rotating
it so that it can be pulled out on the LH side
of the vehicle.
Head Pipe Installation (Front Cylinder)
1. Install NEW head pipe gaskets and NEW cylin-
der gaskets.
2. Install head pipe loosely on cylinder head using
four NEW retaining nuts.
3. Install oxygen sensor, refer to HEATED OXY-
GEN SENSOR (HO2S) in the ELECTRONIC
FUEL INJECTION (EFI) subsection.
4. Install remaining exhaust system components
loosely.

10 rmr2013-008
 Subsection XX (EXHAUST SYSTEM)

5. Torque exhaust system fasteners and ensure 6. Remove and discard the four nuts retaining
proper exhaust system clearance gaps are ob- head pipe to rear cylinder head.
tained. Refer to EXHAUST SYSTEM INSTALLA-
TION SEQUENCE in the beginning of this sub-
section.
6. Install air intake system resonator, refer to AIR
INTAKE SYSTEM subsection.
7. Install LH lateral support, refer to FRAME sub-
section.
Install all remaining removed parts and panels in-
cluding oil cooler duct. Refer to BODY subsection.

HEAD PIPE (REAR CYLINDER)

Head Pipe Removal (Rear Cylinder)
1. Open the seat and both rear side cargo com-
partments. rmr2008-010-015_a

2. For ST and RT models, remove both mirrors,
refer to BODY subsection.
3. Remove the following body panels, refer to
BODY subsection:
– LH and RH middle side panels
– LH and RH wind deflectors
– LH and RH top side panels
– LH and RH acoustic panels
– LH and RH rear side panels.
4. Remove the muffler and catalytic converter,
refer to MUFFLER REMOVAL and CATALYTIC
CONVERTER REMOVAL procedures in this
subsection.
5. Remove the oxygen sensor from the head pipe,
refer to HEATED OXYGEN SENSOR (HO2S) in
the ELECTRONIC FUEL INJECTION (EFI) sub-
section.
TYPICAL
1. Rear cylinder head
2. Nut locations (two are not visible)
3. Gasket, head pipe to cylinder head
7. Pull head pipe from mounting studs and rotate
it so that it can be pulled out on the RH side of
the vehicle.
Head Pipe Installation (Rear Cylinder)
1. Install NEW head pipe gaskets and NEW cylin-
der head gaskets.
2. Install head pipe loosely on cylinder head using
four NEW retaining nuts.
3. Install oxygen sensor, refer to HEATED OXY-
GEN SENSOR (HO2S) in the ELECTRONIC
FUEL INJECTION (EFI) subsection.
4. Install remaining exhaust system loosely.
5. Torque exhaust system fasteners and ensure
proper exhaust system clearance gaps are ob-
tained. Refer to EXHAUST SYSTEM INSTALLA-
TION SEQUENCE in the beginning of this sub-
section.
Install all removed panels, refer to BODY subsec-
tion.

rmr2013-008-209_a

1. Rear oxygen sensor (RH side)

2. Rear head pipe

rmr2013-008 11
 Subsection XX (LUBRICATION SYSTEM)

LUBRICATION SYSTEM
SERVICE TOOLS
Description Part Number Page
ADAPTER HOSE ........................................................................... 529 035 652 ........................................... 10
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 12
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................................... 11
OETIKER PLIERS........................................................................... 295 000 070 ..................................... 13–16
PRESSURE GAUGE....................................................................... 529 035 709 ........................................... 10

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ..................................... 12, 17
LOCTITE 515 ................................................................................. 413 702 700 ........................................... 21
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ..................................... 23, 26
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ........................................... 21
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ............................... 14, 16–17
SUPER LUBE GREASE.................................................................. 293 550 030 ........................................... 24
XPS 4-STROKE SYNTH. BLEND OIL (SUMMER) ......................... 293 600 121 ............................................. 6

rmr2013-009 1
Subsection XX (LUBRICATION SYSTEM)

Engine
oil

See installation
procedure

NEW
Super Lube
Loctite 648 grease
Loctite
243
20 N•m 11 N•m 5 N•m
(15 lbf•ft) (97 lbf•in) (44 lbf•in)
Engine
oil

Loctite
515 Engine
oil

Loctite
515
NEW

Loctite
5910
Loctite 648

SE5
SM5 NEW
1.8 NM
14 N•m
(124 lbf•in) NEW
Engine oil
Engine oil
Loctite 243
NEW
NEW 11 N•m
Engine (97 lbf•in)
20 N•m oil 11 N•m
(15 lbf•ft) (97 lbf•in)
NEW = Component must be replaced when removed.
rmr2013-009-001_a

2 rmr2013-009
 Subsection XX (LUBRICATION SYSTEM)

SE5 engine
28.5 N•m 5.5 N•m
10 N•m (49 lbf•in)
(21 lbf•ft) (89 lbf•in)
NEW Loctite 243
NEW

Engine

NEW
SM5 engine 7 N•m
(62 lbf•in)
5.5 N•m
(49 lbf•in)
28.5 N•m
(21 lbf•ft) Loctite 243
20 N•m
NEW (15 lbf•ft)

7 N•m
20 N•m (62 lbf•in)
NEW
(15 lbf•ft)

NEW

NEW = Component must be replaced when removed.

rmr2008-049-300_c

rmr2013-009 3
Subsection XX (LUBRICATION SYSTEM)

ENGINE LUBRICATION CIRCUIT (RH VIEW)

rmr2011-009-100_a

1. Magnetic drain plug 9. Balance shaft support plain bearing (clutch housing)
2. Engine oil strainer 10. Oil tube (piston cooling and lubrication)
3. Oil scavenge pump 11. Clutch shaft (free pinion and clutch drum)
4. Oil pressure pump 12. Oil duct cover
5. Oil pressure regulator 13. Timing chain tensioner (rear cylinder)
6. 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)

4 rmr2013-009
 Subsection XX (LUBRICATION SYSTEM)

ENGINE LUBRICATION CIRCUIT (LH VIEW)

rmr2011-009-101_a

1. Balance shaft plain bearing (clutch side) 8. Oil nozzle 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) 11. Timing chain tensioner (front cylinder)
5. Connecting rod plain bearings 12. Intake camshaft (front cylinder)
6. Oil hose connector (to oil cooler then oil tank) (oil OUT) 13. Exhaust camshaft (front cylinder)
7. Oil hose connector (from oil tank) (oil IN)

rmr2013-009 5
Subsection XX (LUBRICATION SYSTEM)

GENERAL Engine Oil Level Verification

During assembly/installation, use the torque val-
ues and service products as specified in the ex-
ploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
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.).
NOTICE Hoses, cables or locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
MAINTENANCE
ENGINE OIL
Recommended Engine Oil
Use XPS 4-STROKE SYNTH. BLEND OIL (SUMMER)
(P/N 293 600 121).
NOTE: The XPS oil is specially formulated and
tested for the severe requirements of this engine.
If not available, use a 5W 40 semi-synthetic (min-
imum) or synthetic motorcycle oil meeting the re-
quirements for API service SL, SJ, SH or SG clas-
NOTICE To obtain a precise reading of the
engine oil level, follow this procedure and
make sure engine is at normal operating tem-
perature.
1. Park the vehicle on a level surface.
2. Remove the LH middle side panel. Refer to
BODY subsection.
3. Required conditions:
3.1 Engine at normal operating tempera-
ture.
3.2 Start engine.
3.3 Let idle for at least 30 seconds.
NOTE: Idle time allows the oil to be flowed
back to the oil tank. Otherwise, oil overfilling
might occur.
3.4 Stop engine.
4. Remove the oil dipstick.
rmr2008-011-100_a

sification. Always check the API service label on TYPICAL - RS AND ST MODELS
the oil container. 1. Oil dipstick
2. Oil tank
The same oil is used for the engine, gearbox,
clutch and hydraulic control module (HCM) in the
SE5 models.
NOTICE To avoid damaging the clutch, do
not use a motor oil meeting the API service SM
or ILSAC GF-4 classification. Clutch slippage
will occur.
NOTICE Do not add any oil additives to the
recommended oil. This may lead to gearbox
and clutch malfunctions.

rmo2010-001-062_a

TYPICAL - RT MODELS
1. Oil dipstick
2. Oil tank

6 rmr2013-009
 Subsection XX (LUBRICATION SYSTEM)

5. Wipe off the dipstick. RS/ST Models

6. Install and completely SCREW IN the dipstick 2. Remove the following LH body panels, refer to
to assure an accurate reading. BODY subsection:
7. Remove the dipstick. – Middle side panel
8. Check the oil level on the dipstick; it should be – Heat deflector (ST models only)
near or equal to the upper mark. – Lower side panel.
RT Models
3. Remove the following LH body panels, refer to
BODY subsection:
– Middle side panel
– Bottom rear side panel.
All Models
4. Remove the bottom plate under oil tank.

rmr2008-011-102_a

1. Upper mark (F)

2. Lower mark (ADD)
3. Operating range

Oil Level is Near Upper Mark

1. Do not add oil.
2. Install and tighten dipstick. rmr2008-011-101_a

3. Install the LH middle side panel, refer to BODY TYPICAL - RS AND ST MODELS
subsection. 1. Bottom plate
2. Oil tank
Oil Level Adjustment
1. Adjust oil level to the operating range, close to
the F (upper) mark. Do not overfill.
NOTE: At the ADD (lower) mark, 500 ml
(.5 qt (U.S. liq.)) of oil is required.
2. Install and tighten dipstick.
3. Install the LH middle side panel, refer to BODY
subsection.

Engine Oil Change

1. Prior to changing the oil, ensure vehicle is on a
level surface.
NOTICE The engine oil filter and the hy-
draulic control module (HCM) oil filter (SE5)
rmo2013-005-009_a
must be replaced at the same time. The oil RT MODELS
change should be carried out with a warm 1. Bottom plate
engine. 2. Oil tank

5. Clean area around drain plug under oil tank.

CAUTION Engine oil can be very hot.
6. Place an appropriate drain pan under oil tank.
7. Remove the drain plug and discard the sealing
washer.

rmr2013-009 7
Subsection XX (LUBRICATION SYSTEM)

rmr2008-011-103_a
rmr2008-011-104_a
TYPICAL - RS AND ST MODELS
1. Drain plug TYPICAL - RS AND ST MODELS
2. Oil tank 1. Engine oil drain plug
2. Oil filter cover

rmo2010-001-065_a
rmo2013-005-009_b
RT MODELS
RT MODELS 1. Engine oil drain plug
1. Drain plug 2. Oil filter cover
2. Oil tank
13. Allow sufficient time for oil to completely drain
8. Remove the dipstick. from crankcase.
9. Allow sufficient time for oil to completely drain. 14. Clean the magnet on the engine drain plug.
10. Clean area around engine drain plug. 15. Using NEW sealing washers, install engine
11. Place an appropriate drain pan under the en- and oil tank drain plugs.
gine.
NOTICE Never reuse the drain plug sealing
12. Remove the engine oil drain plug and discard washer. Always replace it with a new one.
the sealing washer.
16. Tighten drain plugs (engine and oil tank) as
specified.
DRAIN PLUGS TORQUE (ENGINE AND OIL TANK)
20 N•m (15 lbf•ft)

17. Replace engine oil filter. Refer to ENGINE OIL

FILTER further in this subsection.
SE5 Model
18. Replace the HCM oil filter. Refer to HY-
DRAULIC CONTROL MODULE (SE5) subsec-
tion.

8 rmr2013-009
 Subsection XX (LUBRICATION SYSTEM)

All Models 29. Dispose of used oil as per your local environ-
19. Pour 3 L (3.2 qt (U.S. liq.)) of the recom- mental regulations.
mended oil into the oil tank.
20. Start engine and let idle for two minutes. ENGINE OIL FILTER
IMPORTANT NOTICE Engine Oil Filter Removal
Do not rev up engine during idling period as this NOTE: Refer to OIL CHANGE for the list of re-
may cause permanent engine damage. quired body panels to be removed.
1. Remove oil filter cover screws.
NOTICE 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.
Check for leaks at:
– Engine oil filter
– HCM oil filter
– Engine drain plug
– Oil tank drain plug.
21. Stop engine. rmr2008-011-105_a

NOTE: The oil level dipstick is accurate when the TYPICAL

1. Oil filter cover
oil temperature is at 80°C (176°F). If the oil level 2. Cover screws
is checked when the oil is at room temperature
(20°C (68°F)), the proper oil level indication is 2. Remove oil filter cover with O-ring. Discard
half way between the lower (ADD) and upper (F) O-ring.
marks on the dipstick. This must be considered 3. Remove oil filter.
to prevent overfilling the oil tank.
4. Dispose of filter as per your local environmental
SM5 Model regulations.
22. Add 1 L (1 qt (U.S. liq.)) of the RECOM-
MENDED ENGINE OIL in the oil tank. Engine Oil Filter Installation
NOTE: The total quantity is within 3.9 L Installation is the reverse of the removal proce-
(4.1 qt (U.S. liq.)) to 4.2 L (4.4 qt (U.S. liq.)). dure. However, pay attention to the following.
23. Check oil level immediately and adjust if re- 1. Check and clean oil inlet and outlet orifices in
quired. crankcase for dirt and contaminants.
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 RECOM-
MENDED ENGINE OIL in the oil tank.
NOTE: The total quantity is 4.2 L
(4.4 qt (U.S. liq.)).
27. Check oil level immediately and adjust if re-
quired. rmr2008-011-004_a

NOTE: When the engine oil filter and the HCM oil
filter are replaced, the total oil quantity to add will
be 4.3 L (4.5 qt (U.S. liq.)).
28. Reinstall all removed body panels.
TYPICAL
1. Oil inlet orifice from oil pressure pump
2. Oil outlet orifice to engine lubrication system
2. Install a NEW O-ring on the oil filter cover.

rmr2013-009 9
Subsection XX (LUBRICATION SYSTEM)

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.
4. Remove the OIL PRESSURE SWITCH, see the
procedure in this subsection.
NOTE: Place a container to retrieve engine oil that
may flow out of engine.
5. Install the hose adapter into the oil pressure
switch port.

rmr2008-011-005_a

1. Apply oil here

INSPECTION rmr2008-011-107_a

TYPICAL
1. Oil pressure gauge
2. Hose adapter
ENGINE OIL PRESSURE TEST
NOTE: The engine oil pressure test should be car- 6. Start engine and measure the engine oil pres-
ried out with a warm engine (80°C (176°F) engine sure.
oil temperature) and with the RECOMMENDED NOTE: Measured engine oil pressure should be
ENGINE OIL at the appropriate level. within the following specifications.
1. Refer to OIL PRESSURE SWITCH ACCESS and OIL
1400 RPM 5000 RPM
remove the required panels. PRESSURE
2. Remove the bottom plate aft of the radiator. 350 kPa
Refer to BODY subsection. MINIMUM 70 kPa (10 PSI)
(51 PSI)
150 kPa 420 kPa
NOMINAL
(22 PSI) (61 PSI)
300 kPa 550 kPa
MAXIMUM
(44 PSI) (80 PSI)

7. After engine oil pressure test, reinstall oil pres-

sure switch, see procedure in this subsection.
8. Reinstall body panels.

rmr2008-011-106_a PROCEDURES
TYPICAL
1. Bottom plate
OIL PRESSURE SWITCH (OPS)
3. Connect the proper adapter hose to the pres-
sure gauge. Oil Pressure Switch Location
The oil pressure switch is located on the RH side
REQUIRED TOOL of vehicle on clutch housing.
ADAPTER HOSE
(P/N 529 035 652)

PRESSURE GAUGE
(P/N 529 035 709)

10 rmr2013-009
 Subsection XX (LUBRICATION SYSTEM)

rmr2008-011-108_a rmr2008-011-108_b

TYPICAL 1. Oil pressure switch connector

1. Oil pressure switch
2. Clutch housing 2. Set a multimeter to selection.
Oil Pressure Switch Access REQUIRED TOOL
RS/ST Models FLUKE 115 MULTIMETER
1. Remove the following RH body panels, refer to (P/N 529 035 868)
BODY subsection:
– Middle side panel 3. Test the resistance of the OPS switch as fol-
– Bottom side panel. lows.
RT Models OPS RESISTANCE TEST ( )
Remove the following RH body panels, refer to ENGINE NOT RUNNING
BODY subsection: Engine
OPS Close to 0
– Middle side panel switch pin ground (normally closed switch)
– Top side panel
– Rear side panel If resistance is incorrect, replace the oil pressure
– Bottom front side panel switch.
– Bottom rear side panel. If the resistance is correct, retest the OPS switch
with engine running. Read result and compare to
Oil Pressure Switch Activation table.
The engine oil pressure switch activates when the OPS RESISTANCE TEST ( )
engine oil pressure is lower than following speci-
ENGINE RUNNING
fied pressure range.
OPS switch pin Engine ground Infinite (OL)
OIL PRESSURE SWITCH ACTIVATION RANGE
45 kPa ± 14 kPa (6.53 PSI ± 2.03 PSI) If resistance is incorrect, replace the oil pressure
switch.
Oil Pressure Switch Inspection If the resistance is correct, test the oil pressure
Ensure engine oil pressure is within specifica- switch wiring circuit.
tions. Refer to ENGINE OIL PRESSURE TEST in
this subsection.
Oil Pressure Switch Circuit Test
If the engine oil pressure is good, carry out an OIL OPS Circuit Dynamic Test
PRESSURE SWITCH RESISTANCE TEST. 1. First, ensure an engine oil pressure test has
been performed and that engine oil pressure is
Oil Pressure Switch Resistance Test within specifications.
NOTE: The engine must be warm to test the oil 2. Start the engine.
pressure switch properly.
3. Disconnect the OPS connector.
1. Disconnect the oil pressure switch connector.
4. Ground the OPS connector. The low oil pres-
sure pilot lamp should turn on.

rmr2013-009 11
Subsection XX (LUBRICATION SYSTEM)

5. Unground the OPS connector. Oil pilot lamp NOTE: This is recommended to avoid oil drainage
should turn off. from engine when removing switch.
If the test succeeded and the low oil pressure pilot 2. Disconnect the oil pressure switch connector.
lamp stays ON when engine is running, try a new 3. Unscrew and remove the oil pressure switch.
OPS.
If the low oil pressure pilot lamp does not come on
with the circuit grounded, test continuity of OPS
circuit wiring.
OPS Circuit Continuity Test
1. Disconnect connector “A” from the ECM. Re-
fer to ELECTRONIC FUEL INJECTION (EFI)
subsection.
2. Install the adapter on ECM-A connector.
REQUIRED TOOL

ECM ADAPTER TOOL rmr2008-011-108_a

(P/N 529 036 166) TYPICAL

1. Oil pressure switch
2. Clutch housing
3. Test for continuity of OPS circuit as per follow-
ing table. Oil Pressure Switch Installation
TEST PROBES RESISTANCE Tighten oil pressure switch as specified.
ECM adapter Close to 0 NOTICE Do not apply Loctite 243 to the first
OPS connector
pin E3 (continuity) thread. If Loctite seeps into pressure switch, oil
pressure switch may malfunction.
OIL PRESSURE SWITCH
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Tightening torque 20 N•m (15 lbf•ft)

OIL TANK
Oil Tank Access
RS/ST Models
smr2009-023-102_b
1. Remove the following LH body panels, refer to
BODY subsection:
If circuit continuity is not within specification, re- – Middle side panel
peat test at the engine disconnect (HIC) connec- – Bottom side panel.
tor. Repair wiring/connectors as required.
RT Models
If circuit continuity is within specification, carry out
a multifunction gauge WOW test in B.U.D.S., re- 2. Remove the following LH body panels, refer to
fer to LIGHTS, GAUGE AND ACCESSORIES sub- BODY subsection:
section. – Top side panel
NOTE: If the engine oil pressure is within spec- – Middle side panel
ification, OPS tests and the OPS wiring circuit – Bottom front side panel.
tested good, check multifunction gauge and ECM.
Oil Tank Removal
Oil Pressure Switch Removal 1. Drain oil tank. Follow the procedure in ENGINE
1. Start vehicle and let engine run approximately 5 OIL CHANGE in the beginning of this subsec-
minutes. tion.
12 rmr2013-009
 Subsection XX (LUBRICATION SYSTEM)

2. Disconnect vent hose from top of oil tank.

rmr2008-011-114_a

TYPICAL
1. Ignition coil bolt

rmr2008-011-111_a
6. At the bottom of oil tank, disconnect the oil tank
TYPICAL
return hose.
1. Vent hose
2. Oil tank

3. Remove screws retaining oil cooler to oil tank.

rmr2008-011-115_a

TYPICAL
1. Return hose
2. Oil tank
rmr2008-011-112_a

TYPICAL REQUIRED TOOL

1. Oil cooler
2. Remove these screws
OETIKER PLIERS
4. Remove bolt above ignition coil securing oil (P/N 295 000 070)
tank to lateral support.
7. Behind oil tank, remove the screw securing oil
tank to oil cooler support bracket.

rmr2008-011-113_a

TYPICAL
1. Ignition coil
2. Remove this bolt
rmr2008-011-116_a

5. Remove ignition coil retaining bolt. TYPICAL

1. Oil cooler support bracket
2. Remove this crew

8. Disconnect the oil cooler outlet hose.

rmr2013-009 13
Subsection XX (LUBRICATION SYSTEM)

DRAIN PLUG
Gasket NEW
Tightening torque 20 N•m (15 lbf•ft)

6. Refill oil tank with recommended oil. Refer to

ENGINE OIL in this subsection.

OIL TANK STRAINER

Oil Tank Strainer Access
rmr2008-011-117_a

TYPICAL RS/ST Models

1. Oil cooler outlet hose
2. Remove this Oetiker clamp 1. Remove the following LH body panels, refer to
BODY subsection:
SE5 Model – Middle side panel
9. Remove the HCM clutch servo hose in the front – Bottom side panel.
of the oil tank.
RT Models
2. Remove the following LH body panels, refer to
BODY subsection:
– Top side panel
– Middle side panel
– Bottom front side panel.

Oil Tank Strainer Removal

1. Drain oil tank. See ENGINE OIL CHANGE pro-
cedure in this subsection.
2. Remove Oetiker clamp and disconnect oil tank
return hose.
rmr2008-046-003_a

TYPICAL REQUIRED TOOL

1. Clutch servo hose
2. Oil tank
OETIKER PLIERS
All Models (P/N 295 000 070)
10. Remove oil tank.

Oil Tank Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
1. Ensure the rubber cushions are properly in-
stalled in the oil tank support.
2. Clean oil residue on oil tank fittings and oil
hoses using PULLEY FLANGE CLEANER (P/N 413
711 809).
3. Install NEW Oetiker clamps.
4. Using a NEW sealing washer, install oil tank rmr2008-011-109_a

drain plug. TYPICAL

1. Strainer end
NOTICE Never reuse a sealing washer a sec- 2. Oil tank return hose
3. Oil tank
ond time. Always replace it with a new one.
3. Unscrew and remove oil tank strainer with its
5. Tighten drain plug to specification. O-ring. Discard the O-ring.

14 rmr2013-009
 Subsection XX (LUBRICATION SYSTEM)

OIL COOLER
Oil Cooler Access
RS/ST Models
1. Remove the following LH body panels, refer to
BODY subsection:
– Middle side panel
– Bottom side panel.
RT Models
2. Remove the following LH body panels, refer to
rmr2008-011-110_a
BODY subsection:
TYPICAL
1. Oil tank strainer – Middle side panel
2. O-ring
– Bottom front side panel.
Oil Tank Strainer Cleaning Oil Cooler Removal
Clean oil tank strainer with a parts cleaner, then 1. Drain oil tank. See ENGINE OIL CHANGE pro-
use air pressure to dry it. cedure in this subsection.
Oil Tank Strainer Inspection 2. Remove screws retaining oil cooler to oil tank.
Check condition of strainer mesh. Replace
strainer as required.

Oil Tank Strainer Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
1. Wipe off any oil spillage on oil tank.
2. Install a NEW O-ring on the oil strainer.
3. Apply engine oil on O-ring.
4. Install strainer in oil tank and tighten to specifi-
cation. rmr2008-011-112_a

OIL STRAINER 1. Oil cooler

2. Remove these screws
Gasket NEW
3. Remove bolt above ignition coil securing oil
Tightening torque 20 N•m (15 lbf•ft) tank to frame.
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 295 000 070)

6. Refill oil tank with recommended oil. Refer to rmr2008-011-113_a

ENGINE OIL at the beginning of this subsec- TYPICAL
tion. 1. Ignition coil
2. Remove this bolt
7. Install all other removed parts.
4. Disconnect oil cooler inlet hose from engine
outlet connector tube.

rmr2013-009 15
Subsection XX (LUBRICATION SYSTEM)

NOTICE Be careful to avoid breaking oil

cooler outlet tube.
SE5 Model
8. Remove the HCM clutch servo hose from the
front of the tank.

rmr2008-011-118_a

TYPICAL
1. Oil cooler inlet hose
2. Engine outlet connector tube

REQUIRED TOOL

OETIKER PLIERS
(P/N 295 000 070)
rmr2008-046-003_a

5. Behind oil tank, remove screw securing oil TYPICAL

1. Clutch servo hose
cooler to support. 2. Oil tank

All Models
9. Move oil tank rearward to remove oil cooler
from vehicle.

Oil Cooler Installation

For installation, reverse the removal procedure
however, pay attention to the following.
Clean oil residue on oil cooler fittings and oil hoses
using PULLEY FLANGE CLEANER (P/N 413 711 809).
Refill oil tank with recommended oil and check en-
rmr2008-011-119_a gine oil level. Refer to ENGINE OIL at the begin-
TYPICAL ning of this subsection.
1. Oil cooler
2. Support
3. Remove this screw
OIL HOSE CONNECTOR TUBES
6. Remove and discard Oetiker clamp securing oil Oil Hose Connector Tube Location
cooler outlet hose.
The oil hose connector tubes are located on the
crankcase, magneto side.

rmr2008-011-120_a

1. Oil cooler
2. Oil cooler outlet hose

7. Disconnect oil cooler outlet hose.

16 rmr2013-009
 Subsection XX (LUBRICATION SYSTEM)

rmr2008-011-007_a
rmr2008-011-008_a
TYPICAL
1. Oil hose connector tube “IN” TYPICAL
2. Oil hose connector tube “OUT” 1. Screws
2. Oil hose connector tube “IN”
3. Oil hose connector tube “OUT”
Oil Hose Connector Tubes Access 4. O-rings

RS/ST Models Oil Hose Connector Tube Inspection

1. Remove the following LH body panels, refer to Clean oil hose connector tubes with a parts
BODY subsection: cleaner, then use air pressure to dry the parts.
– Middle side panel
– Bottom side panel. WARNING
RT Models Always wear skin and eye protection. Chem-
icals can cause skin rash, skin burns and se-
2. Remove the following LH body panels, refer to vere eye injury.
BODY subsection:
– Middle side panel Check connector tubes for cracks or other dam-
– Top side panel ages. Replace if necessary.
– Rear side panel
– Bottom front side panel Oil Hose Connector Tube Installation
– Bottom rear side panel. For installation, reverse the removal procedure.
However, pay attention to the following details.
Oil Hose Connector Tube Removal 1. Clean oil residue on hose fittings using PULLEY
1. Drain engine oil, refer to ENGINE OIL CHANGE FLANGE CLEANER (P/N 413 711 809).
in this subsection. 2. Always replace connector tube O-rings with
2. Remove oil hoses from connectors tubes. NEW ones.
3. Loosen connector tube retaining screws. 3. Tighten connector tube retaining screws to
4. Remove connector tubes and O-rings. Discard specification.
O-rings. CONNECTOR TUBE SCREW
Gasket NEW
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Tightening torque 11 N•m (97 lbf•in)

4. Install hoses as illustrated.

rmr2013-009 17
Subsection XX (LUBRICATION SYSTEM)

– Bottom front side panel

– Bottom rear side panel.

Oil Nozzle Removal

1. Remove screw plug.
2. Remove and discard gasket ring.
3. Unscrew oil nozzle from crankcase and discard
it.

rmr2008-011-007_b

TYPICAL
1. From oil tank
2. To oil cooler

5. Refill oil tank with recommended oil and check

engine oil level. Refer to ENGINE OIL in this
subsection.

OIL NOZZLE
Oil Nozzle Location
The oil nozzle is located on the magneto side,
screwed into the crankcase. It supplies oil to the
Rmr2013-009-003_a
clutch.
TYPICAL
1. Plug screw
2. Gasket ring
3. Oil nozzle

Oil Nozzle Installation

For installation, reverse the removal procedure
however, pay attention to the following details.

rmr2008-011-031_a

TYPICAL
1. Oil nozzle screw plug

Oil Nozzle Access

RS/ST Models
1. Remove the following LH body panels, refer to
BODY subsection:
– Middle side panel
– Bottom side panel. Rmr2013-009-004_a

RT Models OIL NOZZLE IDENTIFICATION

1. Oil Nozzle - SE5
Remove the following LH body panels, refer to 2. Oil Nozzle - SM5
BODY subsection: A. 37 mm (1.5 in)
B. 47 mm (1.9 in)
– Middle side panel
– Top side panel 1. Tighten NEW oil nozzle to specification.
– Rear side panel

18 rmr2013-009
 Subsection XX (LUBRICATION SYSTEM)

OIL NOZZLE
Gasket NEW
Tightening torque 1.8 N•m (16 lbf•in)

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
rmr2008-011-018
pumps are integrated into one oil pump module.
BLOCK HOLES IN CRANKCASE WITH A RAG

Oil Pump Module Location 4. Remove the remaining oil pump module parts:
The oil pump module is located behind the clutch
on the crankcase.

rmr2008-011-019_a
rmr2008-011-010_b

1. Oil pump module 1. Inner rotor (pressure pump)

2. Outer rotor (pressure pump)
3. Needle pins
Oil Pump Module Removal 4.
5.
Oil pump housing
Oil pump shaft
1. Remove clutch. Refer to CLUTCH (SM5) or 6. Inner rotor (scavenge pump)
7. Outer rotor (scavenge pump)
CLUTCH (SE5) subsection. 8. Dowel pin
2. Remove parts listed in the following illustration.
Oil Pump Module Inspection
NOTE: The inspection procedure is the same for
both oil pumps.
1. Check oil pump module housing and crankcase
surface (where the oil pump module housing
fits) for flatness with a straight edge.
2. Inspect oil pumps and oil pump bores for wear
marks, scratches, cracks or other damages.
Replace damaged parts.
3. Check inner rotor for corrosion pin holes, pitting
or other damages. If defects or damages are
found, replace oil pump inner and outer rotor.
rmr2008-011-011_b

1. Snap ring
2. Oil pump gear
3. Needle pin
4. Oil pump module screws
5. Oil pump module cover

3. Using a rag, block the oil passages to prevent

the needle pin from falling into the crankcase.
rmr2013-009 19
Subsection XX (LUBRICATION SYSTEM)

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.

vmr2008-012-016_a

TYPICAL
1. Pitting on the teeth

Radial Clearance
Using a feeler gauge, measure the radial clear-
ance as illustrated. Refer to table following rmr2008-011-020

illustration for service limits. OUTER ROTOR THICKNESS

2. Using a depth gauge, measure the depth of the

corresponding oil pump bore as illustrated.

rmr2008-011-021

OIL PUMP BORE DEPTH (OIL PUMP HOUSING)

vmr2008-012-014_a

TYPICAL
1. Outer rotor
2. Inner rotor

OUTER AND INNER ROTOR CLEARANCE

SERVICE LIMIT
A
B 0.25 mm (.0098 in)
C
rmr2008-011-022

OIL PUMP BORE DEPTH (CRANKCASE)

If clearance between inner and outer rotors ex-
ceeds the tolerance, replace the respective oil
pump.

20 rmr2013-009
 Subsection XX (LUBRICATION SYSTEM)

Calculate the difference between measurements

of the outer rotor and corresponding oil pump
bore; it should not exceed the following specifi-
cation.
OIL PUMP AXIAL CLEARANCE
SERVICE LIMIT 0.15 mm (.0059 in)

If the oil pump axial clearance is out of tolerance,

replace the complete oil pump assembly.
NOTE: When the axial clearance of the oil pump
assembly increases, the oil pressure decreases.

Oil Pump Module Installation rmr2011-009-004_a

OIL PUMP MODULE HOUSING

For installation, reverse the removal procedure. 1. Apply Loctite here
However, pay attention to the following details.
4. Coat inner and outer rotors with oil.
1. Clean all metal components in a solvent.
5. Install oil suction pump rotor into the crankcase.
2. Remove old sealant from mating surfaces of
crankcase, oil pump module housing and oil 6. Preassemble needle pin (into the lower bore)
pump module cover, using LOCTITE CHISEL and inner rotor on oil pump shaft.
(GASKET REMOVER) (P/N 413 708 500) and 7. Install pre-assembled oil pump shaft in
scotch-bride (if necessary). crankcase.
3. Apply a thin film of LOCTITE 515 (P/N 413 702 NOTE: Markings on inner and outer rotors must
700) on crankcase and oil pump module housing face towards the inner side of the crankcase.
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.

rmr2011-009-005_a

1. Outer rotor, suction pump

2. Oil pump shaft
3. Groove for oil pump gear snap ring
4. Needle pin
5. Inner rotor, suction pump
6. Marks on inner and outer rotor

8. Install oil pump module housing on crankcase.

9. Install the dowel pin in the oil pump module
housing and crankcase.

rmr2011-009-003_a

CRANKCASE
1. Apply Loctite here

rmr2013-009 21
Subsection XX (LUBRICATION SYSTEM)

rmr2011-009-008_a
rmr2011-009-006_a
OIL PUMP MODULE COVER
1. Oil pump module housing 1. Retaining screws
2. Dowel pin
14. Tighten oil pump module retaining screws in a
10. Install needle pin in the middle bore of the oil criss-cross pattern to specification.
pump shaft.
11. Assemble inner rotor on oil pump shaft. OIL PUMP RETAINING SCREWS

12. Install outer rotor into oil pump module hous- Tightening torque 11 N•m (97 lbf•in)
ing.
15. After installation, check for smooth operation
NOTE: Markings on inner and outer rotor must be of the oil pump assembly.
visible.
16. Install all other removed parts.
Final Test
After engine is completely reassembled, start en-
gine and make sure oil pressure is within specifi-
cations (refer to ENGINE OIL PRESSURE TEST in
this subsection).

ENGINE OIL PRESSURE

REGULATOR
Engine Oil Pressure Regulator
Location
The engine oil pressure regulator is located inside
the oil pump module cover.
rmr2011-009-007_a

1. Needle pin
2. Inner rotor, pressure pump
3. Outer rotor, pressure pump
4. Markings on inner and outer rotor

13. Install complete oil pump module cover.

rmr2008-011-010_a

1. Engine oil pressure regulator

22 rmr2013-009
 Subsection XX (LUBRICATION SYSTEM)

Oil Pressure Regulator Removal
1. Remove clutch. Refer to CLUTCH (SM5) or
CLUTCH (SE5) subsection.
2. Remove oil pump module cover. Refer to OIL
PUMP MODULE in this subsection.
2. Check if piston moves easily in oil pump module
cover.
3. Check compression spring for any deformation.
4. Check compression spring free length.

rmr2008-011-013

SPRING FREE LENGTH

NEW 37.6 mm (1.48 in)
SERVICE LIMIT 36.6 mm (1.441 in)
rmr2008-011-011_a

1. Oil pump gear 5. Replace worn or damaged components.

2. Oil pump module cover
NOTE: Check the pressure regulator piston for
freedom of movement. If piston moves freely
and oil pressure is within specification, there is
no need to remove the plug screw.
3. Using a vise with aluminium jaws, lightly clamp
oil pump module cover.
4. Unscrew the screw plug.
5. Remove the regulator spring.
6. Remove the regulator piston.
6. Clean bore and screw threads in the oil pump
module cover of metal shavings and other con-
taminants.
Oil Pressure Regulator Installation
For installation, reverse the removal procedure.
However, pay attention to the following details.
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 ± .004 in) deeper
than the outer edge of the bore in the oil pump
module cover, see following illustration.

rmr2008-011-012_a

1. Screw plug
2. Regulator spring rmr2008-011-014_a
3. Regulator piston
4. Oil pump module cover 1. Screw plug
2. Outer bore edge in pump module cover
A. 2.3 mm ± 0.1 mm (.091 in ± .004 in)
Oil Pressure Regulator Inspection
1. Inspect the regulator piston for scoring or other 3. Check if oil pressure regulator functions prop-
damages. Check also the bore of the oil pump erly by pushing on regulator piston.
module cover. 4. Secure plug screw with four (4) center punch
marks.

rmr2013-009 23
Subsection XX (LUBRICATION SYSTEM)

Oil Duct Cover Inspection

Inspect oil duct cover for cracks or other damages.
Replace if necessary.
Clean oil passage in cover with a parts cleaner,
then use an air gun to dry it.

WARNING
rmr2008-011-300_a
Always wear skin and eye protection. Chem-
1. Plug screw
icals can cause skin rash, skin burns and se-
2. Punch marks vere eye injury.

OIL DUCT COVER

NOTE: The oil duct cover supplies additional oil to
the main shaft in the gearbox.

Oil Duct Cover Location

The oil duct cover is located on the crankcase be-
hind the clutch.

Rmr2013-009-005_a

1. Clean oil passages

2. Screw plug

Oil Duct Cover Installation

For installation, reverse the removal procedure.
rmr2008-011-027_a
However, pay attention to the following details.
1. Oil duct cover
1. Install a NEW O-ring.
Oil Duct Cover Removal 2. Apply SUPER LUBE GREASE (P/N 293 550 030) on
1. Remove clutch. Refer to CLUTCH (SM5) or O-ring and oil seal, as shown.
CLUTCH (SE5) subsection.
2. Remove two (2) retaining screws and pull oil
duct cover from the crankcase.

rmr2008-011-030_a

1. Apply Super Lube grease here

3. Install remaining parts, refer to the appropriate

subsections.
rmr2008-011-028_a

1. Retaining screws
2. Oil duct cover
3. O-ring (discard)
4. Oil seal

24 rmr2013-009
 Subsection XX (LUBRICATION SYSTEM)

OIL STRAINER
Oil Strainer Location
The oil strainer (sieve) is located between both
crankcase halves.

rmr2008-011-033_a

1. Oil tube
2. Crankcase halve - magneto side

NOTE: If the engine has to be dismantled within

the scope of repair work, take this opportunity to
clean the oil tube.
rmr2008-011-025_a

1. Engine oil strainer Oil Tube Removal

Oil Strainer Removal Remove oil tube from crankcase only if necessary.
1. Separate both crankcase halves. Refer to Clamp the oil tube in a vice and push crankcase
CRANKCASE AND CRANKSHAFT subsection. half MAG side using a soft hammer.
2. Pull oil strainer from its location.

Oil Strainer Inspection

Clean oil strainer with a parts cleaner then use air
pressure to dry it.
Check oil strainer for damage, replace it if neces-
sary.

Oil Strainer Installation

Refer to CRANKCASE in CRANKCASE AND
CRANKSHAFT subsection.

OIL TUBE
Rmr2013-009-006_a

Oil Tube Access 1. Clamp here

2. Crankcase half MAG side
The oil tube is located inside crankcase, between
both crankcase halves. Oil Tube Inspection
Separate both crankcase halves, refer to Clean oil tube with a parts cleaner, then use air
CRANKCASE AND CRANKSHAFT subsection. 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.
Always install a NEW oil tube.

rmr2013-009 25
Subsection XX (LUBRICATION SYSTEM)

rmr2008-049-001_a

1. Oil tube
2. Loctite 648 (GREEN) (P/N 413 711 400)
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.
NOTICE 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.

26 rmr2013-009
 Subsection XX (COOLING SYSTEM)

COOLING SYSTEM
SERVICE TOOLS
Description Part Number Page
HANDLE ........................................................................................ 420 877 650 ........................................... 15
LARGE HOSE PINCHER................................................................ 529 032 500 ........................................... 12
OETIKER PLIERS........................................................................... 295 000 070 ..................................... 10–13
OIL SEAL PUSHER........................................................................ 529 035 757 ........................................... 15
SEAL PUSHER .............................................................................. 529 035 766 ........................................... 16
SUCTION PUMP ........................................................................... 529 035 880 ........................................... 12
TEST CAP ...................................................................................... 529 035 991 ............................................. 7
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ............................................. 7

SERVICE PRODUCTS
Description Part Number Page
BRP PREMIXED COOLANT .......................................................... 219 700 362 ............................................. 5
DOW CORNING 111 ..................................................................... 413 707 000 ........................................... 15
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 13

rmr2013-010 1
Subsection XX (COOLING SYSTEM)

COOLANT TEMPERATURE SENSOR (CTS)

20 N•m
(15 lbf•ft)

NEW

See
ELECTRONIC FUEL INJECTION (EFI)

rmr2010-010-001_c

2 rmr2013-010
 Subsection XX (COOLING SYSTEM)

WATER PUMP

11 N•m
(97 lbf•in)

Loctite 243

NEW NEW

Hand tighten

Dow
Corning
111

NEW

NEW = Component must be replaced when removed.

rmr2008-012-001_d

rmr2013-010 3
Subsection XX (COOLING SYSTEM)

RADIATOR, COOLING FAN, THERMOSTAT AND COOLANT TANK

T1 2.5 N•m (22 lbf•in)

T2 7 N•m (62 lbf•in)
T3 10 N•m (89 lbf•in)
T4 7.5 N•m (66 lbf•in)

NEW

T1 T3

T1

NEW

T2

NEW

NEW

T2
T4

NEW

NEW = Component must be replaced when removed.

rmr2013-010-050_a

4 rmr2013-010
 Subsection XX (COOLING SYSTEM)

GENERAL NOTICE To prevent rust formation or freez-

During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices must be replaced with new
ones when removed(e.g.: locking tabs, elas-
tic stop nuts, cotter pin, etc.).
NOTICE Hoses, cables or locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
MAINTENANCE
ing condition, always replenish the system
with the BRP premixed coolant or with 50%
antifreeze and 50% distilled water. Do not use
tap water, straight antifreeze or straight water
in the system. Tap water contains minerals
and impurities which build up in the system.
During cold weather, straight water causes
the system to freeze while straight antifreeze
thickens and does not have the same effi-
ciency. Always use ethylene glycol antifreeze
containing corrosion inhibitors specifically
recommended for aluminum engines.
Draining the Cooling System
1. Open the front storage compartment cover.
RS/ST Models
2. Refer to BODY subsection and remove on the
RH side of vehicle:
– Middle side panel
– Bottom side panel
– Service cover.

ENGINE COOLANT RT Models

REPLACEMENT 3. Refer to BODY subsection and remove on the
RH side of vehicle:
WARNING – Middle side panel
To avoid potential burns, do not remove the – Bottom front side panel
coolant tank cap or loosen the cooling drain – Service cover.
plug if the engine is hot.
All Models
Recommended Coolant 4. Place a drain pan under radiator drain plug.
COOLANT 5. Remove the drain plug from radiator.
BRP PREMIXED
BRP RECOMMENDED
COOLANT (P/N 219
PRODUCT
700 362)
A blend of 50%
ALTERNATIVE antifreeze with 50%
distilled water

To prevent antifreeze deterioration, always use

the same brand. Never mix different brands un-
less cooling system is completely flushed and
refilled.

rmr2008-012-101_a

TYPICAL - RADIATOR DRAIN PLUG LOCATION

rmr2013-010 5
Subsection XX (COOLING SYSTEM)

rmr2008-012-024_a

1. Radiator drain plug

6. Discard the O-ring on drain plug.

rmr2013-010-052_b
7. Remove coolant tank pressure cap. 1. COLD level mark

NOTE: You may look inside the reservoir to make

sure the coolant is flush with the reference line.

rmr2013-010-051_a

COOLANT TANK PRESSURE CAP

Refilling the Cooling System

1. Ensure vehicle is on a flat surface and engine is
cold.
2. Install a NEW O-ring on drain plug.
rmo2013-003-012_a
3. Tighten drain plug to specification. 1. Coolant level reference line

DRAIN PLUG NOTE: Do not install coolant tank pressure cap at

Tightening torque 7 N•m (62 lbf•in) this time.
5. Run engine until thermostat opens, then stop
4. Using a long reach funnel, fill cooling system engine.
until coolant reaches the COLD level mark of
coolant tank. NOTE: Use B.U.D.S. to monitor engine tempera-
ture.
APPROXIMATE COOLANT CAPACITY
THERMOSTAT OPENING TEMPERATURE
3 L (.8 U.S. gal.)
75°C (167°F)

6. Let engine cool down.

7. Recheck coolant level and adjust if necessary.
8. Test the density of the coolant using an an-
tifreeze hydrometer. Follow the hydrometer's
manufacturer instruction for proper use.
6 rmr2013-010
 Subsection XX (COOLING SYSTEM)

NOTICE Ensure the coolant density is ade- – Coolant tank

quate to avoid any damage from freezing.
9. Reinstall pressure cap.
10. Reinstall removed parts.
– Engine leak indicator hole, see procedure in
ENGINE LEAK INDICATOR HOLE INSPEC-
TION.

INSPECTION
COOLING SYSTEM LEAK TEST
WARNING
In order to avoid getting burned, do not re-
move the coolant tank cap or loosen the en-
gine drain plug if the engine is hot.

1. Open the front storage compartment cover.

2. Remove the service cover on the RH side. Re-
fer to BODY subsection. rmr2008-012-022_a

TYPICAL
3. Remove coolant tank pressure cap. 1. Leak indicator hole
2. Water pump housing
4. Pressurize the cooling system as follows. 3. Starter

REQUIRED TOOL NOTE: Leaking coolant from the engine leak indi-
cator hole indicates a damaged rotary seal. Leak-
TEST CAP ing oil indicates a damaged oil seal. If either seal is
(P/N 529 035 991)
leaking, both seals must be replaced at the same
time with the water pump shaft.
VACUUM/PRESSURE PUMP 6. If a coolant leak is not visible and the pressure
(P/N 529 021 800)
drops, spray a soap/water solution and look for
air bubbles.

Engine Leak Indicator Hole Inspection

Clean area around leak indicator hole.
Start engine and let it idle for 2 minutes and then
5 times rev up to 7000 RPM.
Inspect leak indicator hole area.
If more than 2 drops of coolant or oil are visible,
replace water pump shaft and seals. Refer to WA-
TER PUMP SHAFT AND SEALS in this subsection.

rmr2008-012-021

TYPICAL

LEAK TEST PRESSURE

90 kPa (13 PSI)

5. If pressure drops, check the following compo-

nents for coolant leaks.
– All hoses
– Radiator
– Cylinder/base

rmr2013-010 7
Subsection XX (COOLING SYSTEM)

PROCEDURES If the fan does not work:

– Check the wiring harness and connectors be-
COOLING FAN tween fuse box and cooling fan.
– Check the relay control circuit wires.
Cooling Fan Operating Condition
If the fan does not work after all tests:
RADIATOR COOLING FAN – Replace it.
ENGINE COOLING FAN COOLING FAN
TEMPERATURE RELAY OPERATION Cooling Fan Removal
> 101°C (214°F) Close Starts RS/ST Models
< 97°C (207°F) Open Stops Refer to BODY subsection and remove:
– Middle side panel
Cooling Fan Test using B.U.D.S. – Bottom side panel.
1. Connect vehicle to latest applicable B.U.D.S. Remove screws securing cooling fan to radiator.
version, refer to COMMUNICATION TOOLS Unplug cooling fan connector.
AND B.U.D.S.
2. In B.U.D.S., select:
– Activation tab
– ECM tab.
3. Click on the cooling fan to activate it.

rmr2008-012-029_a

TYPICAL - SM5 MODEL SHOWN

1. Cooling fan screws
2. Cooling fan connector

rmr2008-016-081_b RT Models
1. Activate fan here Refer to BODY subsection and remove the follow-
ing RH side panels:
If cooling fan works:
– Middle side panel
– Check coolant temperature sensor (CTS).
– Top side panel
If the cooling fan does not work:
– Bottom Rear side panel
– Check the 30 A fuse.
– Bottom Front side panel
If fuse is good: – Rear side panel.
– Check the cooling fan relay.
Remove headlight adjustment cable from RH side
Cooling Fan Relay Test panel support.
1. Remove the cooling fan relay (R3). Refer to Remove RH side panel support.
POWER DISTRIBUTION AND GROUNDS sub-
section.
2. Install a fused jumper wire end between pins
30 and 87.
If the fan works correctly by jumping the relay:
– Replace the relay.

8 rmr2013-010
 Subsection XX (COOLING SYSTEM)

rmr2011-059-003_a

1. Top cooling fan screws (2)

rmr2010-011-001_a

TYPICAL
1. RH side panel support

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.

rmr2011-059-004_a

TYPICAL
1. Bottom cooling fan screws (2)
2. Fan deflector duct

Cooling Fan Installation

RS/ST Models
For the installation, reverse the removal proce-
dure.
rmr2011-059-002_a Be sure to reconnect fan connector.
1. Fan air deflector duct
2. Thermostat RT Models
3. Cooling fan connector
For the installation, reverse the removal proce-
Remove thermostat from the fan air deflector dure however, pay attention to the following.
duct. Be sure to:
Remove screws securing air deflector duct and – Reconnect fan connector
cooling fan to radiator. – Mount thermostat on fan air deflector duct.
All Models
FAN MOUNTING SCREW TORQUE
7 N•m (62 lbf•in)

rmr2013-010 9
Subsection XX (COOLING SYSTEM)

RADIATOR
Radiator Removal
For access, refer to COOLING FAN REMOVAL in
this subsection.
1. Drain engine coolant. Refer to ENGINE
COOLANT REPLACEMENT in this subsec-
tion.
Unscrew bolt on the top of radiator.

rmr2011-059-002_a

1. Fan air deflector duct

2. Thermostat
3. Cooling fan connector

3. Cut Oetiker clamps securing radiator hoses.

REQUIRED TOOL

OETIKER PLIERS
rmr2008-012-025_a (P/N 295 000 070)
1. Radiator bolt

Unplug the cooling fan connector. 4. Disconnect radiator hoses.

5. Lift radiator and remove it from vehicle.
RS/ST Models
6. If replacing radiator, remove cooling fan from
Cut the Oetiker clamps from radiator hoses. radiator.
REQUIRED TOOL
Radiator Inspection
OETIKER PLIERS Check radiator fins for clogging or damage.
(P/N 295 000 070)
Remove insects, mud or other obstructions with
low pressure water.
Disconnect radiator hoses.
Check for any coolant leakage from radiator and
Remove radiator from vehicle. hoses.
RT Models
Radiator Installation
2. Remove thermostat from fan air deflector duct.
For installation, reverse the removal procedure.
However, pay attention to the following.
Ensure rubber mounts are positioned between
bottom of radiator and frame.

10 rmr2013-010
 Subsection XX (COOLING SYSTEM)

All Models
Drain engine coolant. Refer to COOLANT RE-
PLACEMENT in MAINTENANCE in this subsec-
tion.
Pinch cooling hoses from thermostat housing.
Cut hose clamps.
REQUIRED TOOL

OETIKER PLIERS
(P/N 295 000 070)
rmr2008-050-001_a

1. Radiator rubber mounts

Pull out thermostat housing. Catch spilled
Install a NEW radiator drain plug O-ring. coolant.
Refill coolant tank and bleed cooling system. Re- Thermostat Test
fer to MAINTENANCE in this subsection.
Put thermostat housing in water and heat water.
THERMOSTAT THERMOSTAT OPENING TEMPERATURE
Thermostat Location Starts to open 75°C (167°F)
The thermostat is a single action type mounted
externally on the RH side the engine. Thermostat Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
Position thermostat as shown.

rmr2011-059-002_a

TYPICAL - RT MODEL SHOWN

1. Fan air deflector duct
2. Thermostat
3. Cooling fan connector
rmr2013-010-075_a

Thermostat Removal
Install NEW clamps using Oetiker pliers.
RS/ST Models Make sure thermostat is locked in air deflector
Refer to BODY subsection and remove: clamp.
– Middle side panel On RT models, insert it in air deflector.
– Lower side panel. Refill coolant tank and bleed cooling system. Re-
RT Models fer to MAINTENANCE in this subsection.
For access, refer to COOLING FAN REMOVAL in
this subsection. COOLANT TANK CAP
Coolant Tank Cap Inspection
1. Ensure cap seal is in good condition.

rmr2013-010 11
Subsection XX (COOLING SYSTEM)

2. Using a pressure cap tester, check cap opening

pressure.
CAP OPENING PRESSURE
90 kPa ± 7 kPa (13 PSI ± 1 PSI)

COOLANT TANK
Coolant Tank Removal
RS/ST Models
Refer to BODY subsection and remove:
– RH front panel
– Central panel
– RH service cover.
rmr2013-010-076_a
Pinch coolant tank hose.
Remove darts retaining coolant tank and lift it.
REQUIRED TOOL
Cut the Oetiker clamp securing coolant tank hose.
LARGE HOSE PINCHER REQUIRED TOOL
(P/N 529 032 500)
OETIKER PLIERS
(P/N 295 000 070)

rmr2008-012-031_a

TYPICAL
1. Coolant tank hose
rmr2008-012-033_a
RT Models TYPICAL
1. Oetiker clamp
Remove the front fascia. Refer to BODY subsec- 2. Coolant hose
tion.
Remove the RH side headlight. Refer to LIGHTS, Remove hose from coolant tank.
GAUGE AND ACCESSORIES subsection.
Coolant Tank Installation
All Models The installation is the reverse of the removal pro-
Remove coolant tank pressure cap. cedure.
Empty the coolant tank.
COOLANT TEMPERATURE
REQUIRED TOOL
SENSOR (CTS)
SUCTION PUMP Refer to ELECTRONIC FUEL INJECTION (EFI)
(P/N 529 035 880) subsection for testing and replacement proce-
dures of the coolant temperature sensor (CTS).
Disconnect the hoses on the top of coolant tank.

12 rmr2013-010
 Subsection XX (COOLING SYSTEM)

WATER PUMP HOUSING

Water Pump Housing Access
For access, refer to COOLING FAN REMOVAL in
this subsection.

Water Pump Housing Removal

WARNING
To avoid potential burns, do not remove the
coolant tank cap or loosen the cooling drain
plug if the engine is hot.
rmr2008-012-004_a

Draincooling system. Refer to ENGINE 1. Gasket

COOLANT REPLACEMENT in this subsection.
Cut the Oetiker clamp securing water hose.
REQUIRED TOOL
OETIKER PLIERS
(P/N 295 000 070)
Remove water hoses from water pump housing.
Remove screws retaining water pump housing.
Water Pump Housing Installation
Installation is the reverse of the removal proce-
dure however, pay attention to the following.
To avoid coolant leakage:
– Ensure gasket is properly inserted in water
pump housing groove.
To avoid oil leakage:
– Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
the screw indicated in the following illustration.

rmr2008-012-003_a

1. Cooling system drain plug

2. Sealing washer rbs2010-009-001_a
3. Retaining screws 1. Water pump cover
4. Water pump cover 2. Apply Loctite on this screw

Water Pump Housing Inspection
Check if gasket is brittle, hard or damaged, replace
as necessary.
Install a new sealing washer on drain screw.
Tighten screws of water pump housing to specifi-
cation in a crisscross sequence.
WATER PUMP HOUSING SCREWS
Tightening torque 11 N•m (97 lbf•in)

Install a NEW clamp using Oetiker pliers.

WATER PUMP IMPELLER

Water Pump Impeller Removal
1. Remove water pump housing. See procedure
in this subsection.
rmr2013-010 13
Subsection XX (COOLING SYSTEM)

2. Use proper snap ring pliers to unscrew water

pump impeller counterclockwise.

rmr2008-012-006_a

1. Water pump gear

2. Needle pin
3. Thrust washer
rmr2008-012-005_a

TYPICAL 4. Sharply strike the water pump shaft from the

1. Snap ring pliers outside towards the inside to remove it.
2. Water pump impeller
REQUIRED TOOL
Water Pump Impeller Inspection
PLASTIC HAMMER
Check impeller for cracks or other damage. Re-
place impeller if damaged.

Water Pump Impeller Installation

The installation is the opposite of the removal pro-
cedure. However, pay attention to the following.
Tighten water pump impeller by hand.

WATER PUMP SHAFT AND

SEALS
Water Pump Shaft/Seal Removal
Remove: rmr2008-012-007_a

1. Water pump shaft

– Clutch cover, refer to CLUTCH (SM5) or
CLUTCH (SE5) subsection 5. Tap out oil seal and rotary seal together from
– Water pump housing inside towards the outside.
– Water pump impeller.
REQUIRED TOOL
1. Pull water pump gear to remove it.
PUNCH 4 mm (.157 in)
2. Remove needle pin.
3. Remove thrust washer.

rmr2008-012-008_a

1. Clutch cover
2. Punch

14 rmr2013-010
 Subsection XX (COOLING SYSTEM)

Water Pump Shaft/Seal Inspection

Clean leak indicator hole in clutch cover of all con-
tamination.

rmr2008-012-010_a

1. Oil seal
2. Installer handle with oil seal pusher

rmr2008-012-009_a

1. Clutch cover
2. Leak indicator hole

Water Pump Shaft/Seal Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
NOTICE Always replace rotary seal and wa-
ter pump shaft together.
rmr2008-012-011_a
1. Apply specified product on sealing lip of oil seal. 1. Proper installed oil seal
REQUIRED PRODUCT ON OIL SEAL
3. Lubricate water pump shaft end and apply a
DOW CORNING 111 (P/N 413 707 000) bead of lubricating grease according to follow-
ing illustration.
2. Install NEW oil seal.
REQUIRED PRODUCT ON WATER PUMP SHAFT
REQUIRED TOOL
DOW CORNING 111 (P/N 413 707 000)
OIL SEAL PUSHER (P/N 529
035 757)

HANDLE (P/N 420 877 650)

NOTE: Never use oil in the press fit area of the oil
seal.
NOTE: Sealing lip must face towards the inside of
clutch cover.

rmr2013-010-204_a

A. Apply approximately 10 mm (.394 in) wide DOW CORNING

111 (P/N 413 707 000)
1. Water pump shaft end
2. Bore
3. Bead of DOW CORNING 111 (P/N 413 707 000)

4. Carefully press-in water pump shaft assembly

into clutch cover.

rmr2013-010 15
Subsection XX (COOLING SYSTEM)

REQUIRED TOOL

SEAL PUSHER
(P/N 529 035 766)

rmr2008-012-006_a

1. Water pump gear

2. Needle pin
3. Thrust washer

7. Reinstall water pump impeller and check if wa-

ter pump turns smooth after installation.
rmr2008-012-012_a
8. Properly reinstall remaining parts. Refer to ap-
1. Clutch cover
2. Water pump shaft assembly propriate subsections.
3. Rotary seal installer

NOTICE Never use a hammer for water

pump shaft assembly installation. Use press
only.
5. Apply coolant into gap of rotary seal to pre-lu-
bricate ceramic sealing surface.

rmr2013-010-205_a

1. Gap of rotary seal

2. Coolant

6. Reinstall thrust washer, needle pin and water

pump gear.

16 rmr2013-010
 Subsection XX (MAGNETO AND STARTER)

MAGNETO AND STARTER

SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 5–6
MAGNETO PULLER ...................................................................... 529 036 097 ............................................. 8
PULLER/LOCKING TOOL.............................................................. 529 036 098 ............................................. 8

SERVICE PRODUCTS
Description Part Number Page
DIELECTRIC GREASE ................................................................... 293 550 004 ........................................... 12
DOW CORNING 111 ..................................................................... 413 707 000 ....................................... 4, 12
DREI BOND SEALING COMPOUND ............................................ 420 297 906 ......................................... 4, 7
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 5, 7
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ....................................... 9–10
PETAMO GREASE GHY 133N ...................................................... 420 899 271 ..................................... 11–12
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ............................................. 9

rmr2013-011 1
Subsection XX (MAGNETO AND STARTER)

5 N•m
(44 lbf•in)
Loctite 243 7 N•m
(62 lbf•in)

Drei Bond 11 N•m

7 N•m sealing
(62 lbf•in) (97 lbf•in) Loctite
compound
243
CPS, see
Loctite NEW ELECTRONIC FUEL
INJECTION
648 (EFI)
30 N•m
(22 lbf•ft) Loctite Dow
648 Corning 111
Loctite
130 N•m 243
(97 lbf•ft)
11 N•m
(97 lbf•in)
Drei Bond
sealing compound

NEW

11 N•m 3 N•m
(97 lbf•in) (27 lbf•in)
SM5 models

SE5 models
11 N•m
(97 lbf•in) 11 N•m
(97 lbf•in)
Dielectric
grease Engine oil Engine oil

Engine oil
Dow
Corning
111

NEW = Component must be Petamo grease Loctite

replaced when removed. Ghy 133n 648
rmr2013-011-001_a

2 rmr2013-011
 Subsection XX (MAGNETO AND STARTER)

GENERAL Magneto Cover Access

NOTE: It is good practice to check for fault RS/ST Models
codes using the B.U.D.S. software as a first trou- Refer to BODY subsection and remove:
bleshooting step. Refer to the DIAGNOSTIC AND – Middle side panel
FAULT CODES subsection.
– Bottom side panel.
NOTE: To carry out the following instructions, it is
not necessary to remove the engine from the ve- RT Models
hicle. For a better understanding, many of the fol- Remove the following LH body panels, refer to the
lowing illustrations are produced with the engine BODY subsection:
removed from the vehicle. – Middle Side Panel
Always disconnect the negative wire from the bat- – Top Side Panel
tery before working on the engine. – Bottom Rear Side Panel
– Bottom Front Side Panel
WARNING
– Rear Side Panel.
Always disconnect the BLACK (-) cable first
and reconnect last. Remove headlight adjustment cable from LH mid-
dle side panel support.
WARNING Remove LH middle side panel support.
Before carrying out any inspection or main-
tenance procedure on the vehicle, wait until
the engine and exhaust system have cooled
down to avoid potential burns.

Always carry out electrical tests on components

before removing or installing them to ensure their
state of operation.
During assembly/installation, use the torque val-
ues and service products as specified in the ex-
ploded view.
Clean threads before applying threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
rmr2010-011-002_a

WARNING 1. Middle side panel support

Torque wrench tightening specifications Magneto Cover Removal

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 with new
ones.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
Drain engine oil, refer to the LUBRICATION SYS-
TEM subsection.
On SE5 model, remove the hydraulic control mod-
ule. Refer to the HYDRAULIC CONTROL MOD-
ULE (SE5) subsection.
Remove crankshaft position sensor (CPS).
Remove screw and washer securing stator cable
clamp to engine.

PROCEDURES
MAGNETO COVER
The magneto cover can be removed without re-
moving the engine from the vehicle.

rmr2013-011 3
Subsection XX (MAGNETO AND STARTER)

rmr2008-013-002_a
rmr2013-011-002_a
TYPICAL
1. Crankshaft position sensor (CPS) SE5 MODEL
2. Retaining screw 1. Magneto cover
3. Washer 2. Retaining screws
4. Cable clamp

Disconnect stator connector from voltage regu- Magneto Cover Inspection

lator, refer to STATOR CONNECTOR ACCESS in
this subsection.
Remove magneto cover retaining screws and pull
magneto cover from engine.
Clean magneto cover and check for cracks or
other damages. Replace if necessary.
Magneto Cover Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
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.

rmr2008-013-003_a

SM5 MODEL
1. Magneto cover
2. Retaining screws

vmr2006-041-003_a

TYPICAL
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).
Tighten the stator cable clamp screw to specifica-
tion.

4 rmr2013-011
 Subsection XX (MAGNETO AND STARTER)

STATOR CABLE CLAMP SCREW

LOCTITE 243 (BLUE)
Service Product
(P/N 293 800 060)
Tightening Torque 7 N•m (62 lbf•in)

Tighten magneto cover retaining screws to speci-

fication as per the following sequence.
MAGNETO COVER RETAINING SCREWS
Tightening Torque 11 N•m (97 lbf•in)

rmr2010-027-001_d

UNDERNEATH LH LATERAL SUPPORT

1. Voltage regulator/rectifier
2. Stator connector

Stator Continuity Test

Disconnect the stator connector on the voltage
regulator/rectifier.
Set multimeter to and compensate resistance
of the multimeter probes.
REQUIRED TOOL

FLUKE 115 MULTIMETER

(P/N 529 035 868)
rmr2011-011-002_a

TYPICAL – TIGHTENING SEQUENCE

Connect multimeter between YELLOW wires as
Refill engine with recommended oil. per table below.

STATOR
Stator Connector Access
RS/ST Models
Refer to BODY subsection and remove:
– Middle side panel
– Bottom side panel.
RT Models
Remove the following body panels to access volt-
age regulator/rectifier, refer to the BODY subsec-
tion:
rmr2008-024-009_a
– LH Mirror
– LH Wind deflector Read resistance.
– LH Middle side panel
STATOR CONTINUITY TEST
– LH top side panel.
RESISTANCE @
TERMINAL
20°C (68°F)
1 and 2
1 and 3 0.1 - 1
2 and 3

rmr2013-011 5
Subsection XX (MAGNETO AND STARTER)

STATOR INSULATION TEST

RESISTANCE @
TEST PROBES
20°C (68°F)
Any YELLOW wire and
Infinity (open circuit)
engine ground

If there is any resistance or continuity, the stator

coils and/or the wiring is grounded and needs to
be repaired or replaced.
YL
YL Reconnect the stator connector to the voltage reg-
YL ulator/rectifier.
V07G05A Stator Output AC Voltage Test
TYPICAL Disconnect the stator connector on the voltage
regulator/rectifier unit.
If any reading is out of specification, replace sta-
tor. Secure the connector over the lateral frame sup-
port with a locking tie so that the pins are facing
Reconnect the stator connector to the voltage reg-
outwards towards you.
ulator/rectifier.
Install a set of thin, insulated, “clip-on” type
Stator Insulation Test probes on the multimeter.
Disconnect the stator connector. Set multimeter to Vac scale.
Set the multimeter to . Start engine.
REQUIRED TOOL Connect multimeter alternately between the ter-
minals as indicated in the following chart.
FLUKE 115 MULTIMETER
(P/N 529 035 868)

Connect multimeter between any YELLOW wire

and engine ground.

rmr2008-024-009_a

YL
Read voltage.
YL STATOR OUTPUT AC VOLTAGE TEST
YL
TEST ENGINE
TERMINAL VOLTAGE
V07G07A SPEED
TYPICAL 1 and 2
60 Vac
Read resistance. 4000 RPM 1 and 3
minimum
2 and 3

If voltage is lower than specification, replace sta-

tor.

6 rmr2013-011
 Subsection XX (MAGNETO AND STARTER)

Cut the locking tie and reconnect the stator con-

nector 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.

rmr2008-013-006_a

TYPICAL – STATOR ALIGNMENT NOTCH

Install stator in the magneto cover.

STATOR RETAINING SCREWS
LOCTITE 243 (BLUE)
Service Product
(P/N 293 800 060)
Tightening Torque 11 N•m (97 lbf•in)

Apply a bead of DREI BOND SEALING COMPOUND

(P/N 420 297 906) on the stator cable grommet as
shown in next illustration.
rmr2008-013-005_a

1. Stator
2. Stator retaining screws
3. Stator cable holding plate
4. Holding plate screw

Stator Inspection
Check stator condition for signs of rubbing, over-
heating, insulator breakdown and any other dam-
ages which may render it unserviceable. If dam-
aged, replace it.
For electrical tests, refer to the CHARGING SYS-
TEM subsection. rmr2008-013-007_a

DREI BOND SEALING COMPOUND APPLICATION

Stator Installation
Align the stator cable in the case and insert the
For installation, reverse the removal procedure. stator cable grommet.
However, pay attention to the following.
Install the stator cable holding plate to secure the
NOTE: Stator position is determined by a key tab stator cable in its proper position.
on the stator which aligns with a notch in the case.
HOLDING PLATE SCREW
LOCTITE 243 (BLUE)
Service Product
(P/N 293 800 060)
Tightening Torque 5 N•m (44 lbf•in)

rmr2013-011 7
Subsection XX (MAGNETO AND STARTER)

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
MAGNETO PULLER (P/N 529
036 097)

rmr2008-013-101_a

1. Stator cable holding plate

2. Stator cable grommet

ROTOR
Rotor Removal
Lock crankshaft. Refer to CRANKSHAFT AND
CRANKCASE subsection.
rmr2008-013-010_a

REQUIRED TOOL TYPICAL

1. Rotor
PULLER/LOCKING TOOL 2. Magneto puller
(P/N 529 036 098)
For rotor disassembly, see SPRAG CLUTCH in this
Remove MAGNETO COVER, see procedure in subsection.
this subsection.
Rotor Inspection
Remove screw and washer securing rotor to
crankshaft. 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.

rmr2008-013-008_a

TYPICAL
1. Screw M16
2. Washer
3. Rotor

Remove rotor.
vmr2006-041-011_a

TYPICAL
1. Rotor with trigger wheel

8 rmr2013-011
 Subsection XX (MAGNETO AND STARTER)

Check the woodruff key and keyway on the crank-

shaft for wear or damages.
Replace parts as necessary.

Rotor Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
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 rotor cone
must be free of grease.
rmr2008-013-012_a

Apply LOCTITE 648 (GREEN) (P/N 413 711 400) as fol- TYPICAL
1. Starter double gear
lows: 2. Intermediate gear
– On the inside surface of the rotor cone
– On the rotor mounting screw. Tighten rotor retaining screw to specification.
ROTOR RETAINING SCREW
NOTICE Take care not to apply Loctite 648
(GREEN) into the bearing bushing of the sprag LOCTITE 648 (GREEN)
Service Product
clutch gear. (P/N 413 711 400)

Oil sprag clutch in sprag clutch housing and install Tightening Torque 130 N•m (96 lbf•ft)
sprag clutch gear.
SPRAG CLUTCH
Sprag Clutch Removal
Before removing the rotor, loosen sprag clutch
housing screws located inside rotor.
Proceed with ROTOR REMOVAL, see procedure
in this subsection.
Remove sprag clutch gear.
Remove sprag clutch housing screws and sprag
clutch housing.
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
gear. rmr2008-013-013_a

1. Sprag clutch housing screws

2. Rotor
3. Sprag clutch
4. Sprag clutch housing

Sprag Clutch Inspection

Inspect sprag clutch and sprag clutch housing for
wear and other damages.
Check the collar of the sprag clutch gear.

rmr2013-011 9
Subsection XX (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.

rmr2008-013-011_a

1. Sprag clutch
2. Sprag clutch housing
3. Sprag clutch gear
4. Apply engine oil here

rmr2008-013-014_a Install rotor on crankshaft, refer to ROTOR IN-

SPRAG CLUTCH FUNCTIONAL TEST STALLATION in this subsection.
1. Must lock in the clockwise direction
Tighten sprag clutch housing screws to specifica-
NOTE: If defective replace the following parts as tion.
a unit: SPRAG CLUTCH HOUSING SCREWS
– Sprag clutch
LOCTITE 648 (GREEN)
– Sprag clutch housing Service Product
(P/N 413 711 400)
– Sprag clutch gear.
Tightening Torque 30 N•m (22 lbf•ft)
Sprag Clutch Installation
For installation, reverse the removal procedure. SPRAG CLUTCH GEAR
Pay attention to the following details.
Apply LOCTITE 648 (GREEN) (P/N 413 711 400) as fol-
Sprag Clutch Gear Removal
lows: Remove the ROTOR, see procedure in this sub-
– On sprag clutch housing, mating surface to the section.
rotor Pull sprag clutch gear from the rotor.

rmr2008-013-011_b

1. Rotor
2. Sprag clutch gear
rmr2013-011-003_a

1. 6x drop of LOCTITE 648 (GREEN) (P/N 413 711 400)
– On the threads of the sprag clutch housing
screws.
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.
Sprag Clutch Gear Inspection
Inspect gear, especially teeth and sprag clutch col-
lar, for wear and other damages.
Check bushing for scoring, wear and other dam-
ages. Replace sprag clutch gear if necessary.

10 rmr2013-011
 Subsection XX (MAGNETO AND STARTER)

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.

Starter Drive Gear Installation

The installation is the reverse of the removal pro-
cedure. Pay attention to the following details.
Apply PETAMO GREASE GHY 133N (P/N 420 899 271)
on the starter gear before installing the starter
double gear.
vmr2006-041-016_a

INSPECT Apply engine oil on the location pins before in-

1. Teeth stalling the starter double and intermediate gears.
2. Collar
3. Bushing
ELECTRIC STARTER
Sprag Clutch Gear Installation
The installation is the reverse of the removal pro- Starter Test
cedure. However, pay attention to the following. Refer to the STARTING SYSTEM subsection to
Apply engine oil on the bushing and collar of the validate starter operation.
sprag clutch gear.
Starter Troubleshooting Tips
STARTER DRIVE GEARS If starter is noisy, check the condition of the
starter and the starter gears.
Starter Drive Gear Location If starter is noisy and skipping, check the sprag
The starter drive gears are located on the engine clutch.
MAG side behind the magneto cover.
Starter Access
RS/ST Models
Refer to BODY subsection and remove:
– Middle side panel
– Bottom side panel.
RT Models
Remove the following RH body panels, refer to
BODY subsection:
– Middle side panel
– Top side panel
– Bottom rear side panel
– Bottom front side panel
rmr2008-013-016_a
– Rear side panel.
STARTER DRIVE GEARS
1. Intermediate gear Remove headlight adjustment cable from LH mid-
2. Starter double gear dle side panel support.
3. Starter gear
4. Location pins Remove RH middle side panel support.
Starter Drive Gear Removal
Remove ROTOR, see procedure in this subsec-
tion.
Remove the intermediate gear.
rmr2013-011 11
Subsection XX (MAGNETO AND STARTER)

Starter Removal
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.

rmr2010-011-001_a

1. Middle side panel support

All Models
Disconnect the battery.
NOTICE Always disconnect BLACK (–) cable rmr2008-013-017_a

first and reconnect last. 1. Starter (+) terminal

Remove screw retaining top of engine coolant ra-
diator (do not disconnect radiator hoses).
rmr2008-012-025_a
TYPICAL
1. Top radiator bolt
Pull radiator off its mounting plate and move
it back on the lower plate to enable access to
starter.
2. Retaining screws
Starter Installation
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.
NOTICE Premature wear may arise if the
starter is not properly aligned.
Apply PETAMO GREASE GHY 133N (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
Tightening Torque 11 N•m (97 lbf•in)

NOTICE Radiator core is very fragile and eas- Connect the RED (+) cable to the starter and
ily damaged. Special care should be taken to torque nut to specification.
avoid damaging the cooling fins when working
around the radiator. Bent or torn fins reduce STARTER CABLE NUT
the radiator's efficiency and could lead to radi-
ator leaks or higher engine operating tempera- Tightening Torque 6 N•m (53 lbf•in)
tures.
Apply DIELECTRIC GREASE (P/N 293 550 004) on ter-
minal and nut.
Reconnect the battery.

12 rmr2013-011
 Subsection XX (MAGNETO AND STARTER)

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.

rmr2013-011 13
 Subsection XX (CYLINDER HEAD AND CYLINDER)

CYLINDER HEAD AND CYLINDER

SERVICE TOOLS
Description Part Number Page
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ........................................... 15
ENGINE LEAK DOWN TEST KIT ................................................... 529 035 661 ........................................... 6
OIL SEAL INSTALLER ................................................................... 529 036 069 ........................................... 15
PISTON CIRCLIP INSTALLER 991 ................................................ 529 036 072 ........................................... 29
VALVE GUIDE INSTALLER (6 MM) ............................................... 529 036 075 ........................................... 25
VALVE GUIDE REMOVER (6 MM) ................................................ 529 036 074 ........................................... 25
VALVE SPRING COMPRESSOR CUP............................................ 529 036 073 ........................................... 21
VALVE SPRING COMPRESSOR .................................................... 529 035 724 ........................................... 21

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON PISTON RING COMPRESSOR TOOL .......................... RC-980 ........................................... 20
SNAP-ON PLIERS.......................................................................... YA 8230 ........................................... 22

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 518 ................................................................................. 293 800 038 ........................................... 10
LOCTITE 5910 ............................................................................... 293 800 081 ........................................... 20
MOLYKOTE G-N ............................................................................ 420 297 433 ........................................... 25

rmr2013-012 1
Subsection XX (CYLINDER HEAD AND CYLINDER)

FRONT CYLINDER HEAD (NO. 1)

9 N•m 11 N•m
(80 lbf•in) (97 lbf•in)

Dow Corning 111

NEW

Petamo grease
Ghy 133n

11 N•m
(97 lbf•in) Engine
oil
See 19 N•m
tightening (168 lbf•in)
sequence

Petamo grease Engine

Ghy 133n oil

18 N•m
(159 lbf•in)
NEW
58 N•m Loctite 243
(43 lbf•ft)
11 N•m
(97 lbf•in)
Loctite 243
Loctite 648
7 N•m
(62 lbf•in) 11 N•m
58 N•m (97 lbf•in)
(43 lbf•ft)
Engine
See oil
tightening Engine 25 N•m
sequence 12 N•m oil (18 lbf•ft)
(106 lbf•in)
Dow Corning 111

Loctite
11 N•m 243
NEW = Component must be replaced when removed. (97 lbf•in)
rmr2010-012-001_c

2 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

REAR CYLINDER HEAD (NO. 2)

9 N•m
(80 lbf•in)

NEW
11 N•m
(97 lbf•in)
Dow
Loctite Corning
243 111

11 N•m
50 N•m 11 N•m (97 lbf•in)
(37 lbf•ft) (97 lbf•in)
11 N•m
(97 lbf•in) 19 N•m Petamo
Loctite 243 (168 lbf•in) grease
NEW Ghy 133n

Engine Engine oil

oil
Petamo grease
25 N•m Ghy 133n 12 N•m
(18 lbf•ft) (106 lbf•in)

Engine 58 N•m
oil (43 lbf•ft)

18 N•m
Petamo grease (159 lbf•in)
Ghy 133n Engine
oil

Engine
oil Loctite 243
Loctite 648
Dow 7 N•m
Corning 111 (62 lbf•in)
40 N•m NEW
(29 lbf•ft)
Engine oil

rmr2013-012-100_a

rmr2013-012 3
Subsection XX (CYLINDER HEAD AND CYLINDER)

CYLINDERS/PISTONS

30 N•m
(22 lbf•ft)
Engine oil
20 N•m Loctite 243
(15 lbf•ft) Engine oil

30 N•m 19 N•m
(22 lbf•ft) (14 lbf•ft)

NEW
Loctite 243
19 N•m
(14 lbf•ft)

30 N•m Engine oil

(22 lbf•ft) 20 N•m
(15 lbf•ft)

Engine oil
NEW
Petamo grease
Ghy 133n
Petamo grease
Ghy 133n

NEW = Component must be replaced when removed.

rmr2010-012-003_b

4 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

GENERAL
NOTE: When diagnosing an engine problem, al-
ways perform the cylinder leak test. This will help
pinpoint a problem. Refer to LEAK TEST in this
subsection for procedures.
Always place the vehicle on a level surface.
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-
move engine from vehicle.
Always disconnect battery cable before working
on the engine.
NOTICE Always disconnect BLACK (-) cable rmr2010-012-004_a

first and reconnect last. 1. Front cylinder (no. 1)

2. Rear cylinder (no. 2)
During assembly/installation, use the torque val-
ues and service products as in the exploded MAINTENANCE
views.
Clean threads before applying a threadlocker. Re- VALVE CLEARANCE
fer to SELF-LOCKING FASTENERS and LOCTITE
NOTE: Check and adjust valve clearance only on
APPLICATION at the beginning of this manual for
a cold engine.
complete procedure.

WARNING Valve Clearance Inspection

Torque wrench tightening specifications NOTICE Whenever valve covers are re-
must be strictly adhered to. moved, it is recommended to replace valve
Locking devices when removed (e.g.: locking cover gaskets at the same time.
tabs, elastic stop nuts, cotter pin, etc.) must
NOTE: Procedure is the same for both cylinders.
be replaced with new ones.
Remove VALVE COVER. See procedure in this
subsection.
NOTICE Hoses, cables and locking ties re- Bring crankshaft to ignition TDC of the cylinder
moved during a procedure must be reinstalled to be verified. Refer to CRANKSHAFT LOCKING
as per factory standards. PROCEDURE in the CRANKCASE AND CRANK-
Even if the removal of many parts is not neces- SHAFT subsection.
sary to reach another part, it is recommended to Use a feeler gauge and check valve clearance.
remove these parts in order to check them. NOTE: Intake and exhaust valves must be
When disassembling parts that are duplicated checked with cylinder at ignition TDC.
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).

rmr2013-012 5
Subsection XX (CYLINDER HEAD AND CYLINDER)

New shim thickness =

Recorded valve clearance – Adjustment
specification + Old shim thickness

After parts reassembly, recheck valve clearance.

INSPECTION
CYLINDER LEAK TEST
General
Before performing the cylinder leak test, verify the
following:
– Clamp(s) tightness
rmr2008-014-005_a – Radiator and hoses condition.
1. Camshaft
2. Feeler gauge NOTE: For best accuracy, the leak test should be
3. Valve lift bucket done with the engine at normal operating temper-
ature.
VALVE CLEARANCE
0.22 mm to 0.29 mm WARNING
EXHAUST
(.0087 in to .0114 in) Prevent burning yourself due to handling on
0.11 mm to 0.18 mm the hot engine.
INTAKE
(.0043 in to .0071 in)
Preparation
Adjust valve clearance if out of specification.
Remove spark plugs. Refer to IGNITION SYSTEM
NOTE: To ease valve adjustment procedure, note subsection.
each valve clearance prior to proceed.
Remove VALVE COVER. See procedure in this
Valve Clearance Adjustment subsection.
Bring the piston of tested cylinder to ignition TDC.
NOTICE Whenever valve covers are re-
Refer to CRANKSHAFT LOCKING PROCEDURE
moved, it is recommended to replace valve in the CRANKCASE AND CRANKSHAFT subsec-
cover gaskets at the same time. tion.
Adjust valve clearance by replacing the adjust-
ment shim of the required valve. Leak Test
NOTE: When replacing the adjustment shims, Install the tool on engine, and then to an adequate
crankshaft must be locked at ignition TDC of the air supply.
respective cylinder. REQUIRED TOOL
Refer to appropriate procedures in this subsection
to remove the following parts: ENGINE LEAK DOWN TEST
– Timing chain tensioner KIT (P/N 529 035 661)
– Balance shaft drive gears (rear cylinder)
– Camshaft timing gears Set needle of measuring gauge to zero.
– Camshaft NOTE: All testers have specific instructions on
– Valve lifter bucket. gauge operation and required pressure. Refer to
Remove adjustment shim and check its thickness manufacturer's instructions.
with a micrometer. Supply combustion chamber with air pressure.
Choose the proper adjustment shim thickness to
reach the specified valve clearance.

6 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

PROCEDURES
VALVE COVER
Valve Cover Removal
(Engine in Vehicle)
Remove RH lateral support, refer to the FRAME
subsection.
Remove air filter housing and resonator. Refer to
the AIR INTAKE SYSTEM subsection.
rmr2008-014-112_a
Remove fuel tank protectors. Refer to the FUEL
1. Leak tester TANK 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
Fair condition; reduced
26% to 40%
engine performance
Poor condition, diagnose
41% and higher
and repair engine

Diagnosis
Listen for air leaks.
– Air escaping on intake port/throttle body means
leaking intake valve(s).
– Air escaping on exhaust port means leaking ex-
haust valve(s).
– Air bubbles out of radiator means leaking cylin- rmr2008-014-101_a
der head gasket. TYPICAL
– Air/coolant escaping from cylinder/head means
damaged gasket(s) and/or loosened screws (re- Rear Cylinder
fer to CYLINDER 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 CYLINDER and PISTON RINGS 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.

rmr2013-012 7
Subsection XX (CYLINDER HEAD AND CYLINDER)

NOTICE Whenever valve covers are re-

moved, it is recommended to replace valve
cover gaskets at the same time.

rmr2008-014-102_a

TYPICAL

rmr2008-014-104_a

Front Cylinder
Disconnect the camshaft position sensor (CAPS).

rmr2008-014-103_a

TYPICAL

Completely remove valve cover screws.

rmr2008-014-108_a

Completely remove valve cover screws.

rmr2010-012-005_a

Pull out valve cover towards RH side of vehicle.

8 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

rmr2010-012-006_a
rmr2010-012-007_a

Pull out valve cover. REAR CYLINDER

1. Retaining screws
NOTICE Whenever valve covers are re- 2. Valve cover
3. Valve cover gasket
moved, it is recommended to replace valve
cover gaskets at the same time.

rmr2008-014-006_a

FRONT CYLINDER
1. Retaining screws
2. Valve cover
rmr2008-014-107_a
3. Valve cover gasket
4. Camshaft position sensor (CAPS)
Valve Cover Removal
(Engine Removed) Valve Cover Inspection
Unscrew cover retaining screws. Check the valve cover for cracks or other dam-
ages.
Remove the cover with the gasket.
Check if the gasket is brittle, hard or otherwise
damaged.
Replace all defective parts.

Valve Cover Installation

For installation reverse the removal procedure.
However, pay attention to the following.
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.

rmr2013-012 9
Subsection XX (CYLINDER HEAD AND CYLINDER)

NOTE: When installing valve cover while engine

is on vehicle, it may be easier to first install gasket
in cover using LOCTITE 518 (P/N 293 800 038).

rmr2008-014-008_a

1. Balance shaft
2. Screwdriver
3. Nut

Remove nut, balance weight and balance shaft

rmr2010-012-008_a
drive gears.
1. Camshaft position sensor NOTE: Take care not to loose woodruff key when
2. Front cylinder removing balance shaft gear.

BALANCE SHAFT DRIVE GEARS

Balance Shaft Drive Gears Location
The balance shaft drive gears are located in the
rear cylinder head.

Balance Shaft Drive Gears Removal

Remove VALVE COVER, see procedure in this
subsection.
Lock crankshaft at ignition TDC (rear cylinder). Re-
fer to CRANKSHAFT LOCKING PROCEDURE in
the CRANKCASE AND CRANKSHAFT subsection.
NOTE: Always place a rag into timing chain area
to avoid parts falling inside the engine during re-
moval. rmr2008-014-009_a

1. Nut
NOTICE To avoid stretching the timing chain 2. Balance weight
3. Balance shaft gear
when loosening the nut, use a screwdriver to 4. Woodruff key
hold balance shaft.
Remove timing gear screws on exhaust side and
remove balance shaft drive gear.

10 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

rmr2008-014-010_a

1. Timing gear screws

2. Balance shaft drive gear

Balance Shaft Drive Gears Inspection rmr2008-014-011_a

Inspect 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-
place balance shaft drive gears as a set.
Timing Chain Tensioner Removal
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 CRANKSHAFT LOCKING PROCEDURE in the
However, pay attention to following. CRANKCASE AND CRANKSHAFT subsection.
Remove plug screw and gasket ring.
NOTICE Ensure to install longer screws
M6 x 14 to balance shaft drive gear on exhaust Pull out chain tensioner.
camshaft (rear cylinder). If the longer screws
were installed on the other timing gear, the
camshaft would be blocked.

rmr2008-014-007_a

1. Plug screw
2. Gasket ring
rmr2008-014-010_a 3. Chain tensioner
1. Longer M6 x 14 screws here
2. Balance shaft drive gear Timing Chain Tensioner Inspection
Align mark on balance shaft gear with mark on Check chain tensioner for free movement in bore
camshaft timing gear. and/or for scoring.
Compress chain tensioner and check if it works
properly.

rmr2013-012 11
Subsection XX (CYLINDER HEAD AND CYLINDER)

Timing Chain Tensioner Installation

For installation reverse the removal procedure.
However, pay attention to the following.
Apply engine oil on chain tensioner.
Tighten chain tensioner plug screw to specifica-
tion.
CHAIN TENSIONER PLUG SCREW
Tightening Torque 30 N•m (22 lbf•ft)

CAMSHAFT TIMING GEAR

Camshaft Timing Gear Removal rmr2008-014-013_a

FRONT CYLINDER
Remove VALVE COVER. See procedure in this 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 CRANKCASE AND CRANKSHAFT
subsection.
For rear cylinder, proceed with BALANCE SHAFT
DRIVE GEARS REMOVAL. See procedure in this
subsection.
Loosen camshaft timing gear screws.

rmr2008-014-014_a

TYPICAL - FRONT CYLINDER SHOWN

1. Timing chain guide

Remove camshaft timing gear screws.

rmr2008-014-012_a

TYPICAL - FRONT CYLINDER SHOWN

1. Timing gear screws
2. Timing gear (intake)
3. Timing gear (exhaust)

Remove CHAIN TENSIONER. See procedure in

this subsection.
For front cylinder, remove upper chain guide.

rmr2008-014-015

TYPICAL - FRONT CYLINDER SHOWN

12 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

Secure timing chain with a retaining wire. Install timing gears on camshafts so that marks
Remove camshaft timing gears. “IN” on intake and “EX” on exhaust camshaft are
aligned.
Camshaft Timing 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 CRANKSHAFT subsection.
Check upper chain guide for wear, replace if nec-
essary.

Camshaft Timing Gear Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. vmr2008-015-004_a

NOTE: If timing gears of both cylinders have
been removed, refer to ENGINE REASSEMBLY
SEQUENCE in the CRANKCASE AND CRANK-
SHAFT subsection.
NOTICE Improper valve timing will damage
engine components.
TYPICAL
1. Marks on timing gears
Install the TIMING CHAIN TENSIONER. See pro-
cedure in this subsection.
Install the BALANCE SHAFT DRIVE GEARS (rear
cylinder). See procedure in this subsection.

Make sure that crankshaft is locked at TDC of the BALANCE SHAFT

respective cylinder.
Camshaft timing gear with trigger pin has to be Balance Shaft Location
installed at intake camshaft (front cylinder). The balance shaft is located in cylinder head of
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.

rmr2008-014-012_b

FRONT CYLINDER
1. Intake camshaft
2. Timing gear
3. Trigger pin
4. Front cylinder head

rmr2013-012 13
Subsection XX (CYLINDER HEAD AND CYLINDER)

PLAIN BEARING JOURNAL “A”

34.973 mm to 34.983 mm
NEW
(1.3769 in to 1.3773 in)
SERVICE LIMIT 34.953 mm (1.376 in)

BALL BEARING JOURNAL “B”

14.981 mm to 14.992 mm
NEW
(.5898 in to .5902 in)
SERVICE LIMIT 14.970 mm (.5894 in)

Bearing Flange
rmr2008-014-016_a

1. Retaining screw Check plain bearing for scoring or other damages.

2. Washer
3. Upper chain guide Measure plain bearing inside diameter.
4. Bearing flange
5. Balance shaft

Balance Shaft and Bearing Flange

Inspection
Balance Shaft
Check oil seal running surface of balance shaft for
grooves.
Measure diameter of balance shaft bearing jour-
nals.
Replace if necessary.
Clean ventilation orifice in balance shaft using an
air gun.
rmr2010-012-009_a

NOTICE Always wear eye protection. BEARING FLANGE

1. Oil orifice
A. Bearing flange inside diameter

Substract the balance shaft bearing journal from

the plain bearing inside diameter to obtain radial
clearance.
PLAIN BEARING RADIAL CLEARANCE
SERVICE LIMIT 0.07 mm (.0028 in)

Balance Shaft Ball Bearing Inspection

Check ball bearing of balance shaft for excessive
play and smooth operation.

rmr2011-012-003_b

BALANCE SHAFT
1. Identification groove
2. Ventilation orifice
A. Plain bearing journal
B. Ball bearing journal
C. 8 mm (5/16 in) running surface

14 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

rmr2008-014-020_a

1. Ball bearing
Balance Shaft Oil Seal Inspection
Check if oil seal behind ball bearing is brittle hard
or damaged.
Balance Shaft Ball Bearing and Oil
Seal 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.
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 Oil Seal Removal
Use a screwdriver to remove oil seal from
camshaft holder.
NOTICE Take care not to damage oil seal
area.
Balance Shaft Oil Seal Installation
Install oil seal with sealing lip facing towards ball
bearing.
REQUIRED TOOL
OIL SEAL INSTALLER (P/N 529
036 069)
rmr2008-014-022_a
1. Oil seal
2. Oil seal installer
3. Camshaft holder
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.
To properly install camshaft holder, refer to
CAMSHAFT in this subsection.
Balance Shaft Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to following.
To properly install camshaft timing gear, refer to
CAMSHAFT TIMING GEAR.
NOTICE Improper valve timing will damage
engine components.
To properly install balance shaft drive gears, refer
to BALANCE SHAFT DRIVE GEARS in this sub-
section.
CAMSHAFT
Camshaft Removal
Proceed with CAMSHAFT TIMING GEAR RE-
MOVAL. See procedure in this subsection.
Remove camshaft holder.

rmr2013-012 15
Subsection XX (CYLINDER HEAD AND CYLINDER)

rmr2008-014-027_a

1. Lobes
A. Camshaft journal

CAMSHAFT JOURNAL DIAMETER

rmr2008-014-023_a 23.967 mm to 23.980 mm
NEW
1. Retaining screws (.9436 in to .9441 in)
2. Washers
3. Camshaft holder SERVICE LIMIT 23.950 mm (.9429 in)

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.

rmr2008-014-024_a

1. Exhaust camshaft
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 vmr2008-016-066_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.

16 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

rmr2008-014-026_a
vmr2008-016-066_b
1. Smaller washers
1. Pressed plastic gauge
2. Graduated scale
Lubricate camshaft holders with engine oil before
CLEARANCE BETWEEN CAMSHAFT AND placing them into cylinder head.
CAMSHAFT HOLDER Fit camshaft holder and tighten screws to specifi-
SERVICE LIMIT 0.06 mm (.0024 in) cation as per following sequence.
CAMSHAFT HOLDER SCREWS
Camshaft Installation Tightening Torque 11 N•m (97 lbf•in)
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Take care not to interchange intake and exhaust
camshafts.

vmr2008-015-020_a

TIGHTENING SEQUENCE

NOTE: After bearing cover installation check if

camshafts turn easily.
Check VALVE CLEARANCE. See procedure in this
subsection.
rmr2010-012-010_b

1.
2.
Exhaust camshaft
2 marks
VALVE LIFTER BUCKET
3. Yellow + light blue paint mark
4. Intake camshaft Valve Lifter Bucket Removal
5. 1 mark
6. White + brown beige paint mark Remove the following parts, see procedures in
this subsection:
Install smaller washers where shown. – Valve cover
rmr2013-012 17
Subsection XX (CYLINDER HEAD AND CYLINDER)

– Balance shaft drive gears (rear cylinder)

– Chain tensioner
– Camshaft timing gears
– Camshafts.
Use a magnet and lift valve lifter bucket.
NOTICE Adjustment shim could be stuck in
valve lifter bucket. Take care not to loose ad-
justment shim.

vmr2008-016-022_a

1. Adjustment shim
2. Valve spring retainer

CYLINDER HEAD
Cylinder Head Removal
Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION subsection.
Remove support between cylinder heads.
vmr2008-016-021_a

1. Valve lifter bucket

2. Adjustment shim

Valve Lifter Bucket Inspection

Check surface of valve lifter bucket for scoring or
other damages.
Measure diameter of valve lifter bucket. If diam-
eter is out of specification replace it.
VALVE LIFTER BUCKET DIAMETER
33.459 mm to 33.475 mm
NEW
(1.3173 in to 1.3179 in)
rmr2008-014-030_a
SERVICE LIMIT 33.440 mm (1.3165 in)
1. Support

VALVE LIFTER BUCKET RADIAL CLEARANCE Unscrew spark plug.

SERVICE LIMIT 0.08 mm (.0031 in)
Valve Lifter Bucket Installation
NOTICE Place adjustment shim properly in
place before installing valve lifter bucket.
Remove VALVE COVER. See the procedure in this
subsection.
Remove CAMSHAFT TIMING GEAR. See proce-
dure in this subsection.
Remove cylinder head screws.
Remove cylinder head nuts.

18 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

rmr2008-014-031_a
rmr2008-014-033_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.

rmr2008-014-034_a

1. Cylinder base gasket

Cylinder Head Inspection

Check for cracks between valve seats or other
damages, if so, replace cylinder head.
rmr2008-014-032_a
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.

rmr2008-014-035_a

1. Oil orifices to lubricate camshaft bearings

2. Oil orifices
3. Oil orifice (front cylinder only)

rmr2013-012 19
Subsection XX (CYLINDER HEAD AND CYLINDER)

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 VALVE LIFTER 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)
rmr2008-014-036_a

1. Apply Loctite 5910 here

Measure camshaft radial clearance, refer to
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 PISTON RINGS 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
Always install a NEW cylinder head gasket. SNAP-ON PISTON RING COMPRESSOR
Fit cylinder on cylinder head. TOOL (P/N RC-980)
Install cylinder screws and tighten to specification
as per following sequence.
CYLINDER HEAD M8 SCREWS
Tightening Torque 30 N•m (22 lbf•ft)

rmr2008-014-037_a

1. Piston ring compressor tool

2. Cylinder with cylinder head assembly

Slide timing chain through chain passage, then

slide cylinder with cylinder head over piston.
rmr2008-014-032_b
First tighten M10 nuts by hand, then tighten them
TIGHTENING SEQUENCE
according to the following sequence.

20 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

CYLINDER HEAD M10 NUTS REQUIRED TOOLS

Tightening Torque 58 N•m (43 lbf•ft) VALVE SPRING COMPRESSOR
(P/N 529 035 724)

VALVE SPRING COMPRESSOR

CUP (P/N 529 036 073)

Remove valve cotters.

rmr2008-014-038_a

TIGHTENING SEQUENCE

Tighten Allen socket screws in cylinder head.

CYLINDER HEAD M6 SCREWS
Tightening Torque 12 N•m (106 lbf•in) rmr2008-014-120_a

1. Valve spring compressor clamp

2. Valve spring compressor cup
3. Valve cotters

Remove valve spring retainer, then outer and inner

valve spring.

rmr2008-014-041_a

1. Cylinder head screws

Install all other removed parts.

VALVE SPRING
Valve Spring Removal vmr2008-016-031_a

NOTE: Whenever valves are removed, it is rec- 1. Spring retainer

ommended to replace valve stem seal at the same 2. Outer valve spring
3. Inner valve spring
time.
Remove the following parts, see procedures in Valve Spring Inspection
this subsection: Check valve spring for rust or corrosion and free
– Cylinder head length.
– Camshafts
– Valve lifter bucket and adjustment shim.
Compress valve spring.

rmr2013-012 21
Subsection XX (CYLINDER HEAD AND CYLINDER)

VALVE SPRING FREE LENGTH After springs are installed, ensure it is properly
locked by tapping on valve stem end with a soft
INNER VALVE SPRING hammer so that valve opens and closes a few
NEW 39.24 mm (1.5449 in) times.
SERVICE LIMIT 38.00 mm (1.4961 in)
VALVE
OUTER VALVE SPRING
NEW 41.97 mm (1.6524 in)
Valve Removal
Remove VALVE SPRING, see procedure in this
SERVICE LIMIT 40.50 mm (1.5945 in) subsection.
Push the valve stem, then pull intake and exhaust
Valve Spring Installation valves out of cylinder head.
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Colored area of the valve springs must be placed
on top.

rmr2008-014-042_a

1. Intake valves 38 mm (1.5 in)

2. Exhaust valves 31 mm (1.2 in)

Valve Stem Seal Removal

vmr2008-016-031_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 Remove valve spring shim.
valve stem grooves.
NOTICE Improperly locked valve springs will
cause engine damage.

rmr2010-012-011_a

1. Valve spring shim

vmr2008-016-032_a
2. Valve stem seal
1. Valve cotters

22 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

Valve Inspection Valve Face and Seat

Valve Stem Seal
Always install NEW valve stem seals whenever
valves are removed.
Valve
Inspect valve surface, check for abnormal stem
wear and bending. If out of specification, replace 2
by a new one. 3

VALVE STEM RUNOUT

(INTAKE/EXHAUST)
NEW 0.006 mm (.0002 in) 1
SERVICE LIMIT 0.05 mm (.002 in)
R400motr84A

Valve Stem 1. Valve seat

Measure valve stem in three places using a mi- 2. Exhaust valve contaminated area
3. Valve face (contact surface to valve seat)
crometer.
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.

R400motr83A

A. Valves stem diameter

VALVE STEM DIAMETER

INTAKE VALVE
5.961 mm to 5.975 mm
NEW
(.2347 in to .2352 in)
SERVICE LIMIT 5.950 mm (.2343 in)
EXHAUST VALVE rmr2008-014-043_a

1. Valve seat
5.946 mm to 5.960 mm 2. Valve face (contact surface to valve seat)
NEW 3. Turn valve while pushing against cylinder head
(.2341 in to .2346 in)
A. Valve seat angle 45°
SERVICE LIMIT 5.935 mm (.2337 in)
NOTE: Ensure to seat valves properly. Apply
Replace valve if valve stem is out of specification marking paste to ease checking contact pattern.
or has other damages such as wear or friction sur- Repeat procedure until valve seat/valve face fits
face. together.
Measure VALVE GUIDE. See procedure in this Measure valve face contact width.
subsection.
NOTE: The location of contact area should be in
center of valve face.
Measure valve seat width, using a caliper.

rmr2013-012 23
Subsection XX (CYLINDER HEAD AND CYLINDER)

VALVE SEAT CONTACT WITH VALVE GUIDE

INTAKE VALVE Valve Guide Inspection
NEW
1.00 mm to 1.40 mm NOTE: Clean valve guide to remove carbon de-
(.0394 in to .0551 in) posits before measuring.
SERVICE LIMIT 1.60 mm (.063 in) Measure valve guide in three places using a small
bore gauge.
EXHAUST VALVE
1.25 mm to 1.55 mm
NEW
(.0492 in to .061 in)
SERVICE LIMIT 1.80 mm (.0709 in)

If valve seat contact width is too wide, too narrow

or has dark spots, replace the cylinder head.

Valve Installation
For installation reverse the removal procedure.
However, pay attention to the following.
NOTE: Make sure the valve spring shim is in-
stalled before installing valve stem seal.
vmr2008-016-042_b
Apply engine oil on valve stem and install it. A. Valve guide diameter
NOTICE Be careful when valve stem is
VALVE GUIDE DIAMETER
passed through sealing lips of valve stem (INTAKE AND EXHAUST VALVES)
seal.
6.006 mm to 6.018 mm
NEW
(.2365 in to .2369 in)
SERVICE LIMIT 6.050 mm (.2382 in)

If valve guide is out of specification or has other

damages such as wear or friction surface, replace
it.

Valve Guide Replacement

NOTE: Do not heat up cylinder head for valve
guide replacement.
Remove the followings parts, see procedures in
this subsection:
– Cylinder head
rmr2010-012-011_a
– Valve springs
1. Valve spring shim
2. Sealing lips of valve stem seal – Valves.
To ease installation of cotters, apply oil or grease Remove valve stem seal and valve spring shim.
on them so that they remain in place while relea-
sing the spring.
After springs are installed, ensure it is properly
locked by tapping on valve stem end with a soft
hammer so that valve opens and closes a few
times.
NOTICE Improperly locked valve springs will
cause engine damage.

24 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

rmr2010-012-011_a

1. Valve spring shim

2. Sealing lips of valve stem seal vmr2008-016-038_a

1. Valve guide remover

NOTE: Clean valve guide area from contamination
before removal.
Use a special reamer and machine valve guide top
until sharp edge is removed.
NOTICE 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
guide.
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.
Valve Guide Installation
Clean the valve guide bore before reinstalling the
valve guide into cylinder head.
NOTE: Intake and exhaust valve guides are differ-
ent. Intake valve guide has a longer chamfer.

vmr2008-016-042_a

1. Longer chamfer on intake valve guide

Apply MOLYKOTE G-N (P/N 420 297 433) on valve

vmr2008-016-037_a guide and in valve guide bore, prior to install it into
1. Reamer the cylinder head.
2. Valve guide, sharp edge
Install valve guide.
Remove valve guide.
REQUIRED TOOL
REQUIRED TOOL
VALVE GUIDE INSTALLER (6
VALVE GUIDE REMOVER (6 MM) (P/N 529 036 075)
MM) (P/N 529 036 074)
Hammer Push valve guide in the cold cylinder head as per
following illustration.

rmr2013-012 25
Subsection XX (CYLINDER HEAD AND CYLINDER)

CYLINDER
Cylinder Removal
For cylinder removal refer to CYLINDER HEAD
REMOVAL in this subsection.
Cylinder Inspection
Cylinder
Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder.
Piston/Cylinder Clearance
Check piston/cylinder clearance, refer to PISTON
vmr2008-016-040_a in this subsection.
1. Valve guide installer
2. Valve guide Chain Tensioner Hole
3. Thrust surface of cylinder head
A. Measurement from thrust surface to valve guide top
Ensure that chain tensioner and hole in the cylin-
der are in perfect condition.
VALVE GUIDE MEASUREMENT A
MINIMUM NEW 13.10 mm (.5157 in) Cylinder Installation
MAXIMUM NEW 13.50 mm (.5315 in) For cylinder installation refer to CYLINDER HEAD
INSTALLATION in this subsection.
Valve has guide to be adjusted in diameter by us-
ing a reamer. 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.

vmr2008-016-042_b

A. Valve guide diameter

VALVE GUIDE DIAMETER

(INTAKE/EXHAUST)
6.006 mm to 6.018 mm
NEW
(.2365 in to .2369 in)
rmr2008-014-044_a
NOTE: Ensure to turn reamer in the right direc- 1. Piston circlip
tion. Use cutting oil and clean often reamer/valve 2. Small screwdriver
guide from metal shavings.
NOTE: The removal of both piston circlips are not
NOTE: After valve guide installation, ensure necessary to remove piston pin.
valve seats properly against cylinder head. Refer
to VALVE INSPECTION in this subsection. Prior to removing the piston mark piston with a
color dot towards the rear side of the engine.
NOTE: Do not scratch the piston surface.

26 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

vmr2008-016-049_a

1. Measuring perpendicularly (90°) to piston pin

A. 7 mm (.276 in)

rmr2008-014-047_a
The measured dimension should be as described
1. Piston marking in the following table. If not, replace piston.
2. Main shaft
3. Clutch shaft PISTON MEASUREMENT

Push piston pin out of piston. SIZE A

96.940 mm to 96.950 mm
NEW
(3.8165 in to 3.8169 in)
SERVICE LIMIT 96.920 mm (3.8157 in)
SIZE B
96.950 mm to 96.960 mm
NEW
(3.8169 in to 3.8173 in)
SERVICE LIMIT 96.930 mm (3.8161 in)

rmr2008-014-045_a

1. Piston circlip
2. Piston pin
3. Piston

Detach piston from connecting rod.

Piston Inspection
Piston
Inspect piston for scoring, cracking or other dam-
ages. Replace piston and piston rings if neces- rmr2010-012-012_a
sary. 1. Red or green paint mark (size code) of piston
Using a micrometer, measure piston at 7 mm
(.276 in) perpendicularly (90°) to piston pin. NOTE: If the wear limit is exceeded, install a
NEW piston or replace cylinder (complete with
piston.)
Take special care when matching the piston with
cylinder:
PISTON PAINT MARK CYLINDER MARK
Red paint mark =
Size “A”
size “A”
Green paint mark =
Size “B”
size “B”

rmr2013-012 27
Subsection XX (CYLINDER HEAD AND CYLINDER)
The cylinder size code “A” or “B” is stamped on
the lower side of the cylinder.
vmr2008-016-051_a
1. Size code “A” or “B” of cylinder
Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston dimen-
sion.
1 gauge. The result is the exact piston/cylinder wall
F00B08A
1. Micrometer set to the piston dimension
With the micrometer set to the dimension, adjust
a cylinder bore gauge to the micrometer dimen-
sion and set the indicator to 0 (zero).
2 1
F00B09A
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
28
F00B0AA
TYPICAL
1. Indicator set to 0 (zero)
Position the dial bore gauge 16 mm (.63 in) above
cylinder base, measuring perpendicularly (90°) to
piston pin axis.
Read the measurement on the cylinder bore
clearance.
PISTON/CYLINDER CLEARANCE
0.050 mm to 0.075 mm
NEW
(.002 in to .003 in)
SERVICE LIMIT 0.090 mm (.0035 in)
NOTE: Make sure used piston is not worn. See
PISTON MEASUREMENT.
If clearance exceeds specified tolerance, replace
piston by a new one and measure piston/cylinder
clearance again.
If 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.
Piston Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
NOTICE Take care that both pistons will be
installed with the marks (size code of piston)
showing to the rear of the engine.
rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

rmr2008-014-048_a

1. Sleeve
2. Piston circlip installer handle
rmr2008-014-047_a

1. Size code of piston

NOTE: Take care that the hook of the piston circlip
2. Main shaft is positioned properly.
3. Clutch shaft

Assemble the NEW piston circlip as per following

procedure:
REQUIRED TOOL
PISTON CIRCLIP INSTALLER
991 (P/N 529 036 072)

NOTICE Always replace disassembled piston

circlip(s) by NEW ones. Place a rag on cylinder
base to avoid dropping the circlip inside the en-
gine. vmr2008-016-054

CORRECT POSITION OF THE PISTON CIRCLIP

Place circlip in sleeve as per following illustration.
PISTON RINGS
3
Piston Rings Removal
Remove cylinder head with cylinder, refer to
CYLINDER HEAD in this subsection.
Remove PISTON. See procedure in this subsec-
1 tion.
2
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.
R400motr100A

1. Circlip
2. Sleeve
3. Piston circlip installer handle

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.

rmr2013-012 29
Subsection XX (CYLINDER HEAD AND CYLINDER)

RING/PISTON GROOVE CLEARANCE

UPPER COMPRESSION RING
0.025 mm to 0.070 mm
NEW
(.001 in to .0028 in)
SERVICE LIMIT 0.120 mm (.0047 in)
LOWER COMPRESSION RING
0.025 mm to 0.070 mm
NEW
(.001 in to .0028 in)
SERVICE LIMIT 0.120 mm (.0047 in)
OIL SCRAPER RING
rmr2008-014-049_a
0.015 mm to 0.060 mm 1. Upper compression ring
NEW
(.0006 in to .0024 in) 2. Lower compression ring
3. Oil scraper ring
SERVICE LIMIT 0.100 mm (.0039 in)
NOTE: First install spring and then the ring of oil
scraper ring. The oil scraper ring must be installed
by hand.
Install other rings using a ring expander to prevent
breakage.
Check that rings rotate smoothly after installation.
Space the piston ring end gaps 120° apart and do
not align the gaps with the piston pin bore or the
thrust side axis.
vmr2008-016-055_a

1. Piston
2. Feeler gauge A

Ring End Gap A A

To measure the ring end gap place the ring
in the cylinder in the area of 8 mm to 16 mm
(.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.
1
Using a feeler gauge, check ring end gap. Replace
ring if gap exceeds above described specified tol-
erance.
2
RING END GAP
APPLICABLE TO ALL RINGS
0.15 mm to 0.35 mm
NEW
(.0059 in to .0138 in) A31C2OA

SERVICE LIMIT 1 mm (.0394 in) 1. DO NOT align ring gap with piston thrust side axis
2. DO NOT align ring gap with piston pin bore axis
A. 120°
Piston Rings Installation
Install the oil scraper ring first with marking “O“ PISTON PIN
on top, then the lower compression ring with the
stamping “E” and “TOP “ facing up. Piston Pin Removal
For piston pin removal, see PISTON in this sub-
section.

Piston Pin Inspection

Using synthetic abrasive woven, clean piston pin
from deposits.

30 rmr2013-012
 Subsection XX (CYLINDER HEAD AND CYLINDER)

Inspect piston pin for scoring, cracking or other Piston Pin Installation
damages. Refer to PISTON in this subsection.
Measure piston pin. See the following illustration
for the proper measurement positions.

R400motr30A A
A. Piston pin diameter

PISTON PIN DIAMETER

21.997 mm to 22.000 mm
NEW
(.866 in to .8661 in)
SERVICE LIMIT 21.990 mm (.8657 in)

Replace piston pin if diameter is out of specifica-

tions.
Connecting Rod Small End Bushing
Measure inside diameter of connecting rod small
end bushing.

2 1

R1004motr11A

1. Bore gauge
2. Connecting rod

CONNECTING ROD SMALL END DIAMETER

22.010 mm to 22.020 mm
NEW
(.8665 in to .8669 in)
SERVICE LIMIT 22.030 mm (.8673 in)

Compare measurements to obtain the connecting

rod/piston pin clearance.
PISTON PIN RADIAL PLAY
SERVICE LIMIT 0.040 mm (.0016 in)

rmr2013-012 31
 Subsection XX (CRANKCASE AND CRANKSHAFT)

CRANKCASE AND CRANKSHAFT

SERVICE TOOLS
Description Part Number Page
BALANCE SHAFT PLAIN BEARING REM/INST ............................ 529 036 094 ........................................... 16
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ........................................... 15
CRANKSHAFT PLAIN BEARING TOOL......................................... 529 036 093 ........................................... 16
PULLER/LOCKING TOOL.............................................................. 529 036 098 ................................... 4–5, 20

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ..................................... 15, 18
LOCTITE 5910 ............................................................................... 293 800 081 ........................................... 17
PETAMO GREASE GHY 133N ...................................................... 420 899 271 ..................................... 16–17

rmr2013-013 1
Subsection XX (CRANKCASE AND CRANKSHAFT)

CRANKCASE

8 N•m
(71 lbf•in)
Loctite
243

Loctite
5910 Loctite
243

11 N•m
(97 lbf•in)

Engine
oil

Loctite 5910 NEW

NEW 11 N•m 8 N•m
(97 lbf•in) (71 lbf•in)
Petamo Loctite
grease 243
Ghy 133n
Engine
oil Loctite
243

Petamo grease
Ghy 133n NEW

Loctite
243

NEW

11 N•m
NEW = Component must be replaced when removed. (97 lbf•in)
rmr2008-053-004_b

2 rmr2013-013
 Subsection XX (CRANKCASE AND CRANKSHAFT)

CRANKSHAFT AND BALANCE SHAFT

Petamo
grease
Ghy 133n
25 N•m
(18 lbf•ft)

240 N•m
(177 lbf•ft) Petamo NEW
grease
Engine Ghy 133n
oil

Petamo
Loctite grease Engine
243 Ghy 133n oil
Engine
Petamo oil
grease NEW
Ghy 133n See tightening procedure

Petamo
grease
150 N•m Ghy 133n Petamo grease
(111 lbf•ft) Ghy 133n
Petamo
grease
Ghy 133n

Engine
oil Loctite
243
Petamo grease
Ghy 133n 25 N•m
(18 lbf•ft)

Petamo
grease
Ghy 133n 50 N•m 11 N•m
NEW = Component must be replaced when removed. (37 lbf•ft) Loctite 648 (97 lbf•in)
rmr2013-013-001_a

rmr2013-013 3
Subsection XX (CRANKCASE AND CRANKSHAFT)

GENERAL Install timing chain and timing chain drive gears of

rear cylinder, refer to TIMING CHAIN in this sub-
NOTICE Always disconnect battery before section.
working on the engine.
NOTE: Ensure to align mark on timing chain inter-
Even though many parts do not need to be re- mediate gear with mark on crankcase, then install
moved to reach other parts, it is recommended mating gear on crankshaft.
to remove these parts anyway in order to inspect
them.
When disassembling parts that are duplicated
in the engine, (e.g.: timing chain, drive gears),
it is strongly recommended to note their posi-
tion (front/rear cylinder ) and to store them as a
"group".
During assembly/installation, use the torque val-
ues and service products as specified in the ex-
ploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
procedure.

WARNING rmr2008-015-076_a

Torque wrench tightening specifications 1. Align marks

must be strictly adhered to.
Install water pump drive gears, then balance shaft
Locking devices when removed (e.g.: locking
drive gears.
tabs, elastic stop nuts, cotter pin, etc.) must
be replaced with new ones. NOTE: Ensure to align both dots on balance shaft
drive gears.

NOTICE Hoses, cables and locking ties re-

moved during a procedure must be reinstalled
as per factory standards.

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.
NOTICE After a complete engine tear down,
in order to achieve proper camshaft timing,
the following engine reassembly sequence
must be strictly followed.
rmr2008-015-016_a
Rear Cylinder Reassembly 1. Align dots of balance shaft drive gears
Lock crankshaft when connecting rod of rear cylin-
der is at TDC. Install and torque locking nuts of crankshaft and
balance shaft.
REQUIRED TOOL
Refer to CYLINDER HEAD AND CYLINDER to re-
PULLER/LOCKING TOOL install the following components of rear cylinder:
(P/N 529 036 098) – Piston

4 rmr2013-013
 Subsection XX (CRANKCASE AND CRANKSHAFT)

– Cylinder
– Cylinder head
– Camshaft timing gears
– Timing chain guide and chain tensioner
– Balance shaft drive gears of upper balance
shaft.
Reinstall remaining parts of rear cylinder.

Front Cylinder Reassembly

NOTICE Rear cylinder reassembly must be
completed FIRST as explained above.
Unscrew the PULLER/LOCKING TOOL (P/N 529 036
098).
Turn crankshaft on clutch side 300° counterclock-
wise. rmr2008-015-026_a

1. Align marks
Lock crankshaft when connecting rod of front 2. Timing chain drive gear
cylinder is at TDC.
Refer to CYLINDER HEAD AND CYLINDER sub-
section to reinstall the following components of
front cylinder:
– Piston
– Cylinder
– Cylinder head
– Camshaft timing gears
– Timing chain guide and chain tensioner.
Reinstall remaining parts of front cylinder.

PROCEDURES
DRIVE GEARS
Drive Gear Location
rmr2008-015-079_a The drive gears are located on the engine clutch
TYPICAL – TURN CRANKSHAFT 300° COUNTERCLOCKWISE side behind the clutch housing.
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 TIMING CHAIN in this
subsection.
NOTE: Ensure to align mark on timing chain in-
termediate gear with mark on the bearing flange,
then install mating gear on balance shaft.

rmr2013-013 5
Subsection XX (CRANKCASE AND CRANKSHAFT)

rmr2008-015-012_a

1. Crankshaft locking nut

2. Crankshaft spring washer
3. Balance shaft locking nut
rmr2008-015-010_a 4. Balance shaft spring washer
TYPICAL 5. Balancing mass
1. Primary drive gear
2. Balance shaft drive gears Remove:
– Primary drive gear
– Balance shaft drive gears
– Thrust washer
– Water pump drive gear
– 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.

rmr2008-015-011_a

1. Water pump gear

2. Water pump intermediate gear
3. Timing chain drive gears, rear cylinder
4. Timing chain intermediate gear, rear cylinder

Drive Gear Removal

Lock crankshaft at ignition TDC of rear cylinder,
refer to CRANKSHAFT in this subsection.
Remove chain tensioner of rear cylinder. rmr2008-015-014_a

Remove clutch housing and clutch drum assem- 1. Scribe a mark on timing chain intermediate gear
bly. Refer to CLUTCH (SM5) or CLUTCH (SE5) 2. Molded crankcase mark
subsection. Remove timing chain drive gear.
Remove:
– Crankshaft locking nut
– Spring washer
– Balancer shaft locking nut
– Spring washer
– Balancing mass.

6 rmr2013-013
 Subsection XX (CRANKCASE AND CRANKSHAFT)

Balance Shaft Drive Gears

NOTICE The following instruction is only
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-
wise.
Temporarily install balance shaft drive gears in any
position.
Install balancing mass, spring washer and tighten
rmr2008-015-013_a
locking nut to specification.
1. Primary drive gear BALANCE SHAFT GEAR LOCKING NUT
2. Balance shaft drive gears
3. Thrust washers
4. Water pump drive gear Tightening Torque 150 N•m (111 lbf•ft)
5. Water pump intermediate gear
6. Timing 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.
Inspect 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
drive gears are paired. Replace balance shaft drive
gears and timing chain drive gears as a set.

Drive Gear Installation

The installation is the reverse of the removal pro-
cedure, However, pay attention to the following.
NOTE: Crankshaft must still be locked at ignition
TDC of rear cylinder.
Ensure mark (scribed during removal) of timing
chain intermediate gear (rear cylinder) matches
with the molded mark on crankcase.
rmr2008-015-015_a

1. Balancing mass
2. Balance shaft gear

rmr2008-015-014_a

1. Mark on timing chain intermediate gear

2. Crankcase molded mark
rmr2008-015-100_a
NOTICE Wrong position of timing chain drive 1. Align marks
gears will lead to wrong camshaft timing and 2. Balance shaft driven gear
3. Balance shaft drive gear
cause severe engine damage.

rmr2013-013 7
Subsection XX (CRANKCASE AND CRANKSHAFT)

NOTICE 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.
NOTICE To achieve proper camshaft timing,
See the ENGINE REASSEMBLY SEQUENCE in
this subsection. rmr2008-015-103_a

1. Chain tensioner guide

TIMING CHAIN
Remove timing chain intermediate gear and nee-
Timing 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.

Timing Chain Removal (Front Cylinder)

Remove CAMSHAFT TIMING GEARS from front
cylinder. Refer to CYLINDER HEAD AND CYLIN-
DER subsection.
Refer to MAGNETO AND STARTER subsection
and remove:
– Magneto cover
– Rotor rmr2008-015-104_a

– Starter drive gears. TYPICAL

1. Timing chain intermediate gear
Remove: 2. Needle bearings
3. Thrust washer
– Screws and spring washers securing the bear-
ing flange Remove timing chain.
– Bearing flange NOTE: Mark the operating direction of the timing
– Distance sleeve chain before removal.

rmr2008-015-102_a rmr2008-015-105_a

TYPICAL 1. Timing chain

1. Retaining screws
2. Spring washers
3. Bearing flange
4. Distance sleeve

Remove chain tensioner guide.

8 rmr2013-013
 Subsection XX (CRANKCASE AND CRANKSHAFT)

Timing Chain Removal (Rear Cylinder)

Remove CAMSHAFT TIMING GEARS from rear
cylinder. Refer to CYLINDER HEAD AND CYLIN-
DER subsection.
Refer to CLUTCH (SM5) or CLUTCH (SE5) subsec-
tion and remove:
– Clutch housing
– Clutch drum assembly.
Remove primary drive gear and balance shaft
gear. See DRIVE GEARS in this subsection.
Remove: rmr2008-015-108_a
– Screws and spring washers securing the bear- 1. Needle bearings
ing flange 2. Timing chain intermediate gear
3. Thrust washer
– Bearing flange
– Distance sleeve. Remove timing chain.
NOTE: Mark the operating direction of the timing
chain before removal.

rmr2008-015-106_a

1. Retaining screws
2. Spring washers
3. Bearing flange rmr2008-015-109_a

4. Distance sleeve 1. Timing chain

Remove chain tensioner guide. Timing 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
gear for excessive radial play.
Check chain links condition for wear or other dam-
age.
Measure timing chain length. Mark 21 pins on
rmr2008-015-107_a
chain and measure the distance at the outer di-
1. Chain tensioner guide ameter of pins.
Remove timing chain intermediate gear and nee- NOTE: Ensure to eliminate play in chain while
dle bearings. measuring.
Remove thrust washer.

rmr2013-013 9
Subsection XX (CRANKCASE AND CRANKSHAFT)

rmr2008-015-021_a

A. Timing chain length

TIMING CHAIN LENGTH

(DISTANCE OF 21 PINS)
SERVICE LIMIT 165.2 mm (6.504 in)

If chain is excessively worn or damaged, replace it

as a set (camshaft timing gears and timing chain). rmr2008-015-023

Bearing Flange INTERMEDIATE GEAR INSIDE DIAMETER

Inspect bearing flange pin for scoring, pitting or
other damages.
Measure pin diameter at the running surface of
the needle bearings.
SERVICE LIMIT 22.015 mm (.8667 in)
Replace timing chain intermediate gear if out of
specification.
NOTE: Timing chain intermediate gear and timing
chain drive gear are paired. Replace as a set.
Timing Chain Guide and Chain Tensioner
Guide

rmr2008-015-022_a

A. Pin diameter

BEARING FLANGE PIN DIAMETER

rmr2008-015-024_a
SERVICE LIMIT 15.980 mm (.6291 in) 1. Timing chain guide
2. Chain tensioner 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. GROOVE DEPTH
Timing Chain Intermediate Gear SERVICE LIMIT 1.2 mm (.0472 in)
Inspect gear teeth for wear or other damage.
If gear is pitted, scored, rounded, cracked or Timing 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.

10 rmr2013-013
 Subsection XX (CRANKCASE AND CRANKSHAFT)
NOTICE To achieve proper camshaft timing,
See the ENGINE REASSEMBLY SEQUENCE in
this subsection.
Fit thrust washer with grease onto timing chain
intermediate gear, to avoid dropping it into
crankcase.
rmr2008-015-025_a
1. Timing chain intermediate gear
2. Thrust washer
Ensure to align mark on timing chain intermediate
gear with mark on bearing flange during installa-
tion.
rmr2008-015-026_a
1. Align marks
2. Timing chain drive gear
NOTICE Wrong position of timing chain drive
gears will lead to wrong camshaft timing and
cause severe engine damage.
Properly reinstall camshaft timing gears, refer to
CAMSHAFT TIMING GEAR in CYLINDER HEAD
AND CYLINDER subsection.
rmr2013-013
Timing Chain Installation
(Rear Cylinder)
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 rear cylinder, prior to installing timing chain and
timing chain drive.
NOTICE To achieve proper camshaft timing,
See the ENGINE REASSEMBLY SEQUENCE in
this subsection.
Fit thrust washer with grease onto timing chain
intermediate gear, to avoid dropping it into
crankcase.
rmr2008-015-025_a
1. Timing chain intermediate gear
2. Thrust washer
Ensure to align mark on timing chain intermediate
gear with mark on crankcase.
rmr2008-015-014_a
1. Align mark on timing chain intermediate gear
2. Crankcase mark
NOTICE Wrong position of timing chain drive
gears will lead to wrong camshaft timing and
cause severe engine damage.
Properly reinstall camshaft timing gears, refer to
CAMSHAFT TIMING GEAR in CYLINDER HEAD
AND CYLINDER subsection.
11
Subsection XX (CRANKCASE AND CRANKSHAFT)

CRANKCASE Remove the oil filter cover and the oil filter.
Remove engine from vehicle, refer to ENGINE RE- Refer to MAGNETO AND STARTER subsection
MOVAL AND INSTALLATION subsection. and remove:
– Magneto cover
Crankcase Disassembly – Rotor
Lock crankshaft at ignition TDC of front cylinder, – Starter drive gears.
refer to CRANKSHAFT in this subsection. Refer to TIMING CHAIN in this subsection and re-
Remove electric starter from engine. move:
Refer to CYLINDER HEAD AND CYLINDER sub- – Timing chains
section and remove: – Timing chain drive gears.
– Front cylinder head Refer to DRIVE BELT AND REAR 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.

rmr2008-015-027_a

TURN CRANKSHAFT 300° COUNTERCLOCKWISE

Refer to CYLINDER HEAD AND CYLINDER sub- rmr2008-015-028_a

section and remove: 1. Oil duct cover
– Rear cylinder head 2. O-ring
3. Snap ring
– Cylinder 4. Thrust washer
– Piston.
NOTE: Before splitting the crankcase, measure
Refer to CLUTCH (SM5) or CLUTCH (SE5) subsec- crankshaft axial play. Refer to CRANKSHAFT in
tion and remove: this subsection.
– Clutch housing Remove crankcase screws.
– Clutch plates
– Clutch hub
– Clutch drum.
Remove DRIVE 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 LUBRICATION SYSTEM subsec-
tion).

12 rmr2013-013
 Subsection XX (CRANKCASE AND CRANKSHAFT)

NOTE: For oil strainer inspection, refer to LUBRI-

CATION SYSTEM subsection.
Crankcase Inspection and Cleaning
Clean crankcase using a part cleaner.
Dry crankcase using compressed air.
Blow out the oil supply orifices and check if they
are not clogged.

WARNING
Always wear skin and eye protection. Chem-
rmr2008-015-032_a
icals can cause skin rash, skin burns and se-
1. Screws M6 x 65 (qty 13)
2. Screws M6 x 45 (qty 5) vere eye injury.
3. Screw M6 x 30 (qty 1)
4. Screw M6 x 80 (qty 1)

Carefully split crankcase halves by using a soft

hammer.
NOTICE During disassembly, be careful
not to damage the sealing surfaces of the
crankcase halves.

rmr2008-015-037_a

CRANKCASE HALVE — CLUTCH SIDE

1. Check oil supply orifices

rmr2008-015-033

Pull crankshaft and balance shaft out of crankcase.

Refer to GEARBOX and remove:
– Gearbox
– Reverse intermediate gear.
Remove engine oil strainer from crankcase halve
(clutch side).

rmr2008-015-038_a

CRANKCASE HALVE — CLUTCH SIDE

1. Check oil supply orifices

rmr2008-015-036_a

1. Engine oil strainer

rmr2013-013 13
Subsection XX (CRANKCASE AND CRANKSHAFT)
rmr2008-015-039_a
CRANKCASE HALVE — CLUTCH SIDE
1. Check oil supply hole
rmr2008-015-040_a
CRANKCASE HALVE — MAGNETO SIDE
1. Check oil supply orifices
rmr2008-015-041_a
CRANKCASE HALVE — MAGNETO SIDE
1. Check oil supply orifices
14
rmr2008-015-042_a
CRANKCASE HALVE — MAGNETO SIDE
1. Check oil supply hole
Check crankcase halves for cracks or other dam-
age. Replace if damaged.
Check if oil hose connectors are bent or otherwise
damaged. Refer to OIL HOSE CONNECTORS in
LUBRICATION SYSTEM subsection if replace-
ment is necessary.
Lubricate ball bearings and check for smooth oper-
ation. Check for excessive play and/or pitting. Re-
place if necessary.
Check plain bearings for scoring or other dam-
ages.
Measure plain bearing inside diameter and com-
pare with crankshaft/balance shaft bearing journal
diameters (refer to CRANKSHAFT and BALANCE
SHAFT). Replace if the measurements are out of
specification.
rmr2008-015-043_a
TYPICAL — CRANKCASE HALVE
1. 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 (1.8124 in)
BALANCE SHAFT 32.060 mm (1.2622 in)
rmr2013-013
 Subsection XX (CRANKCASE AND CRANKSHAFT)

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).

NOTICE 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.

rmr2008-015-047_a

A. Sealing ring

Reinstall bearing screws, apply LOCTITE 243

(BLUE) (P/N 293 800 060) and tighten to specifica-
tion.
BEARING SCREWS TORQUE
LOCTITE 243 (BLUE)
Service Product
(P/N 293 800 060)
rmr2008-015-045_a Tightening Torque 11 N•m (97 lbf•in)
1. Bearing screws
Plain Bearing Removal
NOTE: Prior to removing, take note of the assem-
bly direction of the ball bearings. Mark the partition of the plain bearings on
crankcase halves, prior to removing the plain
Remove clutch shaft ball bearing from magneto bearings.
side crankcase half.
REQUIRED TOOL

BLIND HOLE BEARING

PULLER SET (P/N 529 036 117)

Press out remaining ball bearings with suitable

punch.
Ball Bearing Installation
NOTE: Disassembled ball bearings must be re-
placed by new ones.
NOTICE Unless otherwise instructed, never
use hammer to install ball bearings. Use press rmr2008-015-057_a

only.
Install NEW ball bearings using a punch.
NOTE: Install ball bearings in the same assembly
direction as previously noted
Slightly oil ball bearings at the outer race to ease
installation.
TYPICAL
1. Partition of crankshaft plain bearings
2. Partition of balance shaft plain bearings
3. Marks
Remove plain bearings with the proper plain bear-
ing remover/installer.

rmr2013-013 15
Subsection XX (CRANKCASE AND CRANKSHAFT)

REQUIRED TOOL
CRANKSHAFT
CRANKSHAFT PLAIN BEARING
TOOL (P/N 529 036 093)
BALANCE SHAFT
BALANCE SHAFT PLAIN
BEARING REM/INST (P/N 529
036 094)

Place suitable support sleeve underneath the rmr2008-015-053

proper bearing seat before removing plain bear- MEASURE INSIDE DIAMETER OF CRANKCASE
ings.
Use the following table to find proper tolerance
Using a press, carefully push the plain bearings group of plain bearing.
out from the crankcase half inside towards the
outside. CRANKCASE PLAIN BEARING
INSIDE DIAMETER TOLERANCE
NOTE: During disassembly, make sure not to (CRANKSHAFT) GROUP
damage the sealing surfaces of the crankcase
halves. 49.899 mm to 49.908 mm
RED
(1.9645 in to 1.9649 in)
Plain Bearing Installation 49.908 mm to 49.918 mm
BLUE
NOTE: Plain bearings are available in 3 tolerance (1.9649 in to 1.9653 in)
groups (red, blue and yellow). 49.918 mm to 49.929 mm
YELLOW
The proper tolerance group is marked with paint (1.9653 in to 1.9657 in)
on the crankcase.
CRANKCASE PLAIN BEARING
INSIDE DIAMETER TOLERANCE
(BALANCE SHAFT) GROUP
35.909 mm to 35.918 mm
RED
(1.4137 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
(1.4145 in to 1.4149 in)

NOTICE Unless otherwise instructed, never

rmr2008-015-052_a
1. Crankcase half
2. Marking of tolerance group
If marking is not visible anymore, measure inside
diameter of crankcase where plain bearing fits.
use hammer to install plain bearings. Use
press only.
Install plain bearings with the same tools as per
removal.
Fit the plain bearings with PETAMO GREASE GHY
133N (P/N 420 899 271).
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.

16 rmr2013-013
 Subsection XX (CRANKCASE AND CRANKSHAFT)

rmr2008-015-057_a

TYPICAL rmr2011-013-007_a
1. Partition of crankshaft plain bearings PLAIN BEARINGS POSITIONING
2. Partition of balance shaft plain bearings 1. Crankcase reference surface
3. Marks
A. 1.5 mm (.059 in)
B. 2 mm (.079 in)
Mark position of oil orifice on crankcase half
(magneto side) and on plain bearing installer. NOTE: Remove O-ring before completely press-in
Align mark on plain bearing installer with mark on plain bearings.
crankcase half.
Make sure not to damage the sealing surfaces of
the crankcase halves.

rmr2008-015-058_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.
Carefully press-in the plain bearings in the same
direction as during disassembly.
Position plain bearings as illustrated:
– Balance shaft plain bearing 1.5 mm (.059 in) be-
low crankcase reference surface.
– Crankshaft plain bearing 2 mm (.079 in) below
crankcase reference surface.
Crankcase Assembly
The assembly of crankcase is essentially the re-
verse of removal procedure. However, pay atten-
tion to the following details.
Install a new crankcase gasket.
Coat the plain bearings with PETAMO GREASE GHY
133N (P/N 420 899 271) before mounting crankshaft
and balance shaft.
NOTE: Correctly reinstall crankshaft (refer to
CRANKSHAFT).
For reinstallation of gearbox and oil seals, refer to
GEARBOX subsection.
Apply a seam of LOCTITE 5910 (P/N 293 800 081) on
the oil strainer to fit into crankcase.

rmr2008-011-025_b

1. Apply Loctite 5910 here

Tighten crankcase screws as per the following se-

quence.
rmr2013-013 17
Subsection XX (CRANKCASE AND CRANKSHAFT)

rmr2013-013-002_a

TIGHTENING SEQUENCE
rmr2008-015-004_a
CRANKCASE SCREWS SM5 MODEL
1. Plug screw
LOCTITE 243 (BLUE) 2. O-ring
Pos. 2 - Service Product
(P/N 293 800 060)
Tightening Torque 11 N•m (97 lbf•in) On SE5 model, remove plug screw on the hy-
draulic control module (HCM) housing.
Install all other removed parts.
NOTICE To achieve proper camshaft timing,
See the ENGINE REASSEMBLY SEQUENCE in
this subsection.

CRANKSHAFT
Crankshaft Locking Procedure
NOTICE The crankshaft must be locked at the
ignition TDC of the respective cylinder for re-
moval and installation work on crankshaft, bal-
ance shaft and camshaft.
NOTE: Crankshaft can be locked at ignition TDC
for each cylinder separately. rmr2013-013-003_a

NOTE: The following procedure is valid for both SE5 MODEL

cylinders. 1. Plug screw
2. O-ring
Remove upper side panels. Refer to BODY sub- 3. HCM housing
section. Remove M8 screw with sealing ring blocking ac-
Remove spark plugs. cess hole.
Remove valve covers. Refer to CYLINDER HEAD
AND CYLINDER subsection.
On SM5 model, remove magneto cover plug
screw.

18 rmr2013-013
 Subsection XX (CRANKCASE AND CRANKSHAFT)

rmr2008-015-110_a

SM5 MODEL
rmr2008-015-006_a
1. Access screw
2. Clutch cover SM5 MODEL
1. Allen wrench

rmr2008-053-002_a
rmr2013-013-003_a
SE5 MODEL
1. Access screw SE5 MODEL
2. Sealing ring 1. Allen wrench
3. Clutch cover
NOTE: When piston is at ignition TDC, the printed
Turn the crankshaft until the piston is at the igni- marks (“IN” and “EX”) on the camshaft timing
tion TDC of the respective cylinder. gears must be aligned, as shown in the next illus-
REQUIRED TOOL
tration.

14 MM ALLEN WRENCH

rmr2008-015-007_a

TYPICAL
1. Align marks

rmr2013-013 19
Subsection XX (CRANKCASE AND CRANKSHAFT)

Use a small screwdriver to check if the groove in Crankshaft Axial Play

the crankshaft is aligned with the hole. NOTE: Axial play needs to be measured before
splitting the crankcase.
Measure play on PTO end, using a dial indicator.

rmr2008-015-008_a rmr2008-015-031

TYPICAL
1. Screwdriver CRANKSHAFT AXIAL PLAY
Lock crankshaft. SERVICE LIMIT 0.7 mm (.0276 in)
REQUIRED TOOL If play is out of specification, replace crankcase
PULLER/LOCKING TOOL and/or crankshaft.
(P/N 529 036 098)
Crankshaft Radial Play (MAG/Clutch Side)
Measure crankshaft journal on MAG/clutch side.

rmr2008-015-009_a rmr2008-015-064_a

TYPICAL 1. Micrometer
1. Crankshaft locking bolt 2. Crankshaft area for clutch side plain bearing

Crankshaft Removal
Refer to CRANKCASE in this subsection.

Crankshaft Inspection
NOTE: Check each bearing journal of crankshaft
for scoring, scuffing, cracks or other signs of wear.
NOTICE Components with less than the ser-
vice limit always have to be replaced. If this is
not observed, severe damage may be caused
to the engine.

20 rmr2013-013
 Subsection XX (CRANKCASE AND CRANKSHAFT)

NOTE: Refer to CLUTCH (SM5) or CLUTCH (SE5)

subsection.
CRANKSHAFT RADIAL PLAY
(CLUTCH SUPPORT BEARING)
SERVICE LIMIT 0.065 mm (.0026 in)

Crankshaft Installation
For installation reverse the removal procedure.
However, pay attention to the following.
Do not mix up the connecting rods of front and
rmr2008-015-065_a rear cylinders during installation.
1. Micrometer
2. Crankshaft area for MAG side plain bearing NOTICE Observe the correct installation po-
sition when fitting the crankshaft with the
CRANKSHAFT BEARING JOURNAL
connecting rods. The connecting rod magneto
(MAG/CLUTCH SIDE)
side must face to rear cylinder.
SERVICE LIMIT 45.955 mm (1.8093 in)

To obtain the radial play:

– Compare crankshaft bearing journal to inside di-
ameter of side plain bearing in crankcase.
NOTE: Refer to CRANKCASE in this subsection.
CRANKSHAFT RADIAL PLAY
(MAG/CLUTCH SIDE)
SERVICE LIMIT 0.06 mm (.0024 in)

Crankshaft Radial Play

(Clutch Support Bearing Side)
Measure the crankshaft bearing journal that in-
serts in the clutch support bearing.
rmr2013-013-005_a

1. Crankcase half MAG side

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.
rmr2008-015-066_a

1. Micrometer
Remove connecting rods from crankshaft.
2. Crankshaft journal (clutch support bearing)
NOTICE Always replace connecting rod
CRANKSHAFT BEARING JOURNAL screws if removing the connecting rod. It is
(CLUTCH SUPPORT BEARING) also recommended to replace plain bearings,
SERVICE LIMIT 29.970 mm (1.1799 in)
within an overhaul of the engine.

To obtain the radial play:

– Compare crankshaft bearing journal to inside di-
ameter of plain bearing in clutch housing.
rmr2013-013 21
Subsection XX (CRANKCASE AND CRANKSHAFT)
vmr2007-037-003_a
TYPICAL
1. Connecting rod screws
Clean crankshaft oil orifices and make sure they
are not clogged.
Measure crankshaft pin. Compare to inside diam-
eter of connecting rod big end.
rmr2008-015-063_a
1. Micrometer
2. Crankshaft pin area for plain bearing
To measure the connecting rod big end diameter,
leave the OLD plain bearings in place.
Install the connecting rod cap and follow the
torque procedure as described in CRANKSHAFT
ASSEMBLY further using the OLD connecting rod
screws.
NOTE: Secure the connecting rod in a vise with
aluminum jaws.
Measure connecting rod big end diameter.
vmr2006-044-039_a
TYPICAL
A. Connecting rod big end diameter (plain bearing in place)
22
CRANKSHAFT PIN DIAMETER
SERVICE LIMIT 41.960 mm (1.652 in)
CONNECTING ROD BIG END DIAMETER
SERVICE LIMIT 42.080 mm (1.6567 in)
CONNECTING ROD BIG END RADIAL PLAY
(WITH USED PLAIN BEARING)
SERVICE LIMIT 0.07 mm (.0028 in)
NOTE: Use NEW plain bearings, when connect-
ing rod big end radial play is out of specification.
Connecting Rod/Piston Pin Clearance
Refer to CYLINDER HEAD AND CYLINDER sub-
section.
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.
rmr2008-015-067_a
1. Half plain bearing of connecting rod big end
2. Split surface of the connecting rod
3. Nose of plain bearing in line with connecting rod groove
Lubricate the plain bearing surface of the connect-
ing rod and crank pin before installation.
NOTICE Properly reinstall connecting rods in
the same assembly direction as marked during
removal.
Printed marks on connecting rod and cap must
point together.
rmr2013-013
 Subsection XX (CRANKCASE AND CRANKSHAFT)

CONNECTING ROD SCREWS TIGHTENING

SEQUENCE
STEP 1 2 N•m (18 lbf•in)
STEP 2 30 N•m (22 lbf•ft)
STEP 3 75°

rmr2008-015-068_a

1. Printed marks

Install connecting rods on crankshaft in a way that

stamped part numbers face together.

rmr2008-015-069_a

1. Angle torque wrench

NOTICE Failure to strictly follow this proce-

dure may cause screw to loosen and lead to en-
gine damage.

BALANCE SHAFT
Balance Shaft Location
rmr2010-013-001_a

1. Stamped marks on connecting rods facing together

rmr2008-015-071_a

1. Balance shaft
2. Crankcase MAG

rmr2010-013-002
TYPICAL - STAMPED MARK
NOTICE Always use NEW connecting rod
screws for the final assembly of the crank-
shaft.
Apply oil on head and thread of NEW connect-
ing rod screws and tighten as per following pro-
cedure:
NOTE: Always perform a step on both connecting
rod screws before going to the next step.
Balance Shaft Removal
Refer to CRANKCASE in this subsection.
Balance Shaft Inspection
NOTE: Check each bearing journal of balance
shaft for scoring, scuffing, cracks or other signs
of wear.
Clean balance shaft oil orifices and make sure they
are not clogged.

rmr2013-013 23
Subsection XX (CRANKCASE AND CRANKSHAFT)

BALANCE SHAFT RADIAL PLAY

(MAG/CLUTCH SIDE)
SERVICE LIMIT 0.06 mm (.0024 in)

Balance Shaft Radial Play

(Clutch Support Bearing Side)
Measure balance shaft bearing journal on clutch
side (support bearing).
rmr2008-015-072_a

1. Clean oil orifices

Balance Shaft Radial Play (MAG/CLUTCH

Side)
Measure balance shaft bearing journals on
MAG/CLUTCH side.

rmr2008-015-075_a

1. Micrometer
2. Bearing journal — clutch support bearing

BALANCE SHAFT BEARING JOURNAL

(CLUTCH SUPPORT BEARING)

rmr2008-015-073_a
SERVICE LIMIT 19.990 mm (.787 in)
1. 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.
BALANCE SHAFT RADIAL PLAY
(CLUTCH SUPPORT BEARING)
SERVICE LIMIT 0.06 mm (.0024 in)

Balance Shaft Installation

The installation is the reverse of the removal pro-
rmr2008-015-074_a cedure.
1. Micrometer
2. Bearing journal — clutch side

BALANCE SHAFT BEARING JOURNAL

(MAG/CLUTCH SIDE)
SERVICE LIMIT 31.980 mm (1.2591 in)

To obtain the radial play:

– Compare balance shaft bearing journal to inside
diameter of plain bearing in crankcase.
NOTE: Refer to CRANKCASE in this subsection.

24 rmr2013-013
 Subsection XX (CLUTCH (SM5))

CLUTCH (SM5)
SERVICE TOOLS
Description Part Number Page
BEARING PUSHER/REMOVER ..................................................... 529 036 095 ........................................... 33
BEARING PUSHER........................................................................ 529 036 096 ........................................... 33
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ........................................... 32
CLUTCH ASSEMBLY HOLDER ..................................................... 529 035 618 ........................................... 34
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 17
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................................... 16–17
SM5 CLUTCH PISTON TOOL ....................................................... 529 036 258 ........................................... 20
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ........................... 9–10, 13, 18

SERVICE PRODUCTS
Description Part Number Page
BRAKE FLUID................................................................................ 293 600 131 ............................................. 7
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................... 21–22, 26
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ..................................... 35, 39
PETAMO GREASE GHY 133N ...................................................... 420 899 271 ..................................... 33, 35
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ........................................... 31

TWN: Please check ALL photograps in this

section if they are still up to date; DMUs are
checked by RTX.

rmr2013-014 1
Subsection XX (CLUTCH (SM5))

RS and ST Models 28 N•m RT Model

NEW (21 lbf•ft)
1.8 N•m
1.8 N•m (16 lbf•in)
(16 lbf•in)

10 N•m 10 N•m
(89 lbf•in) (89 lbf•in)

NEW
28 N•m
(21 lbf•ft)

NEW

10 N•m
NEW (89 lbf•in)

NEW
5 N•m
(44 lbf•in) 28 N•m
NEW
(21 lbf•ft)

NEW = Component must be replaced when removed.

rmr2013-014-105_a

2 rmr2013-014
 Subsection XX (CLUTCH (SM5))

NEW
11 N•m Loctite Brake fluid
(97 lbf•in) 243
6 N•m
(53 lbf•in)
NEW
Brake fluid

15 N•m
(133 lbf•in) Loctite
243
Brake
fluid

Loctite 243 Brake

5 N•m fluid
(44 lbf•in) 15 N•m NEW
(133 lbf•in)

19 N•m
(168 lbf•in)

NEW

11 N•m
(97 lbf•in)

Petamo
Petamo grease
grease Ghy 133n
Ghy 133n

NEW = Component must be replaced when removed.

rmr2008-016-001_e

rmr2013-014 3
Subsection XX (CLUTCH (SM5))

11 N•m
(97 lbf•in)

Engine oil

Engine oil

Loctite 648
190 N•m
(140 lbf•ft)

Petamo grease
Ghy 133n

rmr2013-014-002_a

4 rmr2013-014
 Subsection XX (CLUTCH (SM5))

Engine oil

30 N•m
(22 lbf•ft)
Loctite 648

Engine oil

rmr2013-014-003_a

rmr2013-014 5
Subsection XX (CLUTCH (SM5))

GENERAL
TWN: Vlct responsibility begins

NOTE: For a better understanding, many of the

following illustrations are produced with the en-
gine out of vehicle. To carry out the instructions,
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
first and reconnect last.
rmr2008-016-001_c
During assembly/installation, use torque values
and service products as specified in the exploded A diaphragm assists the hydraulic system in dis-
views. placing the pressure plate to disengage the clutch.
Clean threads before applying a threadlocker. Re- The diaphragm is activated by vacuum applied
fer to SELF-LOCKING FASTENERS and LOCTITE through an electronically controlled solenoid valve
APPLICATION at the beginning of this manual for (controlled by the ECM).
complete procedure.

WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced with new ones.

NOTICE Hoses, cables or locking ties re-

moved during a procedure must be reinstalled
as per factory standards.
NOTICE 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
fitting is unscrewed.
Periodically check the clutch hoses for damages
or leaks. Repair any damages or leaks.
SYSTEM DESCRIPTION
The engine on the SM5 model features a hydrauli-
cally operated pneumatically assisted type clutch
system.
rmr2008-016-122_a
TYPICAL
1. Solenoid
2. Vent to atmosphere
3. Check valve
4. Vacuum to clutch release servo
When the clutch lever is depressed and the en-
gine is running, the ECM modulates the clutch
solenoid valve to provide a variable assist to the
clutch.
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.

6 rmr2013-014

A check valve is used to allow only vacuum pulses
to go towards diaphragm. Therefore, its orienta-
tion is important for proper operation.
rmr2008-016-123_a
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.
MAINTENANCE
CLUTCH FLUID
Recommended Clutch Fluid
Use only DOT 4 BRAKE FLUID (P/N 293 600 131) or
equivalent.
NOTICE To avoid serious damage to the
hydraulic clutch system, use only brake fluid
of the recommended type from a sealed con-
tainer. Do not use fluid from an old or already
opened container, nor mix different fluids for
topping up the system.
Clutch Fluid Level Verification
Ensure vehicle is on a level surface.
Set the handlebar in order to position the top of
clutch fluid reservoir horizontally.
Wipe clean the reservoir cap area.
Remove retaining screws of reservoir cap using a
Phillips screwdriver.
rmr2013-014
Subsection XX (CLUTCH (SM5))
rmo2010-001-005
Carefully remove reservoir cap. Pay attention not
to drop the seal.
Check clutch fluid level inside the reservoir:
– The fluid must be on the fill level line.
rmo2010-001-006_b
FLUID REMOVED FOR CLARITY PURPOSE
1. Fill level line
If the fluid level is lower than specified, add fluid to
the reservoir up to the fill level line. Do not over-
fill.
WARNING
Avoid getting brake fluid on skin or in eyes,
it may cause severe burns. In case of con-
tact with the skin, wash thoroughly. In case
of contact with the eyes, immediately rinse
with plenty of water for at least 10 minutes
and then consult a doctor immediately.
NOTE: A low level may indicate leaks or worn
clutch discs.
Reinstall the reservoir cover.
Ensure seal is located inside reservoir cap and the
seal is completely collapsed.
7
Subsection XX (CLUTCH (SM5))

Clutch Fluid Replacement

Clutch Fluid Draining
Remove the following RH body panels, refer to
BODY subsection:
– Top side panel
– Rear side panel.
Remove clutch reservoir cover screws. Do not re-
move cover at this time.

rmr2008-016-117_a

TYPICAL

Depress and release the clutch lever several times

until no more fluid flows out of bleeder.

rmo2010-001-005

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).

rmr2008-016-113_a

TYPICAL

Tighten bleeder.

rmr2008-016-116

TYPICAL

Loosen the clutch bleeder.

8 rmr2013-014
 Subsection XX (CLUTCH (SM5))

rmr2008-021-016-500

rmr2008-016-117_b TYPICAL - PUMP AND REMOTE RESERVOIR INSTALLATION

TYPICAL
Add recommended fluid in the pump remote
Clutch Fluid Filling reservoir.
Remove reservoir cover. Set pump to the PRESSURE position.
Turn handlebar fully on right side. Loosen clutch bleeder.
NOTE: Turning the handlebar will help the bleed-
ing process.
Fill reservoir with the RECOMMENDED CLUTCH
FLUID.
Ensure that clutch fluid reaches the fill level line.
Bleed system using the CLUTCH FLUID BLEED-
ING USING A PUMP (SYSTEM COMPLETELY
EMPTY) procedure.
NOTE: If a pump is not available, use the CLUTCH
FLUID BLEEDING WITHOUT A PUMP procedure.
Clutch Bleeding Procedures
Clutch Fluid Bleeding using a Pump (System
Completely Empty)
NOTE: If the system is completely empty, it is
rmr2008-016-117_a
easier to bleed the system by pushing the fluid
TYPICAL - LOOSEN CLUTCH BLEEDER
from the bleeder to the reservoir. Use the follow-
ing procedure. Activate the pump lever several times until
Install the vacuum/pressure pump and the re- fluid reaches the clutch reservoir. Then, tighten
mote reservoir onto the clutch bleeder with a bleeder.
clear hose.
NOTICE Do not overfill reservoir.
REQUIRED TOOL

VACUUM/PRESSURE PUMP
(P/N 529 021 800)

rmr2013-014 9
Subsection XX (CLUTCH (SM5))

rmr2008-021-016-501

ACTIVATE PUMP UNTIL FLUID REACHES CLUTCH RESERVOIR rmr2008-021-016-500

TYPICAL - PUMP AND REMOTE RESERVOIR INSTALLATION

Set pump to the VACUUM position.

Loosen clutch bleeder.

rmr2008-016-117_b

TYPICAL - TIGHTEN CLUTCH BLEEDER

Depress clutch lever several times. If it feels

spongy, bleed system again using the CLUTCH
FLUID BLEEDING USING A PUMP (SYSTEM
NOT COMPLETELY EMPTY) procedure.
Top up fluid reservoir.
Install cover on reservoir.
Clutch Fluid Bleeding using a Pump
(System not Completely Empty)
Install the vacuum/pressure pump and the re-
mote reservoir onto the clutch bleeder with a
clear hose.
REQUIRED TOOL
rmr2008-016-117_a
TYPICAL - LOOSEN CLUTCH BLEEDER
Depress and release the pump lever several
times until no more air bubbles flow out of
bleeder. Then, tighten bleeder.
NOTE: Check the clutch fluid level in reservoir of-
ten to prevent air from being drawn into the sys-
tem.

VACUUM/PRESSURE PUMP
(P/N 529 021 800)

10 rmr2013-014
 Subsection XX (CLUTCH (SM5))

rmr2008-021-016-501

ACTIVATE PUMP UNTIL NO MORE AIR COMES OUT

rmr2008-016-116

TYPICAL

Loosen the clutch bleeder.

rmr2008-016-117_b

TYPICAL - TIGHTEN CLUTCH BLEEDER

Depress clutch lever several times. If it feels

spongy, repeat procedure until system is entirely rmr2008-016-117_a
bled of trapped air. TYPICAL
Top up fluid reservoir.
Depress the clutch lever until it reaches the end
Install cover on reservoir. of its stroke.
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.

rmr2013-014 11
Subsection XX (CLUTCH (SM5))
rmr2008-016-113_a
TYPICAL
Tighten the clutch bleeder.
rmr2008-016-117_b
TYPICAL
Release the clutch lever.
12
rmr2008-016-110_b
TYPICAL
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
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
lever a few times.
Note clutch lever resistance.
rmr2013-014
 Subsection XX (CLUTCH (SM5))

rmr2008-016-110_a

TYPICAL rmr2008-016-125

TYPICAL
Start engine and let run at idle.
Set the pump to vacuum and activate its lever sev-
Depress clutch lever a few times. eral times until vacuum specified in the following
Compare lever resistance with and without en- table is obtained.
gine running.
VACUUM LEAK TEST
Lever must be easier to depress when the engine
is running. Otherwise, carry out a VACUUM LEAK VACUUM TIME WITHOUT LEAK
TEST. 25 in Hg 30 seconds

Vacuum Leak Test If vacuum leaks, check the following:

Disconnect vacuum hose from clutch cover fit- – Clutch cover screws for tightness
ting. – Tightness of diaphragm nut
– Diaphragm.
If the vacuum leak test was good, check the
vacuum-assist components.
NOTE: If there is no clutch assist or only partial
assist, the check valve should be suspected.
Remove the vacuum/pressure test pump and
hose.
Install the system vacuum hose on the clutch
cover and secure it as specified in the exploded
view.

Hydraulic Operation Test

Remove hydraulic clutch piston cover.

rmr2008-016-124_a

Install the vacuum/pressure pump onto the clutch

cover vacuum hose fitting.
REQUIRED TOOL

VACUUM/PRESSURE PUMP
(P/N 529 021 800)

rmr2013-014 13
Subsection XX (CLUTCH (SM5))
rmr2008-016-003_a
1. Screws
2. Clutch piston over
Observe the hydraulic piston position.
rmr2008-016-111_a
CLUTCH HYDRAULIC PISTON
Fully depress clutch lever and hold.
14
rmr2008-016-121_b
Again, observe the hydraulic piston position.
rmr2008-016-112_a
MOVEMENT OF CLUTCH HYDRAULIC PISTON
It should move outwards approximately 2 mm
(.079 in).
NOTE: Ensure clutch lever adjustment is set to
allow maximum piston stroke. Also, piston must
maintain its position as long as clutch lever is held
depressed.
If clutch piston does not maintain its position
while clutch lever is depressed, check the hy-
draulic components.
rmr2013-014
 Subsection XX (CLUTCH (SM5))

TROUBLESHOOTING Place master-cylinder reservoir over a drain pan.

Remove the retaining screw and clutch fluid hose
RATTLE AT IDLE OR DURING CLUTCH from the master cylinder.
ENGAGEMENT
1. Check clutch drum and clutch dampener parts
(spring disc(s) and thrust washer) for any wear.
- Replace defective parts in accordance with clutch
layout.

OVERHEATED/WORN CLUTCH PLATES

AND/OR OVERHEATED DIAPHRAGM
1. Faulty pneumatic clutch assist.
- Check CLUTCH SOLENOID VALVE (CSV).
rmr2008-028-030_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 parts 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

Installation is the reverse of the removal proce-
Master-Cylinder Removal dure, however pay attention to the following.
Drain fluid from clutch system. Refer to CLUTCH If clutch fluid hose was disconnected:
FLUID REPLACEMENT procedure 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 FLUID
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
COMMUNICATION TOOLS AND B.U.D.S.
Select the Read Data button.
Select the Faults page tab.
Check for fault codes.
To test the solenoid valve operation, select the
Activation page tab and confirm you are on the
ECM page.
rmr2008-028-029_a
Activate the clutch solenoid valve by selecting the
TYPICAL
1. Screws solenoid symbol.

rmr2013-014 15
Subsection XX (CLUTCH (SM5))

rmr2008-016-081_a

1. Activate here rmr2008-054-003_b

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 CSV CIRCUIT CONTINUITY TEST.
If the solenoid valve does not work, proceed with If voltage is correct:
a voltage test. – Carry out a CSV RESISTANCE TEST.
CSV Input Voltage Test CSV Resistance Test
Remove the RH upper side panel, refer to the Disconnect clutch solenoid valve connector.
BODY subsection.
Set the multimeter to .
Disconnect the clutch solenoid valve connector.
REQUIRED TOOL
Turn ignition switch to ON.
FLUKE 115 MULTIMETER
(P/N 529 035 868)

Measure the clutch solenoid valve resistance as

follows.
CSV RESISTANCE TEST
RESISTANCE @
TEST PROBES
20°C (68°F)
Solenoid pins 1 and 2 23 ± 1.2

rmr2008-016-084_b

1. Clutch solenoid valve connector

2. Clutch solenoid valve

Set the multimeter to Vdc setting.

REQUIRED TOOL

FLUKE 115 MULTIMETER

(P/N 529 035 868)

CSV INPUT VOLTAGE TEST

TEST PROBES VOLTAGE
rmr2008-054-002_a
Clutch solenoid
Battery
valve connector Battery ground If resistance is out of specification:
voltage
Pin 2 – Replace the clutch solenoid valve.

16 rmr2013-014
 Subsection XX (CLUTCH (SM5))

If resistance is good:
– Carry out a CSV CIRCUIT CONTINUITY TEST.

CSV Circuit Continuity Test

Connect ECM connector A on the ECM adapter
tool.
REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)

Set the multimeter to .

rmr2008-054-001_a
REQUIRED TOOL
1. Solenoid valve
2. Solenoid connector
FLUKE 115 MULTIMETER 3. Vacuum hose from throttle body
4. Vacuum hose to clutch housing
(P/N 529 035 868)
Cut Oetiker clamps and remove hoses from clutch
Measure the circuit continuity resistance as fol- valve solenoid.
lows. NOTE: Mark hoses location for reinstallation.
CSV CIRCUIT CONTINUITY TEST
Clutch Solenoid Valve Installation
RESISTANCE
TEST PROBES
@ 20°C (68°F)
For installation, reverse the removal procedure.

Clutch solenoid Fuse F12 CHECK VALVE

connector Front fuse box
pin 2 contact A-9 (CLUTCH SOLENOID VALVE)
Close to 0
Clutch solenoid
ECM-A
Check Valve Removal
connector
Contact L-3 Remove the air filter housing. Refer to AIR IN-
pin 1
TAKE SYSTEM subsection.
If resistance is out of specification: Cut Oetiker clamps retaining the check valve.
– 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.

Clutch Solenoid Valve Removal

Remove the RH top side panel. Refer to the
BODY subsection.
Disconnect clutch solenoid valve connector.
rmr2008-016-082_a
Remove screws securing clutch solenoid valve to 1. Oetiker clamps
support bracket. 2. Check valve

Remove the check valve.

Check Valve Inspection

Using the vacuum/pressure pump, test the check
valve operation.

rmr2013-014 17
Subsection XX (CLUTCH (SM5))

REQUIRED TOOL

VACUUM/PRESSURE PUMP
(P/N 529 021 800)

Check Valve Installation

Install the check valve with the flow arrow point-
ing towards the throttle body.
Install NEW Oetiker clamps.
rmr2008-016-051_a

1. 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.

TWN: next Notice was below illustration

NOTICE Hold the clutch release shaft to

rmr2008-016-083_a
avoid twisting and damaging the diaphragm.
1. Flow arrow towards throttle body

Install all other removed parts.

TWN: Vlct responsibility ends

HYDRAULIC PISTON

TWN: Vlct responsibility begins

Hydraulic Piston Access

RS and ST Models rmr2008-016-052

Refer to BODY subsection and remove the follow-

Squeeze clutch lever a few times to push hy-
ing:
draulic piston out of the clutch cover.
– lower side panel
Remove compression spring.
– Middle side panel.
RT Models
Refer to BODY subsection and remove the follow-
ing:
– Bottom rear side panel
– Rear side panel.

TWN: Vlct responsibility ends

Hydraulic Piston Removal

Remove hydraulic piston cover screws.
rmr2008-016-053_a

1. Hydraulic piston
2. Compression spring

18 rmr2013-014
 Subsection XX (CLUTCH (SM5))

Hydraulic Piston Inspection

Clean piston with new brake fluid.
Visually inspect piston surface for scoring,
scratches or abnormal wear. Replace if nec-
essary.

rmr2013-015-012_a

1. Ball
2. Thread

TWN: rev2 — ends

rmr2008-016-009_a

1. Check piston surface

Compression Spring
Check free length of compression spring.
Hydraulic Piston Installation
Replace piston O-rings with NEW ones.
Coat hydraulic piston and O-rings with new brake
fluid.

TWN: rev2 — begins

Insert piston with compression spring into hy-

draulic cylinder.

TWN: rev2 — ends

rmr2008-016-010

COMPRESSION SPRING FREE LENGTH

37.10 mm to 42.90 mm
NEW
(1.461 in to 1.689 in)
SERVICE LIMIT 35.00 mm (1.378 in)

If the compression spring is out of specifications,

replace it.
rmr2008-016-053_a

TWN: rev2 — begins 1. Hydraulic piston

2. Compression spring

Hydraulic Piston Nut

TWN: rev2 — begins
Clean hydraulic piston nut.
Visually inspect ball and thread condition. Install hydraulic piston nut, refer to CLUTCH
COVER INSTALLATION in this subsection.

TWN: rev2 — ends

Install hydraulic piston cover.

rmr2013-014 19
Subsection XX (CLUTCH (SM5))

Bleed clutch, refer to CLUTCH FLUID in this sub-

section.

CLUTCH COVER

TWN: Vlct responsibility begins

Clutch Cover Access

Refer to BODY subsection and remove the follow-
ing:
– Bottom rear side panel
– Rear side panel. rmr2008-016-056_a

1. Clutch hose
TWN: Vlct responsibility ends 2. Vacuum hose
3. Screw

NOTE: Disconnect both hoses ONLY if cover

TWN: TRANSLATION: The TOPIC Clutch must be removed from the vehicle. Otherwise,
Cover Removal comes from rbs2013–006, AP omit these steps.
21/12/2012 Install the clutch piston tool to secure the hy-
draulic piston in the cylinder and avoid clutch fluid
Clutch Cover Removal leakage.
Lift and safely block RH front of vehicle to prevent REQUIRED TOOL
engine oil leakage when removing components (if
servicing clutch cover in vehicle).
Remove hydraulic piston cover screws. SM5 CLUTCH PISTON TOOL
(P/N 529 036 258)

rmr2008-016-051_a

1. Screws
2. Hydraulic piston cover

Install a drain pan under clutch hose.

Remove clutch fluid and vacuum hoses from
clutch cover. Discard sealing washers. rmr2013-014-012_a

1. Hydraulic piston
2. SM5 clutch piston tool
3. Hydraulic piston cover screws

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.
NOTICE Hold the clutch release shaft to
avoid twisting and damaging the diaphragm.

20 rmr2013-014
 Subsection XX (CLUTCH (SM5))

rmr2013-014-014_a

1. Hold Allen key rmr2008-016-108_a

2. Turn wrench counterclockwise 1. Mounting lug
2. Diaphragm slot inserted on lug
Remove clutch cover retaining screws.
Install clutch cover.
Remove the clutch cover from the engine.
Position cover so that clutch bleeder screw is
NOTICE Do not let the clutch cover hang pointing upwards (when engine is on vehicle).
from the hose and do not stretch or twist the
hose.

TWN: End of the ref, AP 21/12/2012

Clutch Cover Inspection

Clean cover and check for cracks or other damage.

TWN: TRANSLATION: The TOPIC Clutch Cover

Installation comes from rbs2013–006, AP
21/12/2012

Clutch Cover Installation

Ensure slots in diaphragm are properly positioned
on mounting lugs.
rmr2013-014-020_a

1. Bleeder nipple pointing upwards

Install clutch cover screws in a criss-cross pattern.

TIGHTENING TORQUE
Finger tightened
+
Clutch cover screws
LOCTITE 243 (BLUE)
(P/N 293 800 060)

NOTE: Allow clutch cover movement for proper

piston alignment.
Make sure clutch piston tool is still installed.
Apply thread locker on the thread of the hydraulic
piston nut.

rmr2013-014 21
Subsection XX (CLUTCH (SM5))

HYDRAULIC PISTON NUT

LOCTITE 243 (BLUE)
Service Product
(P/N 293 800 060)

Tighten the hydraulic piston nut a few turns by

hand while holding release shaft with a 5 mm
Allen wrench.
Using a 17 mm deep offset wrench, tighten the
hydraulic piston nut while holding the clutch re-
lease shaft with a 5 mm Allen wrench.
NOTICE Hold the clutch release shaft in its
position to avoid twisting and damaging the
diaphragm.
rmr2013-006-050_a

CENTER CLUTCH COVER

1. Clutch cover

Hold the cover in this position and tighten clutch

cover screws to specification in a criss-cross pat-
tern.
TIGHTENING TORQUE
Clutch cover screws 5 N•m (44 lbf•in)

Install clutch fluid hose banjo bolt with NEW seal-

ing washers.
TIGHTENING TORQUE
Clutch fluid hose
28 N•m (21 lbf•ft)
banjo bolt
rbs2013-006-007_a

Step 1: Hold Allen key Bleed clutch. Refer to CLUTCH FLUID in this sub-
Step 2: Turn wrench clockwise section.
TIGHTENING TORQUE Carry out a vacuum leak test. Refer to CLUTCH
OPERATION TEST in this subsection.
Hydraulic piston nut 15 N•m (133 lbf•in)
Test clutch operation.
Remove clutch piston alignment tool. Install hydraulic piston cover and tighten screws
Slightly move clutch cover horizontally and verti- to specification.
cally and center it. TIGHTENING TORQUE
Hydraulic piston cover
11 N•m (97 lbf•in)
screws

TWN: End of the ref.

HYDRAULIC CYLINDER
Hydraulic Cylinder Removal
Remove the HYDRAULIC PISTON. See procedure
in this subsection.
Remove the CLUTCH COVER. See procedure in
this subsection.
Remove the circlip retaining the hydraulic cylinder.

22 rmr2013-014
 Subsection XX (CLUTCH (SM5))

rmr2008-016-011_a

rmr2008-016-057_a 1. Hydraulic cylinder notch

1. Circlip
2. Hydraulic cylinder
Remove hydraulic cylinder from clutch cover.
Hydraulic Cylinder Inspection
Clean parts with new brake fluid.
Visually inspect cylinder surface for scoring,
scratches or abnormal wear. Replace if neces-
sary.
2. Clutch cover embossment
Install cylinder retaining circlip.
CLUTCH DIAPHRAGM
Diaphragm Removal
Remove the CLUTCH COVER. See procedure in
this subsection.
Pull diaphragm out of its mounting lugs, then ro-
tate it away from the lugs to avoid damaging the
diaphragm when removing retaining nut.

rmr2008-016-008_a

1. Inspect cylinder surface

Replace O-rings with NEW ones.

Also inspect the clutch cover bore for scoring,
scratches or other damages.
rmr2008-016-101_a

1. Mounting lugs
Hydraulic Cylinder Installation 2. Diaphragm rotated out of lugs
Coat hydraulic cylinder and O-rings with new
brake fluid and install the cylinder into the clutch Unscrew retaining nut while holding release shaft
cover bore. with a 5 mm Allen wrench.
Ensure the notch in the cylinder is aligned with
the embossment on the clutch cover. See next
illustration.

rmr2013-014 23
Subsection XX (CLUTCH (SM5))

rmr2008-016-060_a

1. Support disc

Remove thrust washer.

rmr2008-016-102_a

Remove thrust washer.

Remove disc plate.

rmr2008-016-061_a

1. Thrust washer

Diaphragm Inspection
Inspect rubber diaphragm for wear, tears, or other
damages. Replace if necessary.
rmr2008-016-058_a

1. Thrust washer Diaphragm Installation

2. Disc plate
Installation is the reverse of the removal proce-
Remove diaphragm. dure. However, pay attention to following.
Install support disc so that its rounded edge will
be against diaphragm.
NOTICE Incorrect mounting position of sup-
port disc will damage diaphragm causing en-
gine oil to be drawn into the air intake from the
clutch area.

rmr2008-016-059

Remove support disc.

24 rmr2013-014
 Subsection XX (CLUTCH (SM5))

rmr2008-016-105_a
rmr2008-016-103_a
1. Mounting lug
1. Rounded edge here 2. Diaphragm out of lug

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).
TWN: rev2 — begins
Install disc plate so that its rounded edge will be
against diaphragm (mark "TOP" must face to out-
side of the engine).
NOTICE Incorrect mounting position of disc
plate will damage diaphragm causing engine
oil to be drawn into the air intake from the
clutch area.

rmr2008-016-106_a

1. Groove

Install diaphragm.
NOTICE Do not install diaphragm into its rmr2013-014-018-a

mounting lugs yet. 1. Disc plate

2. Mark "TOP"
3. Rounded edge here

TWN: rev2 — ends

Ensure diaphragm and disc plate are inserted past

the groove in the shaft.

rmr2013-014 25
Subsection XX (CLUTCH (SM5))

rmr2008-016-107_a
rmr2008-016-108_a
1. Groove
1. Mounting lug
2. Diaphragm slot inserted on lugs
Tighten nut while holding release shaft with a
5 mm Allen wrench. Install clutch cover. Refer to CLUTCH COVER in
RELEASE SHAFT NUT this subsection.
LOCTITE 243 (BLUE)
Service Product
(P/N 293 800 060)
PRESSURE PLATE AND CLUTCH
SPRINGS
Tightening Torque 15 N•m (133 lbf•in)
Pressure Plate and Clutch Spring
Removal
Remove DIAPHRAGM, see procedure in this sub-
section.
Loosen the retaining screws in a crisscross pat-
tern, then remove them with the step washers.

rmr2008-016-102_b

Position the slots in diaphragm onto the mounting

lugs. rmr2008-016-062_a

1. Retaining screw
2. Step washer

Remove clutch springs.

26 rmr2013-014
 Subsection XX (CLUTCH (SM5))

Pressure Plate and Clutch Spring

Inspection
Pressure Plate
Inspect pressure plate for cracks or other dam-
ages. Replace if necessary.
Check if bearing in pressure plate turns smoothly
and freely. Replace if necessary.
Inspect thrust surface for wear or other damages.

rmr2008-016-063_a

1. Clutch spring

Remove pressure plate.

rmr2008-016-016_a

1. Bearing
2. Thrust surface

Clutch Spring
Measure each clutch spring free length. Replace
rmr2008-016-064_a all clutch springs as a set if one is out of specifi-
1. Pressure plate cations.
Remove clutch release shaft from pressure plate. CLUTCH SPRING FREE LENGTH
SERVICE LIMIT 58.50 mm (2.303 in)

rmr2008-016-065_a

1. Clutch release shaft vmr2008-017-016

2. Pressure plate
Clutch Release Shaft
Visually inspect clutch release shaft for wear or
other damage. Replace if necessary.

rmr2013-014 27
Subsection XX (CLUTCH (SM5))

Pressure Plate and Clutch Spring

Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
Tighten retaining screws in a crisscross pattern to
specification.
PRESSURE PLATE SCREWS
Tightening Torque 11 N•m (97 lbf•in)

CLUTCH PLATES
V02D0KA
Clutch Plate Removal
TYPICAL
Remove pressure plate. Refer to PRESSURE
PLATE AND CLUTCH SPRING in this subsection. Measure the thickness of the clutch plates as-
Remove friction plates and steel driven plates. sembly (friction plates (10) and steel driven plates
(11)).
CLUTCH PLATES ASSEMBLY THICKNESS
SERVICE LIMIT 43.5 mm (1.713 in)

rmr2013-014-004_a

1. 10x Steel driven plates

2. 10x Friction plates
3. 1x Hardened steel driven plate

Clutch Plate Inspection

Inspect each plate for cracks, bent or broken
teeth, missing or excessively worn friction mate-
rial and any other damage.
Check steel driven plates for warpage.
Place plates on a flat surface. Use a feeler gauge
to measure warpage.
STEEL DRIVEN PLATE WARPAGE
SERVICE LIMIT 0.15 mm (.006 in)

28 rmr2013-014
 Subsection XX (CLUTCH (SM5))

rmr2008-016-019_a

1. Hardened steel driven plate

2. Marked with notch

Beginning with a friction plate, install friction

plates and steel driven plates in alternate order.
Ensure the rounded side of the friction plate tabs
show towards the clutch hub.

TWN: rev2 — begins

rmr2013-014-005_a

A. Service limit

If plates are warped, damaged, or worn out of tol-

erance, replace all clutch plates.

Clutch Plate Installation

For installation, reverse the removal procedure.
However, pay attention to the following. Rmr2013-014-011_a

Thoroughly lubricate NEW clutch plates with en- 1. Friction plate tabs
2. Rounded side of the friction plate tab
gine oil before assembly to prevent clutch plates 3. Clutch hub
burning during break-in period.
First, install a hardened steel driven plate marked
with a notch.

rmr2013-014 29
Subsection XX (CLUTCH (SM5))

Drain engine oil, refer to LUBRICATION SYSTEM

subsection.
Drain engine coolant. Refer to COOLING SYS-
TEM subsection.
Remove the bolt securing the top of the coolant
radiator.

rmr2013-015-016_a

1. Rounded side of the friction plate tab

2. Towards clutch drum

Place the tabs of the last friction plate into the

shorter slots in the clutch drum. rmr2008-016-066_a

TYPICAL
1. Radiator mounting bolt

Remove water pump cover screws.

rmr2008-016-067_a

TYPICAL
1. Water pump cover screws
rmr2013-014-007_a

1. Shorter slot Move radiator rearward and unscrew the front en-
2. Last friction plate gine mount bolt.

TWN: rev2 — ends

Reinstall remaining parts, refer to the applicable

instructions.

CLUTCH HOUSING
Clutch Housing Access
TWN: Vlct responsibility begins

rmr2008-008-039_a

TWN: content of this body was included in L6 TYPICAL

“Engine Installed in Vehicle”
Remove DIAPHRAGM. See procedure in this sub-
section.

30 rmr2013-014
 Subsection XX (CLUTCH (SM5))

Disconnect the oil pressure switch connector.

rmr2008-016-070_a
rmr2008-016-068_a
1. M6 retaining screws (11)
1. Oil pressure switch connector 2. M8 retaining screws (4)
3. Starter screws
Remove exhaust spring.
Remove the clutch housing. Gently tap on clutch
Unscrew exhaust clamp and turn it in order to ac- housing using a soft hammer to separate it from
cess the clutch housing screw behind. the crankcase.

rmr2008-016-024
rmr2008-016-069_a

TYPICAL
1. Exhaust spring Clutch Housing Inspection
2. Exhaust clamp
Inspect the clutch housing for cracks or other
TWN: Vlct responsibility ends damages. Replace if necessary.
Check sealing surface for flatness.
Clutch Housing Removal Clean oil orifices in clutch housing from contami-
nants using PULLEY FLANGE CLEANER (P/N 413 711
TWN: L6 deleted 809), then use an air gun to dry it.

TWN: content of this body was included in L6

“Engine Removed from Vehicle”

Place a drain pan under the clutch housing to catch

oil spillage.
Remove starter screws.
Remove all clutch housing screws.

rmr2008-016-025_a

1. Clutch housing
2. Clean oil bores

rmr2013-014 31
Subsection XX (CLUTCH (SM5))

Inspect plain bearings for scoring or other dam-

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.

rmr2008-016-027

Plain Bearing Installation

Crankshaft support plain bearings are available in
3 tolerance groups (red, blue and yellow). The
proper tolerance group is marked with paint on
the clutch housing.

rmr2008-016-026_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
30.040 mm (1.1827 in)
bearing
Balance shaft support
20.060 mm (.7898 in)
bearing rmr2008-016-028_a

1. Clutch housing
2. Paint marking of tolerance group
Plain Bearing Replacement in Clutch
Housing If paint marking is not visible anymore, measure
Plain Bearing Removal inside diameter of clutch housing bore where plain
bearings are inserted.
Mark the joint locations of the plain bearing seg-
ments on the clutch housing, prior to removing
the plain bearings.
Pull out the plain bearings.
REQUIRED TOOL

BLIND HOLE BEARING

PULLER SET (P/N 529 036 117)

rmr2008-016-029

MEASURE CLUTCH HOUSING BORE DIAMETER

Use the following table to find proper tolerance

group of plain bearing.

32 rmr2013-014
 Subsection XX (CLUTCH (SM5))

CLUTCH HOUSING PLAIN BEARING

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
Blue
(1.2965 in to 1.2969 in)
32.940 mm to 32.951 mm
Yellow
(1.2969 in to 1.2973 in)

NOTICE Unless otherwise instructed, never

use a hammer to install plain bearings. Plain
bearings should only be installed using a rmr2008-016-072
press. PLAIN BEARING INSTALLATION — BALANCE SHAFT SUPPORT
BEARING
Heat clutch housing up to 100°C (212°F) before
installing plain bearings. NOTE: Remove O-ring just before plain bearings
Support the clutch housing with a suitable support are completely pressed in.
under the bearing seat. NOTICE The plain bearing segments must be
Apply PETAMO GREASE GHY 133N (P/N 420 899 271) positioned as marked during removal.
on plain bearings outer diameter.
Install plain bearings using the appropriate plain
bearing installer.
Use an O-ring to hold the plain bearings together
during installation.
REQUIRED TOOL
Crankshaft support bearing
BEARING PUSHER/REMOVER
(P/N 529 036 095)

rmr2008-016-032_a

1. Partition of crankshaft support plain bearing

2. Partition of balance shaft support plain bearing
3. Clutch housing

Clutch Housing Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
Install a NEW clutch housing gasket and NEW
sealing washers.
rmr2008-016-071
Lubricate plain bearings with PETAMO GREASE
PLAIN BEARING INSTALLATION — CRANKSHAFT SUPPORT
BEARING GHY 133N (P/N 420 899 271), before installing
clutch housing.
REQUIRED TOOL
Tighten clutch housing screws to specification as
Balance shaft support bearing per the following sequence.
BEARING PUSHER (P/N 529
036 096)

Then carefully press-in the plain bearings.

rmr2013-014 33
Subsection XX (CLUTCH (SM5))

CLUTCH HOUSING SCREWS TORQUE

M8 SCREWS (4) 19 N•m (168 lbf•in)
M6 SCREWS (11) 11 N•m (97 lbf•in)

WATER PUMP HOUSING SCREWS TORQUE

M6 SCREWS (4) 11 N•m (97 lbf•in)

rmr2008-016-073_a

1. Clutch hub locking nut

2. Spring washer

Remove clutch hub.

rmr2011-014-002_a

TIGHTENING SEQUENCE (19 SCREWS)

Reinstall remaining parts, refer to the appropriate

instructions. rmr2008-016-074_a

1. Clutch hub

CLUTCH HUB Clutch Hub Inspection

Clutch Hub Removal Inspect grooves in clutch hub for dents, damages
Remove the following items, see procedures in or wear caused by steel driven plates. Replace if
this subsection: necessary.
– Clutch cover
– Clutch plates.
Lock crankshaft in TDC position, refer to
CRANKCASE AND CRANKSHAFT.
Lock clutch hub.
REQUIRED TOOL

CLUTCH ASSEMBLY HOLDER

(P/N 529 035 618)

Remove the clutch hub locking nut and spring

washer.

rmr2013-014-008_a

INSPECT GROOVES IN CLUTCH HUB FOR WEAR

GROOVE DEPTH
SERVICE LIMIT 0.3 mm (.012 in)

34 rmr2013-014
 Subsection XX (CLUTCH (SM5))

Clutch Hub Installation CLUTCH DRUM

Ensure clutch drum thrust washer is installed on Clutch Drum Removal
clutch shaft ahead of clutch drum assembly be-
fore installing the clutch hub. Remove the following items, see procedures in
this subsection.
– Clutch cover
– Clutch diaphragm
– Pressure plate
– Clutch plates
– Clutch housing
– Clutch hub.
Remove the clutch drum thrust washer.

rmr2008-016-075_a

1. Clutch drum thrust washer

Apply PETAMO GREASE GHY 133N (P/N 420 899 271)

on clutch hub teeth.
Insert clutch hub.
Reinstall spring washer and hub retaining nut.

TWN: ELaplante: What direction is washer in-

rmr2008-016-075_a
stalled in
1. Clutch drum thrust washer

Remove the clutch drum.

TWN: rev2: there is no assembly instruction.

rmr2008-016-076_a

rmr2008-016-073_a 1. Clutch drum

1. Clutch hub retaining nut
2. Spring washer Clutch Drum Disassembly
Tighten nut to specification. Remove:
CLUTCH HUB NUT
– Oil pump drive gear
– Retaining nuts
LOCTITE 648 (GREEN)
Service Product – Outer support plate
(P/N 413 711 400)
– Distance sleeves.
Tightening Torque 190 N•m (140 lbf•ft)

Reinstall remaining parts, refer to the appropriate

instructions in this subsection.

rmr2013-014 35
Subsection XX (CLUTCH (SM5))

rmr2011-014-003_a
rmr2008-016-037_a
1. Outer compression springs
1. Oil pump drive gear 2. Inner compression springs
2. Retaining nuts 3. Spring retainers
3. Outer support plate 4. Springs discs
4. Distance sleeves 5. Thrust washer, 1.6 mm (.063 in)
6. Inner support plate
NOTE: Mark the position of springs and retainers,
prior to removing them. Clutch Drum Inspection
Remove clutch drum gear together as well as both Compression Springs and Retainers
white marked springs and their spring retainers.
Measure free length of each compression spring,
refer to the following table.
COMPRESSION SPRING FREE LENGTH
SERVICE LIMIT
Outer springs and
26.75 mm (1.053 in)
white marked springs
Inner springs 25.65 mm (1.01 in)

If a spring is out of specification, replace all

springs as well as all spring retainers.
Inspect spring retainers for wear, cracks or scor-
ing. Replace all springs and all spring retainers as
rmr2008-016-038_a
an assembly.
1. Clutch drum gear Support Plates
2. Springs with white marks
Inspect support plates for cracks or abnormal
Remove: wear. Replace if necessary.
– All other springs with their spring retainers
Inspect the thrust surface of inner support plate
– Spring discs for abnormal wear or grooves. If necessary,
– Thrust washer replace inner support plate, thrust washer and
– Inner support plate. spring disc(s) as an assembly.

36 rmr2013-014
 Subsection XX (CLUTCH (SM5))

Replace clutch drum gear with drive gear if nec-

essary.
Clutch Drum
Inspect slots in clutch drum for dents, damages or
wear caused by friction plates. Replace if neces-
sary.

rmr2008-016-049_a

1. Inspect thrust surface of inner support plate

Clutch Drum Gear

Inspect bearing sleeve for scoring and wear.

rmr2008-016-040_a

INSPECT SLOTS IN CLUTCH DRUM FOR WEAR

SLOT DEPTH
SERVICE LIMIT 0.3 mm (.012 in)

Inspect spring cavities for deep grooves caused

by springs. Replace clutch drum if necessary.
NOTE: Slight markings caused by the springs are
rmr2010-014-001_a normal. Do not replace clutch drum needlessly.
1. Bearing sleeve surface

Measure inner diameter of bearing sleeve.

rmr2008-016-048_a

1. Inspect spring cavity

rmr2008-016-078_a

A. Inner diameter Clutch Drum Assembly

BEARING SLEEVE INNER DIAMETER NOTICE Assembly of the clutch drum must
be carried out with the utmost care. Failure to
SERVICE LIMIT 30.060 mm (1.183 in)
strictly follow procedures may cause parts to
Inspect teeth condition for pitting or other dam- loosen and/or malfunction of the clutch drum
age. and may lead to serious engine damage.

rmr2013-014 37
Subsection XX (CLUTCH (SM5))

Assemble the clutch drum in the reverse order of

disassembly. However, pay attention to the fol-
lowing details.
NOTICE The position of the 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.

rmr2013-014-009_a

1. Inner support plate

2. Thrust washer, 1.6 mm
3. Spring discs

TWN: rev2 — begins

Install the clutch drum gear, ensure the location

holes are aligned with each other.
Install both white marked springs with spring
rmr2008-016-042_a
retainers into the corresponding spring cavities
ALIGNMENT OF LOCATION HOLES OF CLUTCH DRUM PARTS
1. Hole in clutch drum which are marked with punched holes inside the
2. Hole in inner support plate inner support plate.
3. Hole in clutch drum gear
4. Hole in outer support plate

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.
Install inner support plate on clutch drum, ensure
the location holes are aligned with each other.

TWN: rev2: apply engine oil MUST remain

here, later it is not possible to lubricate the
spring disks.

Install NEW spring discs with the concave side

facing the inner support plate. Apply engine oil on
both clutch springs before installation.
rmr2013-015-020_a

1. White marked springs

TWN: do we need to clarify the following im- 2. Spring cavities marked with punched holes
age?
TWN: rev2 — ends

Install remaining springs and retainers into spring

cavities.
Install distance sleeves on clutch drum screws,
then outer support plate. Ensure that the location
holes are aligned with each other.

38 rmr2013-014
 Subsection XX (CLUTCH (SM5))

rmr2008-016-045_a

1. Distance sleeves
2. Outer support plate
3. Location holes rmr2008-016-200_a

1. Thrust washer
Tighten clutch drum retaining nuts to specifica- 2. Clutch drum
tion.
Install the other thrust washer on clutch shaft.
CLUTCH DRUM NUTS
LOCTITE 648 (GREEN)
Service Product
(P/N 413 711 400)
Tightening Torque 30 N•m (22 lbf•ft)

Finally install oil pump gear. Ensure that tabs of

oil pump gear engage in cavities of outer support
plate.

rmr2008-016-075_a

1. Thrust washer

Clutch Drum Functional Test

rmr2008-016-046_a
1. Tabs of oil pump gear
2. Cavities of outer support plate
Clutch Drum Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
Insert the first thrust washer on the clutch shaft.
Insert clutch drum on the clutch shaft.
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:
– Finalize installation (clutch hub and other re-
maining parts).
If free-play is detected:
– Inspect clutch drum components. Refer to
CLUTCH DRUM INSPECTION in this subsec-
tion.

rmr2013-014 39
 Subsection XX (CLUTCH (SE5))

CLUTCH (SE5)
SERVICE TOOLS
Description Part Number Page
BEARING PUSHER/REMOVER ..................................................... 529 036 095 ........................................... 18
BEARING PUSHER........................................................................ 529 036 096 ........................................... 19
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ........................................... 18
CLUTCH ASSEMBLY HOLDER ..................................................... 529 036 133 ........................................... 20
CLUTCH PACK COMPRESSION TOOL......................................... 529 036 144 ........................................... 15

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 7
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ..................................... 21, 28
PETAMO GREASE GHY 133N ...................................................... 420 899 271 ............................... 18–19, 21
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ..................................... 11, 17

rmr2011-064 1
Subsection XX (CLUTCH (SE5))

Engine oil
11 N•m NEW 19 N•m
(97 lbf•in) NEW (168 lbf•in)

NEW
Engine
oil
15 N•m Finger tight
(133 lbf•in)
Loctite
243
11 N•m
(97 lbf•in)
NEW

Engine
oil 5 N•m
(44 lbf•in)

NEW

30 N•m
(22 lbf•ft)
NEW

19 N•m
(168 lbf•in) NEW

30 N•m NEW
(22 lbf•ft)

NEW = Component must be replaced when removed.

rmr2008-055-001_d

2 rmr2011-064
 Subsection XX (CLUTCH (SE5))

Engine
Loctite oil
243
11 N•m
(97 lbf•in) Engine
oil

190 N•m
(140 lbf•ft)
Loctite 648

Engine oil
Petamo grease
Ghy 133n

Engine oil
Engine
oil
30 N•m
(22 lbf•ft)
Loctite 648 Loctite 648

rmr2013-015-002_a

rmr2011-064 3
Subsection XX (CLUTCH (SE5))

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,
it is not necessary to remove the engine from ve-
hicle.
Always disconnect the battery negative cable be-
fore working the engine.

WARNING
Always disconnect BLACK (-) cable first and
reconnect last.

During assembly/installation, use torque values

and service products as specified in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING rmr2013-015-003_a

Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.
NOTICE Hoses, cables or locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
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.
1. Clutch solenoid
2. Clutch modulation solenoid
3. Hydraulic control module (HCM)
One valve engages/disengages the clutch and the
other valve modulates the clutch to control the
speed of the clutch engagement for smooth op-
eration.
Depending on which solenoid valve is activated,
oil flows either from the HCM to the hydraulic
clutch piston or from the hydraulic clutch piston
to HCM.

SYSTEM DESCRIPTION
The engine on the SE5 model features a sequen-
tial electronically controlled mechanical 5-speed
transmission with a hydraulic type clutch system.
The clutch is disengaged and engaged by 2 valves
in the hydraulic control module (HCM) that are rmr2008-055-004_a

controlled by the transmission control module 1. HCM side

2. Hydraulic clutch side
(TCM). 3. Oil hose between hydraulic clutch and HCM

The SE5 clutch system uses the same oil as the

engine.

4 rmr2011-064
 Subsection XX (CLUTCH (SE5))

TROUBLESHOOTING
TROUBLESHOOTING
GUIDELINES
SHIFTING PROBLEMS
1. For any shifting problems, refer to TROU-
BLESHOOTING in ELECTRONIC SHIFT SYSTEM
(SE5) subsection.

RATTLE AT IDLE OR DURING CLUTCH

ENGAGEMENT
rmr2008-055-006_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
Hydraulic Piston Removal
Remove hydraulic piston cover screws.

rmr2008-055-003_a

1. Hydraulic piston nut

2. Retaining ring

Remove the hydraulic piston, compression spring

and hydraulic cylinder sleeve.

rmr2008-055-005_a

1. Screws (x4)
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.

rmr2008-055-007_a

1. Hydraulic piston
2. Compression spring
3. Hydraulic cylinder sleeve

rmr2011-064 5
Subsection XX (CLUTCH (SE5))

Hydraulic Piston Inspection COMPRESSION SPRING FREE LENGTH

Clean piston and visually inspect piston surface for 32.50 mm to 33.50 mm
scoring, scratches or abnormal wear. Replace if NEW
(1.28 in to 1.319 in)
necessary.
SERVICE LIMIT 32.00 mm (1.26 in)
Remove and discard piston seals.
If the compression spring is out of specifications,
replace it.
Hydraulic Piston Nut
Clean hydraulic piston nut.
Visually inspect ball and thread condition.

rmr2008-055-008_a

1. Inspect piston surface

2. Inspect piston seals

Hydraulic Cylinder Sleeve Inspection

Clean hydraulic cylinder sleeve and visually in-
spect sleeve surface for scoring, scratches or
abnormal wear. Replace if necessary.
Remove and discard sleeve O-ring.
rmr2013-015-012_a

1. Ball
2. Thread

Hydraulic Piston and Hydraulic

Cylinder Sleeve Installation
Installation is the reverse of the removal proce-
dure. However, pay attention to following details.
Install NEW hydraulic piston seals and hydraulic
cylinder sleeve O-ring.
rmr2008-055-009_a
Open side of outer seal must face toward the
1. Inspect hydraulic cylinder sleeve clutch.
2. Discard O-ring

Compression Spring
Check free length of compression spring.

rmr2008-016-010

6 rmr2011-064
 Subsection XX (CLUTCH (SE5))

rmr2013-015-013_a

1. Hydraulic piston
2. Allen wrench
3. Hydraulic piston nut
rmr2010-015-005_a

LARGE SEAL POSITIONING Tighten hydraulic piston nut to specification.

1. Piston
2. Large seal HYDRAULIC PISTON NUT
3. Open side of seal
LOCTITE 243 (BLUE)
Coat hydraulic piston, seals, hydraulic cylinder Service Product
(P/N 293 800 060)
sleeve and O-ring with engine oil before installing
Tightening Torque 15 N•m (133 lbf•in)
them in the clutch cover.
Install hydraulic piston cover.

CLUTCH COVER
Clutch Cover Access
Remove RH bottom rear side panel. Refer to the
BODY subsection.
Lift and safely block RH front of vehicle to prevent
engine oil leakage when removing components (if
servicing clutch cover in vehicle).

Clutch Cover Removal

NOTE: Install a drain pan under the clutch cover
rmr2008-055-007_a
and oil line to catch engine oil spillage.
1. Hydraulic piston
2. Compression spring Remove hydraulic piston cover screws.
3. Hydraulic cylinder sleeve

Push in hydraulic piston and screw hydraulic pis-

ton nut 2-3 turns in by hand.
NOTE: Use a 5 mm Allen wrench to hold clutch
release shaft

rmr2011-064 7
Subsection XX (CLUTCH (SE5))

rmr2008-055-011_a
rmr2008-055-005_a
1. Clutch cover
1. Screws (x4) 2. Retaining screws
2. Hydraulic piston cover 3. Gasket

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.
Remove clutch cover from the engine.
Clutch Cover Inspection
Clean clutch cover and inspect for cracks or other
damages.

Clutch Cover Installation

Installation is the reverse of the removal proce-
dure. However, pay attention to following details.
Ensure clutch cover gasket is in good condition
and positioned correctly. Replace if necessary.
Ensure the clutch cover is properly positioned on
the two alignment pins on the clutch housing.

rmr2008-055-006_a

1. Deep offset wrench

2. Allen wrench
3. Hydraulic piston nut

Remove oil hose from clutch cover.

rmr2008-055-011_b

1. Clutch cover
2. Retaining screws (x8)
3. Gasket
4. Alignment pins

NOTE: Install oil line with NEW gasket rings.

rmr2008-055-010_a
PRESSURE RETAINING VALVE
1. Banjo bolt Pressure Retaining Valve Access
2. Oil hose
3. Gaskets Remove RH bottom rear side panel. Refer to
BODY.
Remove clutch cover retaining screws.

8 rmr2011-064
 Subsection XX (CLUTCH (SE5))

Pressure Retaining Valve Removal

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
cover.

rmr2008-016-010

TYPICAL

COMPRESSION SPRING FREE LENGTH

38.00 mm to 39.00 mm
NEW
(1.496 in to 1.535 in)
SERVICE LIMIT 36.00 mm (1.417 in)

If the compression spring is out of specification,

replace it.

rmr2008-055-012_a Pressure Retaining Valve Installation

1. Clutch cover
2. Pressure retaining valve Installation is the reverse of the removal proce-
3. Compression spring dure. However, pay attention to following details.
4. Gasket ring
5. Plug screw NOTE: Install the plug screw with a NEW gasket.
Using a flat screw driver, remove air nozzle from
clutch cover. PRESSURE PLATE
Pressure Plate Removal
Remove CLUTCH COVER, see procedure in this
subsection.
Loosen the inner plate retaining screws using a
crisscross pattern, then remove them.

rmr2008-055-013_a

1. Air nozzle

Pressure Retaining Valve Inspection

Clean all parts and inspect for damage.
NOTE: Ensure the port in the air nozzle is not
clogged or dirty. Clean as required. rmr2008-055-014_a

1. Inner plate retaining screws (x6)

Compression Spring
Check free length of compression spring. Remove inner plate and spring disc.

rmr2011-064 9
Subsection XX (CLUTCH (SE5))

rmr2008-055-015_a

1. Inner plate
rmr2008-055-017_a
2. Spring disc
1. Pressure plate
2. Thrust washer
Pressure Plate Disassembly 3. Trust surfaces
4. Retaining ring
Remove pressure plate with retaining ring and
clutch release shaft. Inspect pressure plate related parts as follows.
NOTE: Remove retaining ring from pressure plate Spring Disc
only if necessary.
Inspect spring disc for cracks, wear or other dam-
ages. Replace if necessary.
Place spring disc on a flat surface so that the outer
circumference of the disc is flat on the surface.
Measure the height of the spring in a crosswise
direction, with reference to the flat surface.
SPRING DISC FREE LENGTH
SERVICE LIMIT 7.00 mm (.2756 in)

rmr2008-055-016_a

1. Retaining ring
2. Pressure plate
3. Clutch release shaft

Pressure Plate Inspection

Inspect pressure plate for cracks or other dam-
ages. Replace if necessary.
Inspect pressure plate thrust washer for cracks,
wear or other damages. Thrust washer must fit rmr2008-055-018

tightly in pressure plate. Replace if necessary. MEASURING SPRING DISC FREE LENGTH

Inspect retaining ring for damage or wear. Re- Rotate tool and measure spring free length across
place if necessary. several of the disc fingers. Replace spring disc if
out of specification.
Clutch Release Shaft
Visually inspect clutch release shaft, thrust wash-
ers and axial needle bearing for wear or other dam-
ages. Replace if necessary.
10 rmr2011-064
 Subsection XX (CLUTCH (SE5))

CLUTCH PLATES
Clutch Plate Removal
Remove pressure plate. See PRESSURE PLATE,
SPRING DISC AND CLUTCH RELEASE PIN in this
subsection.
Remove spring disc.
Remove friction plates and steel driven plates.

rmr2008-055-019_a

1. Clutch release shaft

2. Trust washer
3. Axial needle bearing
4. Thrust washer
5. Retaining ring

Pressure Plate Installation

For installation, reverse the removal procedure.
However, pay attention to the following:

CAUTION Spring disc must be installed

with the concave side towards the pres-
sure plate. Incorrectly assembled spring disc
causes a clutch malfunction. Clutch will not Rmr2013-015-004_a
disengage. 1. Spring disc
2. Adjustment plate
3. Friction plates
4. Steel driven plates
5. Steel plate (3 mm (.118 in) thick)

Spring Disc Inspection

Inspect spring disc for cracks, wear or other dam-
ages. Replace if necessary.
Clean spring disc using a PULLEY FLANGE
CLEANER (P/N 413 711 809).
Place spring disc on a flat surface so that the outer
circumference of the disc is flat on the surface.
Use a feeler gauge to measure warpage between
rmr2010-015-014_a
spring disc and flat surface.
TYPICAL
1. Pressure plate
2. Spring disc
3. Assembly direction of spring disc
4. Adjustment plate(s)
5. Friction plate

Tighten retaining screws to specification using a

crisscross pattern.
RETAINING SCREWS
Tightening Torque 11 N•m (97 lbf•in)

rmr2013-015-011

MEASURING WARPAGE OF SPRING DISC

rmr2011-064 11
Subsection XX (CLUTCH (SE5))

SPRING DISC WARPAGE

SERVICE LIMIT 0.2 mm (.008 in)

Measure height of the spring disc in a crosswise

direction, in reference to the flat surface

V02D0KA

TYPICAL

Plate warpage must not exceed service limit.

Measure the thickness of the clutch plate assem-
bly (friction and steel driven plates).
NOTE: Thickness of the clutch plate assembly is
rmr2013-015-015 measured without the spring disc, the adjust-
MEASURING SPRING DISC FREE LENGTH ment plate and the 3 mm (.118 in) thick plate.
SPRING DISC FREE LENGTH CLUTCH PLATES ASSEMBLY THICKNESS
(FRICTION PLATES (10X) AND STEEL
3.3 mm to 3.5 mm DRIVEN PLATES (9X))
NEW
(.13 in to .138 in)
SERVICE LIMIT 41.00 mm (1.614 in)
SERVICE LIMIT 3.2 mm (.126 in)

Clutch Plate Inspection

Inspect each plate for cracks, bent or broken
teeth, missing or excessively worn friction mate-
rial and any other damage.
Check steel driven plates for warpage.
Steel driven plates must be free of scores and
blueing (overheating).
Place plates on a flat surface. Use a feeler gauge
to measure warpage between plates and flat sur-
face.
STEEL DRIVEN PLATE WARPAGE
SERVICE LIMIT 0.15 mm (.006 in)

12 rmr2011-064
 Subsection XX (CLUTCH (SE5))

Rmr2013-015-006_a

1. Steel plate (3 mm (.118 in) thick)

2. Step facing to friction plate

Beginning with a friction plate, install friction

plates (10x) and steel driven plates (9x) in alter-
nate order.
Ensure the rounded side of the friction plate tabs
is facing towards the 3 mm (.118 in) steel plate
(centrifugal clutch).

rmr2013-015-005_a

1. Friction plates (10x)

2. Steel driven plates (9x)
A. Service limit

If plates are warped, damaged, or worn out of tol- Rmr2013-015-007_a

erance, replace all clutch plates. 1. Steel plate (3 mm (.118 in) thick)
2. Friction plate
3. Steel plate
Clutch Plate Installation 4. Rounded side of the friction plate tab

For installation, reverse the removal procedure.

However, pay attention to the following.
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 3 mm (.118 in) thick steel plate.
NOTE: Step of the 3 mm (.118 in) steel plate must
face to friction plate.

rmr2011-064 13
Subsection XX (CLUTCH (SE5))

rmr2013-015-016_a

1. Rounded side of the friction plate tab Rmr2013-015-004_b

2. Towards 3 mm (.118 in) steel plate (centrifugal clutch)
1. Adjustment plate
Place the tabs of the last friction plate into the
Use the following adjustment plate kit and proce-
shorter slots of clutch drum.
dure to achieve proper clutch free-play.
ADJUSTMENT PLATE KIT P/N 420 281 535
PLATE
PLATE
PLATE THICKNESS INCREMENT
QUANTITY
THICKNESS
1 mm to 2 mm 0.1 mm
11
(.039 in to .079 in) (.004 in)

Measurement A
Install the spring disc with the concave side to-
wards the pressure plate.

CAUTION Incorrectly assembled spring

disc causes a clutch malfunction. Clutch will
not disengage.
Rmr2013-015-008_b
Measure the distance from the top of the spring
1. Shorter slot
2. Last friction plate disc to the machined surface of the pressure
plate.
Adjust clutch plate free-play.
Clutch Plate Free-Play Adjustment Procedure
Adjust clutch plate free-play by installing an adjust-
ment plate of the appropriate thickness.

rmr2008-055-047_a

MEASUREMENT A
1. Machined surface on pressure plate
2. Spring disc

14 rmr2011-064
 Subsection XX (CLUTCH (SE5))

Measurement B EXAMPLE OF CALCULATION

(B - A - CONSTANT = PLATE THICKNESS)
REQUIRED TOOL
B A CONSTANT RESULT
CLUTCH PACK COMPRESSION
TOOL (P/N 529 036 144) 10.3 mm 7 mm 1 mm 2.3 mm
(4.055 in) (.276 in) (.039 in) (.906 in)
Install the tool on top of the plate assembly.
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.
Reinstall remaining parts, refer to the appropriate
instructions.

CLUTCH HOUSING
Clutch Housing Removal
Engine Installed in Vehicle
Refer to BODY and remove the following panels
on the RH side:
rmr2008-055-801_a – Middle side panel
1. Tool installed – Top side panel
Alternately tighten tool screws to eliminate un- – Bottom rear side panel
evenness and to recover all play between plates. – Bottom front side panel
Measure the distance from the top of the clutch – Rear side panel.
hub to the top of the last friction plate. Remove headlight adjustment cable from LH mid-
dle side panel support.
On RT Models, remove RH middle side panel sup-
port.

rmr2013-015-017_a

MEASUREMENT B
1. Top of friction plate
2. Top of clutch hub

Use the following course of calculation to deter-

mine the thickness of the adjustment plate. rmr2010-011-001_a

1. Middle side panel support

ADJUSTMENT PLATE THICKNESS
CALCULATION
B - A - CONSTANT (1 mm (.039 in)) =
ADJUSTMENT PLATE THICKNESS
For example: -
Drain engine oil, refer to LUBRICATION SYSTEM.
Drain engine coolant. Refer to COOLING SYS-
TEM.
Disconnect coolant hose from top of thermostat.

rmr2011-064 15
Subsection XX (CLUTCH (SE5))

Disconnect coolant hose from top of radiator.

Disconnect the top coolant hose of the water
pump cover.
Remove the radiator retaining bolt.

rmr2008-011-108_b

TYPICAL
1. Oil pressure switch connector

Remove exhaust spring.

rmr2008-016-066_a

TYPICAL - TOP OF RADIATOR

Loosen exhaust clamp and turn it in order to ac-
1. Radiator retaining bolt cess the clutch housing screw behind.
Remove water pump cover screws.

rmr2008-016-067_a

TYPICAL
1. Water pump cover screws
rmr2013-015-030_a

Disconnect cooling fan connector. TYPICAL

Remove radiator, thermostat and water pump
cover as an assembly.
Remove CLUTCH COVER. See procedure in this
subsection.
Disconnect the oil pressure switch connector.
1. Exhaust clamp
Complete the clutch housing removal by following
the steps detailed in ENGINE 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.

16 rmr2011-064
 Subsection XX (CLUTCH (SE5))

rmr2008-016-070_a rmr2008-016-025_a

TYPICAL
1. M6 retaining screws (11)
2. M8 retaining screws (4)
3. M6 Starter retaining screws (2)
Remove the clutch housing. Gently tap on clutch
housing using a soft rubber mallet to separate it
the from the crankcase.
TYPICAL
1. Clutch housing
2. Clean oil bores
Inspect plain bearings for scoring or other dam-
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.

rmr2008-016-024

TYPICAL

Clutch Housing Inspection

Inspect the clutch housing for cracks or other rmr2008-016-026_a

damages. Replace if necessary. TYPICAL

Check sealing surface for flatness.
Clean oil orifices in clutch housing from contami-
nants using PULLEY FLANGE CLEANER (P/N 413 711
809), then use compressed air to dry it.
1. Plain bearing (crankshaft support)
2. Plain bearing (balance shaft support)
A. Measure plain bearing inside diameter
PLAIN BEARING INSIDE DIAMETER
CRANKSHAFT SUPPORT BEARING
SERVICE LIMIT 30.040 mm (1.1827 in)
BALANCE SHAFT SUPPORT BEARING
SERVICE LIMIT 20.060 mm (.7898 in)

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.

rmr2011-064 17
Subsection XX (CLUTCH (SE5))

Pull out the plain bearings.

REQUIRED TOOL

BLIND HOLE BEARING

PULLER SET (P/N 529 036 117)

rmr2008-016-029

MEASURE CLUTCH HOUSING BORE DIAMETER

Use the following table to find proper tolerance

group of plain bearing.
CLUTCH HOUSING PLAIN BEARING
BORE DIAMETER TOLERANCE GROUP
rmr2008-016-027

32.921 mm to 32.930 mm
Plain Bearing Installation Red
(1.2961 in to 1.2965 in)
Crankshaft support plain bearings are available in 32.930 mm to 32.940 mm
3 tolerance groups (red, blue and yellow). The Blue
(1.2965 in to 1.2969 in)
proper tolerance group is marked with paint on
the clutch housing. 32.940 mm to 32.951 mm
Yellow
(1.2969 in to 1.2973 in)

NOTICE Unless otherwise instructed, never

use a hammer to install plain bearings. Plain
bearings should only be installed using a
press.
Heat clutch housing up to 100°C (212°F) before
installing plain bearings.
Support the clutch housing with a suitable support
under the bearing seat.
Apply PETAMO GREASE GHY 133N (P/N 420 899 271)
on the plain bearings outer diameter.
rmr2008-016-028_a

TYPICAL Install plain bearings using the appropriate plain

1. Clutch housing bearing installer.
2. Marking of tolerance group
Use an O-ring to hold the plain bearings together
If paint marking is not visible anymore, measure during installation.
inside diameter of clutch housing bore where plain
bearings are inserted. REQUIRED TOOL
Crankshaft support bearing
BEARING PUSHER/REMOVER
(P/N 529 036 095)

18 rmr2011-064
 Subsection XX (CLUTCH (SE5))

rmr2008-016-071

PLAIN BEARING INSTALLATION — CRANKSHAFT SUPPORT

BEARING rmr2008-016-032_a

1. Plain bearing segments (crankshaft support)

REQUIRED TOOL
Balance shaft support bearing
BEARING PUSHER (P/N 529
036 096)
Then carefully press-in the plain bearings.
2. Plain bearing segments (balance shaft support)
3. Clutch housing
Clutch Housing Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
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.
Tighten clutch housing screws following the illus-
trated sequence
CLUTCH HOUSING SCREWS TORQUE
M6 screws (11x) 11 N•m (97 lbf•in)
M8 screws (4x) 19 N•m (168 lbf•in)

WATER PUMP HOUSING SCREWS TORQUE

rmr2008-016-072 M6 screws (4) 11 N•m (97 lbf•in)
PLAIN BEARING INSTALLATION — BALANCE SHAFT SUPPORT
BEARING

NOTE: Remove O-ring just before plain bearings

are completely pressed in.
NOTICE The plain bearing segments must be
positioned as marked during removal.

rmr2011-015-005_a

TIGHTENING SEQUENCE

rmr2011-064 19
Subsection XX (CLUTCH (SE5))

Reinstall remaining parts, refer to the appropriate

instructions.

CLUTCH HUB
Clutch Hub Removal
Remove:
– Clutch cover
– Pressure plate
– Clutch plates.
See procedures in this subsection.
Lock crankshaft in TDC position, refer to
CRANKCASE AND CRANKSHAFT. rmr2013-015-019_a

Lock clutch hub. 1. Clutch hub

REQUIRED TOOL Clutch Hub Inspection

CLUTCH ASSEMBLY HOLDER Inspect grooves in clutch hub for damages or
(P/N 529 036 133) wear caused by steel driven plates. Replace if
necessary.
Insert the clutch assembly holder completely to
the bottom of the clutch drum.
Remove the clutch hub retaining nut and spring
washer.

rmr2013-015-010_a

INSPECT GROOVES IN CLUTCH HUB FOR WEAR

rmr2013-015-018_a

1. Clutch hub retaining nut

Clutch Hub Installation
2. Spring washer Ensure thrust washer is installed on clutch shaft
Remove clutch hub. ahead of clutch drum assembly before installing
the clutch hub.

20 rmr2011-064
 Subsection XX (CLUTCH (SE5))

– Clutch plates
– Clutch hub.
Remove retaining ring.

rmr2008-055-035_a

1. Clutch drum thrust washer

Apply PETAMO GREASE GHY 133N (P/N 420 899 271)

on clutch hub teeth.
Insert clutch hub. rmr2008-055-023_a

1. Retaining ring
Reinstall spring washer and hub retaining nut.
Remove centrifugal clutch assembly.

rmr2008-055-022_a

1. Clutch hub retaining nut rmr2008-055-024_a

2. Spring washer
1. Centrifugal clutch assembly
Tighten nut to specification.
Centrifugal Clutch Disassembly
CLUTCH HUB RETAINING NUT
Clean and thoroughly dry the centrifugal clutch as-
LOCTITE 648 (GREEN) sembly to remove all lubricating oil.
Service Product
(P/N 413 711 400)
Trace index marks on the following parts with a
Tightening Torque 190 N•m (140 lbf•ft) permanent marker for reassembly:
– Pressure plate
Reinstall remaining parts, refer to the appropriate
instructions in this subsection. – Cam
– Centrifugal weights (rollers).
CENTRIFUGAL CLUTCH
Centrifugal Clutch Removal
Remove the following components, see proce-
dure in this subsection:
– Clutch cover
– Pressure plate

rmr2011-064 21
Subsection XX (CLUTCH (SE5))

rmr2010-015-011_a
rmr2008-055-026_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 necessary.
Pressure Plate
Inspect pressure plate for cracks, deformation or
abnormal wear. Replace if necessary.
Inspect the thrust surfaces on both sides of the
pressure plate for abnormal wear or grooves.

rmr2008-055-025_a

1. Retaining ring
2. Centrifugal clutch assembly

Remove:
– Stop plate
– Wave spring
– Pressure plate
– Centrifugal weights
– Cam.

rmr2008-055-029_a

INSPECT THRUST SURFACE OF PRESSURE PLATE

Centrifugal Weights
Inspect centrifugal weights for scoring and wear.
Check if needle bearings of centrifugal weights
move freely. Replace if necessary.
Cam
Inspect cam for cracks, deformation or abnormal
wear. Replace if necessary.
Inspect the cam thrust surfaces for grooves or ab-
normal wear.
22 rmr2011-064
 Subsection XX (CLUTCH (SE5))

rmr2008-055-030_a rmr2008-055-032_a

INSPECT THE CAM THRUST SURFACES PRESSURE PLATE AND CAM ALIGNMENT
1. Pressure plate long fingers
Bushing 2. Cam long fingers

Inspect bushing for cracks, grooves, or abnormal
wear. Replace if necessary.
Measure inner diameter of bushing.
NOTE: Be sure to align corresponding numbers
on cam, pressure plate and centrifugal weights
(rollers) as marked prior to disassembly.
Insert the assembled clutch pressure plate, cam
and weights over the bushing with the clutch
pressure plate on top.
Install wave spring, stop plate and retaining ring.

Centrifugal Clutch Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
Install centrifugal clutch with cam alignment hole
in line with clutch drum alignment pin.
rmr2008-055-031_a
NOTICE Make sure to correctly position cen-
INNER DIAMETER MEASUREMENT
1. Bushing trifugal clutch in the clutch drum.

BUSHING INNER DIAMETER

SERVICE LIMIT 63.10 mm (2.484 in)

Replace bushing if inner diameter is worn beyond

specification.

Centrifugal Clutch Assembly

NOTICE Assemble the centrifugal clutch with
the utmost care. Failure to strictly follow pro-
cedures may cause parts to loosen and/or mal-
function of clutch, and may lead to serious en-
gine damage.
Centrifugal clutch assembly is the reverse of dis- rmr2008-055-034_a

assembly. However, pay attention to the follow-
ing details.
Assemble cam and pressure plate so the longer
fingers are facing each other.
1. Alignment hole in centrifugal clutch
2. Alignment pin on clutch drum
Install centrifugal clutch retaining ring.

rmr2011-064 23
Subsection XX (CLUTCH (SE5))

rmr2008-055-023_b rmr2008-055-036_a

1. Centrifugal clutch retaining ring 1. Clutch drum

Remove the thrust washer.

CLUTCH DRUM
Clutch Drum Removal
Remove the following items, see procedures in
this subsection.
– Clutch cover
– Clutch disc assembly
– Clutch housing
– Clutch hub
– Centrifugal clutch assembly.
Remove the clutch drum thrust washer.

rmr2008-055-037_a

1. Thrust washer

Clutch Drum Disassembly

Remove:
– Oil pump drive gear
– Retaining nuts
– Outer support plate
– Distance sleeves.

rmr2008-055-035_a

1. Clutch drum thrust washer

Remove the clutch drum.

24 rmr2011-064
 Subsection XX (CLUTCH (SE5))

rmr2008-016-037_a rmr2010-015-012_a

1. Oil pump drive gear 1. Outer compression springs

2. Retaining nuts 2. Inner compression springs
3. Outer support plate 3. Spring retainers
4. Distance sleeves 4. Disc springs
5. Thrust washer
6. Inner support plate
NOTE: Mark the position of springs and retainers,
prior to removing them.
Clutch Drum Inspection
Remove clutch drum gear together as well as both
white marked springs and their spring retainers. Compression Springs and Retainers
Measure free length of each compression spring,
refer to the following table.
COMPRESSION SPRING FREE LENGTH
OUTER SPRINGS AND WHITE MARKED SPRINGS
SERVICE LIMIT 26.75 mm (1.053 in)
INNER SPRINGS
SERVICE LIMIT 25.65 mm (1.01 in)

If a spring is out of specification, replace all

springs as well as all spring retainers.
Inspect spring retainers for wear, cracks or scor-
ing. Replace all springs and all spring retainers as
rmr2008-055-038_a an assembly.
1. Clutch drum gear
2. Springs with white marks Support Plates
3. Spring retainers
Inspect support plates for cracks or abnormal
Remove: wear. Replace if necessary.
– All other springs with their spring retainers Inspect the thrust surface of inner support plate
– Spring discs and thrust washer for abnormal wear or grooves. If necessary,
– Inner support plate. replace inner support plate, thrust washer and
spring disc as an assembly.

rmr2011-064 25
Subsection XX (CLUTCH (SE5))

Inspect teeth condition for pitting or other dam-

age.
Replace clutch drum drive gear if necessary.
Clutch Drum
Inspect slots in clutch drum for damages or wear
caused by friction plates. Replace if necessary.

rmr2008-016-049_a

1. Inspect thrust surface of inner support plate

Clutch Drum Gear

Inspect bearing sleeve surface for scoring and
wear.

rmr2008-055-040_a

INSPECT SLOTS IN CLUTCH DRUM FOR WEAR

Inspect the slots where there is a small hole.

Slight markings or grooves caused by the centrifu-
gal clutch are normal. If grooves on the side of the
rib are deeper than 0.5 mm (.02 in), replace clutch
drum.

rmr2010-015-004_a

1. Bearing sleeve surface

Measure inner diameter of bearing sleeve.

rmr2008-055-550_a

1. Slot with a small hole

2. Slight markings or grooves here are normal
3. Maximum groove depth allowable here is 0.5 mm (.02 in)

rmr2008-016-078_a
Inspect spring cavities for deep grooves, caused
A. Inner diameter by springs. Replace clutch drum if necessary.
BEARING SLEEVE INNER DIAMETER NOTE: Slight markings caused by the springs are
normal. Do not replace clutch drum needlessly.
SERVICE LIMIT 30.060 mm (1.183 in)

26 rmr2011-064
 Subsection XX (CLUTCH (SE5))

Install inner support plate on clutch drum, ensure

the location holes are aligned with each other.

rmr2008-055-041_a

1. Inspect spring cavities

Clutch Drum Assembly rmr2008-055-043_a

NOTICE Assembly of the clutch drum must 1. Support plate

2. Spring discs
be carried out with utmost care. Failure to 3. Drum assembly screw
strictly follow the procedures may cause parts
to loosen and/or malfunction of the clutch Install thrust washer.
drum and may lead to serious engine damage. Apply engine oil on the spring discs.
Assemble the clutch drum in the reverse order of Install spring discs with the concave side facing to
disassembly. However, pay attention to the fol- the inner support plate.
lowing details.
NOTICE The position of the 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.

rmr2010-015-013_a

1. Concave side of spring discs

Install the clutch drum gear, ensure the location

holes are aligned with each other.
rmr2008-055-042_a
Install both white marked springs with spring
ALIGNMENT OF LOCATION HOLES FOR CLUTCH DRUM
ASSEMBLY retainers into the corresponding spring cavities
1. Hole in clutch drum which are marked with punched holes inside the
2. Hole in inner support plate
3. Hole in clutch drum gear inner support plate.
4. Hole in outer support plate

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.

rmr2011-064 27
Subsection XX (CLUTCH (SE5))

rmr2008-016-046_a

1. Drive tabs on oil pump gear

2. Drive tabs on outer support plate
rmr2013-015-020_a

1. White marked springs Functional Test

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
holes aligned with each other.
rmr2008-016-045_a
After assembly of the clutch drum is complete,
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 INSPECTION in this subsection.
Clutch Drum Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
Insert the first thrust washer on the clutch shaft
before installing clutch drum.

1. Distance sleeves
2. Outer support plate
3. Location holes

Tighten nuts to specification.

CLUTCH DRUM NUTS
LOCTITE 648 (GREEN)
Service Product
(P/N 413 711 400)
Tightening Torque 30 N•m (22 lbf•ft)

Finally, install the oil pump gear. Ensure the drive

tabs on the oil pump gear engage in the drive tabs
on the outer support plate.
rmr2008-055-037_a

1. Thrust washer

Insert clutch drum on the clutch shaft.

28 rmr2011-064
 Subsection XX (CLUTCH (SE5))

rmr2008-055-036_a

1. Clutch drum

Install the other thrust washer on clutch shaft.

rmr2008-055-035_a

1. Thrust washer

Install clutch hub and all remaining parts. See pro-

cedures in this subsection.

rmr2011-064 29
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

HYDRAULIC CONTROL MODULE (SE5)

SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................................... 13
OIL PRESSURE GAUGE................................................................ 529 036 142 ........................................... 11

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ..................................... 15–16

rmr2013-016 1
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

11 N•m
NEW (97 lbf•in)

NEW Loctite 243

Loctite 767
(antiseize lubricant)
NEW
NEW
19 N•m
Engine (168 lbf•in)
NEW oil
5 N•m
(44 lbf•in)
NEW 23 N•m
(17 lbf•ft)
NEW
6 N•m 11 N•m
(53 lbf•in) (97 lbf•in)
Loctite
243 Engine oil

NEW

NEW
Engine
oil
Loctite
NEW 243 3 N•m
(27 lbf•in)

Loctite 243 Engine oil NEW

2 N•m NEW
(18 lbf•in) 23 N•m
(17 lbf•ft)
11 N•m
(97 lbf•in)

NEW = Component must be replaced when removed.

rmr2013-016-001_a

2 rmr2013-016
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

GENERAL
Always disconnect the negative battery cable be-
fore working on the engine.

WARNING
Always disconnect the BLACK (-) cable first
and reconnect last.

Always carry out electrical tests on components

before removing or installing them to ensure their
state of operation.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a thread locker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING
Torque wrench tightening specifications rmr2013-016-002_a
must be strictly adhered to. 1. Upshift solenoid
Locking devices when removed (e.g.: locking 2. Downshift solenoid
tabs, elastic stop nuts, cotter pins, etc.) must 3. Clutch solenoid
4. Clutch modulation solenoid
be replaced. 5. Hydraulic control module (HCM)

Shift Solenoids
NOTICE Hoses, cables and locking ties re-
The shift solenoids are located on top of the HCM
moved during a procedure must be reinstalled module.
as per factory standards.
The front side solenoid function is to upshift to a
higher gear.
SYSTEM DESCRIPTION
(COMPONENTS) The rear side solenoid function is to downshift to
a lower gear.
The transmission control module (TCM) manages
4 solenoid valves located on the hydraulic control
module (HCM) which control and activate the gear
shifting process.
NOTE: Consult also the ELECTRONIC SHIFT
SYSTEM (SE5) subsection for an overview of the
gearshift operation and troubleshooting.

rmr2008-077-025_a

1. Shifting valve
2. Upshift solenoid
3. Downshift solenoid

rmr2013-016 3
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

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 HCM moves the
clutch piston.
At engaging the clutch, the clutch modulation so-
lenoid function is to bleed the oil pressure from
the clutch piston (through the clutch solenoid) to
control the clutch engagement speed.

rmr2013-016-022_a

TYPICAL
1. Oil tank
2. Oil supply line to HCM

The HCM includes its own oil pump specifically

used for the clutching and gear shifting.

rmr2008-077-025_b

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.

rmr2013-016-005_a

1. Oil pump
2. Oil 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
1 200 kPa (174 PSI) when shifting. An oil pres-
sure regulator is used to stabilize the pressure.
A self bleeding regulator valve, located at the
rmr2013-016-003_a
highest point of the shifting system, is used to
1. Oil filter bleed away air trapped in the system back the to
crankcase.
The oil tank supplies oil to the HCM.

4 rmr2013-016
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

rmr2008-078-020_a

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.

Rmr2013-016-006_a

1. Link rod between HCM and shift shaft

rmr2008-078-008_a

1. Link rod
2. Hydraulic piston location

rmr2013-016 5
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

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.

rmr2008-078-009

ENGINE RUNNING, NO SHIFT

1. Oil tank
2. HCM oil pump
3. Clutch solenoid

6 rmr2013-016
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

Hydraulic Operation when Shifting Occurs

When a shift is selected, the clutch solenoid is activated by the TCM 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.

rmr2008-078-010

CLUTCH DISENGAGEMENT
1. Clutch solenoid
2. Clutch servo
3. HCM oil pressure regulator

rmr2013-016 7
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

After the clutch solenoid is activated and the clutch is disengaged, one of the shift solenoid is then ac-
tivated 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.

rmr2008-078-011

SHIFTING
1. Clutch solenoid
2. Shift solenoid
3. Hydraulic piston
4. Crankcase sump

8 rmr2013-016
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

When the TCM 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.

rmr2008-078-012

CLUTCH ENGAGEMENT MODULATION

1. Clutch solenoid
2. Clutch modulation solenoid
3. Crankcase sump

rmr2013-016 9
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

MAINTENANCE
HCM OIL FILTER
NOTE: The HCM uses the same oil as the engine,
but has its own oil filter.

HCM Oil Filter Removal

NOTE: Replace HCM oil filter and engine oil fil-
ter at the same time. Refer to MAINTENANCE
SCHEDULE for frequency.
rmr2008-077-003_a
Drain engine oil. Refer to LUBRICATION SYSTEM 1. Oil inlet orifice to the hydraulic control module lubrication system
subsection. 2. Oil outlet orifice from the oil pump
Remove: Install a NEW O-ring on oil filter cover.
– Oil filter cover screws
To ease assembly and prevent displacement of
– Oil filter cover the O-ring during installation, slightly oil O-ring and
– O-ring - discard it oil filter, refer to following illustration.
– Oil filter - discard it.

rmr2013-016-007_a
rmr2013-016-003_b 1. Apply oil here
1. Oil filter cover screws
2. Oil filter cover
3.
4.
O-ring
Oil filter
INSPECTION
Dispose filter as per your local environmental reg- HCM OIL PRESSURE TEST
ulations.
Oil pressure test prerequisite:
HCM Oil Filter Installation – Warm engine (80°C (176°F))
The installation is the reverse of the removal pro- – The recommend oil in engine
cedure. Pay attention to the following. – The proper oil level.
Check and clean the oil inlet and outlet orifices in Remove the following LH body panels, refer to
hydraulic control module for dirt and contamina- BODY subsection:
tions. – Top side panel
– Rear side panel.
Remove plug screw located behind HCM oil filter
housing.

10 rmr2013-016
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

rmr2008-078-022

ACTIVATION PAGE, TCM FOLDER

Start engine.
rmr2013-016-015_a
Let engine idle.
TYPICAL
1. HCM plug screw NOTE: If more than 400 kPa (58 PSI) is read when
the engine is idling, check for blockage in clutch
Install oil pressure gauge in HCM oil pressure solenoid valve and in HCM passageways.
threaded tap hole.
Select Clutch activation on the Routine section
REQUIRED TOOL of the B.U.D.S. Activation page.
While clutch is activating, watch pressure gauge
OIL PRESSURE GAUGE and note the value.
(P/N 529 036 142)

rmr2008-077-101

TYPICAL

rmr2013-016-017_a NOTE: The nominal oil pressure is only achieved

TYPICAL - OIL PRESSURE GAUGE IS TO BE CONNECTED TO during clutch activation or shifting.
THE HCM THREADED TAP HOLE
1. HCM threaded tap hole The oil pressure should be within the following
values.
Connect the latest version of B.U.D.S. and logon.
IDLE SPEED,
Make sure TCM is operational. Refer to TCM OIL PRESSURE
WHILE SHIFTING
STATUS VALIDATION in the ELECTRONIC SHIFT
SYSTEM (SE5) subsection. MINIMUM 900 kPa (131 PSI)
Select the Activation page and TCM folder. Look NOMINAL 1 200 kPa (174 PSI)
at the Routine section of the page.
MAXIMUM 1 600 kPa (232 PSI)

rmr2013-016 11
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

If oil pressure is not within the specifications,

check the following:
– Oil leaks (internal or external)
– HCM oil filter
– HCM oil pressure regulator
– HCM self bleeding valve
– Hydraulic valve(s) and solenoid(s)
– HCM oil pump
– HCM.
Drain pressure gauge into oil tank.
rmr2008-078-022

ACTIVATION PAGE, TCM FOLDER

Clutch to activate each solenoids on the Activa-

tion section of the B.U.D.S. Activation page. Ac-
tivate the solenoids in the following order while
listening and feeling the solenoids.
– Upshift solenoid
– Downshift solenoid
– Clutch solenoid
– Modulation solenoid.
Use the following electrical tests if any solenoids
did not activated.

Solenoid Test
Remove LH upper side panel. Refer to BODY sub-
rmr2008-077-102

TYPICAL
section.
Disconnect TCM connector.
Reinstall removed parts.
Disconnect B.U.D.S.

PROCEDURES
SHIFT AND CLUTCH SOLENOIDS
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
STATUS VALIDATION in the ELECTRONIC SHIFT
SYSTEM (SE5) subsection.
Select the Activation page and TCM folder. Look
at the Routine section of the page.
rmr2013-031-006_a

1. TCM connector

Disconnect the 8-pin solenoid connector.

12 rmr2013-016
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

SOLENOID
SWITCH CONNECTOR VOLTAGE
PIN
8 and battery
No voltage
ground
Upshift
1 and battery
Battery voltage
ground
7 and battery
No voltage
ground
Downshift
2 and battery
Battery voltage
ground
6 and battery
No Voltage
ground
rmr2013-016-018_a
Clutch
3 and battery
1. 8-pin solenoid connector location Battery voltage
ground
Solenoid Resistance 5 and battery
No voltage
Set multimeter to . Clutch ground
modulation 4 and battery
REQUIRED TOOL Battery voltage
ground
FLUKE 115 MULTIMETER
(P/N 529 035 868)

Measure the resistance between the following

pins.
SOLENOID RESISTANCE
SOLENOID CONNECTOR PIN AT 20°C
(WIRE COLOR) (68°F)
1 8
Upshift 2.50 – 2.80
(RED) (WHITE)
2 7
Downshift 2.50 – 2.80
(RED) (WHITE)
3 6
Clutch 2.50 – 2.80
(RED) (WHITE)
rmr2008-078-030_b

Clutch 4 5
1.00 – 1.50 If a solenoid test failed, check sol + TCM fuse (2)
modulation (ORANGE) (WHITE)
in rear fuse box. If it is good, check wiring and
If the resistance measuring is not within the spec- connectors between TCM and battery.
ification replace faulty parts.
Power Circuit
Turn ignition switch ON.
Set multimeter to Vdc.
Read voltage as follows.

rmo2008-001-023_c

REAR FUSE BOX

1. Sol + TCM fuse

If solenoid test succeeded, continue testing.

rmr2013-016 13
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

Contact Circuit NOTE: Solenoids are available as single parts, re-

Turn ignition switch OFF. place complete solenoid valve set only if neces-
sary. For removing pins of the connector refer to
Set multimeter to . CONNECTOR INFORMATION subsection.
Check continuity as follows.
TCM SOLENOID
SWITCH CONNECTOR CONNECTOR RESISTANCE
PIN PIN
Upshift 32 8
Downshift 33 7
Clutch 34 6 Close to 0

Clutch
30 5
modulation

rmr2013-016-010_a

1. Allen screws
2. Solenoid valve body
3. Solenoid valve screws

Remove solenoids from HCM.

NOTE: Use caution when pulling the shifting
solenoid from the body as engagement pin and
washer may fall out.

rmr2008-078-030_a

If a resistance failed, check wiring and connectors

between TCM and solenoid connector.

Solenoid Access
Refer to the BODY subsection and remove the fol-
lowing parts from the LH of vehicle:
– side panel
– Top side panel
– Rear side panel.
Remove the lateral panel support.
V01C3EA 1 2 4
Solenoid Removal TYPICAL
Disconnect solenoid connector from wiring har- 1. Shifting solenoid
ness. 2. Engagement pin
3. Washer
Remove screws retaining solenoid valve body to 4. Valve body
HCM.
Solenoid Inspection
Remove Allen screws securing the modulation
and the clutch solenoids from the side of HCM. Check solenoids and gaskets for any damage. Re-
place if necessary.

14 rmr2013-016
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

Solenoid Cleaning WIRE IDENTIFICATION

Clean tip of clutch and modulation solenoids with SOLENOID NUMBER AT CONNECTOR
a contact cleaner. (WIRE COLOR)
1 8
Upshift
(RED) (WHITE)
2 7
Downshift
(RED) (WHITE)
3 6
Clutch
(RED) (WHITE)
Clutch 4 5
modulation (ORANGE) (WHITE)

OIL HOSE NIPPLE

rmr2008-077-028_a
The oil hose nipple is located on the front of the
1. Clean this area with contact cleaner HCM.

Solenoid Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Tighten solenoid valve body screws to specifica-
tion.
SOLENOID VALVE BODY SCREWS
(TORX SCREWS)
LOCTITE 243 (BLUE)
Service Product
(P/N 293 800 060)
Tightening Torque 6 N•m (53 lbf•in)

Tighten solenoid valve screws to specification.

rmr2013-016-011_a
SOLENOID VALVE SCREWS (ALLEN SCREWS) 1. Oil hose nipple “IN”
LOCTITE 243 (BLUE)
Service Product Oil Hose Nipple Removal
(P/N 293 800 060)
Tightening Torque 2 N•m (18 lbf•in) Drain engine oil, refer to LUBRICATION SYSTEM
subsection.
Check oil level in oil tank and refill with recom- Remove oil hose from nipple.
mended oil if necessary. Refer to LUBRICATION Unscrew oil hose nipple.
SYSTEM subsection.
Install pins of the solenoid valves in the correct
place of the connector, refer to following table:

rmr2013-016 15
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

rmr2008-077-007_a

1. HCM oil pressure regulator location

rmr2013-016-012_a

1. Oil hose nipple HCM Oil Pressure Regulator Removal

Remove oil pressure regulator from HCM.
Oil Hose Nipple Inspection
Clean oil hose nipple with a part cleaner, then use
air pressure to dry it.

WARNING
Always wear skin and eye protection. Chem-
icals can cause skin rash, skin burns and se-
vere eye injury.

Check if threads of the oil hose nipple is damaged.

Replace if necessary.
Check oil hose nipple for cracks. Replace if nec-
essary.
rmr2013-016-013_a

Oil Hose Nipple Installation 1. Plug screw

2. Sealing washer
For installation, reverse the removal procedure. 3. Spring
4. Pressure regulator piston
Pay attention to the following details.
Torque oil hose nipple to specification. HCM Oil Pressure Regulator Inspection
HOSE NIPPLE Check:
LOCTITE 243 (BLUE) – Oil pressure regulator bore and its sealing sur-
Service Product face for wear or scoring
(P/N 293 800 060)
Tightening Torque 11 N•m (97 lbf•in)
– Regulator piston and its seat for wear or scoring
– If the regulator piston moves easily in the bore.
Install oil hose. NOTE: A leaking piston causes low oil pressure
Refill oil tank with recommended oil and check and will cause shifting problems.
engine oil level. Refer to LUBRICATION SYSTEM Inspect compression spring for any deformation
subsection. and free length.

HCM OIL PRESSURE

REGULATOR
The HCM oil pressure regulator is located inside
the hydraulic control module.

rmr2008-077-009

16 rmr2013-016
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

SPRING FREE LENGTH

SERVICE LIMIT 110 mm (4.331 in)

Replace worn or damaged components.

Clean bore and thread in the hydraulic control unit
from metal shavings and other contaminations.

HCM Oil Pressure Regulator

Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
rmr2008-077-204_a
Always install a NEW sealing washer. 1. Remove this bolt
Torque plug screw to specification. 2. Ignition coils support
3. Lateral support
OIL PRESSURE REGULATOR PLUG SCREW
Unplug the solenoids connector and remove con-
Tightening Torque 19 N•m (168 lbf•in) nector housing from the ignition coils support.
Refill oil tank with recommended oil and check
engine oil level. Refer to LUBRICATION SYSTEM
subsection.

HYDRAULIC CONTROL MODULE

(HCM)
HCM Access
Make sure gearbox is on N position.
Remove the LH lower side panel. Refer to BODY
subsection.
rmr2008-077-205_a
Drain engine oil. Refer to LUBRICATION SYSTEM TYPICAL
subsection. 1. Solenoid connector
2. Ignition coils support
Unscrew bolt securing the ignition coil. 3. Oil tank

Disconnect the oil tank vent from crankcase.

rmr2008-077-203_a

1. Ignition coils bolt

Remove bolt retaining ignition coil support to lat-

eral support.
rmr2013-016-019_a

TYPICAL
1. Oil tank vent
2. Oil tank

rmr2013-016 17
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

Detach the clutch servo hose from the bottom of

oil tank.

rmr2013-016-021_a

TYPICAL
1. Engine inlet connector tube bolts
2. Oil cooler outlet hose
rmr2013-016-019_b

TYPICAL Move oil tank and oil cooler aside to make room.
1. Clutch servo hose
2. Oil tank Remove HCM OIL FILTER, see procedure above
in this subsection.
Disconnect oil cooler inlet hose from engine outlet
connector tube. HCM Removal
Unscrew the Banjo fitting securing the clutch
hose to HCM. Discard sealing washers.

rmr2013-016-020_a rmr2008-077-200_a

TYPICAL 1. Banjo fitting

1. Oil cooler inlet hose 2. Clutch hose
2. Engine outlet connector tube 3. Sealing washers

Remove engine inlet connector tube from Remove circlip of shift linkage.
crankcase. Discard O-rings.

18 rmr2013-016
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

rmr2008-077-201_a

1. Circlip
2. Shift linkage
rmr2013-016-005_b
NOTE: For easier removal of plug screws, loosen
1. Oil pump
them before removing the HCM from the engine.
Remove screws retaining the HCM to the mag- Oil Pump Removal
neto cover. Remove the HCM from the engine, refer to HY-
DRAULIC CONTROL MODULE (HCM) in this sub-
section.
Remove intermediate oil pump gear.

rmr2008-077-202_a

1. HCM screws

Pull the HCM and discard its gasket. rmr2008-077-011_a

1. Intermediate oil pump gear

HCM Installation
Remove retaining ring.
The installation is the reverse of the removal pro-
cedure.

OIL PUMP
The oil pump is located inside the hydraulic control
module (HCM).
The HCM is equipped with its own oil pump.

rmr2008-077-012_a

1. Retaining ring
2. Oil pump gear

Remove:
– Oil pump gear

rmr2013-016 19
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

– Needle pin Inspect rotor set and oil pump bore for serious
– Thrust washer. marks, scratches or other damages. If so, replace
damaged parts.
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.

rmr2008-077-013_a

1. Oil pump gear

2. Needle pin
3. Thrust washer

Remove oil pump cover. Discard the O-ring.

rmr2008-077-016_a

TYPICAL
1. Pitting on the teeth

Radial Clearance
Using a feeler gauge, measure the radial clear-
ance as illustrated. Refer to table following
illustration for service limits.
rmr2008-077-014_a

1. Oil pump cover screws

2. Oil pump cover
3. O-ring

Remove oil pump shaft with rotor set.

rmr2008-077-017_a

TYPICAL
1. Outer rotor
2. Inner rotor

rmr2008-077-015_a

1. Inner rotor
2. Oil pump shaft
3. Needle pin
4. Outer rotor
5. Groove

Oil Pump Inspection

Check oil pump cover and hydraulic control mod-
ule surface (where the oil pump cover fits) for
damage.

20 rmr2013-016
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

OUTER AND INNER ROTOR CLEARANCE
SERVICE LIMIT
A lowed.
B 0.25 mm (.0098 in)
C
If clearance between inner and outer rotors ex-
ceeds the tolerance, replace the oil pump.
If clearance between outer rotor and its bore in
hydraulic control module exceeds the tolerance,
replace the complete oil pump assembly and/or
the hydraulic control module.
Axial Clearance
Measurement A: outer rotor thickness.
Check oil pump gear for serious marks and dam-
age. If so, replace damaged part.
NOTE: Minimal imperfections or scratches are al-
Oil Pump Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Clean all metal components in a solvent.
Coat inner and outer rotors with oil.
Install oil pump shaft.
NOTE: The groove must face outwards and be
visible when installing oil pump cover.

rmr2008-077-015_a

1. Inner rotor
2. Oil pump shaft
3. Needle pin
4. Outer rotor
5. Groove
rmr2008-077-018

MEASUREMENT A: OUTER ROTOR THICKNESS Assemble oil pump into hydraulic control module.
Measurement B: depth of the oil pump bore. Markings on inner and outer rotor must face to-
ward oil pump cover.

rmr2008-077-019

MEASUREMENT B: OIL PUMP BORE DEPTH (HYDRAULIC

CONTROL MODULE)

Substract measurement A from measurement B rmr2008-077-017_b

to obtain axial clearance MARKINGS ON INNER AND OUTER ROTOR
1. Markings
OIL PUMP AXIAL CLEARANCE
SERVICE LIMIT 0.15 mm (.0059 in)
Install oil pump cover with a NEW O-ring.

NOTE: When the axial clearance of the oil pump

assembly increases, the oil pressure decreases.

rmr2013-016 21
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

rmr2008-077-011_a

1. Intermediate oil pump gear

rmr2008-077-021_a

1. Oil pump cover Remove circlip of needle bearing.

2. New O-ring

HCM Oil Pressure Test

After assembly, start engine and make sure HCM
oil pressure is within specifications (refer to HCM
OIL PRESSURE TEST in this subsection).

INTERMEDIATE OIL PUMP GEAR

The intermediate oil pump gear is located on the
backside of the hydraulic control module.
The intermediate oil pump gear is driven by the
hexagonal nut of the crankshaft and drives the oil
pump gear. rmr2008-077-023_a

1. Circlip

Remove:
– Needle bearing
– Thrust washer.

rmr2008-077-022_a

1. Intermediate oil pump gear

2. Hexagonal nut of crankshaft

Intermediate Oil Pump Gear Removal

Drain engine oil, refer to LUBRICATION SYSTEM
subsection.
Disconnect solenoid connector from wiring har-
ness.
Remove oil hose from hydraulic control module
nipple.
Remove hydraulic control module from engine.
Remove intermediate oil pump gear.
rmr2008-077-024_a
1. Needle bearing
2. Thrust washer
Intermediate Oil Pump Gear Inspection
Check if teeth and internal hexagon of intermedi-
ate oil pump gear are damaged, check intermedi-
ate oil pump gear for cracks. Replace if necessary.
Clean needle bearing with a part cleaner and
check for any damage. Replace if necessary.

22 rmr2013-016
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

Check needle bearing journal for any damage or

abnormal wear. Replace hydraulic control module
if necessary.

Intermediate Oil Pump Gear

Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Apply engine oil on needle bearing.
Refill oil tank with recommended oil and check
engine oil level. Refer to LUBRICATION SYSTEM
subsection. rmr2008-077-047

HYDRAULIC PISTON NOTICE 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
valves and is shifting the gears via the shifting link-
age.

rmr2008-077-050_a

1. HCM retaining screw

rmr2008-077-029_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-
sary replace faulty parts.

Hydraulic Piston Removal

Drain engine oil, refer to LUBRICATION SYSTEM
subsection.
Remove HCM OIL FILTER, see procedure above
in this subsection.
Remove the HCM cover by removing the follow-
ing screws. rmr2008-077-048_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.

rmr2013-016 23
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

rmr2008-077-031_a
rmr2008-077-033_a
1. Allen screw
2. Gear shift lever 1. Needle bushing
3. Shift linkage
Remove locking tie from bellow and slide bellow
Remove hydraulic piston plug screws. backwards.

rmr2008-077-034_a

1. Locking tie
rmr2008-077-049_a 2. Bellow
1. Plug screws
2. Plug screw O-rings Remove shift linkage from hydraulic piston.
Remove retaining ring from guide pin.

rmr2008-077-035_a

1. Shift linkage
2. Hydraulic piston
rmr2008-077-032_a

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.

24 rmr2013-016
 Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

Hydraulic Piston Installation

For installation, reverse the removal procedure.
Pay attention to the following details.
Install NEW piston linings.
NOTE: Sealing lip of piston linings must face
away of each other.

rmr2008-077-036_a

1. Hydraulic piston

Hydraulic Piston Inspection

Check hydraulic piston for any damage, scores or
abnormal wear. Replace if necessary.
Remove and discard piston linings

rmr2008-077-039_a

1. Position of piston linings

Oil hydraulic piston and piston linings prior of in-

rmr2008-077-037_a
1. Check hydraulic piston in this area for wear
2. Piston linings
Check hydraulic piston bore inside the hydraulic
control module for any damage, scores or abnor-
mal wear. Replace parts if necessary.
Check needle bushing, guide pin and sliding slot
of needle bushing inside hydraulic control module
for wear, scores and abnormal damage. Replace
parts if necessary.
stallation.
NOTE: Make sure not to damage the piston lin-
ings when installing the hydraulic piston.
After completing the installation check oil level in
oil tank and refill with recommended oil if nec-
essary. Refer to LUBRICATION SYSTEM subsec-
tion.
SHIFT LINKAGE
The shift linkage is the link between the hydraulic
piston and the shift shaft.

rmr2008-077-040_a
rmr2008-077-038_a

1. Needle bushing 1. Shifting linkage

2. Guide pin 2. Hydraulic piston
3. Sliding slot 3. Shift shaft

rmr2013-016 25
Subsection XX (HYDRAULIC CONTROL MODULE (SE5))

Shift Linkage Removal

NOTE: To carry out the following instruction, it is
not necessary to remove the HCM from the en-
gine. For better understanding, many of the fol-
lowing illustrations are taken with the HCM re-
moved from the engine.
Select NEUTRAL position. rmr2008-077-043_a

Remove body panels, refer to the BODY subsec-
tion.
Remove locking tie from bellow and slide bellow
backwards.
1. Check both ball joints in this area for wear
Shift Linkage Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
For basic adjustment assemble the shift linkage to
approximately 210 mm (8.268 in).

rmr2008-077-044_a

rmr2008-077-034_a
SHIFT LINKAGE BASIC LENGTH
A. 210 mm (8.268 in)
1. Locking tie
2. Bellow
Ball joints must face in opposite direction.
Remove both circlips from shift linkage.

rmr2008-077-045_a

1. Position of ball joints

Install NEW locking tie on bellow.

Install the gear shift lever. Align its slot with the
rmr2008-077-042_a dot on the end of shift shaft.
1. Circlips

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.

rmr2008-077-046_a

1. Gear shift lever slot

2. Shift shaft dot

26 rmr2013-016
 Subsection XX (GEARBOX)

GEARBOX
SERVICE TOOLS
Description Part Number Page
CRANKCASE SEAL PUSHER ........................................................ 529 036 092 ............................................. 8
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 6
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ....................................... 9–10
HANDLE ........................................................................................ 420 877 650 ............................................. 8
MAIN SHAFT PROTECTOR........................................................... 529 036 123 ....................................... 8, 19
MAIN SHAFT SEAL INSTALLER ................................................... 529 036 088 ............................................. 8
MAIN SHAFT SEAL PUSHER........................................................ 529 036 124 ............................................. 8
OIL SEAL INSTALLER ................................................................... 529 036 070 ............................................. 8
PROTECTION SLEEVE .................................................................. 529 036 071 ............................................. 8

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON SNAP RING PLIERS ..................................................... SRP3 ........................................... 14

SERVICE PRODUCTS
Description Part Number Page
DOW CORNING 111 ..................................................................... 413 707 000 ............................................. 8

rmr2013-017 1
Subsection XX (GEARBOX)

NEW

Engine oil

NEW
NEW
Engine oil

11 N•m
(97 lbf•in)
Engine oil

Loctite
243
Engine
oil

Engine
oil

NEW

Dow Corning 111

NEW
SM5 Models Only
NEW
NEW
NEW = Component must be replaced when removed. Dow Corning 111
rmr2008-056-100_b

2 rmr2013-017
 Subsection XX (GEARBOX)

SM5 Model

Engine oil

11 N•m
(97 lbf•in)

Engine
oil
Loctite Engine
243 oil

11 N•m
(97 lbf•in)

NEW

Engine oil 11 N•m

(97 lbf•in)

Loctite
243

Loctite
243
9 N•m
(80 lbf•in)
Loctite
243
11 N•m
(97 lbf•in)

NEW = Component must be replaced when removed.

rmr2011-017-001_a

rmr2013-017 3
Subsection XX (GEARBOX)

SE5 Model

Engine oil

Engine oil

Engine oil
11 N•m
(97 lbf•in)
Loctite 243

NEW

Engine oil 9 N•m

(80 lbf•in)
Loctite 243

NEW = Component must be replaced when removed.

rmr2011-017-002_a

4 rmr2013-017

GENERAL
NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle.
However, it is not always necessary to remove en-
gine from vehicle to perform some instructions.
Always disconnect the BLACK (-) cable from the
battery before working on the engine.
WARNING
Always disconnect BLACK (-) cable first and
reconnect last.
During assembly/installation, use torque values
and service products as in the exploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
NOTICE Hoses, cables or locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.
TROUBLESHOOTING
TROUBLESHOOTING
GUIDELINES
Gearbox Does not Shift Into Reverse
SM5 Models
Check fuse F7 of the front fuse box.
Check REVERSE ACTUATOR CABLE ADJUST-
MENT. See procedure in this subsection.
SM5 and SE5 Models
Carry out a REVERSE BUTTON TEST WITH
B.U.D.S. See procedure in this subsection.
Error Code (E) Displayed in Gauge
1. Proceed with ECM FIRST INITIALIZATION.
Refer to ELECTRONIC FUEL INJECTION (EFI)
subsection.
2. Check GBPS. See GEARBOX POSITION SEN-
SOR TEST in this subsection.
rmr2013-017
Subsection XX (GEARBOX)
3. On SE5 models, inspect HCM operation. Refer
to HYDRAULIC CONTROL MODULE (SE5) sub-
section.
PROCEDURES
REVERSE BUTTON
Reverse Button Test with B.U.D.S.
Connect vehicle to B.U.D.S.
Select the TCM tab in the Monitoring page.
Check the Switch Inputs.
If LED turns ON when the reverse button is
pressed in, it indicates that the button sends the
message.
– On SM5 model, carry out the REVERSE ACTU-
ATOR ACTIVATION WITH B.U.D.S. in this sub-
section.
– On SE5 model, verify the shift system oper-
ation. Refer to ELECTRONIC SHIFT SYSTEM
(SE5) and HYDRAULIC CONTROL MODULE
(SE5) subsections.
If LED does not turn ON when reverse button is
pressed in:
– Check left multifunction switch (MSL), refer to
LIGHTS, GAUGE AND ACCESSORIES subsec-
tion.
GEARBOX POSITION SENSOR
(GBPS)
GBPS Reset
To reset GBPS, refer to ECM FIRST INITIALIZA-
TION in the ELECTRONIC FUEL INJECTION (EFI)
subsection.
GBPS Test
Check fault codes in B.U.D.S. software.
Ensure vehicle is on NEUTRAL.
Unplug the GBPS connector.
Perform the following tests.
5
Subsection XX (GEARBOX)

GBPS Input Voltage Test RESISTANCE

MULTIMETER PROBE
@ 20°C
MULTIMETER PROBE POSITIONS VOLTAGE POSITIONS
(68°F)
GBPS connector (pin 1) and GBPS GBPS connector (pin 2) and ECM
connector (pin 3) adapter tool on ECM A (pin F4)

Below 1
5 volts

If resistance is out of specification, check wires

If voltage is adequate, check GBPS communica- and connector pins. Repair and reset fault codes.
tion link (CAN). If resistance is good, replace the GBPS and reset
If there is no voltage, check each GBPS input as fault codes.
follows.
GBPS Removal
MULTIMETER PROBE POSITIONS VOLTAGE
Make sure that gearbox is in NEUTRAL position.
GBPS connector (pin 1) and
battery ground On SM5 model, remove the control lever and the
control lever spring.
Remove GBPS screws.
5 volts
Remove the GBPS.

GBPS connector (pin 3) and

battery + terminal

Battery
voltage

rmr2008-017-003_a

If there is no voltage, check wires and connector SM5 MODEL

1. Control lever
pins. 2. Control lever spring
3. Gearbox position sensor (GBPS)
Replace or repair defective parts and reset fault
codes.
GBPS Communication Link Continuity Test
Unplug “A” connector from ECM and connect it
to the adapter.
REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)

6 rmr2013-017
 Subsection XX (GEARBOX)

OIL SEALS
Oil Seals Access
Main Shaft Oil Seal
Remove FRONT SPROCKET. Refer to DRIVE
BELT AND REAR WHEEL subsection.
Gear Locking Shaft Oil Seal (SM5)
Remove the GEARBOX POSITION SENSOR. See
procedure in this subsection.
Shift Shaft Oil Seal
rmr2008-056-002_a

SE5 MODEL Remove gearshift lever.

1. Gearbox position sensor (GBPS)
Shift Drum Shaft Oil Seal
GBPS Installation Remove the GEARBOX POSITION SENSOR. See
For installation reverse the removal procedure. procedure in this subsection.
However, pay attention to the following.
Align GBPS with the flat on the shift drum shaft.

rmr2008-017-004_a
rmr2008-017-005_a
TYPICAL
1. Flat on shift drum shaft SM5 MODEL
1. Main shaft oil seal
2. Gear locking shaft oil seal
On SM5 model, install the control lever spring as 3. Shift shaft oil seal
shown in the next illustration. 4. Shift drum shaft oil seal

rmr2008-017-200_a

1. Spring hook
rmr2008-056-003_a
2. Straight end of spring
SE5 MODEL
Proceed with ECM FIRST INITIALIZATION in the 1. Main shaft oil seal
2. Shift shaft oil seal
ELECTRONIC FUEL INJECTION (EFI) subsection. 3. Shift drum shaft oil seal

rmr2013-017 7
Subsection XX (GEARBOX)

Oil Duct Cover Oil Seal Gear Locking Shaft Oil Seal
Remove the OIL DUCT COVER as described in Protect gear locking shaft and move oil seal on
the LUBRICATION SYSTEM subsection. shaft.
REQUIRED TOOL
PROTECTION SLEEVE
(P/N 529 036 071)

Push oil seal into place.

REQUIRED TOOL
OIL SEAL INSTALLER (P/N 529
036 070)

Shift Shaft Oil Seal

Protect gear locking shaft and move oil seal on
rmr2008-017-036_a shaft.
1. Oil seal, oil duct cover
2. Main shaft, clutch side REQUIRED TOOL
PROTECTION SLEEVE
Oil Seals Inspection (P/N 529 036 071)
Replace oil seals if they are brittle, hard or dam-
aged. Push oil seal into place.
Check running surface of shafts for scratches. Re- REQUIRED TOOL
place if necessary, refer to SHIFTING SYSTEM or
GEARBOX in this subsection. OIL SEAL INSTALLER (P/N 529
036 070)
Oil Seals Removal
Shift Drum Shaft Oil Seal
Use a small flat screwdriver to remove oil seals.
Put oil seal on shift drum shaft and push oil seal
NOTICE Avoid scoring surfaces when replac- into place.
ing oil seals.
REQUIRED TOOL
Oil Seals Installation CRANKCASE SEAL PUSHER
(P/N 529 036 092)
NOTICE All oil seals must be installed with
sealing lip towards gearbox. Oil Duct Cover Oil Seal
Apply DOW CORNING 111 (P/N 413 707 000) inside Push oil seal into main shaft.
each seal.
REQUIRED TOOL
Main Shaft Oil Seal MAIN SHAFT SEAL PUSHER
Protect main shaft (PTO side) and move oil seal on (P/N 529 036 124)
shaft.
HANDLE (P/N 420 877 650)
REQUIRED TOOL
MAIN SHAFT PROTECTOR
(P/N 529 036 123)

Push oil seal in place.

REQUIRED TOOL

MAIN SHAFT SEAL INSTALLER

(P/N 529 036 088)

HANDLE (P/N 420 877 650)

8 rmr2013-017
 Subsection XX (GEARBOX)

If actuator operates:
– Check control lever.
– Check actuator cable and bracket condition.
– Check REVERSE ACTUATOR CABLE ADJUST-
MENT.
If actuator does not operate:
– Carry out a REVERSE ACTUATOR INPUT VOLT-
AGE TEST.
Reverse Actuator Input Voltage Test
1. Make sure fuse F7 is good.
2. Disconnect the reverse actuator connector.
rmr2008-017-038_a

1. Oil seal installer with handle

2. Oil seal
3. Main shaft

REVERSE ACTUATOR (SM5

MODEL)
Reverse Actuator Access
Refer to BODY subsection and remove the follow-
ing panels:
– LH rear side panel
– LH bottom rear side panel.
rmr2010-017-002_c
Reverse Actuator Activation with 1. Reverse actuator connector
B.U.D.S.
3. Set the multimeterto Vdc.
1. Connect vehicle to B.U.D.S.
2. Select the Activation and ACC tabs. REQUIRED TOOL

3. Keep an eye on the reverse actuator. FLUKE 115 MULTIMETER

4. Click on the Reverse actuator button. (P/N 529 035 868)

4. Measure voltage as follows.

REVERSE ACTUATOR INPUT VOLTAGE TEST
TEST PROBES RESULT
Actuator
Battery
connector pin Battery voltage
negative (-) post
2 (BU)

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.
rmr2010-036-201_c

TYPICAL
Step 1: Activation tab Reverse Actuator Control Circuit Test
Step 2: ACC tab
Step 3: Reverse actuator button 1. Disconnect the reverse actuator connector.

rmr2013-017 9
Subsection XX (GEARBOX)

rmr2010-017-002_c rmr2010-017-002_c

1. Reverse actuator connector 1. Reverse actuator connector

2. Set multimeter to Vdc. 2. Remove reverse actuator mounting screws.

REQUIRED TOOL 3. Remove cable guide bracket mounting screws.

FLUKE 115 MULTIMETER

(P/N 529 035 868)

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.
rmr2010-017-101_c

NOTE: Once reverse button is pressed, the CABLE GUIDE BRACKET

ground signal (control) will be held for 2 to 3
seconds wether the button is held or not. After a 4. Detach actuator cable from control lever.
few attempts, it is normal for the system to shut 5. Installation is the reverse of removal however, it
down the reverse function for a few minutes. is critical to carry out the REVERSE ACTUATOR
REVERSE ACTUATOR CONTROL CIRCUIT TEST
CABLE ADJUSTMENT.
NOTE: Start adjustment procedure before in-
RESULT (REVERSE
TEST PROBES stalling the new actuator on the vehicle.
BUTTON PRESSED)
Actuator Battery Reverse Actuator Cable Adjustment
connector pin positive (+) Battery voltage
1. Lay the cable guide bracket on a workbench and
1 (RD) post
loosen the adjusting nuts.
If voltage is as specified: 2. Set the lower adjusting nut against the bottom
– Replace reverse actuator. of the cable guide threads.
If voltage is not as specified:
– Check open circuit between reverse actuator
connector and cluster connector pin 3.

Reverse Actuator Replacement

1. Disconnect the reverse actuator connector.

10 rmr2013-017
 Subsection XX (GEARBOX)

rmr2010-017-003_a

ACTUATOR AND CABLE GUIDE IN LINE

1. Actuator
2. Cable guide
rmr2010-017-101_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
37 mm ± 1 mm (1.46 in ± .04 in)
7. Place enough shims (P/N 710 002 024) under-
neath the actuator mounting plate front hole to
obtain alignment.
8. Once parts are aligned, thread the front mount-
ing screw through the shims.

rmr2010-017-100_a

1. Front mounting screw

2. Shims

rmr2010-017-101_a 9. Tighten mounting screws.

A. 37 mm ± 1 mm (1.46 in ± .04 in) 10. Make sure that there is an axial free play at
4. Tighten the upper adjustment screw. actuator rod.
5. Install the cable guide bracket on the engine. ACTUATOR ROD AXIAL FREE PLAY
6. Position actuator on the frame member, then Minimum 2 mm (1/16 in)
loosely thread the rear mounting bolt.
NOTE: The actuator center axis must be in line
with the cable guide vertically.

rmr2010-017-002_b

A. Free play at the actuator rod

rmr2013-017 11
Subsection XX (GEARBOX)

11. Validate that gearbox engages in reverse. Use a flat screwdriver to turn index lever counter-
clockwise while removing index shim.
SHIFTING MECHANISM
Parts of the shifting mechanism can be replaced
without removing the engine:
– Shift shaft
– Index lever
– Index shim
– Index spring.

Shifting Mechanism Removal

Remove clutch cover and clutch drum. Refer to
CLUTCH (SM5) or CLUTCH (SE5) subsection.
Pull out shift shaft assembly from crankcase.
rmr2011-017-005_a

TYPICAL
1. Index lever
2. Screw
3. Index shim

Remove the following parts:

– Screw
– Index lever
– Step ring
– Index spring.

rmr2011-017-003_a

TYPICAL
1. Shift shaft assembly

Remove oil pump gear.

rmr2011-017-006_a

TYPICAL
1. Screw
2. Index lever
3. Step ring
4. Index spring

Shifting Mechanism Inspection

Shift Shaft
rmr2011-017-004_a
Check shift shaft for worn splines or other dam-
TYPICAL ages.
1. Retaining ring
2. Oil pump gear Check pawl and pawl spring for wear and proper
3. Needle pin
operation.
Remove index shim screw.

12 rmr2013-017
 Subsection XX (GEARBOX)

Separate both crankcase housings. Refer to

CRANKCASE AND CRANKSHAFT subsection.
Remove both shift fork shafts from shift forks.

rmr2008-017-016_a

TYPICAL
1. Pawl
2. Spring
3. Check for free movement

Index Lever rmr2008-017-014_a

1. Shift fork shafts

Roller of index lever must move freely. Replace if 2. Shift forks
necessary.
On SM5 model, disengage shift forks and gear
Shifting Mechanism Installation locking shaft from shift drum.
The installation is the reverse of the removal pro- Remove shift drum and bearing.
cedure. However, pay attention to the following.
After installation, check if the gears engagement
is accurate and shifting system works properly.

GEARBOX

rmr2008-017-015_a

1. Shift forks
2. Gear locking shaft (SM5 Model only)
3. Shift drum
4. Bearing

Before removing the gearbox from crankcase

withdraw the following separate parts from main
shaft.
rmr2008-017-018_a

1. 1st speed
2. 2nd speed
3. 3rd speed
4. 4th speed
5. 5th speed
6. R (Reverse speed)

Gearbox Disassembly
Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION subsection.
Remove FRONT SPROCKET. Refer to DRIVE
BELT AND REAR WHEEL subsection.
Remove the SHIFTING MECHANISM. See proce-
dure in this subsection.

rmr2013-017 13
Subsection XX (GEARBOX)

rmr2008-017-019_a
rmr2008-017-021_a
1. Thrust washer
1. Screws
2. Free pinion (1st gear) 2. Retaining plate
3. Needle bearing
4. Thrust washer 3. Intermediate gear
4. Needle bearing
5. Shifting gear (4th gear)

Tap main shaft to assist withdrawing main shaft Ball Bearings

assembly together with clutch shaft assembly. When gearbox is removed check gearbox ball
bearings for contamination and/or metal shav-
REQUIRED TOOL ings. Check if bearings turn freely and smoothly.
SOFT HAMMER Replace if necessary, refer to CRANKCASE AND
CRANKSHAFT.
Main Shaft
Remove and discard the snap ring.
RECOMMENDED TOOL
SNAP-ON SNAP RING PLIERS (P/N SRP3)

Remove free pinions and needle bearings.

rmr2008-017-020_a

1. Main shaft assembly

2. Clutch shaft assembly
3. Soft hammer

NOTICE Take care not to damage oil seal dur-

ing gearbox disassembly.
Reverse Intermediate Gear
Remove screws and retaining plate and withdraw rmr2008-017-022_a
intermediate gear and needle bearing. 1. Snap ring
2. Free pinion (3rd gear)
3. Needle bearings
4. Free pinion (2nd gear)
5. Main shaft assembly

Remove and discard snap ring retaining the shift-

ing gear (5th gear).
Withdraw shifting gear.

14 rmr2013-017
 Subsection XX (GEARBOX)

rmr2008-017-023_a

1. Snap ring
2. Shifting gear (5th gear) rmr2008-017-025_a

1. Fixed gear (reverse gear)

Remove and discard snap ring securing the re- 2. Free pinion (5th gear)
verse gear. 3. Needle bearing
4. Shifting gear (2nd and 3rd gear)
5. Clutch shaft assembly
Withdraw free pinion with needle bearing and
bearing sleeve. Remove and discard snap ring securing the free
Remove thrust washer. pinion (4th gear).
Withdraw thrust washer and free pinion from
clutch shaft.

rmr2008-017-024_a

1. Snap ring
2. Bearing sleeve
3. Needle bearing rmr2008-017-026_a
4. Free pinion (reverse gear) 1. Snap ring
5. Thrust washer
2. Thrust washer
3. Free pinion (4th gear)
Clutch Shaft 4. Clutch shaft (1st gear)
Remove the following parts from clutch shaft.
– Fixed gear
Gearbox Inspection
– Free pinion Always check the following when inspecting gear-
box components:
– Needle bearing
– Gear teeth damage
– Thrust washer
– Worn or scored bearing surfaces
– Shifting gear.
– 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
– Bent, worn or scored shift fork shafts
– Bent, worn or scored shift fork.

rmr2013-017 15
Subsection XX (GEARBOX)

Shift Fork
Check shift forks for visible damage, wear or bent
shift fork claws.
Measure the shift fork claw thickness.

vmr2008-019-052_a

TYPICAL — FREE PINION

1. Teeth
2. Bearing surface
3. Engagement slot

vmr2006-022-075_a

TYPICAL
1. Micrometer
A. Shift fork claw thickness

SHIFT FORK CLAW THICKNESS

4.00 mm to 4.10 mm
NEW
(.1575 in to .1614 in)
SERVICE LIMIT 3.90 mm (.1535 in)

Measure the shift fork engagement pin diameter.

vmr2008-019-053_a

TYPICAL — SHIFTING GEAR

1. Engagement dog
2. Shift fork engagement groove
3. Inner splines

Shift Drum
Check shift drum tracks for scouring or heavy
wear, like rounded engagement slots.

vmr2006-022-076_a

TYPICAL
1. Micrometer
A. Shift fork engagement pin diameter

rmr2008-017-017_a
SHIFT FORK ENGAGEMENT PIN DIAMETER
1. Track for 1st/3rd gear shift fork 5.92 mm to 5.97 mm
2. Track for 4th/5th gear shift fork NEW
3. Track for 2nd/Reverse gear shift fork (.2331 in to .235 in)
4. Track for gear locking shaft (SM5 model only)
SERVICE LIMIT 5.850 mm (.2303 in)
Gear Locking Shaft (SM5)
Roller of gear locking shaft must move freely. Re-
place as necessary.
16 rmr2013-017
 Subsection XX (GEARBOX)

Gears
Measure the width of shift fork engagement
groove.

rmr2008-017-050_a

MAIN SHAFT — FREE PINION

1. 1st gear
vmr2008-019-054_a 2. 3rd gear
3. 2nd gear
TYPICAL — SHIFTING GEAR 4. Reverse gear
A. Width of shift fork engagement groove
CLUTCH SHAFT FREE PINIONS
WIDTH OF SHIFT FORK ENGAGEMENT GROOVE
NEW
4.20 mm to 4.30 mm
NEW
(.1654 in to .1693 in) 29.080 mm - 29.100 mm
4th GEAR
(1.1449 in - 1.1457 in)
SERVICE LIMIT 4.50 mm (.1772 in)
26.000 mm - 26.013 mm
5th GEAR
Check free pinions for wear. (1.0236 in - 1.0241 in)
Measure the inside diameter of free pinion. SERVICE LIMIT
4th GEAR 29.125 mm (1.1467 in)
5th GEAR 26.025 mm (1.0246 in)

vmr2008-019-055_a

TYPICAL
A. Diameter free pinion bearing rmr2008-017-051_a

CLUTCH SHAFT — FREE PINION

MAIN SHAFT FREE PINIONS 1. 4th gear
2. 5th gear
NEW
Main Shaft
1st GEAR
29.007 mm to 29.020 mm Check main shaft for wear.
2nd GEAR
(1.142 in to 1.1425 in)
3rd GEAR Check retaining ring grooves.
40.009 mm to 40.025 mm Check splines for wear and/or damages.
REVERSE GEAR
(1.5752 in to 1.5758 in) Blow out the oil orifices and check if they are not
SERVICE LIMIT clogged.
1st GEAR
2nd GEAR 29.035 mm (1.143 in)
3rd GEAR
REVERSE GEAR 40.040 mm (1.5764 in)

rmr2013-017 17
Subsection XX (GEARBOX)

rmr2008-017-027_a

1. Retaining ring grooves

2. Splines
3. Oil orifices

Measure diameters of main shaft bearing journals.

rmr2008-017-028_a

1. Oil orifices

Measure external diameter of reverse gear free

pinion bearing.

rmr2008-017-027_b

A. Magneto side bearing journal

B. Free pinion bearing journal
C. Clutch side bearing journal

MAIN SHAFT BEARING JOURNAL

NEW
MAGNETO SIDE 34.989 mm - 35.000 mm
BEARING JOURNAL (1.3775 in - 1.378 in)
rmr2008-017-028_b
FREE PINION BEARING 24.980 mm - 24.993 mm
A. External diameter
JOURNAL (.9835 in - .984 in)
CLUTCH SIDE 19.987 mm - 20.000 mm FREE PINION BEARING EXTERNAL DIAMETER
BEARING JOURNAL (.7869 in - .7874 in) 34.984 mm - 35.000 mm
NEW
SERVICE LIMIT (1.3773 in - 1.378 in)
MAGNETO SIDE SERVICE LIMIT 34.970 mm (1.3768 in)
34.975 mm (1.377 in)
BEARING JOURNAL
Clutch Shaft
FREE PINION BEARING
24.970 mm (.9831 in) Check clutch shaft for wear.
JOURNAL
CLUTCH SIDE Check retaining ring groove.
19.970 mm (.7862 in)
BEARING JOURNAL Check splines for wear and/or damages.
Bearing Sleeve Blow out the oil orifices and check if they are not
clogged.
Check if oil orifices are free. Clean if required.

rmr2008-017-029_a

1. Retaining ring groove

2. Splines
3. Oil orifices

18 rmr2013-017
 Subsection XX (GEARBOX)

Measure diameters of clutch shaft bearing jour- For gearbox installation, protect the main shaft
nals. (PTO side) in order to avoid damaging main shaft
oil seal.
REQUIRED TOOL
MAIN SHAFT PROTECTOR
(P/N 529 036 123)

rmr2008-017-029_b

A. Magneto side bearing journal

B. Free pinion bearing journal (5th gear)
C. Free pinion bearing journal (4th gear)
D. Clutch side bearing journal

CLUTCH SHAFT BEARING JOURNAL

NEW
MAGNETO SIDE 19.987 mm - 20.000 mm
BEARING JOURNAL (.7869 in - .7874 in)
rmr2008-017-031_a
FREE PINION BEARING 21.987 mm - 22.000 mm
JOURNAL (5th GEAR) (.8656 in - .8661 in) 1. Main shaft protector
2. Main shaft
3. Clutch shaft
FREE PINION BEARING 29.041 mm - 29.054 mm
JOURNAL (4th GEAR) (1.1433 in - 1.1439 in) Using a plastic hammer, ensure shafts are prop-
CLUTCH SIDE 29.980 mm - 29.993 mm erly seated into crankcase housing.
BEARING JOURNAL (1.1803 in - 1.1808 in) Install the shifting mechanism.
SERVICE LIMIT Install all other removed parts.
MAGNETO SIDE
19.970 mm (.7862 in)
BEARING JOURNAL
FREE PINION BEARING
21.970 mm (.865 in)
JOURNAL (5th GEAR)
FREE PINION BEARING
29.030 mm (1.1429 in)
JOURNAL (4th GEAR)
CLUTCH SIDE
29.965 mm (1.1797 in)
BEARING JOURNAL

Reverse Intermediate Gear

Check reverse intermediate gear, needle bearing
and bearing pin visually for wear, pitting and/or
scoring. Replace parts if necessary.

Gearbox Assembly and Installation

For assembly and installation, reverse the disas-
sembly and removal procedures. However, pay
attention to the following.
Install NEW snap rings.
NOTICE Snap rings must be installed using a
retaining ring pliers only. Take care not to over-
stress them during installation.

rmr2013-017 19
 Subsection XX (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 Management System)
– VSS (Vehicle Stability System)
– DPS (Dynamic Power Steering).

rmr2013-018 1
Subsection XX (OVERVIEW)

ENGINE MANAGEMENT SYSTEM (EMS)

SM5 Model

FRONT FRONT

Injector front
cyl. (no. 1)
Injector rear
cyl. (no. 2)

Starter solenoid

Engine stop

Ignition front

Ignition rear
cyl. (no. 2)
Clutch valve

cyl. (no.1)
Cooling fan

switch
Fuel pump

EVAP

D.E.S.S.

Clutch
Inj. 1

switch GBPS
TPS
MAPS
Starter
switch CPS Ignition switch
CAPS
Basic data
TAS OPS
Ignition coil
Brake light
switch
CAN VCM
ETA DPS
KS2 CLUSTER + LCD
CTS Correction
HO2S1 factors
RADIO
KS1
WPM or PBM
HO2S2
Inj. 2

inputs
AAPTS ECM ECM
outputs
ECM
rmr2013-018-100_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 parking brake module or Parking brake Module)
EVAP Valve (Evaporative Emissions)

2 rmr2013-018
 Subsection XX (OVERVIEW)

SE5 Model

FRONT FRONT
Injector front
cyl. (no. 1)
Injector rear
cyl. (no. 2)

Starter solenoid
Clutch valve

Ignition front
Cooling fan

Ignition rear
Fuel pump

cyl. (no. 2)
cyl. (no.1)
Engine stop
EVAP
switch

D.E.S.S.
Inj. 1

GBPS
TPS
Starter MAPS
switch CPS Ignition switch
CAPS
Basic data
TAS OPS
Ignition coil
Brake light CAN VCM
switch
ETA TCM
KS2 DPS
CTS Correction
HO2S1
factors
CLUSTER + LCD
KS1
HO2S2 RADIO
Inj. 2

AAPTS WPM OR PBM

ECM
inputs outputs
ECM ECM
rmr2013-018-101_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 parking brake module or Parking brake Module)
EVAP Valve (Evaporative Emissions)

rmr2013-018 3
Subsection XX (OVERVIEW)
A highly advanced engine management system
(EMS) has been used to ensure a high power out-
put with cleaner combustion.
There are 6 main systems that are controlled by
the engine management system (EMS):
1. Electronic Fuel Injection (EFI)
2. Cooling system
3. Evaporative emission control system (EVAP)
4. Ignition system
5. Starting system
6. Engine clutch system.
Engine Control Module (ECM)
The ECM is the central point of the engine man-
agement system. It reads the inputs, makes
computations, uses pre-determined parameters
and sends the proper signals to the outputs for
proper engine management.
smr2009-027-005
TYPICAL - ECM
The ECM is located in front of steering column.
rmr2010-019-003_a
TYPICAL
1. ECM location
The ECM features a permanent memory that will
keep the fault codes, customer information and
other engine information, even when the battery
is removed from the vehicle.
4 rmr2013-018
Drowned Mode (Flooded Engine)
If engine is fuel-flooded and does not start, this
special mode can be activated to prevent fuel in-
jection and ignition while cranking. Proceed as fol-
lows to activate it.
With ignition switch turned ON while engine is
stopped, twist and HOLD throttle at WOT posi-
tion.
Press the start button and hold to crank engine.
The mode is now on.
Releasing throttle will bring back the normal
mode.
VEHICLE STABILITY SYSTEM
(VSS)
The VSS helps to maintain vehicle control in nor-
mal riding conditions as well as in emergency
avoidance maneuvers.
To maintain vehicle stability, the VSS interacts
with the several other subsystems as well as
with the engine management system. Refer to
the VEHICLE STABILITY SYSTEM (VSS) subsec-
tion for more details.
DYNAMIC POWER STEERING
(DPS)
The Dynamic Power Steering (DPS) system pro-
vides a computer controlled, variable steering as-
sist achieved by an electric motor to optimize the
amount of steering input required by the rider.
Refer to the STEERING (DPS) AND WHEELS sub-
section for more details.
ELECTRONIC SHIFT SYSTEM
(SE5)
The SE5 engine features a sequential electroni-
cally controlled mechanical 5-speed gearbox with
a hydraulically-actuated type clutch system.
NOTE: The SE5 is an electronically controlled ver-
sion of a sequential manual gearbox.
Refer to the ELECTRONIC SHIFT SYSTEM (SE5)
subsection for more details.
 Subsection XX (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 COMMUNICA-
TION 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 or PBM (windshield parking brake module or parking brake module).

rmr2013-019-001_a

CLUSTER: Multifunction Gauge

DLC: Diagnostic Link Connector
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 or PBM: Windshield Parking Brake Module or Parking Brake Module
YRS: Yaw Rate Sensor

rmr2013-019 1
Subsection XX (CONTROLLER AREA NETWORK (CAN))

The MSL broadcast the following signals through

CAN:
– Reverse
– Push to talk (CB PTT)
– Mode
– Set
– Cruise
– 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 key antenna.
For more information, refer to DIAGNOSTIC AND
FAULT CODES.
Communication Between Modules
Through the CAN Bus
The following table shows what modules commu-
nicate with each other.
COMMUNICATE WITH
MODULE/SENSOR
MODULE/SENSOR
ECM (engine control
All except SAS and YRS
module)
Multifunction cluster
All
gauge
VCM (vehicle control
All
module)
TCM (transmission
All except SAS
control module) (SE5)
SAS (steering angle Multifunction cluster
sensor) gauge, VCM, DPS
VCM, TCM, DPS,
YRS (yaw rate sensor) Multifunction cluster
gauge
DPS (dynamic power
All except MSL
steering)
ECM, multifunction
Radio cluster gauge, TCM,
DPS, VCM
MSL (multifunction All except SAS, YRS,
switch LH side) DPS and radio
WPM (windshield and All except SAS, YRS,
parking brake module) and radio

2 rmr2013-019
 Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.)

COMMUNICATION TOOLS AND

B.U.D.S.
SERVICE TOOLS
Description Part Number Page
MPI-2 DIAGNOSTIC CABLE.......................................................... 710 000 851 ........................................... 3
MPI-2 INTERFACE CARD .............................................................. 529 036 018 ........................................... 3

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
MALE-FEMALE EXTENSION SERIAL CABLE............................... DB9 ........................................... 3

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.
BLESHOOTING 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
and diagnostic cable connector.
MPI-2 Connection Troubleshooting Light is
– Check connection between diagnostic
OFF
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-
Light is – Check CAN wires/connectors
erly. Otherwise, refer to the following charts.
RED on vehicle.

Communication Problems when Using

B.U.D.S.
Missing Module
Ensure the appropriate number of modules is
shown at the bottom of B.U.D.S. screen.

vdd2006-001-151_b
MODEL NUMBER OF MODULES

Prerequisite for USB Communication: RS MODELS

– PC Computer turned ON 5
SM5
– MPI-2 connected to PC computer. (ECM, VCM, DPS, LCD
Model
(RS-S only) and multifunction gauge)
COMMUNICATION PROBLEM (USB)
6
STATUS WHAT TO DO SE5
(ECM, VCM, DPS, TCM,
Model
LCD and multifunction gauge)
– Check USB connection between
Light is MPI-2 and PC computer.
OFF – Check USB operation on PC computer
(hardware or Windows drivers).

rmr2013-020 1
Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.)

MODEL NUMBER OF MODULES

ST MODELS
6
SM5
(ECM, VCM, DPS, PBM,
Model
LCD and multifunction gauge) rmr2010-020-010_a

7
SE5
Model
(ECM, VCM, DPS, TCM, PROCEDURES
PBM, LCD and multifunction gauge)
RT MODELS MULTI-PURPOSE INTERFACE-2
6 (MPI-2)
SM5 (ECM, VCM, DPS, WPM,
The MPI-2 (Multi-Purpose Interface-2) in conjunc-
LCD and multifunction gauge)
tion with the MPI-2 diagnostic cable is used with
7 B.U.D.S. to communicate with the Electronic Con-
SE5 (ECM, VCM, DPS, TCM, trol Units (ECUs).
WPM, LCD and multifunction gauge)
MPI-2 Power
The MPI-2 interface card uses the power from the
PC computer's USB port.

Connecting the PC to the Vehicle

WARNING
rmr2011-020-002_a
If the computer you are using is connected to
1. Number of modules
a power outlet, there is a potential risk of elec-
trocution when working in contact with water.
NOTE: The LCD (liquid crystal display) is part of Be careful not to touch water while working
the cluster. with the computer.
If one or more “ECU” is not communicating
with the MPI, refer to DIAGNOSTIC AND FAULT 1. Open front storage compartment cover.
CODES. 2. Remove the RH service cover.
No Vehicle is Detected
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-
cating with the MPI.

rmr2010-020-009 rmr2010-020-002_a

1. Service cover
Check the following:
– Connections between the PC computer and the 3. Locate the vehicle communication connector.
vehicle
– 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.

2 rmr2013-020
 Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.)

529036018

rmr2010-020-005_a

TYPICAL
1. Vehicle communication connector location

Remove the communication connector from its

holder (protective cap). vdd2006-001-151

Connect one end of the MPI-2 DIAGNOSTIC CABLE

(P/N 710 000 851) to the vehicle communication Connect the MPI-2 USB connector to the USB
connector. port on the PC (personal computer).

710000851

mmr2006-079-200

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.

rmr2010-020-006_a

TYPICAL - MPI-2 CONNECTION TO VEHICLE COMMUNICATION

CONNECTOR

Connect the other end of the diagnostic cable to

the MPI-2 INTERFACE CARD (P/N 529 036 018) con-
nector.

rmr2013-020 3
Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.)

vmr2006-012-100_aen

529035697

OPTIONAL MALE-FEMALE EXTENSION SERIAL CABLE Writing Changes in an ECU

If the word Modified appears at the end of the
B.U.D.S. vehicle file name at the top of the B.U.D.S. page,
B.U.D.S. (BRP Utility and Diagnostic Software) is then a change has been made that requires it to
designed to allow electrical and electronic compo- be saved to the proper electronic module.
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.

Reading the Electronic Control Units rmr2010-020-008_a

Using B.U.D.S. 1. Indicate setting or data modified; Write Data to save
IMPORTANT: Ensure all connections have been
Click the Write Data button.
made before starting B.U.D.S. to allow proper
operation. Refer to CONNECTING THE PC TO
THE VEHICLE in this subsection.
1. Turn ignition key to ON.
2. Start B.U.D.S. and logon.
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.

vmr2006-012-100_ben

NOTE: A message box will confirm a successful

operation.
Disconnect the MPI connections and store the
communication connector in its protective cap.
rmr2011-020-002_a

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.

4 rmr2013-020
 Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.)

rmr2011-070-010

rmr2010-020-005_a
TYPICAL - MODULE SUBMENU LIST, SE5 MODEL ILLUSTRATED
1. Communication connector stored in protective cap
1. If the Update option is greyed out, no update
NOTICE Failure to secure the diagnostic con- file is available for this module.
nector in its protective cap may result in corro- 2. If the Update option is black, an update file is
sion or other damage to the terminals. available for this module. Select the update op-
tion and load the proper file.
Electronic Modules (ECU) Update
Whenever B.U.D.S. is first connected to a vehicle,
check for an update icon in the B.U.D.S. status bar
at the bottom of the Vehicle page.

rmr2010-020-004_a

TYPICAL
1. Greyed out: No update to perform
Black: Update file available

rmr2010-020-003_a

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.

rmr2013-020 5
 Subsection XX (DIAGNOSTIC AND FAULT CODES (RS SERIES))

DIAGNOSTIC AND FAULT CODES (RS

SERIES)
GENERAL
MONITORING SYSTEM
The Engine Management System (EMS) and Vehicle Stability System (VSS) (including their sub systems)
feature a monitoring system that self-diagnose their electronic components. This mode becomes active
when ignition key is turned on.
NOTE: Some components need the engine to be running so that they can be monitored (fuel injectors
for example).
The monitoring system continuously validates that the electronic components (control modules, sensors
and actuators) are not faulty or defective. When a malfunction is detected, the involved electronic mod-
ule:
– Sets an active fault code.
– Adapts the proper protection strategy according to the failure.
– Sends out signals to the multifunction gauge to inform the rider of a particular condition.
If a minor fault occurs, engine and vehicle will continue to operate without noticeable loss of performance.
If a more significant fault occurs, engine RPM may be limited and engine/vehicle will continue to operate
with reduced performance.
If a major fault is detected by the EMS or VSS, engine RPM will be limited as well as vehicle speed.
These strategies are used to protect engine/electrical system from damage and to maintain safe opera-
tion of the vehicle.

rmr2013-042 1
Subsection XX (DIAGNOSTIC AND FAULT CODES (RS SERIES))

Pilot Lamps
When a problem is detected, a pilot lamp will turn on or blink in the multifunction gauge. Refer to the
following chart.
RS Model
INDICATOR LAMPS (MALFUNCTIONS)
INDICATOR LAMP(S) MAIN DIGITAL
CAUSE WHAT TO DO
Or Icons DISPLAY
Gearbox position
None Limited power steering assist.
sensor malfunction
E displayed instead of
selected gear Stop vehicle and allow to reach neutral.
Undetermined gear
N + R flashing quickly GBPS may need to be re initialized or has
position
failed.
Wrong or defective
None BAD KEY Use the right key for the vehicle.
key
Engine is Turns on when engine temperature
HI TEMP
overheating reaches 113°C (235°F).
On Engine RPM is limited to protect engine
HI TEMP Engine is
when engine temperature is above 115°C
LIMP HOME overheating
(239°F).
Low battery Turns on when battery voltage is lower
LO BATT VOLT
voltage than 11.5 V or higher than 16 V.
On
High battery Engine RPM is limited to protect
HI BATT VOLT engine/electrical system.
voltage
ABS malfunction. No ABS operation. Wheel lock may occur
ABS On ABS FAULT
No ABS operation when braking hard.
VSS FAULT Engine RPM is limited to maintain safe
VSS malfunction
LIMP HOME operation.
On
SEAT SWITCH Defective pillion
Check fuse
DEFECTIVE rider seat switch
No EBD operation. Rear wheel lock may
EBD FAULT VSS malfunction
occur when braking hard.
! On Low brake fluid – Check for brake fluid leaks.
BRAKE FAILURE level or faulty – Check brake fluid level and
sensor adjust

2 rmr2013-042
 Subsection XX (DIAGNOSTIC AND FAULT CODES (RS SERIES))

INDICATOR LAMPS (MALFUNCTIONS)

INDICATOR LAMP(S) MAIN DIGITAL
CAUSE WHAT TO DO
Or Icons DISPLAY
Engine
Engine RPM may be limited to protect
management
CHECK ENGINE engine depending on the fault.
component
A fault code is active.
malfunction
Dynamic
power steering Partial or no assist from DPS depending on
CHECK DPS
On component the fault.
malfunction
Transmission Engine RPM may be limited.
Control Module Shifting may be harsh.
CHECK TCM
component Transmission may not shift or may
malfunction have restrictions.
KEY ERR Anti theft Key not programmed for the vehicle.
Important engine
management
LIMP HOME Vehicle speed is limited.
component or VSS
Flashing malfunction
Brake applied while
LIMP HOME Vehicle speed is limited.
driving
– Check for oil leaks.
On None Low oil pressure
– Check oil level and adjust .

RS-S Model
INDICATOR LAMPS (MALFUNCTIONS)
INDICATOR LAMP(S) MAIN DIGITAL
CAUSE WHAT TO DO
OR ICONS DISPLAY
Gearbox position
None Limited power steering assist.
sensor malfunction
E displayed instead of
selected gear Stop vehicle and allow to reach neutral.
Undetermined gear
N + R flashing quickly GBPS may need to be re initialized or
position
has failed.
Wrong or defective
BAD KEY Use the right key for the vehicle
key
Turns on when battery voltage is less
None CAN (controller
than 11.5V or higher than 16V. Engine
COMMUNI- area network)
RPM is limited during low battery voltage
CATION FAULT communication
condition to protect engine/electrical
problem
system.
Engine RPM is limited to protect engine
HI TEMP Engine is
On when engine temperature is above
LIMP HOME overheating
115°C (239°F).
LO BATT VOLT Low battery voltage Turns on when battery voltage is lower
than 11.5 V or higher than 16 V.
On
HI BATT VOLT High battery voltage Engine RPM is limited to protect
engine/electrical system.
ABS malfunction. No ABS operation. Wheel lock may
ABS On ABS FAULT
No ABS operation occur when braking hard.

rmr2013-042 3
Subsection XX (DIAGNOSTIC AND FAULT CODES (RS SERIES))

INDICATOR LAMPS (MALFUNCTIONS)

INDICATOR LAMP(S) MAIN DIGITAL
CAUSE WHAT TO DO
OR ICONS DISPLAY
VSS FAULT Engine RPM is limited to maintain safe
VSS malfunction
LIMP HOME operation.
On
SEAT SWITCH Defective pillion
Check fuse
DEFECTIVE rider seat switch
No EBD operation. Rear wheel lock may
On EBD FAULT VSS malfunction
occur when braking hard.
! Low brake fluid level – Check for brake fluid leaks.
On BRAKE FAILURE
or faulty sensor – Check brake fluid level and adjust
Engine
Engine RPM may be limited to protect
management
CHECK ENGINE engine depending on the fault.
component
A fault code is active.
malfunction
Dynamic power
Partial or no assist from DPS depending on
On CHECK DPS steering component
the fault.
malfunction
Transmission Engine RPM may be limited.
Control Module Shifting may be harsh.
CHECK TCM
component Transmission may not shift or may
malfunction have restrictions.
Important engine
management
LIMP HOME Vehicle speed is limited.
component or VSS
Flashing malfunction
Brake applied while
LIMP HOME Vehicle speed is limited.
driving
– Check for oil leaks.
On None Low oil pressure – Check oil level and adjust

Engine RPM may be limited.

CHECK Shifting may be harsh.
On TCM fault
TRANSMISSION Transmission may not shift or may
have restrictions.
Partial or no assist from DPS depending
On CHECK DPS DPS fault
on the fault.

On KEY ERR Anti theft Key not programmed for the vehicle.

Limp Home Mode LIMP HOME will be displayed in the multifunction

When a major component of the EMS and/or gauge.
VSS (including their sub-systems) is not operating
properly the limp home mode will be set. FAULT CODES
Engine RPM will be limited and vehicle speed may A fault code is an indication that a glitch or mal-
be limited depending on the failure. function is detected by the monitoring system of
This mode allows the rider to safely return home. the vehicle.
This would not be possible without this advanced
system.

4 rmr2013-042
 Subsection XX (DIAGNOSTIC AND FAULT CODES (RS SERIES))

A fault code consists of an alphanumeric designa-

tor followed by a hexadecimal number of 3 digits.
The alphanumeric designator defines the category
of the fault code while the hexadecimal number
refers to a unique fault.
FAULT CODE
EXAMPLE
CATEGORY MODULE/
OF FAULT
(ALPHANUMERIC SYSTEM rmr2011-021-001_a
CODE
DESIGNATOR) TYPICAL
1. Drop down list
Power train,
From P0 to P3 P062F Choose the fault code state you want to display.
TCM and DPS
Vehicle stability Active Fault Codes
From C0 to C3 C0031
system (VSS)
An active fault code is an indication of a fault that
Communication is currently triggered.
between
From U0 to U3 U0073 The active fault may or may not compromise nor-
module and
sensors mal operation of the related system(s). Service
action in B.U.D.S. should be used to correct the
RELATED MODULE AND FAULTS problem that caused the fault code.
FAULT CODE
Once the fault condition(s) of the active fault is no
MODULE longer present, its state will change to "occurred".
CATEGORY
NOTE: An active fault code cannot be cleared.
ECM P
The problem relevant to the fault code must be
TCM (SE5 model) P and U repaired before clearing the fault.
VCM Mainly C and some U Occurred Fault Codes
DPS Mainly P and some U An occurred fault code indicates a fault that was
active, but no longer is.
When a minor fault occurs, turn OFF igni-
The occurred fault does not presently affect sys-
tion key, wait 30 seconds then turn it ON.
tem or component operation but is retained as a
This should change the fault state from active
history of the faults that were detected.
to occurred. The vehicle should then oper-
ate normally. If a fault persists, you may try The fault may have been generated due to a
disconnecting/reconnecting its related sensor. system or component that was momentarily op-
erating outside normal parameters. Repeated
When many fault codes which, may or not be
occurred faults of this type should be considered
related to a specific system are set at the same
when troubleshooting a problem, and may require
time, it is likely to be the result of a burnt fuse(s)
that maintenance action be taken.
or a faulty relay.
An occurred fault may also be generated when
Fault Code States disconnecting and reconnecting a component, re-
The various electronic control units (ECUs) used placing a burnt fuse, or may be due to a momen-
in the vehicle generate a variety of fault codes de- tary high or low voltage.
pending on the level of monitoring they are capa- Inactive Fault Codes
ble of. Fault codes have 3 possible states:
An inactive fault code represents a fault code that
– Active is neither active, nor occurred. It is simply part
– Occurred of a list of all possible faults which may be moni-
– Inactive. tored by the various ECUs, which may become ac-
Only fault codes in an active state may be viewed tive or occurred if the monitoring system detects
in the cluster. an applicable fault. These codes can be viewed in
B.U.D.S.
All types of fault codes may be viewed in B.U.D.S.
Click the Fault tab then click on the drop-down list
on the LH lower corner.

rmr2013-042 5
Subsection XX (DIAGNOSTIC AND FAULT CODES (RS SERIES))
How to Display Fault Codes on the
Multifunction Gauge
NOTE: A fault code must be active to be dis-
played in the multifunction gauge.
If a fault is detected, an indicator light and a fault
message may come on in the gauge.
Proceed as follows to display an active fault code:
Procedure if Engine can be Started
1. Turn ignition key to ON.
2. Wait for the multifunction gauge to complete its
self test function.
3. Simultaneously press the following three but-
tons on the LH multifunction switch assembly.
– MODE
– SET
– Turn signal button.
rmo2010-001-020_j
1. MODE button
2. SET button
3. Turn signal button
If there is no active fault code, nothing will be dis-
played.
FAULT CODE DIAGNOSTIC
Diagnostic Tips
ECUs share information and their systems may in-
teract with each other. Certain faults may cause
more than one ECU to set a fault code or indica-
tion (pilot lamp or message) as the failure of some
components may affect the operation of several
systems.
6 rmr2013-042
IMPORTANT NOTE
The primary electronic systems depend on
other secondary system(s) or sensor(s) for their
normal operation.
If a primary system generates a fault code,
usually the fault belongs to it. However, in
some cases, the primary system may not
be at fault. A malfunction in a secondary
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.
Missing Module
If a module is missing, several fault codes might
appear. To quickly find which module is missing,
check the following:
1. Connect vehicle to the latest applicable
B.U.D.S. software. Refer to COMMUNICA-
TION TOOLS AND B.U.D.S. subsection.
2. Click on the Read Data button.
3. Click Module in the menu bar.
4. Look at the list of modules. If a module is not
visible, then it is not communicating through
the CAN bus (controller area network).
rmr2011-019-001
TYPICAL - MODULE LIST SE5 MODEL
 Subsection XX (DIAGNOSTIC AND FAULT CODES (RS SERIES))

NOTE: The TCM listed is only available with the

SE5 model.
5. Refer to the following table to find the appropri-
ate subsection in this manual to diagnose the
missing module.
MISSING
SECTION TO REFER TO
MODULE
ECM ELECTRONIC FUEL INJECTION (EFI)
Cluster LIGHTS, GAUGE AND ACCESSORIES
VCM VEHICLE STABILITY SYSTEM (VSS)
rmr2011-021-002_a
STEERING (DPS) AND FRONT
DPS SOME COLUMNS REMOVED FOR CLARITY PURPOSE
WHEELS 1. Module that reports a fault
2. Fault description
TCM
(SE5 HYDRAULIC CONTROL MODULE Click on the More Details button, on the RH lower
model) corner, to display the "Possible Causes" and the
"Service Actions" to step further in the diagnosis.
How to Read Fault Codes Using
B.U.D.S.
1. Connect vehicle to the latest applicable
B.U.D.S. software. Refer to COMMUNICA-
TION TOOLS AND B.U.D.S. subsection.
2. Click on the Read Data button.
3. Click on the Faults tab.
4. Click on the drop-down list on the LH lower cor-
ner.

rmr2011-021-050_a

1. Click here

rmr2011-021-001_a

1. Drop down list

5. Choose to display the Active Faults.

When reading a fault code in B.U.D.S., pay partic-
ular attention to which module reports a fault. It
is indicated in the Module column.
The Description column gives a short description
of the fault.

rmr2013-042 7
Subsection XX (DIAGNOSTIC AND FAULT CODES (RS SERIES))
Interpreting the Fault Codes
A fault code number may indicate different faulty
components.
For example:
Fault code P0600, Communication problem de-
tected by ECM.
– The fault is reported by the ECM (module col-
umn).
– The ECM cannot communicate (description col-
umn).
– Since there is no other module involved, the
faulty module is likely to be the ECM (internal
problem).
Fault code P0600, Communication fault with
VCM, no response.
– For the same fault number, reported by the
same module (ECM), the faulty module is dif-
ferent. This time, the fault description points
to the VCM.
– Therefore the problem is in the connec-
tions/wiring harness between the ECM and
the VCM or the VCM itself (not the ECM).
How to Clear Fault Codes Using
B.U.D.S.
Before reading fault codes, ignition switch must
have been OFF 30 seconds before using B.U.D.S.
Connect vehicle to the latest applicable B.U.D.S.
Refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection.
Click on the Read Data button.
Click on the Faults tab.
NOTE: Only the"occured" state faults can be
cleared.
Click the "Clear Occurred Faults" button.
rmr2008-039-009
CLEAR OCCURED FAULTS
This will reset the appropriate counter(s) and will
also record that the problem has been fixed in the
related module memory.
Then, follow the prompts in B.U.D.S.:
– Turn ignition switch OFF.
– Wait 30 seconds.
8 rmr2013-042
– Turn ignition switch ON.
– Validate in B.U.D.S. that fault(s) were properly
cleared.
SPECIFIC FAULT CODES
The following gives information related to specific
fault codes.
P2545 and C0040 Simultaneous Faults
These faults, when occurring, are likely to be
caused by disconnected or burnt taillight bulbs.
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
Likely to be disconnected or faulty wheel speed
sensor(s).
VSS, ABS, EBD Simultaneous Faults
Likely to be a disconnected or faulty:
– VCM
– Rear wheel speed sensor(s).
PRS (Pillion Rider Sensor) Fault
When there is a fault, the VSS will work in safe
mode as if 2 passengers were seated. If only the
driver is seated, the VSS will be intervening more
frequently.
Cruise Control Faults
The cruise control system is closely interlinked
and dependent on the proper operation of many
other systems for its' operation which, may in-
volve several ECUs.
If the cruise system cannot be engaged or dis-
plays a fault, check for and correct other system
faults before assuming the cruise system is at
fault.
Simultaneous Faults:
- U0400 (DPS, TCM (SE models))
- C1281 (VSS after key OFF then ON)
- C006C (ECM after key OFF then ON)
These faults, when occurring, are likely to be
caused by a wrong "Platform" option in the Vehi-
cle Configuration within B.U.D.S. Refer to ECM
 Subsection XX (DIAGNOSTIC AND FAULT CODES (RS SERIES))

REPLACEMENT in ELECTRONIC FUEL INJEC-

TION (EFI) and set the option that reflects the
vehicle involved.

FAULT CODES
The fault code descriptions use the same
acronyms and connector identifications as per
wiring diagrams.
For the latest fault codes, use Knowledge Center
and enter the following search criterias:
– Enclose the search within quotes " "
– Enter: "Roadster DTC + Fault code + Module"
– Examples: "Roadster DTC P0036 ECM"
"Roadster DTC C1220 VCM"
"Roadster DTC U0073 VCM"
NOTE: The module may be omitted in the search
criterias (example: "Roadster DTC U0073".

rmr2013-042 9
 Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

DIAGNOSTIC AND FAULT CODES (ST

AND RT SERIES)
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. rmo2013-001-016_aen

NOTE: Some components require the engine to 1. Indicator lamp in multifunction gauge
2. Digital display
be running for them to be monitored for normal
operation (fuel injectors for example). The message displayed in the digital display ap-
The monitoring system continuously validates pears over a flashy background color.
that the electronic components (control modules,
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 rmr2011-079-005_a
be limited. The engine/vehicle will continue to op- 1. Message over a flashy background
erate with reduced performance.
If a major fault is detected by the EMS or VSS, en- After a moment, the message disappears and is
gine RPM will be limited as well as vehicle speed. replaced by an icon in the lower central portion of
the digital display.
These strategies are used to protect
engine/electrical system from damage and
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.

rmr2013-021 1
Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

rmr2011-079-006_a

1. Icon

TWN: ST table taken from rmo2013–003 indicator lamps (malfunctions)

ST Models

TWN: LOW fuel level row deleted

TWN: RH columns modified as per shop 2011 when cell is all in green. When there is red, as per 2013
operator’s guide

INDICATOR LAMPS (MALFUNCTIONS)

INDICATOR LAMP(S) MAIN DIGITAL
CAUSE WHAT TO DO
OR ICON DISPLAY
Gearbox
None position sensor Limited power steering assist.
E displayed instead malfunction
of selected gear
Undetermined Stop vehicle and allow to reach neutral. GBPS
N + R flashing quickly
gear position may need to be re initialized or has failed.
Wrong or
None BAD KEY Use the right key for the vehicle
defective key
– Stop and wait for engine to cool off.
Engine is – Check for leaks.
On HI TEMP
overheating – Check coolant level and adjust

HI TEMP Engine is Engine RPM is limited to protect engine when

On
LIMP HOME overheating engine temperature is above 115°C (239°F).
Low battery Turns on when battery voltage is lower
On LO BATT VOLT
voltage than 11.5 V or higher than 16 V.
High battery Engine RPM is limited to protect
On HI BATT VOLT engine/electrical system.
voltage
ABS malfunction. No ABS operation. Wheel lock may occur
ABS On ABS FAULT
No ABS operation when braking hard.

2 rmr2013-021
 Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

INDICATOR LAMPS (MALFUNCTIONS)

INDICATOR LAMP(S) MAIN DIGITAL
CAUSE WHAT TO DO
OR ICON DISPLAY
VSS FAULT Engine RPM is limited to maintain safe
On VSS malfunction
LIMP HOME operation.
SEAT SWITCH Defective pillion
On Check fuse
DEFECTIVE rider seat switch
No EBD operation. Rear wheel lock may occur
On EBD FAULT VSS malfunction
under hard braking.
! Low brake fluid
– Check for brake fluid leaks.
On BRAKE FAILURE level or faulty
sensor – Check brake fluid level and adjust.

Faulty parking – Make sure battery tension is at least at 10,5

PARKING BRAKE
On brake or V.
FAILURE
component – Check fuse no. 1 on the right fuse box

Engine
Engine RPM may be limited to protect
management
On CHECK ENGINE engine depending on the fault.
component
A fault code is active.
malfunction
Dynamic
power steering Partial or no assist from DPS depending on
On CHECK DPS
component the fault.
malfunction
Transmission Engine RPM may be limited.
Control Module Shifting may harsh.
On CHECK TCM
component Transmission may not shift or may
malfunction have restrictions.
Important engine
management
Flashing LIMP HOME Vehicle speed and/or engine RPM is limited.
component or
VSS malfunction
Brake applied
Flashing LIMP HOME Vehicle speed and/or engine RPM is limited.
while driving
– Check for oil leaks.
On None Low oil pressure
– Check oil level and adjust .
CHECK
On TCM fault
TRANSMISSION

rmr2013-021 3
Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

INDICATOR LAMPS (MALFUNCTIONS)

INDICATOR LAMP(S) MAIN DIGITAL
CAUSE WHAT TO DO
OR ICON DISPLAY
On CHECK DPS DPS fault

On KEY ERR Anti theft Key not programmed for the vehicle.

TWN: ST table taken from rmo2013–005 indicator lamps (malfunctions)

RT Models

TWN: Low fuel level row deleted

INDICATOR LAMPS (MALFUNCTIONS)

INDICATOR LAMP(S) MAIN DIGITAL
CAUSE WHAT TO DO
OR ICON DISPLAY
Gearbox position
None Limited power steering assist.
sensor malfunction
E displayed instead of
selected gear Stop vehicle and allow to reach neutral.
Undetermined gear
N + R flashing quickly GBPS may need to be re initialized or has
position
failed.
Wrong or defective
BAD KEY Use the right key for the vehicle.
key
Top or side storage Close and latch cover.
REAR STORAGE
compartment cover
COMPARTMENT OPEN
open
None
Turns on when battery voltage is lees
CAN (controller
than 11. 5 V or higher than 16 V.
COMMUNI- area network)
Engine RPM is limited to 3700 during
CATION FAULT communication
low battery voltage condition to protect
problem
engine/electrical system
Engine RPM is limited to protect engine
HI TEMP Engine is
On when engine temperature is above 115°C
LIMP HOME overheating
(239°F).
LO BATT VOLT Low battery voltage Turns on when battery voltage is lower
than 11.5 V or higher than 16 V.
On
HI BATT VOLT High battery voltage Engine RPM is limited to protect
engine/electrical system.
ABS malfunction. No ABS operation. Wheel lock may occur
ABS On ABS FAULT
No ABS operation when braking hard.
VSS FAULT Engine RPM is limited to maintain safe
VSS malfunction
LIMP HOME operation.
On
SEAT SWITCH Defective pillion
Check fuse .
DEFECTIVE rider seat switch

4 rmr2013-021
 Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

INDICATOR LAMPS (MALFUNCTIONS)

INDICATOR LAMP(S) MAIN DIGITAL
CAUSE WHAT TO DO
OR ICON DISPLAY
No EBD operation. Rear wheel lock may
On EBD FAULT VSS malfunction
occur under hard braking.
! Low brake fluid level – Check for brake fluid leaks.
On BRAKE FAILURE
or faulty sensor – Check brake fluid level and adjust
– Make sure battery tension
PARKING BRAKE Faulty parking brake
On is at least at 10,5 V.
FAILURE or component
– Check fuse no.1 on the left fuse box
Engine management Engine RPM may be limited to protect
CHECK ENGINE component engine depending on the fault.
malfunction A fault code is active.
Dynamic power
Partial or no assist from DPS depending
CHECK DPS steering component
On on the fault.
malfunction
Engine RPM may be limited.
Transmission Control
Shifting may harsh.
CHECK TCM Module component
Transmission may not shift or
malfunction
may have restrictions.
Important engine
management Vehicle speed and/or engine RPM is
LIMP HOME
component or VSS limited.
Flashing malfunction
Brake applied while Vehicle speed and/or engine RPM is
LIMP HOME
driving limited.

– Check for oil leaks.

On None Low oil pressure
– Check oil level and adjust

CHECK
On TCM fault
TRANSMISSION

On CHECK DPS DPS fault

On MANUAL ACS fault

On KEY ERR Anti theft Key not programmed for the vehicle.

* BRP recommends having the vehicle transported when in LIMP HOME. If you operate the vehicle in LIMP
HOME, avoid abrupt maneuvers and immediately go to the nearest authorized Can-Am roadster dealer to have
your vehicle serviced before riding again. In LIMP HOME, the engine RPM is limited and therefore the vehicle
speed.

Limp Home Mode
When a major component of the EMS and/or
VSS (including their sub-systems) is not operating
properly, fault code(s) will be triggered and limp
home mode will be set.
Engine RPM will be limited and vehicle speed may
be limited depending on the failure.
This mode allows the rider to safely return home.
This would not be possible without this advanced
system.
LIMP HOME will be displayed in the multifunction
gauge.

rmr2013-021 5
Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

FAULT CODES
Fault Code Categories
A fault code consists of an alphanumeric designa-
tor followed by a hexadecimal number of 3 digits.
The alphanumeric designator defines the category
of the fault code while the hexadecimal number
refers to a unique fault. rmr2011-021-001_a

TYPICAL
FAULT CODE CATEGORIES 1. Drop down list
EXAMPLE Active Fault Codes
ALPHANUMERIC MODULE/
OF FAULT
DESIGNATOR SYSTEM An active fault code is an indication of a fault that
CODE
is currently triggered.
Power train, TCM
From P0 to P3 P062F The active fault may or may not compromise nor-
and DPS
mal operation of the related system(s). Service
Vehicle stability action in B.U.D.S. should be used to correct the
From C0 to C3 C0031
system (VSS)
problem that caused the fault code.
Communication Once the fault condition(s) of the active fault is no
From U0 to U3 between module U0073
longer present, its state will change to "occurred".
and sensors
Body Occurred Fault Codes
From B0 to B3 (including luggage B1000 An occurred fault code indicates a fault that was
compartments) active, but no longer is.
The occurred fault does not presently affect sys-
RELATED MODULE AND FAULTS
tem or component operation but is retained as a
FAULT CODE history of the faults that were detected.
MODULE
CATEGORY
Inactive Fault Codes
ECM Mainly P and some U
An inactive fault code represents a fault code that
TCM (SE5 model) Mainly P and some U is neither active, nor occurred. It is simply part of a
VCM Mainly C and some U list of all possible faults which may be monitored
by the various ECUs, which may become active
DPS Mainly P, some C and U or occurred if the monitoring system detects an
Cluster P, B, C and U applicable fault.
WPM TWN: fin de la copie
(Windshield and Park P, U and C
Brake Module)
How to Display Fault Codes Using the
Multifunction Gauge
TWN: Following L5 was below, déplacer ici
NOTE: A fault code must have the "Active" state
to be displayed in the multifunction gauge. Other
Fault Code States fault code states must be read using B.U.D.S.
The various electronic control units (ECUs) used in
If a fault is detected, an indicator light and a fault
the vehicle can generate a variety of fault codes
message may come on in the gauge.
depending on the level of monitoring they are ca-
pable of. Fault codes have 3 possible states: Proceed as follows to view the fault codes:
– Active 1. Turn ignition key to ON.
– Occurred 2. Wait for the multifunction gauge to complete its
– Inactive. self test function.
Click the Fault tab then click on the drop-down list 3. Simultaneously press the following three but-
on the LH lower corner. tons on the LH multifunction switch assembly.
Choose the fault code state you want to display. – MODE

6 rmr2013-021
 Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

– SET
– Turn signal button.

rmr2011-021-001_a

1. Drop down list

FAULT
INFORMATION
STATE
Display all possible faults regardless
All faults
of state
Active Display only faults matching this state
rmo2010-001-020_j
faults Empty area if there is no active fault
1. MODE button Active and Display only faults that have either state
2. SET button
3. Turn signal button occurred Empty area if there is neither active
faults nor occurred fault
If there is no active fault code, nothing will be dis-
played.

How to Read Fault Codes Using

B.U.D.S.
NOTE: All fault code types can be read with
B.U.D.S.
1. Connect vehicle to the latest applicable
B.U.D.S. software. Refer to COMMUNICA-
TION TOOLS AND B.U.D.S. subsection.
2. Click on the Read Data button.
3. Click on the Faults tab.
rmr2011-070-001_a

FAULT PAGE
1. Fault tab
2. Fault indicator light
3. Fault code state drop box
4. Fault nomenclature
5. More details button
6. Clear occurred faults button
7. Selected fault

FAULT PAGE DESCRIPTION

ITEM INFORMATION
Fault tab Click tab to display the fault page
Fault When flashing, it indicates there is
indicator light active fault(s)
Fault code
Click drop box to select the type of
rmr2011-070-011_a state drop
1. Fault tab faults to display
box
4. Click on the drop-down list on the LH lower cor- Display specific information and
Fault
ner. statistics related to the fault (see
nomenclature
fault nomenclature table)
5. Choose the fault state to display.

rmr2013-021 7
Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

FAULT PAGE DESCRIPTION FAULT NOMENCLATURE

ITEM INFORMATION COLUMN INFORMATION
To display possible causes and Fault code number.
More details
service actions related to the When 2 stars (**) precedes the
button
selected fault Code code, detailed conditions when the
fault occurred, can be displayed by
Clear clicking the "More details" button
To clear all occurred faults in related
occurred
ECU(s)
faults button Display the fault state (active, occurred,
State
inactive)
When a fault is selected, additional
information pertaining to that Displays the module that reports the
fault will be displayed when fault code. This is the module that
Selected
clicking the "More details" button detects or has received a message
fault
To select a fault, click on the fault of an anomaly and reports it.
with the mouse or use the cursor up List of modules:
or down to scroll to the desired fault LCD (liquid crystal display) or
Module Cluster (multifunction gauge)
DPS (dynamic power steering)
ECM (engine control module)
TCM (transmission control module)
VCM (vehicle control module)
WPM (windshield and parking brake
module)
Number of times this fault
Count occurred within the driving cycle
Value: From 0 to 255
Not to be used
Cycle time
Value: From 0 to 255 minutes
Not to be used
Total time
Value: From 0 to 64 255 minutes
Description Provides a short description of the fault

When reading a fault code in B.U.D.S., pay partic-

ular attention to which module reports a fault. It
is indicated in the Module column.
The Description column gives a short description
of the fault.

rmr2011-021-002_a

SOME COLUMNS REMOVED FOR CLARITY PURPOSE

1. Module that reports a fault
2. Fault description

8 rmr2013-021
 Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

Click on the More Details button, on the RH lower NOTE: Only the Occurred state faults can be
corner, to display the "Possible Causes" and the cleared.
"Service Actions" to step further in the diagnosis. Click the "Clear Occurred Faults" button.

rmr2008-039-009

CLEAR OCCURED FAULTS

This will reset the appropriate counter(s) and will

also record that the problem has been fixed in the
related module memory.
rmr2011-021-050_a Observe the "Occurred" fault(s). They should all
1. Click here disappear. Otherwise, follow this procedure.
– Turn ignition switch OFF.
– Wait 30 seconds.
– Repeat procedure to clear faults again.

FAULT CODE DIAGNOSTIC

Missing Module
If a module is missing, several fault codes will ap-
pear.
To quickly find which module is missing, perform
rmr2011-070-002_a the following:
MORE DETAILS PAGE 1. Connect vehicle to the latest applicable
1. Possible causes related to the selected fault
2. Service actions B.U.D.S. software. Refer to COMMUNICA-
3. Operating conditions when fault occurred TION TOOLS AND B.U.D.S. subsection.
MORE DETAILS PAGE DESCRIPTION 2. Click on the Read Data button.
ITEM INFORMATION 3. Click Module in the menu bar.
Possible List the possible causes that 4. Look at the list of modules.
causes triggered the fault 5. If a module is not visible, then it is not commu-
Service List the possible actions to perform nicating through the CAN bus (controller area
actions to solve the fault network).
Conditions List the operating conditions of the
when fault engine and/or vehicle when the fault
occurred was triggered

TWN: following topic “fault code states” dé-

placer plus haut

How to Clear Fault Codes Using

B.U.D.S.
Connect vehicle to the latest applicable B.U.D.S.
software. Refer to COMMUNICATION TOOLS
AND B.U.D.S. subsection.
Click on the Read Data button. rmr2011-070-010

Click on the Faults tab. TYPICAL - MODULE SUBMENU LIST SE5 MODEL

rmr2013-021 9
Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

NOTE: The TCM listed is only available with the – Wait 30 seconds.
SE5 model. – Turn ignition key ON.
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 module.
The vehicle should then operate normally.
MISSING If a sensor-related fault persists, you may try
SECTION TO REFER TO
MODULE disconnecting/reconnecting the sensor.
ECM ELECTRONIC FUEL INJECTION (EFI) Read the following for a general approach to trou-
LCD and bleshoot fault codes (active or occurred).
LIGHTS, GAUGE AND ACCESSORIES
Cluster
VCM VEHICLE STABILITY SYSTEM (VSS)
STEERING (DPS) AND FRONT
DPS
WHEELS
TCM
(SE5 HYDRAULIC CONTROL MODULE
model)
WPM BODY

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.

rmr2011-070-003_a

1. History tab
2. Additional history pages

HISTORY PAGE DESCRIPTION

ITEM INFORMATION
Display the minimum and maximum
Minimum/
values encountered. Click "Clear
Maximum
Min/Max" to reset the values
Display the time proportion in what
Run time
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.

10 rmr2013-021
 Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))
GUIDELINES TO SOLVE FAULT CODES
CONDITION
Troubleshooting vehicle
New fault(s) appear after a vehicle
maintenance or repair
Communication faults displayed as
"Occurred" after module flashing
Sensor "Active" fault
Low system voltage
on one module
Power problem on sensor(s)
Low system voltage
on several modules
(several communication faults
will also appear)
High system voltage on several
modules
When all modules report that a
module is missing
When several modules are in fault
CAN bus failure, CAN buss OFF
rmr2013-021
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 system(s), sensor(s), switches and actual conditions.
Activate component(s) 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).
After vehicle maintenance:
Read the electronic modules with B.U.D.S.
Compare the fault code(s) 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.
Normal behavior when flashing a module
Clear all occurred faults and check again
Read the fault description in B.U.D.S.
Click on the "More Details" button.
Look at the "Conditions" when available.
Read the "Possible Causes".
Apply the "Service Actions".
Check related fuse(s) and relay.
Check related power and ground wires.
Check for common power supply to several sensors/modules
(refer to POWER DISTRIBUTION AND GROUNDS).
NOTE: Some sensors are supplied by the battery while others are
supplied by a module.
Check battery condition and connections.
Check related fuse(s) and relay.
Check voltage regulator/rectifier.
A battery charger has likely been used to substitute the vehicle battery.
Clear all occurred faults and check again.
Check voltage regulator/rectifier.
Check the module that is reported as missing.
Check related fuse(s) and relay.
Check related power and ground wires.
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
ground, short between CAN low and high).
Check module pins and wiring terminals.
Then, the other modules should stop reporting that module is missing.
11
Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

GUIDELINES TO SOLVE FAULT CODES

CONDITION ACTION
May have been generated due to a system or component that was
momentarily operating outside normal parameters.
May 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
Fault count (connections, terminal contact/shape etc.).
(0 - 255) High value: Suggests a frequent and unsolved problem.
The problem should be investigated.
Fault conditions
Look for abnormal, excessive values.
(More details button)
When the basic troubleshooting has been done and the fault
code(s) 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.

12 rmr2013-021
 Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

ECUs share information and their systems may in-
teract with each other. Certain faults may cause
more than one ECU to set a fault code or indica-
tion (pilot lamp or message) as the failure of some
components may affect the operation of several
systems.
IMPORTANT NOTE
The primary electronic systems depend on
other secondary system(s) or sensor(s) for their
normal operation.
If a primary system generates a fault code,
usually the fault belongs to it. However, in
some cases, the primary system may not
be at fault. A malfunction in a secondary
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.
PRS (Pillion Rider Sensor) Fault
When there is a PRS fault, the VSS will operate
in safe mode as if both a driver and a passenger
were seated. If only the driver is seated, the VSS
will be more active.
Cruise Control Faults
The cruise control system is closely interlinked
and dependent on the proper operation of many
other systems for its' operation which, may in-
volve several ECUs.
If the cruise system cannot be engaged or dis-
plays a fault, check for and correct other system
faults before assuming the cruise system is at
fault.
Simultaneous Faults:
- U0400 (DPS, TCM (SE models))
- C1281 (VSS after key OFF then ON)
- C006C (ECM after key OFF then ON)
These faults, when occurring, are likely to be
caused by a wrong "Platform" option in the Vehi-
cle Configuration within B.U.D.S. Refer to ECM
REPLACEMENT in ELECTRONIC FUEL INJEC-
TION (EFI) and set the option that reflects the
vehicle involved.

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 sensor(s).

VSS, ABS, EBD Simultaneous Faults

The problem is likely to be a disconnected or
faulty:
– VCM
– Rear wheel speed sensor(s).

rmr2013-021 13
Subsection XX (DIAGNOSTIC AND FAULT CODES (ST AND RT SERIES))

FAULT CODES
The fault code descriptions use the same acronyms and connector identifications as per wiring diagrams.
For the latest fault codes, use Knowledge Center and enter the following search criterias:
– Enclose the search within quotes " "
– Enter: "Roadster DTC + Fault code + Module"
– Examples: "Roadster DTC P0036 ECM"
"Roadster DTC C1220 VCM"
"Roadster DTC U0073 VCM"
NOTE: The module may be omitted in the search criterias (example: "Roadster DTC U0073".

TWN: Traduction: Même structure en fançais

14 rmr2013-021
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

ELECTRONIC FUEL INJECTION (EFI)

SERVICE TOOLS
Description Part Number Page
ECM ADAPTER TOOL................................................................... 529 036 166 .............. 9–10, 16, 19, 23, 26,
29, 32, 35, 37, 39–41
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............... 9–10, 16, 20, 23, 28

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................... 20–21, 35
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ........................................... 33

GENERAL NOTICE Never use a hose pincher on injec-

WARNING
Fuel is flammable and explosive under cer-
tain conditions. Ensure work area is well ven-
tilated. Do not smoke or allow open flames or
sparks in the vicinity.
WARNING
Always disconnect battery prior to working
on the fuel system. Always disconnect bat-
tery exactly in the specified order, BLACK (-)
cable first. It is recommended to disconnect
electrical connections prior to disconnecting
fuel lines.
WARNING
Fuel lines remain under pressure at all times.
Always proceed with care and use appro-
priate safety equipment when working on a
pressurized fuel system. Wear safety glasses.
Proceed with care when removing/installing
pressure test equipment or disconnecting
fuel line connections.
To release fuel pressure prior to removing a hose,
disconnect the fuel pump electrical connector and
crank the engine.
Cover the fuel line connection with an absorbent
shop rag before disconnecting it. Slowly discon-
nect the fuel hose to minimize spillage.
tion system high pressure hoses. Replace any
damaged or deteriorated fuel line.
When the repair or test is completed, ensure that
all hoses are connected and secured. Perform the
FUEL SYSTEM PRESSURE TEST and the FUEL
SYSTEM LEAK TEST as explained in FUEL TANK
AND FUEL PUMP subsection.
WARNING
Always perform the fuel pressure test if any
fuel line has been disconnected from a com-
ponent, or the fuel component has been re-
moved. A pressure test must be carried out
before turning the ignition key to ON. The fuel
pump is activated each time the ignition key
is turned ON.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan-
dards.
SYSTEM DESCRIPTION
ECM

WARNING
smr2009-027-005
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.

rmr2013-022 1
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
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
such as temperature sensors are used as sec-
ondary inputs.
The AAPTS (Ambient Air Pressure and Temper-
ature Sensor) functions in conjunction with the
MAPS. The AAPTS reading is compared with the
MAPS reading. The ECM uses the comparative
results to improve engine operation in high alti-
tude areas.
The injection system is a closed loop type. This
is achieved by the addition of two heated oxygen
sensors (HO2S1 and HO2S2).
rmr2013-022-153_a
HEATED OXYGEN SENSORS
Closed loop system operation (also called a feed-
back system) regulates the air/fuel ratio based on
predetermined values stored within the ECM. The
stored values are used in relation to the informa-
tion received from the input sensors and the resid-
ual amount of oxygen in the exhaust-gas, which
is measured by the oxygen sensors (Lambda sen-
sors).
2 rmr2013-022
The engine will begin to operate in open loop
when first started, and switch to closed loop
operation when the oxygen sensors reach their
operating temperature. At high engine loads, the
engine reverts again to the open loop.
Throttle Body
A 51 mm (2 in) twin draft throttle body is mounted
directly on the intake flange of each cylinder. The
TPS and the MAPS are fitted on the throttle body.
rmr2010-022-002_a
1. Twin draft throttle body
2. TPS
3. Fuel pressure regulator
4. MAPS
5. Electric throttle actuator (ETA)
An electric throttle actuator (ETA) is used to con-
trol air delivery by opening or closing the throttle
plates. It allows the ECM to electrically control the
position of the throttle plates throughout the full
range of engine operation.
The TPS provides the ECM with a signal of the
actual angle position of the throttle plates. When
the ETA changes the position of the throttle
plates, the ECM uses the TPS signal to monitor
the throttle plate position, and modulate the ETA
through pulse width modulation to move the
throttle plates until the targeted position of the
throttle plates is achieved.
The use of an ETA controlled by the ECM also al-
lows for an electronic cruise control function.
If there is a system malfunction and the ETA is
not powered by the ECM, return springs move
the throttle plate back to the LIMP HOME posi-
tion against a mechanical stop, not the idle posi-
tion. The throttle plates are electrically driven to
the idle position by the ETA when commanded by
the ECM.
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
ETA Closed Throttle Feature
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 motor (R5).
Throttle Accelerator Sensor (TAS)
TAS Description
This vehicle is designed with an electronic throt-
tle accelerator sensor (TAS) that is used to deter-
mine the driver requested torque. There are no
mechanical cables between the throttle grip and
the throttle body. This is often referred to as a
"throttle by wire" system.
The TAS sensor is composed of two magnets and
a double output hall effect sensor that are incorpo-
rated within the throttle grip assembly.
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.
TAS Operation
The ECM provides a supply voltage and a ground
to each hall effect sensor. The hall effect sensors
in the TAS each produce a command signal volt-
age that is proportional to the throttle position.
Turning the throttle grip varies the two command
signal voltages produced by the TAS accordingly.
The ECM will then power the ETA to open or close
the throttle plates in the throttle body according to
the torque commanded by the operator, or other
inputs such as cruise control or transmission con-
trol module (SE5 model).
If the brake pedal is depressed and the throttle is
not released, engine torque remains the same if
both TAS sensors are operating normally. If only
one TAS sensor is operating normally when brak-
ing is applied, and the throttle is not released, en-
gine torque will be reduced to idle. Normal engine
control will resume when braking action is ceased.
rmr2013-022
Fuel Injector
Two fuel injectors mounted on the throttle body
(one per cylinder) are used to inject fuel into the
intake port of the cylinder head.
rmr2010-022-003_a
1. Fuel injector
2. Fuel rail
3. Banjo fitting for fuel pressure hose
The fuel pump pressure hose is connected to the
fuel rail on the RH side of the throttle body. The
LH and RH fuel rails interconnect through a port in
the throttle body to provide fuel pressure to both
injectors. The fuel pressure regulator mounted on
the LH fuel rail bypasses excess fuel flow to the
fuel pump
ADJUSTMENT
IDLE SPEED
Idle speed is not adjustable. It is controlled by
the engine management system through modula-
tion of the throttle plates and the ignition timing.
THROTTLE POSITION SENSOR
RESET
General Information
This operation performs a reset of the values
stored in the ECM for the TPS when it is at the
closed position and at the limp home position.
The TPS position is used to determine the basic
parameters for all fuel mapping and several ECM
calculations.
A reset must be carried out each time any of the
following situations has occurred:
– Throttle position sensor (TPS) has been loos-
ened, removed, or replaced.
– Throttle body has been replaced.
– ECM has been replaced.
3
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

NOTE: The TPS is not adjustable. The ECM must

learn the TPS values when carrying out the Throt-
tle position sensor initialization reset procedure
in B.U.D.S. An improperly set TPS may lead to
poor engine performance. Emission compliance
could possibly be affected.
TPS initialization
1. Connect vehicle to the latest applicable
B.U.D.S. version.
2. Turn the ignition key to ON. Do not start the
engine.
3. In B.U.D.S., click on the Read Data button.
4. Follow the steps shown in the following illustra-
tions.
rmr2013-022-300_f

THROTTLE POSITION SENSOR INITIALIZATION

Step 1: Click on Reset button.

rmr2013-022-300_c

Step 1: Click on Setting tab

Step 2: Select the ECM tab
Step 3: Ensure the TPS Learned LED is OFF
rmr2013-022-300_e

THROTTLE POSITION SENSOR INITIALIZATION

Step 1: Ensure the TPS Learned LED is ON

5. Start engine and make sure it operates nor-

mally throughout its full engine RPM range. If
fault codes appear, refer to DIAGNOSTIC AND
FAULT CODES subsection for more informa-
tion.

TROUBLESHOOTING
DIAGNOSTIC TIPS
The first step in troubleshooting the EFI system
is to check for fault codes using B.U.D.S.; refer
to DIAGNOSTIC AND FAULT CODES subsection.
However, engine problems are not necessarily re-
lated to the electronic fuel injection system.

4 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
It is important to ensure that the engine, fuel de-
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.
Fuel Delivery System Related
Problems
The following items may affect the fuel injection
system:
– Faulty fuel pump
– Faulty fuel pressure regulator
– Dirty or clogged fuel filter
– Faulty purge valve
– Leaking, kinked, or obstructed fuel line.
Electrical Related Problems
It is important to check that the following items in
the electrical system are functioning properly:
– Battery
– Fuses
– Relay(s)
– Ignition (misfiring spark plug)
– Ground connections
– Wiring connectors.
Pay particular attention to ensure that pins are not
out of their connectors or out of shape.
When probing terminals, pay attention to the
condition of terminal pins and sockets. Be sure
not to bend the terminal pins. Multimeter probes
should never be inserted in terminal sockets as
this could deform the socket and create a loose
connection that would be difficult to troubleshoot.
Always use special tools (such as an ECM adapter
tool) when carrying out electrical tests. Refer to
WIRING HARNESS AND CONNECTORS subsec-
tion for more details on electrical connectors.
Never use a battery charger to temporarily substi-
tute the battery, as it may cause the ECM (engine
control module) to function erratically, or not at all.
rmr2013-022
WARNING
Some EMS components are continuously
powered when the ignition key is turned on.
The ECM switches the circuit to the ground
to complete the electrical circuits it controls.
Take this into account when troubleshoot-
ing. Always disconnect the battery prior to
disconnecting any electric or electronic com-
ponent.
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-
NOSTIC AND FAULT CODES subsection.
After a problem has been solved, always clear the
fault(s) in the ECM (and other ECUs as applicable)
using the B.U.D.S. software.
Check related circuit fuse solidity and condition
with an ohmmeter. A visual inspection may lead
to a false conclusion.
Temperature Sensors
When measuring the resistance with an ohmme-
ter, all values are given for a temperature of 20°C
(68°F). The resistance value of a resistance varies
with the temperature. The resistance value for
commonly used resistors or windings (such as in-
jectors) increases as the temperature increases.
However, temperature sensors normally used in
this vehicle are NTC types (Negative Temperature
Coefficient), which means that the resistance
value decreases as their temperature increases.
This must be taken into account when measuring
them at temperatures other than 20°C (68°F).
The resistance value of a temperature sensor may
test good at a certain temperature but may not be
within acceptable limits at other temperatures. If
in doubt, try a new sensor.
Also remember that this validates the operation
of the sensor at room temperature. It does not
validate the functionality of the sensor at higher
(or normal) operating temperatures. To test it, the
sensor could be removed from the engine and
heated with a heat gun while it is still connected
to the harness to see if the ECM will detect the
high temperature condition and generate a fault
code.
5
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

Fuel Injection Related Problems 6. Unscrew banjo fitting (RH side).

Also check for the following items:
– Leaking/faulty injector(s)
– Kinked or leaking vacuum tubes
– Dirty or obstructed air orifices
– MAPS sensor vacuum tubes and nipples for
cracks, bending, obstruction, leakage or dam-
age. Ensure that the tube lengths are correct.
Refer to MAPS SENSOR in this subsection.
– Throttle body, nipples, air passages, gaskets
and O-rings for leakage or obstructions
– Intake flanges for leakage.

PROCEDURES
FUEL RAIL
rmr2008-021-062_b
Fuel Rail Replacement TYPICAL
Fuel Rail Access
7. Remove fuel pressure regulator retaining
– Remove air filter housing. Refer to AIR INTAKE screws (LH side).
SYSTEM subsection.
– Remove fuel tank protectors. Refer to FUEL 8. Remove MAPS sensor retaining screw (LH
TANK AND FUEL PUMP subsection. side).

Fuel Rail Removal

1. Disable fuel pump by removing the electrical
connector from the fuel pump.
2. Crank engine to relieve the fuel pressure in the
fuel system.
3. Remove main relay 1 motor (R5) in LH fuse
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
4. Remove the air filter housing. Refer to AIR IN-
TAKE SYSTEM subsection.
5. Disconnect the injector connectors.
rmr2010-022-014_a

1. Pressure regulator retaining screw

2. MAPS sensor retaining screw

9. Move MAPS sensor and fuel pressure regulator

away (LH injector only).
10. Unscrew fuel rail retaining screws.

rmr2011-071-002_a

TYPICAL - RH INJECTOR CONNECTOR

6 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

rmr2010-022-018_a

TYPICAL - RETAINING SCREW LOCATIONS RH FUEL RAIL

rmr2008-021-064_b

TYPICAL

5. Install fuel rail while carefully inserting injector

in throttle body.

rmr2008-021-067_b

TYPICAL - RETAINING SCREW LOCATIONS LH FUEL RAIL

11. Pull out fuel rail and injector from throttle body.
Fuel Rail Installation
Installation is the reverse of the removal proce- rmr2008-021-068_a

dure however, pay attention to the following. 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.

rmr2013-022 7
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

2. Using the latest applicable B.U.D.S. version, en-

ergize the fuel injector(s).
2.1 In B.U.D.S., click on the Read Data button.
2.2 Click on the Activation tab.
2.3 Select the ECM tab.
2.4 Click on the fuel injector to be tested to
activate it.

rmr2008-021-069_a

TYPICAL

7. Install fuel rail retaining screws.

NOTE: Tighten screws a little at a time each side
until specified torque is obtained.
M6 SCREW TORQUE (ALL)
9 N•m (80 lbf•in)
rmr2010-022-012_a
8. Install banjo fitting and tighten as specified. TYPICAL - FUEL INJECTOR ACTIVATION
BANJO FITTING TORQUE
You should hear the injector working.
22 N•m (16 lbf•ft) This will validate the injector mechanical and elec-
trical operation.
9. Reconnect fuel pump connector.
If the injector does not function, carry out an IN-
WARNING JECTOR RESISTANCE TEST.
Perform a FUEL SYSTEM PRESSURE TEST Injector Resistance Test
and ensure that there is no fuel system leak.
Refer to FUEL TANK AND FUEL PUMP sub-
(at ECM and Fuse Box)
section. 1. Turn ignition key OFF.
2. Remove main relay 1 motor (R5) in LH fuse
FUEL INJECTOR box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
Fuel Injector Connector Access
3. Disconnect ECM-A connector from the ECM;
– Remove air filter housing. Refer to AIR INTAKE refer to ECM CONNECTOR ACCESS in EN-
SYSTEM subsection. GINE CONTROL MODULE (ECM) in this sub-
– For the RH injector connector, remove fuel tank section.
protectors. Refer to FUEL TANK AND FUEL
PUMP subsection. 4. Check injector resistance using the following
tools.
Fuel Injector Leak Test
The fuel injector leak test is carried out when per-
forming the fuel system pressure test. Refer to
FUEL TANK AND FUEL PUMP subsection.
Fuel Injector Functional Test Using
B.U.D.S.
1. Turn ignition key ON.

8 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

FLUKE 115 If reading is not as specified, replace injector.

ECM ADAPTER TOOL
MULTIMETER If reading is as specified, carry out a:
(P/N 529 036 166)
(P/N 529 035 868)
– CONTINUITY TEST OF INJECTOR POWER
CIRCUIT
– CONTINUITY TEST OF INJECTOR CONTROL
CIRCUIT in this subsection.
Injector Input Voltage Test
1. Turn ignition key OFF.
FUSE 2. Ensure main relay 1 motor (R5) in installed in LH
ECM RESISTANCE
INJECTOR BOX fuse box.
ADAPTER @ 20°C (68°F)
CONTACT
3. Disconnect the electrical connector from the in-
FRONT J1 jector(s).
B3 11.4 - 12.6
REAR K1

If resistance value is as specified, the injector and

its circuits from the fuse contact are good. Refer
to INJECTOR INPUT VOLTAGE TEST in this sub-
section.
If resistance value is NOT as specified, refer to
INJECTOR RESISTANCE TEST (AT INJECTOR) in
this subsection.

Injector Resistance Test

(at Injector)
1. Disconnect injector electrical connector.
2. Check resistance value between injector pins
as follows. rmr2010-022-019_a

TYPICAL - REAR INJECTOR (LH SIDE)

RESISTANCE @
INJECTOR INJECTOR PIN
20°C (68°F)
FRONT
1 2 11.4 - 12.6
REAR

rmr2011-071-002_a

TYPICAL - FRONT INJECTOR (RH SIDE)

4. Turn ignition key to ON.

5. Using a FLUKE 115 MULTIMETER (P/N 529 035
868) set to Vdc, measure the injector input volt-
age as per following table.
rmr2008-021-062_a

TYPICAL

rmr2013-022 9
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

529035868 529035868

INJECTOR CONNECTOR INJECTOR CIRCUIT

CYLINDER WIRE MEASUREMENT CYLINDER MEASUREMENT
INJECTOR LH FUSE
VT/ WIRE BOX PIN
FRONT
BU Battery FRONT VT/BU
Battery voltage Close to 0
VT/ ground B3
REAR REAR VT/GN (continuity)
GN

rmr2013-024-001_a

LH FUSE BOX PIN-OUT

rmr2008-021-061_a
If the injector input voltage is good, the injector
problem may be mechanical.
If the injector input voltage is not good, check fuse
F6 in the LH fuse box. If the fuse is good, the
problem may be in the power distribution system
before the fuse, or in the ECM (does not provide
a ground signal).
Continuity Test of Injector Power
Circuit
1. Refer to POWER DISTRIBUTION AND
GROUNDS subsection and remove from the
LH fuse box:
– Main relay 1 motor (R5)
– Fuse F6
2. Using a FLUKE 115 MULTIMETER (P/N 529 035
868) set to " ", test for continuity of the injec-
tor power circuit as per following table.
If continuity is good, carry out the CONTINUITY
TEST OF INJECTOR CONTROL CIRCUIT in this
subsection.
If continuity is faulty, repair wiring or connector be-
tween fuse box and injector.
Continuity Test of Injector Control
Circuit
1. Remove main relay 1 motor (R5) in LH fuse
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
2. Disconnect connector “A” from the ECM. Re-
fer to ECM CONNECTOR ACCESS in ENGINE
CONTROL MODULE (ECM) in this subsection.
3. Install connector on the ECM ADAPTER TOOL
(P/N 529 036 166)

10 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

Injector Installation
For the installation, refer to FUEL RAIL in this sub-
section.
WARNING
Perform a FUEL SYSTEM PRESSURE TEST
and ensure there are no fuel system leaks.
Refer to FUEL TANK AND FUEL PUMP sub-
section.
529036166

ECM ADAPTER THROTTLE BODY

4. Test the injector ground circuit continuity be- Throttle Body Description
tween the injector and ECM adapter as per fol- A 51mm twin draft throttle body with an electronic
lowing table. throttle actuator (ETS) is used.
INJECTOR ECM “A”
CYLINDER CONNECTOR CONNECTOR MEASUREMENT
WIRE PIN
FRONT BN/RD J-1 Close to 0
REAR BN/BU K-1 (continuity)

If control circuit is faulty, repair wiring or connec-

tor.

Injector Replacement
Injector Removal
1. Remove main relay 1 motor (R5) in LH fuse rmr2010-022-003_b

1. Twin draft throttle body

box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
2. Remove fuel rail. Refer to FUEL RAIL in this
subsection.
3. Pull injector out of fuel rail.
2. ETA (Electric Throttle Actuator)
ETA Closed Throttle Feature
The ECM will power the ETA to electrically hold
the throttle plates closed for 40 minutes after any
ignition key OFF selection.
To deactivate the ETA closed throttle feature and
remove power from the ECM and the engine man-
agement circuits, remove main relay 1 motor (R5).
Refer to POWER DISTRIBUTION AND GROUNDS
subsection.
NOTICE When working on the throttle body,
ensure the ETA closed throttle feature is deac-
tivated and the ECM is NOT powered.

Throttle Body Access

– Remove air filter housing. Refer to AIR INTAKE
SYSTEM subsection.
Throttle Body Mechanical Inspection
rmr2008-021-064_a
1. Remove main relay 1 motor (R5) in LH fuse
TYPICAL
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.

rmr2013-022 11
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

2. Slowly and alternately rotate the throttle plates

by hand between the full open and full close
stops. Ensure throttle plates move freely,
smoothly, and return to the limp home posi-
tion.
NOTICE The ETA drives the throttle plates
through a gear drive mechanism. Open the
throttle plates slowly to avoid damaging the
mechanism.
NOTICE Never attempt to adjust the sealed
stop screws on the levers between the throt-
tle body and the ETA. They are precisely cali-
brated at the factory.
3. Before replacing the throttle body, check the
rmr2008-021-001_a
following as these could be the root cause of TYPICAL
a related throttle body problem. 1. Throttle plate edge
2. Throttle body bore
– Throttle body stop screw(s) are loose or 3. Air orifice
worn.
– TPS is loose or not reset correctly. Look for:
– MAPS vacuum tubes are leaking, kinked, – Dirt
blocked, disconnected or not of the proper – Oily surfaces
length. – Carbon deposits on throttle plates and the sur-
– The MAPS plastic manifold and fittings for rounding bores.
cracks, blockage or leakage. 5. Clean as necessary using a throttle body
– ETA (Electric Throttle Actuator) not respond- cleaner such as Gunk Intake Medic or the
ing, bad electrical connection. equivalent.
– Dirty throttle body.
NOTICE Only use an appropriate throttle
Throttle Body Cleaning body cleaner that will not damage O-rings,
MAPS sensor, and catalytic converter. Do not
1. Remove main relay 1 motor (R5) in LH fuse spray any cleaning fluid on the ETA (electric
box. Refer to POWER DISTRIBUTION AND throttle actuator).
GROUNDS subsection.
2. Remove air filter housing cover. Refer to AIR WARNING
INTAKE SYSTEM subsection. Use the cleaning product in a well ventilated
3. Check throttle body cleanliness using a flash- area. Refer to product manufacturer's warn-
light. ings.
4. With throttle plates fully open, inspect each of
the following: 6. To avoid getting dirt in the engine, spray cleaner
– Throttle body bore on a clean rag, then rub rag against throttle
plates and bores. A toothbrush also works
– Throttle plate edge well.
– Air orifice.

12 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

NOTICE 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

Throttle Body Removal
1. Remove air filter housing. Refer to AIR INTAKE
SYSTEM subsection.
2. Remove fuel tank covers and disconnect the
fuel pump electrical connector. Refer to FUEL
TANK AND FUEL PUMP subsection.
3. Crank engine to release fuel pressure in the sys-
tem.
rmr2008-021-002

TYPICAL
7. Hold throttle plates fully open to reach all sur-
faces.
8. To remove residual dirt, spray cleaner on throt-
tle plates and on bores.
9. Spray cleaner inside air orifices.
4. Remove main relay 1 motor (R5) in LH fuse
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
5. Disconnect TPS connector from the throttle
body.

rmr2010-022-020_a

1. TPS connector

6. On LH side of the throttle body, disconnect

items in the following illustration:
rmr2008-021-003_a

TYPICAL
1. Air orifice

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.

rmr2013-022 13
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
rmr2010-022-021_a
LH SIDE
Step 1: MAPS connector
Step 2: Fuel injector connector
7. On RH side of the throttle body, disconnect
items listed in the following illustration.
rmr2010-022-022_a
RH SIDE
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
NOTE: Discard compression washers on banjo fit-
ting.
8. Remove retaining screw from fuel pressure
regulator.
9. Remove MAPS retaining screw and vacuum
hoses from throttle body.
14
rmr2010-022-014_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
the removal procedure however, pay attention to
the following details.
1. Clean throttle body as necessary. Refer to
THROTTLE BODY CLEANING in this subsec-
tion.
2. Tighten air intake adapter clamps as specified.
INTAKE ADAPTER CLAMP TORQUE
2 N•m (18 lbf•in)
3. Ensure all electrical connectors, vacuum hoses,
and fuel hoses are properly connected.
4. Install NEW compression washers on banjo fit-
ting of fuel pressure hose and tighten banjo fit-
ting as specified.
5. Install and tighten banjo fitting as specified.
BANJO FITTING TORQUE
23 N•m (17 lbf•ft)
6. Reconnect fuel pump.
7. Reconnect main relay 1 motor (R5).
8. 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.
9. IMPORTANT: Carry out a Throttle Position
Sensor Initialization reset in B.U.D.S. Refer
to ADJUSTMENTS at the beginning of this
subsection.
rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

10. In B.U.D.S., check for and reset fault codes. POSSIBLE CAUSES ACTION
Refer to DIAGNOSTIC AND FAULT CODES
subsection. Check if connector is
Fix.
disconnected from TPS

THROTTLE POSITION SENSOR Tighten and reset

Check if sensor is loose Throttle Position
(TPS) Sensor.
General Replace and reset
Inspect sensor for
The throttle position sensor (TPS) is a twin poten- Throttle Position
damage or corrosion
tiometer that sends two signals to the ECM, that Sensor.
are proportional to the throttle shaft angle. Inspect wiring
Repair.
IMPORTANT: Prior to testing the TPS, ensure (voltage test)
throttle body components are properly installed If bad wiring, repair.
Inspect wiring and
and connected. sensor (resistance test)
If bad TPS, replace and
reset Throttle Sensor.
Use the latest applicable B.U.D.S. version to
check for related fault codes the EMS may have Test sensor operation
Replace and reset
generated. Refer to DIAGNOSTIC AND FAULT (wear test)
Throttle Position
CODES subsection for more information. Sensor.

TPS Location NOTE: The TPS sensor reset (initialization) is car-

ried out using B.U.D.S.
The TPS is mounted on the throttle body.
TPS Adaptation Fault

The following problems can be caused by a TPS

adaptation failure fault, or a TPS adaptation can-
celed fault:
– Idle speed is out of range.
– Engine stops when throttle is released quickly.
– Engine runs inconsistent in low partial loading
or low RPM limp home.
POSSIBLE CAUSES ACTION
Sensor has been
replaced and TPS Reset Throttle Position
initialization was not Sensor.
performed
rmr2010-022-020_b

TYPICAL — LH REAR VIEW Throttle body and TPS Reset Throttle Position
1. Throttle position sensor (TPS) has been replaced Sensor.
2. Throttle body
ECM has been replaced
Reset Throttle Position
TPS Access and TPS initialization was
Sensor.
not performed
Refer to BODY subsection and remove:
– LH middle side panel Tighten and reset
Sensor is loose Throttle Position
– LH top side panel Sensor.
TPS Faults Tighten and reset
Throttle bracket is loose Throttle Position
The TPS is a redundant sensor with two opposite Sensor.
outputs.
NOTE: If a TPS fault occurs, the ECM will trigger NOTE: The TPS sensor reset (initialization) is car-
a fault and the vehicle will be in limp home mode. ried out using B.U.D.S. software.
TPS Plausibility Error or Deviation Fault
These faults are caused by the sensor reading.

rmr2013-022 15
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

TPS Wear Test NOTE: The data transfer rate of the PC computer
1. Disconnect the ETA (electric throttle actuator) used may be too slow for real-time display.
connector.
TPS Resistance Test
2. While engine is not running, manually rotate
throttle open and close on the throttle body to 1. Remove main relay 1 motor (R5) in LH fuse
ensure smooth operation of the throttle plates. box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
3. Connect the vehicle to the latest applicable
B.U.D.S. version, refer to COMMUNICATION 2. Make sure TPS is properly connected to wiring
TOOLS AND B.U.D.S. subsection. harness.
4. Turn ignition key ON to energize electrical sys-
tem.
NOTE: Do not start the engine.
5. Ensure engine stop switch is set to RUN.
6. In B.U.D.S., click on the Read Data button.
7. Then click on the Monitoring tab, then select
the ECM tab.
8. Monitor the Throttle Opening indication.

rmr2010-022-020_a

TYPICAL LH REAR VIEW — SEVERAL PARTS REMOVED FOR

CLARITY PURPOSE
1. TPS connected

3. Disconnect connector “A” from the ECM. Re-

fer to ECM CONNECTOR ACCESS in ENGINE
CONTROL MODULE (ECM) in this subsection.
4. Install connector on the ECM ADAPTER TOOL
(P/N 529 036 166)

rmr2010-022-016_a

Step 1: Click on Read Data

Step 2: Click on Monitoring tab
Step 3: Select the ECM monitoring tab
Step 4: Monitor the Throttle Opening indication

CAUTION Before manually rotating the

throttle plates with electrical power ON, be
sure to disconnect the ETA to prevent it from
being activated by the ECM. vmr2008-022-005_a

9. Slowly rotate throttle plates at an even pace and
observe the indication in B.U.D.S.
The indication in B.U.D.S. must change gradually
and smoothly as you move the throttle plates. If
the indication is erratic, suddenly drops off, or if
any discrepancy between the throttle plate move-
ment and indication is noticed, it may indicate that
the TPS needs to be replaced.
5. Using a FLUKE 115 MULTIMETER (P/N 529 035
868) set to " ", check resistance values at ECM
adapter as per the following table.
NOTE: Throttle plate must be manually opened or
closed.

16 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

FULLY CLOSED FULLY OPEN

ECM THROTTLE THROTTLE
ADAPTER PLATE (1) PLATE
RESISTANCE ( ) at 20°C (68°F)
PIN MIN. MAX. MIN. MAX.
A-K4 A-A2 700 1300 700 1300
A-F3 A-K3 2445 3255 2445 3255
(1)To obtain the fully closed position, it is necessary
to push against throttle plate in throttle body with
your fingers and hold it in this position for the
measurement.

NOTE: The resistance value should change

smoothly and proportionally to throttle move- rmr2010-022-023_a

ment. Otherwise, replace TPS. TPS INPUT VOLTAGE TEST

If resistance values are correct, perform the TPS If voltage test is not good, test and repair the wire
INPUT VOLTAGE TEST in this subsection. from ECM to the TPS as required. Refer to appli-
If any resistance values are incorrect, check cable WIRING DIAGRAM.
wiring harness continuity between ECM and TPS. If wire is good, refer to ECM REPLACEMENT in
If wiring is faulty, repair/replace as required. If this subsection.
wiring is good, replace TPS.
If voltage test is good, test for continuity of the
6. Reconnect ECM connector. signal wires and the ground wire between the TPS
and ECM. Refer to applicable WIRING DIAGRAM.
TPS Input Voltage Test
1. Ensure main relay 1 motor (R5) in installed in LH TPS Replacement
fuse box. 1. Remove main relay 1 motor (R5) in LH fuse
2. Disconnect connector from TPS. box. Refer to POWER DISTRIBUTION AND
3. Turn ignition key ON. GROUNDS subsection.
4. Measure for voltage at TPS harness connector 2. Disconnect TPS connector.
as follows. 3. Remove TPS retaining screws.
CONNECTION VOLTAGE
Pin 3 with battery ground 3.3 V
Pin 1 with battery ground 0 V

rmr2010-022-023_b

TYPICAL
1. TPS connector
2. Retaining screws

4. Remove TPS from throttle body.

NOTE: Install the new TPS.
rmr2013-022 17
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
5. Be sure to align tab on TPS with tab on throttle
body lever as per following illustration.
rmr2008-021-073_a
TYPICAL
1. Tab on TPS
2. Tab on throttle body lever
6. Slightly tighten retaining screws.
7. Reconnect TPS connector.
8. Refer to TPS ADJUSTMENT in this subsection.
TPS Adjustment
NOTE: There is no adjustment that can be carried
out on the TPS, however a TPS POSITION SEN-
SOR INITIALIZATION reset must be carried out
when the TPS has been removed or replaced. Re-
fer to ADJUSTMENTS in the beginning of this sub-
section.
While using B.U.D.S., check for and reset fault
codes. Refer to DIAGNOSTIC AND FAULT
CODES subsection.
CRANKSHAFT POSITION
SENSOR (CPS)
CPS Location
The CPS is located on top of the clutch cover on
the LH side of the engine.
18
rmr2008-021-037_a
TYPICAL - CPS LOCATION
CPS Access
Refer to BODY subsection and remove the follow-
ing:
– LH middle side panel
– LH top side panel
– LH acoustic panel (if applicable).
CPS Troubleshooting
When troubleshooting a CPS fault, take into ac-
count that a CPS fault can be triggered by bent or
missing encoder wheel teeth.
First check for applicable fault codes, refer to DI-
AGNOSTIC AND FAULT CODES subsection.
If there is a fault code and the CPS and its circuit
test good, check the encoder wheel teeth condi-
tion, refer to MAGNETO AND STARTER 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 Resistance Test
1. Remove main relay 1 motor (R5) in LH fuse
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
2. Disconnect CPS connector.
rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

2. Disconnect connector “A” from the ECM. Re-

fer to ECM CONNECTOR ACCESS in ENGINE
CONTROL MODULE (ECM) in this subsection.
3. Install connector on the ECM ADAPTER TOOL
(P/N 529 036 166)
4. Using a multimeter, recheck resistance as per
following table.

rmr2013-022-150_a

1. CPS connector
2. CPS
vmr2008-022-005_a
3. Set multimeter to " " selection and probe CPS
terminals as per following table. ECM ADAPTER MEASUREMENT
CPS CONNECTOR MEASUREMENT RESISTANCE
PIN
@ 20°C (68°F)
RESISTANCE
PIN H1 K2 700 - 900
@ 20°C (68°F)
1 2 700 - 900 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.
3. Remove the CPS.

rmr2008-021-076_a

TYPICAL

If resistance is not within specifications, replace

the CPS.
If the CPS resistance tests good, reconnect the
CPS connector and carry out the CPS CIRCUIT
CONTINUITY TEST.
CPS Circuit Continuity Test
rmr2008-021-037_b
1. Remove main relay 1 motor (R5) in LH fuse TYPICAL
box. Refer to POWER DISTRIBUTION AND 1. CPS
2. Retaining screw
GROUNDS subsection.
rmr2013-022 19
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

4. Install new CPS as per following table. CAPS Access

CPS INSTALLATION Refer to BODY subsection and remove:
– LH middle side panel
PRODUCT ON SCREW
TORQUE – LH top side panel
THREADS
– LH acoustic panel (if applicable).
LOCTITE 243 (BLUE)
11 N•m (97 lbf•in)
(P/N 293 800 060)
CAPS Input Voltage Test
5. Secure CPS wire harness using locking ties and NOTE: First ensure the CAPS connector is not
clamp as per factory installation. mixed up with the MAPS connector.
1. Turn ignition key ON.
CAMSHAFT POSITION SENSOR 2. Using a FLUKE 115 MULTIMETER (P/N 529 035
(CAPS) 868) set to Vdc, back-probe CAPS connector as
per following table.
CAPS Location
CAPS sensor is located behind the MAPS sensor. CAPS CONNECTOR VOLTAGE
Battery
OG/GN BK/GN
voltage

rmr2008-021-077_b

1. MAPS
2. CAPS
rmr2008-021-077_a

TYPICAL — CAPS CONNECTOR

If input voltage is good, carry out the CAPS OUT-

PUT VOLTAGE TEST.
If input voltage is not good, repeat test as per fol-
lowing table.
PROBE VOLTAGE
CAPS CONNECTOR Vehicle Battery
OG/GN wire ground voltage

If input voltage is not good, repair or replace

wiring/connectors between CAPS and fuse F12.
Refer to applicable WIRING DIAGRAM.

CAPS Output Voltage Test

rmr2008-021-038_a

TYPICAL - LH SIDE OF FRONT CYLINDER VALVE COVER 1. Remove CAPS sensor from engine. Refer to
CAPS REPLACEMENT below. Do not remove
main relay 1 motor (R5).

20 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

2. Make sure CAPS connector is properly con- CAPS Replacement

nected. 1. Remove main relay 1 motor (R5) in LH fuse
3. Using a multimeter set to Vdc, back-probe con- box. Refer to POWER DISTRIBUTION AND
nector as per following tables. GROUNDS subsection.
CAPS 2. Detach MAPS sensor from throttle body and
CAPS CONNECTOR VOLTAGE move down for access to CAPS.
CONDITION
OG/ YE/ Close to NOTE: Only remove the MAPS mounting screw.
Free Do not disconnect the MAPS.
GN GN 0 Vdc
3. Disconnect connector from CAPS.
4. Remove the CAPS retaining screw and replace
the CAPS. Be sure to install a new O-ring on the
new CAPS.

rmr2008-021-078_a

TYPICAL

CAPS
CAPS CONNECTOR VOLTAGE
CONDITION
rmr2008-021-038_b
Metallic 1. CAPS
OG/ YE/ Battery
object on 2. Retaining screw
GN GN voltage
sensor
CAPS INSTALLATION
PRODUCT ON SCREW
SCREW TORQUE
THREADS
LOCTITE 243 (BLUE)
5 N•m (44 lbf•in)
(P/N 293 800 060)

5. Reinstall removed parts.

rmr2008-021-079_a

TYPICAL

If voltage does not change, check continuity of

YE/GN wire from CAPS to ECM. If it tests good,
try a new CAPS.

rmr2013-022 21
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

MANIFOLD ABSOLUTE
PRESSURE SENSOR (MAPS)
MAPS Location

rmr2008-021-039_a

TYPICAL
rmr2010-022-014_c A. 85 mm (4.33 in) long
LH SIDE OF THROTTLE BODY
1. MAPS MAPS Test Using B.U.D.S.
1. Connect vehicle to the latest applicable
MAPS Access B.U.D.S. version, refer to COMMUNICATION
Refer to BODY subsection and remove: TOOLS AND B.U.D.S. subsection.
– LH middle side panel 2. Start engine.
– LH top side panel
3. Click on the Read Data button.
– LH acoustic panel (if applicable).
4. Click on Monitoring tab, then on ECM tab at
MAPS Troubleshooting the bottom LH corner of the page.
The sensor continuously measures the manifold
absolute pressure.
When troubleshooting, ensure the MAPS sensor
vacuum tubes, fittings and manifold are:
– Properly connected
– Not leaking
– Not kinked
– Not damaged.
Tube length is calibrated and should not be tam-
pered with. If otherwise, the engine may be im-
properly calibrated.
If you suspect incorrect tube lengths, measure
them. Each tube length should be as illustrated.
If tube lengths are incorrect, install new tubes.

rmr2010-022-016_b

Step 1: Click on Read Data

Step 2: Click on Monitoring tab
Step 3: Select the ECM monitoring tab
Step 4: Read the Manifold abs. press. cyl. 1 indication

The manifold absolute pressure read should be

within specification.
MANIFOLD ABSOLUTE PRESSURE
28 kPa to 69 kPa (4 PSI to 10 PSI)

22 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

rmr2010-022-024

5. As you throttle the engine, read the manifold

absolute pressure. The value should become rmr2008-021-080_a

TYPICAL - MAPS INPUT VOLTAGE TEST

more stable and move as you throttle the en-
gine. Otherwise, perform the MAPS INPUT
VOLTAGE TEST.
NOTE: If there is no reading, first make sure the
MAPS connector is not mixed up with the CAPS
connector. If the problem persists, perform the
MAPS INPUT VOLTAGE TEST and the MAPS CIR-
CUIT CONTINUITY TEST.
If voltage test is good, replace the MAPS.
If voltage test is not good, carry out the MAPS
CIRCUIT CONTINUITY TEST.
NOTE: The ECM provides a common voltage
to the MAPS and AAPTS (Ambient Air Pres-
sure/Temp Sensor).

MAPS Input Voltage Test MAPS Circuit Continuity Test

1. Ensure main relay 1 motor (R5) in installed in LH 1. Remove main relay 1 motor (R5) in LH fuse
fuse box. box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
2. Disconnect the MAPS connector.
2. Disconnect connector “A” from the ECM. Re-
3. Turn ignition key ON. fer to ECM CONNECTOR ACCESS in ENGINE
4. Using a FLUKE 115 MULTIMETER (P/N 529 035 CONTROL MODULE (ECM) in this subsection.
868) set to Vdc, measure the MAPS input volt- 3. Install connector on the ECM ADAPTER TOOL
age as per following table. (P/N 529 036 166)
CONNECTION VOLTAGE Using a FLUKE 115 MULTIMETER (P/N 529 035 868)
Terminal 1 with engine ground 5 V set to " ", test the continuity of the MAPS circuit
wiring as per following table.
Terminal 2 with engine ground 0 V
MAPS CIRCUIT CONTINUITY TEST
Terminal 3 with engine ground 0 V
ECM MAPS RESISTANCE
ADAPTOR CONNECTOR READING
B4 Pin 1 (PK/BU)
Close to 0
G4 Pin 3 (WH/BU)
(continuity)
H2 Pin 2 (BK/BU)

If continuity is not good, repair the connectors or

replace the wiring harness between ECM connec-
tor and the MAPS connector.

rmr2013-022 23
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

MAPS Replacement AMBIENT AIR PRESSURE

1. Remove main relay 1 motor (R5) in LH fuse AND TEMPERATURE SENSOR
box. Refer to POWER DISTRIBUTION AND (AAPTS)
GROUNDS subsection.
2. Carefully disconnect vacuum tubes from MAPS AAPTS Location
sensor.

rmr2008-021-040_a

rmr2008-021-009_a
TYPICAL - MAPS VACUUM TUBES
3. Remove MAPS sensor.
4. Install the new MAPS sensor.
5. Properly position sensor tabs as shown.
TYPICAL - AAPTS LOCATION
The sensor continuously measures the atmo-
spheric air pressure and temperature.
PTS Connector Location
The PTS connector is located just above the RH
front suspension. It connects the AAPTS sensor
to the ECM connector.

rmr2008-021-081_a

TYPICAL - POSITION OF MAPS LOCATION TABS

rmr2010-022-010_a
6. Carefully connect vacuum tubes.
TYPICAL - PTS CONNECTOR
7. Install MAPS connector.
8. Tighten screw. PTS Connector and AAPTS Access
9. Reinstall removed parts. Remove the RH air duct panel. Refer to BODY
subsection.

24 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
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-
NICATION TOOLS AND B.U.D.S. subsection.
2. Turn ignition key ON.
3. In B.U.D.S., select the following:
– Read Data button
– Monitoring tab
– Cluster tab.
4. Read the atmospheric pressure indication.
NOTE: The atmospheric pressure indication is vis-
ible near the center of the page.
rmr2008-021-041_b
TYPICAL - ATMOSPHERIC PRESSURE INDICATION IN B.U.D.S.
5. Blow some compressed air in the sensor area
as you observe the atmospheric pressure indi-
cation. The reading should change.
rmr2008-021-082_a
TYPICAL
rmr2013-022
If there is no reading or if it does not change, carry
out the AAPTS INPUT VOLTAGE TEST.
If you doubt the AAPTS reading, compare it to an
atmospheric pressure gauge (barometer), or try a
new AAPTS.
When comparing the readings, values must be
within specification.
AAPTS ALLOWED DISCREPANCY
PRESSURE VALUE
± 3.4 kPa (.5 PSI)
If the vehicle AAPTS value is out of this range, re-
place it.
AAPTS Temperature Function Test
1. As in the previous AAPTS PRESSURE FUNC-
TION TEST, read the ambient air temperature
indication.
rmr2008-021-041_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.
25
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

rmr2008-021-083_a
rmr2008-021-084
TYPICAL
TYPICAL
If voltage test is not good, carry out the AAPTS
If there is no reading or if it does not change, carry CIRCUIT CONTINUITY TEST.
out an AAPTS INPUT VOLTAGE TEST.
If voltage test is good and the problem is related to
If you doubt the temperature reading, compare the temperature indication, carry out the AAPTS
it with a known good thermometer, or try a new RESISTANCE TEST. If the problem is related to
AAPTS. the pressure function of the AAPTS, carry out the
When comparing, readings must be within speci- AAPTS CIRCUIT CONTINUITY TEST.
fication.
AAPTS Circuit Continuity Test
AAPTS ALLOWED DISCREPANCY
TEMPERATURE VALUE 1. Remove main relay 1 motor (R5) in LH fuse
box. Refer to POWER DISTRIBUTION AND
± 2°C (3°F) GROUNDS subsection.
If the vehicle AAPTS value is out of this range, re- 2. Disconnect connector “A” from the ECM. Re-
place it. fer to ECM CONNECTOR ACCESS in ENGINE
CONTROL MODULE (ECM) in this subsection.
AAPTS Input Voltage Test 3. Install connector on the ECM ADAPTER TOOL
1. With the ignition key turned to OFF, disconnect (P/N 529 036 166)
AAPTS connector.
2. Turn ignition key ON.
3. Using a multimeter set to Vdc, test the voltage
output from the ECM to the pressure sensor as
per following table.
NOTE: This test may first be carried out at the
PTS connector. If test is good there, then repeat
test at AAPTS connector.
AAPTS CONNECTOR MEASUREMENT
PIN VOLTAGE 529036166

1 3 5 Vdc 4. Using a multimeter set to " ", test wiring har-

ness continuity between ECM and AAPTS as
per following table.

26 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

AAPTS CIRCUIT CONTINUITY TEST SENSOR TEMPERATURE TABLE

ECM AAPTS RESISTANCE
RESISTANCE TEMPERATURE
ADAPTER CONNECTOR (ohms)
F2 Pin 1 °C °F AAPTS
H4 Pin 2 Close to 0 - 10 14 9425
G3 Pin 4 (continuity) 0 32 5587
B4 Pin 3 20 68 2510
30 86 1715
If continuity test is good and the problem is re-
lated to the pressure function, replace the AAPTS. 40 104 1200
If the problem is related to the temperature func- 50 122 850
tion, carry out the AAPTS RESISTANCE TEST.
60 140 610
If continuity is not good, repair or replace
wiring/connectors between ECM and AAPTS 70 158 445
connector. 80 176 330
AAPTS Resistance Test 90 194 245
1. Disconnect PTS connector. 100 212 185
2. Using a multimeter set to " ", test the resis- 110 230 140
tance of the sensor as illustrated. Compare re-
120 248 110
sult with the sensor temperature table.
130 266 85
AAPTS
Pin 1 Pin 2 If resistance value measured is not close specifi-
cation, replace the AAPTS.
If an open circuit or an abnormal resistance value If resistance tests good, carry out the AAPTS CIR-
is measured, repeat the test at the AAPTS sensor. CUIT CONTINUITY TEST.
AAPTS Replacement
1. Loosen AAPTS retaining screw.
2. Slide AAPTS out.
3. When installing sensor, be sure to position
foam around sensor tip.

rmr2008-021-085_a

SENSOR TEMPERATURE TABLE

RESISTANCE
TEMPERATURE
(ohms)
°C °F AAPTS
- 30 - 22 26860
- 20 - 4 15614 rmr2008-021-086_a

4. Reinstall removed parts.

rmr2013-022 27
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

COOLANT TEMPERATURE If engine temperature indicated in B.U.D.S. is cor-

SENSOR (CTS) rect for actual engine temperature, the CTS and
it's circuit is functioning normally.
CTS Location If there is no temperature reading, or if reading
does not reflect actual engine temperature, pro-
ceed with CTS RESISTANCE TEST.

CTS Resistance Test

1. Remove main relay 1 motor (R5) in LH fuse
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
2. Disconnect CTS connector.
3. Using a FLUKE 115 MULTIMETER (P/N 529 035
868) set to " ", measure the resistance through
the CTS resistance and compare the resistance
value obtained to the sensor temperature table.
CTS SENSOR
rmr2008-021-043_a Pin 1 Pin 2
TYPICAL - LH SIDE OF ENGINE

CTS Access
Refer to BODY subsection and remove:
– LH middle side panel
– LH top side panel
– LH acoustic panel (if applicable).

CTS Test Using B.U.D.S.

1. Connect vehicle to latest applicable B.U.D.S.
version, refer to COMMUNICATION TOOLS
AND B.U.D.S. subsection.
2. In B.U.D.S., select the following:
– Read Data button
– Monitoring tab rmr2008-021-044_a
– ECM tab. TYPICAL

SENSOR TEMPERATURE TABLE

RESISTANCE
TEMPERATURE
(ohms)
°C °F CTS
- 30 - 22 28600
- 20 - 4 16200
- 10 14 9560
0 32 5880
20 68 2450
30 86 1650

rmr2011-071-001_a
40 104 1140
1. Engine temperature (analog readout) 50 122 808
2. Engine temperature (digital readout)

28 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

SENSOR TEMPERATURE TABLE If resistance value is incorrect, repair the connec-

tors or replace the wiring harness between ECM
RESISTANCE connector and the CTS.
TEMPERATURE
(ohms)
°C °F CTS CTS Replacement
60 140 584 1. Remove main relay 1 motor (R5) in LH fuse
box. Refer to POWER DISTRIBUTION AND
70 158 430 GROUNDS subsection.
80 176 322 2. Disconnect CTS connector.
90 194 245 3. Remove CTS from engine.
100 212 189 4. Install new CTS and tighten as specified.
110 230 148 CTS TORQUE
120 248 117 17 N•m (150 lbf•in)
130 266 90
5. Reinstall remaining removed parts.
If resistance measured is out of specification, re- 6. Refill and bleed the cooling system, refer to
place the CTS. COOLING SYSTEM subsection.
If resistance measured is within specification, 7. Use the latest applicable B.U.D.S. version to
reconnect the CTS and carry out the following check for and reset fault codes. Refer to DIAG-
steps. NOSTIC AND FAULT CODES subsection.
4. Remove main relay 1 motor (R5) in LH fuse
box. Refer to POWER DISTRIBUTION AND HEATED OXYGEN SENSOR
GROUNDS subsection. (HO2S)
5. Disconnect connector “A” from the ECM. Re-
fer to ECM CONNECTOR ACCESS in ENGINE Oxygen Sensor Location
CONTROL MODULE (ECM) in this subsection. This vehicle is equipped with 2 heated oxygen
6. Install connector on the ECM ADAPTER TOOL sensors (HO2S):Both sensors are located up-
(P/N 529 036 166)
stream of the catalytic converter.

529036166

7. Using a multimeter, recheck resistance at the

ECM adapter as per following table.
ECM CONNECTOR MEASUREMENT rmr2013-022-153_a

HEATED OXYGEN SENSORS

RESISTANCE
PIN
@ 20°C (68°F)
Oxygen Sensor and Connector Access
Refer to TEMPERATURE
A1 J2
SENSOR TABLE above Refer to BODY subsection and remove the follow-
ing:
– LH and RH middle side panels
– LH and RH top side panels

rmr2013-022 29
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
– LH and RH acoustic side panels (as applicable)
– Air intake resonator. Refer to AIR INTAKE SYS-
TEM subsection.
– RH rear side panel
rmr2013-022-151_a
LH SIDE — SOME PARTS REMOVED FOR CLARITY PURPOSE
1. Front head pipe
2. Oxygen sensor
3. Oxygen sensor connector
rmr2013-022-152_a
RH SIDE — SOME PARTS REMOVED FOR CLARITY PURPOSE
1. Rear head pipe
2. Oxygen sensor
3. Oxygen sensor connector
Oxygen Sensor General Precautions
Take the following precautions to avoid sensor
malfunction:
– Do not use any product on sensor probe.
– Do not expose sensor to water, oil, windshield
cleaner, anticorrosion oil, grease, terminal
cleaner, etc.
– Do not drop or use an oxygen sensor that has
been dropped.
30
– Do not use any compound on sensor threads
unless labeled as compatible with oxygen sen-
sor.
– Do not use impact wrench or conventional
socket type wrench to install sensor.
– Do not allow sensor or wire to touch exhaust
system or any other hot component.
– Do not route sensor wires to create tension in
the wires. This could cause faults or sensor
malfunction.
Oxygen Sensor Service Life
The following tips may indicate whether a sensor
has reached the end of its service life and need to
be replaced:
– Poor fuel economy
– Higher exhaust emissions
– Engine surging and/or hesitation
– Rough idling
– Catalytic converter failure
– Check engine light is ON
– An oxygen sensor fault code can be read in
B.U.D.S.
NOTE: Most sensors slowly degrade in terms of
performance, sending an excessively enriched
signal to the ECM, causing the engine to run too
lean. However, a failure may happen at any time
and is usually due to contamination.
Oxygen Sensor Test Using B.U.D.S.
1. Using the latest applicable B.U.D.S. version,
monitor the oxygen sensors.
2. Click on Monitoring tab, then on ECM tab.
3. Start engine.
4. Observe the Oxygen Sensor Status indica-
tions in B.U.D.S.
rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
rmr2010-022-017_a
OXYGEN SENSOR STATUS INDICATIONS
If a fault code related to an oxygen sensor is ac-
tive, the oxygen sensor indicator will not turn on.
The fault code(s) need(s) to be solved first.
When a properly functioning oxygen sensor cir-
cuit is first initiated, the oxygen sensor heats up
and the ECM is operating in a closed loop control
mode. The status of the oxygen sensor circuit will
change from “Init” to “Active” as it progresses
through a series of steps. These steps may be
viewed on the ECM Monitoring page of B.U.D.S.
in the Oxygen Sensor Status window.
NOTE: The steps listed in the following sensor
status table may not all be displayed, and may
vary from one time to the next. The steps dis-
played will depend on the engine operating status
and oxygen sensor operating status.
LIST OF OXYGEN SENSOR STATUS
INDICATIONS
Init
Heating Active
Control Active
Error
When the oxygen sensors reach the “Active”
state, they become operational and their indica-
tors will turn on in B.U.D.S.
rmr2013-022
rmr2010-022-028_a
NOTE: Engine needs to run for approximately
2 - 3 minutes before the oxygen sensors become
CONTROL ACTIVE and their indicator lights turn
on in B.U.D.S.
If a sensor status does not change or does not
reach the CONTROL ACTIVE state, or the oxygen
sensor indicator light does not come on, try a new
oxygen sensor.
NOTE: Before replacing a sensor, check wiring,
terminals and sensor condition.
Oxygen Sensor Input Voltage Test
1. Ensure main relay 1 motor (R5) in installed in LH
fuse box.
NOTE: This test validates the heater element cir-
cuit.
2. Disconnect the oxygen sensor connectors.
3. Turn ignition switch ON.
4. Using a multimeter set to Vdc, read the input
voltage provided to the sensor heater.
OXYGEN SENSOR
CONNECTOR
(HARNESS SIDE) MEASUREMENT
PIN
C Battery ground Battery voltage
If Input voltage is good, carry out an OXYGEN
SENSOR RESISTANCE TEST and an OXYGEN
SENSOR CIRCUIT CONTINUITY TEST.
If input voltage is not good, test the continuity of
the power circuit from fuse F8 in LH fuse box.
Refer to the applicable WIRING DIAGRAM for de-
tails.
31
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

If input voltage wire continuity is at fault, repair or OXYGEN SENSOR 2

replace wiring or connector.
ECM
OXYGEN RESISTANCE
Oxygen Sensor Resistance Test CONNECTOR
SENSOR PIN @ 20°C (68°F)
“B”
Test the resistance value of the oxygen sensor be-
tween the sensor pins as follows. A H4
B G3 Close to 0
OXYGEN RESISTANCE
SENSOR PIN @ 20°C (68°F) D L3
Approximately
C D
7 - 11 If a resistance value is NOT as specified, repair or
replace the wiring and connectors.
If reading is not within specification, replace the
oxygen sensor. Oxygen Sensor Removal
1. Remove main relay 1 motor (R5) in LH fuse
Oxygen Sensor Circuit Continuity Test box. Refer to POWER DISTRIBUTION AND
NOTE: This test validates the heater element cir- GROUNDS subsection.
cuit and the sensor circuits.
2. Disconnect oxygen sensor connector.
1. Remove main relay 1 motor (R5) in LH fuse
3. Cut locking ties securing oxygen sensor har-
box. Refer to POWER DISTRIBUTION AND
ness lateral supports.
GROUNDS subsection.
4. Unscrew oxygen sensor from head pipe.
2. Disconnect connector “B” from the ECM. Re-
fer to ECM CONNECTOR ACCESS in ENGINE NOTICE Handle oxygen sensor with clean
CONTROL MODULE (ECM) in this subsection. hands. Oxygen sensor probe must remain free
3. Install connector on the ECM ADAPTER TOOL of oil, grease, antiseize lubricant and any other
(P/N 529 036 166) foreign matter that could affect its operation.

529036166

4. Using a multimeter set to " ", test for continuity

between the oxygen sensor harness connector
and the ECM adaptor as per following tables.
rmr2013-022-153_a
OXYGEN SENSOR 1
HEATED OXYGEN SENSORS
ECM
OXYGEN RESISTANCE
SENSOR PIN
CONNECTOR
@ 20°C (68°F)
Oxygen Sensor Inspection
“B” A visual inspection is usually insufficient to deter-
A J1 mine whether the oxygen sensor is functioning
correctly. However, the following should be
B D2 Close to 0 checked:
D L2 – Signs of erosion
– Overheating
– Carbon build up
– Obstruction of the holes in the probe.

32 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

NOTICE Do not apply any antiseize lubricant

to the sensor probe as it could affect its opera-
tion.
Screw sensor in the applicable exhaust pipe.
OXYGEN SENSOR TORQUE
50 N•m (37 lbf•ft)

Install all other removed parts.

TYPICAL VIEW
Oxygen Sensor Installation (New
Sensor)
VISUAL
CAUSE REMEDY If a new oxygen sensor is installed, threads are
ASPECT
already coated with an anti-seize product. Sensor
Replace sensor. is ready for installation.
Drain fuel tank
Shiny Install sensor in the applicable exhaust pipe and
A Lead in fuel and refill with
deposits tighten to specification.
the recommended
unleaded fuel
OXYGEN SENSOR TORQUE
Excessive
Too rich a fuel mixture 50 N•m (37 lbf•ft)
B carbon/thick Replace sensor
or faulty sensor heater
soot deposits
Install all other removed parts.
Silicone contamination
Replace sensor.
by use of adhesives/ KNOCK SENSOR (KS)
White Use only products
C silicone-based
deposits compatible with
products on sensor This engine is equipped with two knock sensors
oxygen sensors
or threads (KS1 and KS2).
Replace oxygen sensor as required. If the ECM receives a signal of a KNOCK condition
from either sensor, the ECM will adjust ignition
NOTICE The cause of a problem should be timing by retarding it to correct the situation.
rectified and the sensor changed to avoid
further problems including damage to the cat- Knock Sensor Location
alytic converter.

Oxygen Sensor Installation (Same

Sensor)
If the same oxygen sensor is installed, apply LOC-
TITE 767 (ANTISEIZE LUBRICANT) (P/N 293 800 070)
on its first two threads.

rmr2013-022-154_a

REAR KNOCK SENSOR KS2 (LH SIDE)

rmr2008-048-003_a

TYPICAL
1. Apply antiseize lubricant first two threads
2. Must be free of any product

rmr2013-022 33
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
rmr2013-022-155_a
FRONT KNOCK SENSOR KS1 (RH SIDE)
Knock Sensor Connector Location
Refer to BODY subsection and remove the follow-
ing:
– LH and RH middle side panels
– LH and RH top side panels
– LH and RH acoustic side panels (as applicable)
rmr2013-022-156_a
REAR KNOCK SENSOR CONNECTOR KS2 (LH SIDE)
1. Knock sensor
2. Knock sensor connector
34
rmr2013-022-158_a
FRONT KNOCK SENSOR CONNECTOR KS1 (RH SIDE)
1. Knock sensor
2. Rear of air intake silencer
3. Knock sensor connector
To unplug the RH knock sensor connector,
squeeze lock tabs of connector from the LH
side.
rmr2013-022-157_a
UNLOCKING RH (FRONT) KNOCK SENSOR CONNECTOR FROM
THE LH SIDE
1. Squeeze lock tabs here
Knock Sensor Troubleshooting
Knock sensor problems may be related to, but not
limited to any of the following items:
– Loose or improperly torqued knock sensor
– Dirty or corroded mounting surface
– Cracked knock sensor from over torquing
– Bad wiring and connections
– An internal engine knock
– An induced knock (or vibration) due to a loose
part external to the engine
– Knock sensor and CPS sensor harness connec-
tors swapped (mixed up).
rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

KS Dynamic Test 6. Using a multimeter, measure the resistance be-

1. Using the latest applicable B.U.D.S. software tween both terminals on the knock sensor and
version, monitor the knock sensors using the compare the measurement with the preceding
Faults section. table.
2. Start engine and throttle up to above 5000 If resistance is not as specified, replace knock
RPM. sensor.
3. Look for a knock sensor fault code in B.U.D.S. If resistance is good at the knock sensor, carry
out a continuity check of the wiring between the
If no fault code occurs, the knock sensor is good. knock sensor connector and ECM connector "A".
If a fault occurs, do the following: Refer to applicable WIRING DIAGRAM for details.
– Ensure sensor and cylinder head contact sur- NOTE: Although the knock sensor resistance is
faces are clean. as specified, it may still be at fault as it may not
– Ensure mounting bolt and washer are correct be producing a signal within its design specifica-
and properly torqued down. tion.
– Carry out a knock sensor resistance. Repair or replace wiring and connectors between
the ECM and knock sensor.
KS Resistance Test
1. Disconnect connector “A” from the ECM. Re- KS Replacement
fer to ECM CONNECTOR ACCESS in ENGINE 1. Disconnect KS sensor connector and cut lock-
CONTROL MODULE (ECM) in this subsection. ing ties securing wire harness.
2. Install connector on the ECM ADAPTER TOOL 2. Remove knock sensor deflector (as applicable).
(P/N 529 036 166)
3. Remove knock sensor mounting screw.
3. Using a multimeter set to " ", measure the
4. Clean knock sensor contact surface on cylinder.
knock sensor circuit resistance as per follow-
Also clean threaded hole.
ing table.
5. Apply thread locker in threaded hole.
ECM ADAPTER MEASUREMENT
6. Install new knock sensor and tighten as speci-
RESISTANCE fied.
SENSOR PINS
@ 20°C (68°F)
KNOCK SENSOR INSTALLATION
KS1 C3 G2
5 M PRODUCT IN
KS2 B1 D2 TORQUE
THREADED HOLE
LOCTITE 243 (BLUE)
23 N•m (17 lbf•ft)
(P/N 293 800 060)

NOTICE Improper torque may prevent sen-

vmr2008-022-005_a
If knock sensor circuit resistance is as specified,
wiring harness is good.
If resistance measured at ECM connector is not
close to specification, carry out the following
steps.
4. Remove the required body parts to access the
applicable knock sensor connector.
5. Disconnect the knock sensor connector.
sor from functioning properly and lead to
severe damage of internal engine compo-
nents.
7. Ensure knock sensor connector is clean and
corrosion free before connecting it.
8. Install new locking ties as per factory specifica-
tion.
9. Reinstall all remaining removed parts.
THROTTLE ACCELERATOR
SENSOR (TAS)
TAS Location
The TAS is part of the throttle grip assembly.

rmr2013-022 35
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

TAS Voltage Test

1. Turn ignition key to ON.
2. Set engine cut-off switch to RUN.
3. 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
rmr2013-022-159_a 4.5 - 5.5
Pin D (VT) ground
TAS Connector Location and Access Pin A (RD) Pin B (BK)
Refer to BODY subsection and remove the follow- 4.5 - 5.5
Pin D (VT) Pin E (BN)
ing:
– RH middle side panels 0.495 -
Pin C (GN) Pin B (BK) 2.87 - 2.97
0.597
– RH top side panels
– RH acoustic side panels (as applicable) 0.248 - 1.385 -
Pin F (BU) Pin E (BN)
0.348 1.485

rmr2013-022-160_a

TAS CONNECTOR ON RH SIDE

TAS Troubleshooting rmr2013-022-161_a

When troubleshooting a throttle related problem, TAS VOLTAGE TEST

proceed in this order:
– Check for an applicable fault code using the lat-
est applicable B.U.D.S. software version.
– Carry out recommended service actions.
– Carry out the TAS VOLTAGE TEST.
NOTE: With vehicle electrical power ON and
engine not running, the throttle plates will not
move when the throttle grip (TAS) is rotated.
If voltage readings are as specified, the TAS and
its wiring are in good working order.
If no voltage is measured between any of the pin
combinations in the table, test for continuity of the
applicable wiring between the TAS harness con-
nector and the ECM connector before concluding
that the problem is related to the TAS, or to the
ECM. Refer to the WIRING DIAGRAM for details.

TAS Resistance Test

The throttle accelerator sensor is a double hall ef-
fect sensor. A resistance test cannot be carried
out.

36 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

TAS Replacement
If one or both sensors are not functioning nor-
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 529036166
the position of the throttle plates in the throttle
body. 4. Set multimeter to " " selection and measure
When troubleshooting, first check for an applica- the ETA motor coil resistance as per following
ble fault code in B.U.D.S. and follow service action table.
recommended. ETA RESISTANCE TEST
ETA Location ECM ADAPTER PINS RESISTANCE
The ETA is mounted to the front end of the throttle L1 L2 9.5
body.
If resistance measured is not close to specifica-
tion, repeat test at the ETA connector. If resis-
tance is still not to specification, replace the throt-
tle body.
If resistance is also as specified at ETA, carry out a
continuity test of the wiring from ECM connector
to ETA connector. Refer to applicable WIRING DI-
AGRAM for details. Repair or replace wiring and
connectors as required.
If the wiring and ETA test good, inspect the throt-
tle body. Refer to THROTTLE BODY MECHANI-
CAL INSPECTION and THROTTLE BODY CLEAN-
rmr2010-022-022_b

1. ETA Connector
ING.
2. ETA If the throttle body checks good, refer to ENGINE
3. Throttle body
CONTROL MODULE (ECM) in this subsection.
ETA Access The problem may be related to the ECM.
Remove the air filter housing. Refer to AIR IN- NOTE: ECM requires proper signals from the TAS
TAKE SYSTEM. (throttle accelerator sensor) and the TPS (throttle
position sensor) for proper control of the ETA.
ETA Resistance Test
1. Remove main relay 1 motor (R5) in LH fuse
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
2. Disconnect connector “A” from the ECM. Re-
fer to ECM CONNECTOR ACCESS in ENGINE
CONTROL MODULE (ECM) in this subsection.
3. Install connector on the ECM ADAPTER TOOL
(P/N 529 036 166)

rmr2013-022 37
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

ENGINE CONTROL MODULE

(ECM)
ECM Location

rmr2013-026-011_a

1. ECM
A. Connector "A"
B. Connector "B"

rmr2013-026-010_a Power Supply to ECM

LH SIDE VIEW
When the ignition switch is turned to ON, the
ECM Connector Access ECM receives 12 Vdc initialization voltage to
wake up the ECM.
1. Remove the J4 fuse in LH fuse box. Refer to
POWER DISTRIBUTION AND GROUNDS sub- The ECM then provides a ground to the main
section. power relays (R4 and R5) which close their con-
tacts and provide power to a large portion of the
2. Remove air intake resonator on LH side of vehi- electrical system.
cle. Refer to AIR INTAKE SYSTEM subsection.
When main relay 1 motor (R5) closes, it provides
3. Remove retaining screws securing the ECM to the main 12 Vdc battery power to the ECM.
frame.
Anytime the ignition key is turned to the OFF po-
sition, the ECM will maintain main relay 1 motor
(R5) energized for 40 minutes, therefore maintain-
ing the ECM and the engine management circuits
and sensors energized at a ready state. This is re-
quired for the ETA closed throttle feature.
If it is necessary to disconnect the ECM within 40
minutes after a key OFF, remove main relay 1 mo-
tor (R5). Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
ECM Power Supply and Ground Pinout
FUNCTION CONNECTOR PIN
Main 12 Vdc power ECMB-M4
rmr2013-026-012_a Initialization 12 Vdc ECMB-A2
PARTS REMOVED FOR CLARITY Grounds ECMB Pins L1, M2, M3

4. Disconnect the ECM connectors. Refer to

WIRING HARNESS AND CONNECTORS sub-
section for details on removing ECM connec-
tors.

38 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

If these items test good, connect vehicle to the

latest applicable B.U.D.S. software version and
look for relevant fault codes before replacing an
ECM.

ECM Fault (U0300)

If a fault code indicating wrong engine control
smr2009-027-005 module (ECM) is generated, the installed ECM is
ECM CONNECTORS not appropriate for the vehicle. Engine will crank
but will not start. Refer to PARTS CATALOG for
ECM Troubleshooting appropriate ECM part number according to vehi-
Turn the ignition key to ON and look for the items cle.
in the following two lists to come ON.
ECM Input Voltage Test (Ignition
NOTE: The following listed items provide a visual Switch)
or audible indication that the ECM is initialized.
Other electronic modules and engine electrical 1. Remove main relay 1 motor (R5) in LH fuse
components not listed will be powered when box. Refer to POWER DISTRIBUTION AND
these relays close. GROUNDS subsection.
Main relay 2 acc (R4) will provide power to the: 2. Disconnect connector “B” from the ECM.
– Cluster 3. Install connector on the ECM ADAPTER TOOL
– Analog fuel gauge (optional) (P/N 529 036 166)
– Analog coolant temp gauge (optional)
– Light in the parking brake switch.
Main relay 1 motor (R5) will provide power to the:
– ECM (main power)
– Fuel pump.
If none of the items previously listed come on, the
ECM may not be initialized. Carry out the follow-
ing:
– ECM INPUT VOLTAGE TEST (IGNITION
SWITCH) 529036166

– ECM GROUND CIRCUIT TEST

– Ignition switch test (refer to IGNITION SYS- 4. Turn ignition switch ON.
TEM) subsection. 5. Using a multimeter set to Vdc, test for ignition
If only items listed under one of the two main re- switch voltage (ECM initialization voltage) as
lays do not come on, the ECM is initialized and per following table.
the related main relay or its circuit may be at fault. ECM CONNECTOR “B” MEASUREMENT
Refer to POWER DISTRIBUTION AND GROUNDS
PIN VOLTAGE
subsection.
If the fuel pump does not cycle on for a few sec- A2 Battery ground Battery voltage
onds when the ignition switch is first turned on,
and the engine will not crank, the ECM may not If battery voltage is not read, test ignition switch
receive its main 12 Vdc or is at fault. Test the fol- circuit. Refer to IGNITION SYSTEM subsection.
lowing: 6. Turn ignition switch OFF.
– ECM fuse (F5) in LH fuse box
– ECM main 12 Vdc input (refer to ECM INPUT
ECM Input Voltage Test (Battery)
VOLTAGE TEST (BATTERY)) 1. Ensure ignition switch is set to OFF.
– Main relay 2 acc (R4), refer to POWER DISTRI- 2. Temporarily remove main relay 1 motor (R5) in
BUTION AND GROUNDS subsection. LH fuse box. Refer to POWER DISTRIBUTION
AND GROUNDS subsection.
3. Disconnect connector “B” from the ECM.

rmr2013-022 39
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

4. Install connector on the ECM ADAPTER TOOL

(P/N 529 036 166)

529036166

4. Connect the alligator clip of a 12 Vdc test light

to the battery positive terminal.
529036166
5. Connect the probe of the test light to each
5. Reinstall main relay 1 motor (R5) in LH fuse box. ground circuit as per following table to test
6. Install an appropriate insulated jumper wire as ECM ground circuit.
per table. ECM GROUND CIRCUIT TEST
JUMPER WIRE BATTERY ECM “B” CONNECTOR
ECM adapter pin H2 Chassis ground Pin L-1

NOTE: This provides a ground to energize closed
main relays 1 motor (R5). R5 provides the main
12 Vdc to the ECM.
7. Set multimeter to Vdc.
8. Read voltage as per following table.
ECM CONNECTOR “B” MEASUREMENT
PIN VOLTAGE
M-4 Battery ground Battery voltage
If battery voltage is not measured, test the follow-
ing:
– Fuse J4 in LH fuse box.
– RMain relay 1 motor (R5) (refer to POWER DIS-
TRIBUTION AND GROUNDS subsection)
– Continuity of wiring and connectors from ECM
to R5 (refer to WIRING DIAGRAM subsection).
If battery voltage is measured, carry out an ECM
GROUND CIRCUIT TEST as follows.
ECM Ground Circuit Test
1. Remove main relay 1 motor (R5) in LH fuse
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
2. Disconnect connector “B” from the ECM. Re-
fer to ECM CONNECTOR ACCESS in ENGINE
CONTROL MODULE (ECM) in this subsection.
3. Install connector on the ECM ADAPTER TOOL
(P/N 529 036 166)
Positive terminal (+) Pin M-2
Pin M-3
If the test light does not come ON (or is dim) when
testing any of the ground circuits, check wiring
and connector pins for corrosion, loose pins, cut
wire or broken wire at a connector pin. Repair or
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.
2. Remove main relay 1 motor (R5) in LH fuse
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
3. Disconnect diagnostic link connector (DLC).
4. Ensure the ECM connectors are properly con-
nected.
5. Disconnect the VCM connector, refer to VEHI-
CLE STABILITY SYSTEM (VSS) subsection.
6. Measure ECM CAN resistor through DLC con-
nector as follows.
NOTICE To avoid damaging the connector,
probe only the terminal tip.

40 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

ECM CAN RESISTOR TEST 5. Test for circuit continuity between diagnostic
link connector (DLC) and ECM as per following
PROBE DLC CONNECTOR MEASUREMENT table.
Pin 1 Pin 2 110 - 130 NOTE: Refer to ECM POWER SUPPLY, GROUND
AND CAN PINOUT in this subsection for pin iden-
tification.
NOTICE To avoid damaging the connector,
probe only the terminal tip.
ECM CONNECTOR
CAN* PROBES RESULT
Diagnostic
ECM-B
High link connector
pin C1
pin 1 Close to 0
Diagnostic (continuity)
ECM-B
Low link connector
pin C2
pin 2
* CAN: Serial data communication
rmr2013-022-162_a

ECM CAN RESISTOR TEST

If the resistance value is NOT as specified, carry
out the ECM CAN LINE CONTINUITY TEST in this
subsection.
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-
place ECM.
7. Reconnect VCM connector and diagnostic con-
nector.
ECM CAN Line Continuity Test
1. Deactivate main relay 1 motor (R5) via
B.U.D.S.; refer to POWER DISTRIBUTION
AND GROUNDS subsection.
2. Disconnect diagnostic connector.
3. Disconnect connector “B” from the ECM. Re-
fer to ECM CONNECTOR ACCESS in ENGINE
CONTROL MODULE (ECM) in this subsection.
4. Install connector on the ECM ADAPTER TOOL
(P/N 529 036 166)
If continuity is not good, check wiring and con-
nectors from diagnostic link connector (DLC) to
ECM connector. Refer to applicable WIRING DI-
AGRAM.
If everything tested good and ECM does not work,
try a new ECM.
6. Reconnect DLC and ECM connectors.
ECM Removal
NOTE: If a new ECM is to be installed, first read
the procedures in ECM REPLACEMENT further in
this subsection.
Refer to ECM CONNECTOR ACCESS in this sub-
section.
ECM Installation
1. Reconnect ECM connectors.
2. Install the ECM in vehicle.
3. If a new ECM is installed, enter data and
perform the required resets using the latest
applicable B.U.D.S. version. Refer to ECM
REPLACEMENT further in this subsection.
4. Reinstall the J4 fuse in LH fuse box.
5. Reinstall air intake resonator, refer to AIR IN-
TAKE SYSTEM subsection.
6. Reinstall all removed body parts, refer to BODY
subsection.

529036166

rmr2013-022 41
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

ECM Replacement Click once on the Folder Up button in the Open

1. Prior to replacing a possibly faulty ECM, ensure box.
the following:
– Check for an applicable fault code using the
latest applicable B.U.D.S. software version.
Carry out service actions and clear fault
codes.
– ECM power supply and all grounds have
been checked for proper contact/cleanli-
ness, tightness and continuity.
– Make sure terminals are free of corrosion
or moisture, properly crimped on wires and
locked in connector housing.
– Check wiring harness for any signs of scor-
ing, cuts, bare or pinched wires that may mmr2009-023-081_a
cause short or open circuits.
– All the other recommended tests have been Double click on the AutoSave folder.
carried out.
2. Collect the following data and settings required
for entry into new ECM:
There are 2 possible methods to collect the re-
quired information. The 1st being the easiest.
– Use B.U.D.S. software and retrieve the data
from a saved .mpem file on your PC computer.
Refer to 1ST COLLECTING METHOD: RETRIEV-
ING DATA FROM A SAVED .MPEM FILE.
– Collect the information from the vehicle
and BOSSWeb. Refer to 2ND COLLECTING
METHOD: COLLECT THE INFORMATION
FROM THE VEHICLE AND BOSSWEB. mmr2009-023-082_a

3. Replace the ECM.

NOTE: You may have to go to another AutoSave
4. Carry out an ECM INITIALIZATION RESET in folder from a previous version of B.U.D.S.
B.U.D.S.
Choose the latest file saved for this specific vehi-
1st Collecting Method: Retrieving Data from a cle.
Saved .mpem File
1. Connect vehicle to the latest applicable
B.U.D.S. software version.
2. Turn the ignition key to ON.
3. In B.U.D.S., click on the Open button.

smr2009-030-006

IMPORTANT: Ensure to use the file that specifi-

cally matches the vehicle you are servicing.
mmr2009-023-080

42 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

The file name structure is as follows:

BUDS version_VIN_date read (yyyymmdd)_hour read
(hhmmss).mpem

Example:

P2.3.22.12_2BPSBK8C68V000168_20090206_111640.mpem
Therefore:
B.U.D.S. version: P2.3.22.12
VIN: 2BPSBK8C68V000168
Date: 2009 02 06
Hour: 11h 16m 40s

On the Vehicle page, collect the following infor- rmr2010-022-030_a

mation. BAR CODE STICKER
1. Customer name
2. V.I.N. (Vehicle Identification Number)
3. Engine serial number (without the leading
“M”)
4. Vehicle model number
5. Total hours.

rmr2010-022-031_a

ETCHING

2. Record the following numbers using

rmr2010-022-026_a
BOSSWeb. Look in Service menu and
DATA TO RETRIEVE
1. Customer (name) choose Unit history.
2. Vehicle (V.I.N.)
3. Engine (serial number) 3. 1. Customer name
4. Model 2. V.I.N. (Vehicle Identification Number)
5. Total hours
3. Vehicle model number
Enter recorded data in ECM as detailed in ENTER-
ING THE COLLECTED DATA IN THE ECM.
2nd Collecting Method: Collect the
Information from the Vehicle and BOSSWeb
1. Record engine serial number.
NOTE: The engine serial number may be obtained
from 2 locations on the RH side of engine:
– A bar code sticker on top of the rear cylinder
head
– Etched on the engine crankcase

mmr2009-118-011

SERVICE, UNIT HISTORY

rmr2013-022 43
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

4. Enter the recorded data in ECM as detailed

in ENTERING THE COLLECTED DATA IN THE
ECM.
Entering Collected Data in the ECM
1. After the ECM is replaced, connect vehicle
to the latest applicable B.U.D.S. software ver-
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.

rmr2013-022-001_a

1. Setting tab
2. Vehicle Configuration tab

6. In the Vehicle Configuration page:

6.1 Ensure the drop boxes reflect the vehicle
connected to B.U.D.S. in the Vehicle Con-
vmr2006-012-100_aen
figuration area.
3. On the Vehicle page of B.U.D.S., enter cus-
tomer and vehicle data in ECM.

rmr2010-022-026_b

DATA TO ENTER IN VEHICLE PAGE OF B.U.D.S.

1. Customer (name) rmr2013-022-001_b
2. Vehicle (V.I.N.)
3. Engine (serial number) 1. Vehicle Configuration area
4. Model 2. Drop boxes

4. Click on Setting tab. 6.2 In the Vehicle Option area, select the ACS
5. Click on the Vehicle Configuration tab at the box if the vehicle is equipped with an air
bottom of the page. controlled suspension.

44 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

rmr2008-021-021_a

10. In the Part Type area, choose ECM and add

the ECM serial number.

rmr2013-022-001_c

1. Vehicle Option area

2. ACS box

6.3 In the Vehicle Option area, select the CE

box if the vehicle is used in the European
Community or in Brazil.

rmr2010-022-027_a

1. ECM selection
2. Enter ECM serial number here

11. Click OK to save the ECM serial number and

exit the window.
12. Carry out the ECM FIRST INITIALIZATION RE-
SET procedure in this subsection.
Security Exchange
rmr2013-022-001_d
If the warning message in the following illustra-
1. Vehicle Option area
2. CE box tion appears when B.U.D.S. is connected to the
vehicle, the installed ECM is not the appropriate
7. Click on History tab. ECM for the vehicle, or its calibration has been
8. Click on Part Replacement tab. changed.
9. Click on Add Part in History tab.

vmr2006-020-058_a

rmr2013-022 45
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

If it occurred just after replacing the ECM, refer 2.5 Click the "OK" button.
to the PARTS CATALOG to obtain the appropriate
ECM required for the vehicle type.
If this message appears after the ECM calibration
has been purposely changed, click Yes to update
the system, and to allow engine starting.
It is not recommended to start an en-
gine with the wrong calibration.
rbg2012-006-114

ECM First Initialization 3. When the following message will appear:

When the ECM First Initialization will be started,
3.1 Turn ignition key OFF.
the ECM will automatically initiate a:
– Throttle position sensor initialization 3.2 Wait 3 seconds.
– Gear position sensor initialization 3.3 Turn ignition key ON.
– Brake pressure adaptation 3.4 Click the "OK" button.
Ensure transmission is set to NEUTRAL.
NOTE: On SE5 models, the engine may need to
be started to set transmission to N. When done,
stop engine.
IMPORTANT: Do not activate anything on the ve-
hicle while performing a module reset.
1. In B.U.D.S., click the items in the illustrated or-
der. rbg2012-006-115

4. When the following message will appear, click

the "OK" button.

rbg2012-006-116

5. When the following message will appear:

5.1 Turn ignition key to OFF.
rmr2013-022-300_a 5.2 Wait until the message vanishes.
Step 1: Setting tab
Step 2: ECM tab
Step 3: Reset (ECM First Initialization)

2. When the following message will appear, make

sure that:
2.1 The throttle grip is completely released. rbg2012-006-050

2.2 The transmission in set to neutral. 6. When the following message will appear:
2.3 The brake pedal is released. 6.1 Turn ignition key to ON.
2.4 The engine temperature and intake air 6.2 Click the "OK" button.
temperature are above 5°C (41°F)

46 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

1.3 Position a floor jack under the lower por-

tion of the rear shock absorber and lift the
rear of vehicle until the rear wheel is off
rbg2012-006-051 the ground.

7. When the following message will appear, click The floor jack must be posi-
the "OK" button. tioned so that it cups the lower portion of
the rear shock absorber.

rbg2012-006-208

8. Ensure all the gear LEDs are OFF in B.U.D.S.

rbg2010-004-002_a

1. Lower portion of shock absorber

NOTE: It is highly recommended to install 4

wheel chocks at front wheels ( in front and rear
of wheels).

rmr2013-022-301_a

GEAR POSITION SENSOR LEDS

1. All the gear LEDs OFF

GBPS Learning rbg2010-004-001_a

WHEEL CHOCK INSTALLATION, EACH FRONT WHEEL

WARNING
Ensure the rear tire is well off the ground and
cannot come into contact with any obstacle
(ground, jack stand, etc.). Ensure the wheel
and tire assembly is free of particles that
could be thrown outward while rotating.
1. Lift and secure rear of vehicle off the ground so
rear wheel may turn freely.
1.1 Place vehicle on a level surface.
2. Start engine.
1.2 Ensure transmission is set to NEUTRAL.
WARNING
Before starting engine, ensure the rear tire
is well off the ground and cannot come into
contact with any obstacle (ground, jack stand,
etc.). Keep hands, tools, feet and clothing
clear of rotating parts (rear wheel assembly,
drive belt). Ensure no one is standing in
close proximity to the vehicle.

rmr2013-022 47
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

3. Run transmission through all gears (N, R, NOTE: During the GBPS learning procedure, the
1-2-3-4-5 and back to N) waiting until its LED cluster may show an orange screen and numer-
turns green (in B.U.D.S.) before changing gear. ous indicator lights may come on (CHECK ENG,
VSS, ABS, LIMP HOME, etc).
Apply brake to stop wheel before
shifting from reverse to forward. 5. Turn ignition key OFF.
6. Wait 3 seconds.
NOTE: Engine speed above 3000 RPM is required
to shift forward gears. 7. Turn the ignition key ON.
Clearing Faults
CAUTION Do not exceed 3800 RPM. 1. Remain in B.U.D.S..
2. In B.U.D.S., click on Read Data.

vmr2006-012-100_aen

3. Click the items in the illustrated order.

rmr2013-022-300_b

GEAR POSITION SENSOR LEARNING LEDS

1. Wait until the gear LED turns green (learned) before shifting

4. All gear position sensor LEDs must be green in

B.U.D.S. to confirm the GBPS learning is com-
pleted.

rbg2010-003-033_b

CLEARING FAULTS
Step 1: Faults
Step 2: Click "Clear Occurred Faults" button

4. When the following message will appear, click

the "Yes" button.

rmr2013-022-300_g

1. All LEDs must be green rbg2012-006-119

5. Turn ignition key OFF.

48 rmr2013-022
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

6. Exit B.U.D.S.
To avoid potential vehicle damage,
it is very important to turn ignition key off BE-
FORE exiting B.U.D.S. or unplugging the MPI-2
diagnostic cable from the vehicle.
7. Unplug MPI-2 diagnostic cable from vehicle.
Road Test
1. Test drive vehicle. Ensure its proper operation
and that every gear position is correctly indi-
cated in the multifunction gauge.
On SE5 models, it is extremely important to en-
sure the transmission can be shifted into each
gear.

rmr2013-022 49
 Subsection XX (FUEL TANK AND FUEL PUMP)

FUEL TANK AND FUEL PUMP

SERVICE TOOLS
Description Part Number Page
ECM ADAPTER TOOL................................................................... 529 036 166 ..................................... 15, 22
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................................... 17, 22
FUEL HOSE ADAPTER.................................................................. 529 036 023 ............................................. 7
OETIKER PLIERS........................................................................... 295 000 070 ....................... 5, 9–10, 12, 23
PRESSURE GAUGE....................................................................... 529 035 709 ............................................. 7
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ................................. 5, 20, 23

rmr2013-023 1
Subsection XX (FUEL TANK AND FUEL PUMP)

29 N•m NEW
(21 lbf•ft)

NEW

NEW

NEW
10 N•m
(89 lbf•in)
NEW

NEW

NEW
7.5 N•m NEW
(66 lbf•in)

NEW

NEW = Component must be replaced

when removed.
rmr2013-023-100_a

2 rmr2013-023
 Subsection XX (FUEL TANK AND FUEL PUMP)

GENERAL SYSTEM DESCRIPTION

WARNING
Torque wrench tightening specifications
must be strictly adhered to. Locking devices
must be replaced when removed (e.g.: lock-
ing tabs, elastic stop nuts, cotter pins, etc.).
WARNING
Always disconnect battery prior to working
on the fuel system.
WARNING
Fuel is flammable and explosive under cer-
tain conditions. Always work in a well venti-
lated area.
The fuel tank and fuel pump system main compo-
nents are:
– A fuel tank
– An electric fuel pump module
– An in line fuel filter
– An evaporative emission system
– A purge valve.
Fuel Pump Module
The fuel pump module is inserted through the top
of the fuel tank. It includes an electric fuel pump
and a float type fuel level sensor that varies in re-
sistance according to fuel level.

WARNING
Do not allow fuel to spill on hot engine parts
and/or on electrical connectors.

WARNING
Always proceed with care and use appropri-
ate safety equipment when working on pres-
surized fuel system. Wear safety glasses.

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. rmr2008-019-006_a

TYPICAL
Fuel lines remain under pressure at all times. 1. 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
procedure must be reinstalled as per factory stan-
dards.
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.

rmr2013-023 3
Subsection XX (FUEL TANK AND FUEL PUMP)
rmr2013-023-002_a
TYPICAL
1. Fuel pressure regulator
2. Filter
3. Fuel return line to fuel tank
Evaporative Emission System (EVAP)
rmr2013-023-004
TYPICAL - EVAP CANISTER - WITHOUT CARB
rmr2013-023-015
TYPICAL - EVAP CANISTER WITH CARB
4 rmr2013-023
rmr2013-023-001_a
TYPICAL
1. EVAP canister
2. EVAP purge solenoid valve
3. Vent hose from fuel tank
4. Vacuum hose from throttle body
5. Overflow hose
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.
Once the engine is running and reaches a prede-
termined engine RPM, the ECM energizes the
purge solenoid valve open. Thus, vacuum from
the engine draws (or purges) the hydrocarbon
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
overflow hose is provided to direct the fuel under
the vehicle.
On CARB models, the vacuum hose from throttle
body is connected to a Y fitting.
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 BODY subsection.
2. Fill up fuel tank (recommended).
 Subsection XX (FUEL TANK AND FUEL PUMP)

3. Disconnect vent line from EVAP canister.

REQUIRED TOOL
OETIKER PLIERS (P/N 295 000 070)

295000070
rmr2008-022-015_a

TYPICAL

5. Set hand pump to pressure and pressurize fuel

tank as per following table.
FUEL SYSTEM LEAK TEST
TIME WITHOUT
PRESSURE
PRESSURE DROP
28 kPa (4 PSI) 10 minutes

If pressure drops, locate fuel leak(s) and

rmr2013-023-001_b
TYPICAL - EVAP CANISTER VENT LINE
1. Remove vent line here
4. Install VACUUM/PRESSURE PUMP (P/N 529 021
800) onto EVAP canister vent line.
repair/replace leaking component(s).
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.
6. Reinstall fuel tank vent hose on EVAP canister.
7. Reinstall all removed body parts, refer to BODY
subsection.

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:
529021800 – Internal component and external fuel system
leak checks (high pressure system)
– Static fuel pressure test (engine not running).
Proceed as follows to conduct test:
1. Ensure the battery is fully charged. Battery volt-
age must be over 12 volts.

rmr2013-023 5
Subsection XX (FUEL TANK AND FUEL PUMP)

2. Ensure there is enough gas in fuel tank.

3. Remove body parts on the RH side of the ve-
hicle as required to access fuel system compo-
nents. Refer to BODY subsection.
4. Remove RH fuel tank cover.
4.1 Cut locking tie securing RH fuel tank cover
into place.

rmr2013-023-008_a

1. Fuel pump electrical connector

6. Release fuel pressure in system by cranking the

engine prior to disconnecting any fuel hose.
7. Remove fuel filter retaining screw.

rmr2013-023-012_a

TYPICAL - RH FUEL TANK COVER

1. Locking tie

4.2 Remove plastic rivets securing fuel tank

cover to frame.

rmr2013-023-005_a

TYPICAL - FUEL FILTER RETAINING SCREW

rmr2013-023-007_a
8. Remove main relay motor (R5) in LH fuse box
TYPICAL - FUEL TANK COVER PLASTIC RIVETS
(LFB) to remove power from the ECM, refer to
5. Disconnect fuel pump electrical connector. POWER DISTRIBUTION AND GROUNDS sub-
section.
9. Disconnect the pressure hose from the fuel
pump module.

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.

6 rmr2013-023
 Subsection XX (FUEL TANK AND FUEL PUMP)
rmr2013-023-009_a
TYPICAL - PUMP MODULE PRESSURE HOSE
10. Connect a fuel PRESSURE GAUGE (P/N 529 035
709) to the FUEL HOSE ADAPTER (P/N 529 036
023).
529035709
529036023
11. Install gauge T-fitting between disconnected
fuel system hoses (in-line installation).
rmr2013-023
rmr2008-022-007
TYPICAL - PRESSURE TEST GAUGE INSTALLATION
12. Reconnect fuel pump electrical connector.
13. Reinstall main relay motor (R5).
14. Set engine stop switch to RUN.
15. Turn ignition key to ON. Do not crank engine.
16. Observe fuel pressure on test gauge.
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 ± 20 kPa
FUEL PRESSURE
(48 PSI ± 3 PSI)
NOTE: Pump can build more than 330 kPa
(48 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 (DYNAMIC).
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
– Fuel pump (under partial load)
– Pressure regulator.
1. Follow the instructions in the FUEL SYSTEM
PRESSURE TEST (STATIC) procedure to discon-
nect the fuel pump pressure hose and install
the pressure gauge.
7
Subsection XX (FUEL TANK AND FUEL PUMP)

2. Start engine.
3. Increase and vary engine RPM.
4. Observe fuel pressure.
FUEL SYSTEM PRESSURE TEST (DYNAMIC)
330 kPa ± 20 kPa
FUEL PRESSURE
(48 PSI ± 3 PSI)

NOTE: Pump can build more than 330 kPa rmr2013-023-007_b

(48 PSI). TYPICAL

1. Align locating pin
5. If pressure is not within specifications, refer to 2. Align locking tab
DIAGNOSTIC FLOW CHART (FUEL PUMP) in
TROUBLESHOOTING in this subsection. Use locking ties to secure wiring and hoses as per
factory specifications.
6. Stop engine and turn ignition key to OFF.
7. Release fuel system pressure by disconnecting TROUBLESHOOTING
fuel pump electrical connector and cranking en-
gine. TROUBLESHOOTING TIPS
8. Remove main relay motor (R5) in LFB to re-
move power from the ECM, refer to POWER ENGINE SURGING OR NOT HOLDING A
DISTRIBUTION AND GROUNDS subsection. STEADY SPEED
9. Remove all test equipment. 1. EVAP purge valve stuck opened.
10. Reconnect fuel hoses. 2. Fuel system pressure out of specification.
NOTE: Be sure to reconnect the quick connect fit-
3. Air intake system leak.
ting on the fuel pump pressure hose with the flat
portion facing down. 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.

PROCEDURES
FUEL FILTER
Fuel Filter Removal
rmr2013-023-010_a 1. Remove body parts on the RH side of the ve-
TYPICAL hicle as required to access fuel system compo-
1. Fuel pump pressure hose flat side
nents. Refer to the BODY subsection.
11. Reinstall fuel pump electrical connector. 2. Remove RH fuel tank cover.
12. Reinstall fuel filter retaining screw. 2.1 Cut locking tie securing RH fuel tank cover
13. Reinstall main relay motor (R5). into place.
14. Reinstall all removed body parts, refer to
BODY subsection.
When reinstalling fuel tank covers, pay attention
to the following.

8 rmr2013-023
 Subsection XX (FUEL TANK AND FUEL PUMP)

rmr2013-023-012_a rmr2013-023-011_a

TYPICAL - RH FUEL TANK COVER TYPICAL - FUEL FILTER OETIKER CLAMPS

1. Locking tie
6. Remove fuel hoses from fuel filter.
2.2 Remove plastic rivets securing fuel tank
cover to frame. 7. Remove fuel filter support retaining screw.

rmr2013-023-007_a

TYPICAL - FUEL TANK COVER PLASTIC RIVETS

3. Disconnect fuel pump electrical connector and

release fuel system pressure. Refer to FUEL
SYSTEM PRESSURE TEST (STATIC) in this sub-
section. rmr2013-023-005_a

4. Remove main relay motor (R5) in LFB to re-
move power from the ECM, refer to POWER
DISTRIBUTION AND GROUNDS subsection.
5. Remove the Oetiker clamps retaining the fuel
hoses on each side of the fuel filter.
REQUIRED TOOL
OETIKER PLIERS (P/N 295 000 070)
TYPICAL - FUEL FILTER RETAINING SCREW
Fuel Filter Installation
1. Install fuel filter.
NOTE: Be sure to install the fuel filter with the
flow direction arrow on the fuel filter in the direc-
tion of fuel flow; from fuel pump towards throttle
body.

295000070

rmr2013-023 9
Subsection XX (FUEL TANK AND FUEL PUMP)

7. Reinstall all removed body parts, refer to BODY

section.

FUEL TANK
Fuel Tank Draining
Siphon fuel from tank into an approved fuel stor-
age container.

Fuel Tank Removal

rmr2013-023-011_b

TYPICAL
1. Direction of flow arrow on fuel filter

2. Install new Oetiker clamps on fuel filter hoses.

WARNING
Always install new Oetiker clamps as per
PARTS CATALOG.

REQUIRED TOOL
OETIKER PLIERS (P/N 295 000 070) rmr2013-023-001_c

TYPICAL
1. Fuel tank
2. Fuel pump
3. In-line fuel filter
4. Fuel supply hose
5. Fuel return hose

1. Siphon fuel tank.

2. Remove body parts on both sides of the vehi-
cle as required to access the fuel tank, refer to
BODY subsection.
295000070
3. Remove both fuel tank covers.
3.1 Cut locking tie securing RH fuel tank cover
3. Secure fuel filter to chassis. into place.
FUEL FILTER SCREW TORQUE
10 N•m (89 lbf•in)

4. Reconnect fuel pump electrical connector.

5. Reinstall main relay motor (R5).
6. Turn ignition switch ON to activate fuel pump
and check for:
– Proper fuel pump operation
– Fuel leaks in the system.
NOTICE When checking for fuel system
leaks, pay particular attention to the hose
connections that were disconnected for the
procedure.

10 rmr2013-023
 Subsection XX (FUEL TANK AND FUEL PUMP)

8. Disconnect parking brake cable from actuator

pulley, refer to BRAKE SYSTEM subsection.
9. Remove the RH lateral frame support, refer to
FRAME subsection.

rmr2013-023-012_a

TYPICAL - RH FUEL TANK COVER

1. Locking tie
rmr2010-023-006_a
3.2 Remove plastic rivets securing fuel tank TYPICAL
covers to frame. Step 1: Disconnect parking brake cable here
Step 2: Remove lateral frame support

10. Remove 2 retaining screws from the master

cylinder.

rmr2013-023-007_a

TYPICAL - FUEL TANK COVER PLASTIC RIVETS (RH SIDE

ILLUSTRATED)

rmr2008-022-018_a

TYPICAL - MASTER CYLINDER RETAINING SCREWS

11. Remove the remaining screws that secure the

rmr2013-023-006_a
RH footpeg support to the frame, and remove
TYPICAL - FUEL TANK COVER PLASTIC RIVETS (LH SIDE the support from the vehicle.
ILLUSTRATED)
NOTE: The remaining screws are screwed into
4. Disconnect fuel pump connector. the rear face of the foot peg support.
5. Crank engine to release fuel pressure in the fuel
pump pressure hose.
6. Remove main relay motor (R5) in LFB to re-
move power from the ECM, refer to POWER
DISTRIBUTION AND GROUNDS subsection.
7. Remove the rear cargo compartment assembly,
refer to BODY subsection.

rmr2013-023 11
Subsection XX (FUEL TANK AND FUEL PUMP)

295000070

rmr2010-023-007_a

TYPICAL - RT MODEL SHOWN

1. RH foot peg support

12. Cut locking ties securing master cylinder

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.
rmr2011-072-004_a

TYPICAL - VENT HOSE DISCONNECT

1. Fuel tank vent valve
2. Disconnect vent hose here

18. Pull fuel tank up and out from RH side of ve-

hicle.
NOTE: Move master cylinder from side to side as
necessary to allow removal of fuel tank. Be spe-
cially careful not to damage brake oil hoses and
fittings.

rmr2013-023-014_a

1. Fuel tank
2. Remove this bushing and grommet (LH aft bolt hole)

16. Disconnect fuel supply and fuel return hoses

from fuel pump.
17. Disconnect fuel tank vent hose from fuel tank
vent valve.
REQUIRED TOOL
OETIKER PLIERS (P/N 295 000 070)

rmr2008-022-020_a

TYPICAL - LIFT AND PULL OUT OVER BRAKE OIL HOSES

12 rmr2013-023
 Subsection XX (FUEL TANK AND FUEL PUMP)

Fuel Tank Inspection

Inspect fuel tank for any damage or cracks which
may result in fuel leaks. Replace fuel tank as re-
quired.

Fuel Tank Installation

Reverse the removal procedure. However, pay at-
tention to the following:
1. Reinstall fuel tank. Install hardware as illus-
trated in exploded view at the beginning of this
subsection.
NOTE: Be sure to install ground wire on the RH
aft fuel tank mounting bolt.
rmr2013-023-010_a

TYPICAL
1. Flat side

7. Install the fuel tank vent hose on fuel tank vent

valve fitting.
8. Reconnect fuel pump electrical connector after
all fuel hoses have been connected.
9. Reinstall main relay motor (R5).
10. Refill fuel tank.
11. Pressurize fuel system by turning ignition key
ON, and checking for leaks. Refer to FUEL
SYSTEM LEAK TEST in this subsection.
rmr2011-072-005_a 12. Reinstall lateral frame support, refer to
1. Install fuel tank ground wire here (RH aft bolt). FRAME subsection.
2. Torque fuel tank mounting screws as specified. 13. Install fuel tank covers. Ensure proper inser-
tion of alignment pins.
FUEL TANK RETAINING BOLTS
7.5 N•m (66 lbf•in)

3. Reinstall foot peg support. Refer to the BODY

subsection.
4. Properly reinstall the following parts, refer to
the BRAKES subsection:
– Brake system master cylinder
– Brake system reservoir
– Parking brake cable on actuator pulley. rmr2013-023-007_b

TYPICAL
1. Align locating pin
WARNING 2. Align locking tab
Be sure to carry out a leak test and an opera- 14. Reinstall rear cargo assembly and all other re-
tional test of the brake system as indicated in moved body parts, refer to BODY subsection.
the BRAKES subsection.

5. Use locking ties to secure wiring and hoses as FUEL PUMP

per factory specification. Fuel Pump Location
6. Connect fuel supply hose and fuel return hose The fuel pump module is mounted on top of the
quick connects. Flat section of quick connect fuel tank.
must face down towards fuel tank.

rmr2013-023 13
Subsection XX (FUEL TANK AND FUEL PUMP)

rmr2008-019-006_a
rmr2013-023-008_a
TYPICAL - FUEL PUMP MODULE
1. Fuel pump (in pump reservoir) 1. Fuel pump electrical connector
2. Fuel level sensor
4. Connect a 12 Vdc test light between the fuel
Fuel Pump Quick Test pump harness connector pins "B" and "C".
1. Open the seat for access to top of fuel tank. 5. Turn the ignition switch to ON. The test light
2. Apply the metal end of a screwdriver to the top should turn ON for a few seconds, then turn
of the fuel pump module and, the other end OFF.
against your ear.
3. Turn ignition switch to ON and listen for the fuel
pump.
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 F8 (LFB). If fuse is good, carry
out a FUEL PUMP POWER CIRCUIT TEST USING
A TEST LIGHT.
NOTE: If fuse F8 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 rmr2008-022-026_d

Test Light
1. Remove the RH upper side panel, refer to
BODY subsection.
2. Remove the RH fuel tank cover, see FUEL
TANK REMOVAL in this subsection.
3. Disconnect fuel pump electrical connector.
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 CIRCUIT VOLTAGE
TEST.
Fuel Pump Operational Test
Install small insulated jumper wires between the
fuel pump module connector and a known good
12 volt battery as in following illustration.

14 rmr2013-023
 Subsection XX (FUEL TANK AND FUEL PUMP)
Ensure normal pump circuit polarity is respected
as illustrated.
rmr2008-022-025_a
TYPICAL
NOTICE Running the fuel pump connected in
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.
rmr2008-022-026_b
TYPICAL
If battery voltage is not read, carry out a FUEL
PUMP POWER CIRCUIT CONTINUITY TEST.
If battery voltage is read, carry out a FUEL PUMP
POWER CIRCUIT CONTINUITY TEST.
rmr2013-023
If voltage is low to battery ground, test for a short
or partial short circuit to ground with the pump
circuit isolated from parallel circuits, refer to the
WIRING DIAGRAM.
NOTE: A fault in the ECM or in a parallel circuit
may prevent fuel pump operation. Use B.U.D.S.
to check for fault codes.
Fuel Pump Power Circuit Continuity
Test
1. Remove fuse F8 in LFB.
2. Disconnect fuel pump connector.
3. Set multimeter to and test circuit continuity
as per following table.
FUEL PUMP POWER CIRCUIT CONTINUITY TEST
PUMP
RESISTANCE
FUSE BOX HARNESS
@ 20°C (68°F)
CONNECTOR
LFB - B1 Pin B Close to 0
If test failed, repair or replace the faulty wiring.
If test succeeded, wiring is good. Perform the
FUEL PUMP CONTROL CIRCUIT CONTINUITY
TEST.
Fuel Pump Control Circuit Continuity
Test
1. Remove main relay motor (R5) in LFB to re-
move power from the ECM, refer to POWER
DISTRIBUTION AND GROUNDS subsection.
2. Disconnect ECM connector “B” and install it on
the ECM ADAPTER TOOL (P/N 529 036 166).
529036166
3. Set multimeter to and test circuit continuity
as per following table.
15
Subsection XX (FUEL TANK AND FUEL PUMP)

FUEL PUMP CIRCUIT CONTINUITY

(CONTROL WIRE)
ECM PUMP
RESISTANCE
CONNECTOR HARNESS
@ 20°C (68°F)
“B” CONNECTOR
Pin M-1 Pin C Close to 0

If test failed, repair or replace the faulty wiring.

If test succeeded, wiring is good. Try a new ECM.
4. Reinstall main relay motor (R5).

Fuel Pump Removal

1. Remove fuel tank, see FUEL TANK REMOVAL
in this subsection.
rmr2008-022-022_a

2. Use an appropriate screwdriver to carefully pry Step 1: Rotate pump backward

out the tapered end of fuel pump retainer ring. Step 2: Pull out pump

5. Discard O-ring seal on pump module.

Fuel Pump Installation

Reverse removal procedure. However, pay atten-
tion to the following:

WARNING
Install a new fuel pump ring seal and retainer
ring.

1. Install and hold a NEW ring seal against fuel

pump flange.
NOTE: Apply some oil on ring seal to ease instal-
lation.
rmr2008-022-021_a
2. Carefully insert pump in fuel tank; be careful not
to damage the float arm on the fuel level sen-
3. Remove and discard retainer ring.
sor.
4. Carefully pull out fuel pump paying attention to
float arm.

rmr2008-022-023_a

TYPICAL - PUMP RING SEAL INSTALLATION

16 rmr2013-023
 Subsection XX (FUEL TANK AND FUEL PUMP)

3. Index fuel pump tab with notch in fuel tank

and ensure pump and O-ring seal are properly
seated.

rmr2008-066-002_a

CLUSTER CONNECTOR PIN OUT

If resistance readings are not as specified, carry

out the CONTINUITY TEST OF FUEL LEVEL SEN-
SOR WIRING.
If resistance readings are as specified, fuel level
sensor and harness wiring are good. Carry out a
rmr2008-022-024_a WOW test of the multifunction gauge using appli-
TYPICAL - PUMP INDEXING cable B.U.D.S. Refer to LIGHTS, GAUGE AND AC-
1. Index tab with notch CESSORIES subsection. Check for proper opera-
4. Install a new fuel pump retaining ring. tion of the fuel level indication during the WOW
test.
WARNING With Analog Fuel Gauge
Ensure retainer ring is properly seated and 1. Remove the analog fuel gauge connector (FG1).
locked.
2. Carry out a fuel level sensor resistance test as
5. Turn ON ignition key to activate fuel pump and per following table.
pressurize fuel system, then check for fuel TEST PROBES
leaks. Refer to FUEL SYSTEM LEAK TEST.
FG1 pin S Chassis ground
FUEL LEVEL SENSOR FUEL LEVEL SENSOR RESISTANCE TEST
Fuel Level Sensor Resistance Test RESISTANCE READING
FUEL LEVEL
AT 21°C (70°F)
With Digital Fuel Indication in Multifunction
Gauge Empty Approx. 290
1. Remove the multifunction gauge (cluster), re- Full Approx. 80
fer to the LIGHTS, GAUGE AND ACCESSORIES
subsection. If resistance readings are as specified, the fuel
2. Disconnect the multifunction gauge connector. level sensor and it's wiring harness are good. Re-
fer to the LIGHTS, GAUGE AND ACCESSORIES
3. Set the FLUKE 115 MULTIMETER (P/N 529 035 subsection.
868) to selection.
If resistance readings are not as specified, carry
4. Alternately fill and empty fuel tank, and mea- out the CONTINUITY TEST OF FUEL LEVEL SEN-
sure the fuel sensor resistance through the SOR WIRING that follows.
wiring harness as per following table.
FUEL LEVEL SENSOR RESISTANCE TEST Continuity Test of Fuel Level Sensor
Wiring
RESISTANCE
CLUSTER 1. Disconnect the fuel pump module electrical
FUEL LEVEL READING AT
CONNECTOR connector.
21°C (70°F)
Empty Pin 15 to Approx. 290
Full chassis ground Approx. 80

rmr2013-023 17
Subsection XX (FUEL TANK AND FUEL PUMP)

With Digital Fuel Indication in Multifunction CONTINUITY TEST OF FUEL LEVEL

Gauge SENSOR WIRING
2. Measure for continuity of the wiring from the RESISTANCE
fuel pump connector (FP) and the multifunction PROBE CONNECTORS READING AT
gauge cluster connector (CL) as per following 21°C (70°F)
table. Refer to WIRING DIAGRAM for details.
FG1-S FP-A Close to 0
CONTINUITY TEST OF FUEL LEVEL (BU wire) Chassis ground OL (infinite)
SENSOR WIRING
FP-D
RESISTANCE Chassis ground Close to 0
(BK/VT wire)
PROBE CONNECTORS READING AT
21°C (70°F)
If resistance readings are as specified, refer to
FP-A CL-15 Close to 0 FUEL LEVEL SENSOR BENCH TEST.
(BU wire) Chassis ground OL (infinite) If resistance readings are not as specified, carry
out continuity test at DIC1-D connector pin. Re-
FP-D
(BK/VT wire)
Chassis ground Close to 0 pair or replace wiring/connectors as required.
NOTE: The DIC1 connector is located between
the air inlet resonator and the instrument console.

Fuel Level Sensor Bench Test

1. Remove fuel pump module from fuel tank, refer
to FUEL PUMP in this subsection.
2. Ensure the fuel level sensor is properly con-
nected in the fuel pump module.
3. Measure the resistance at the fuel pump mod-
ule connector, pins A and D.
FUEL LEVEL SENSOR BENCH TEST
FLOAT ROTATIONAL
PROBE RESISTANCE
POSITION ANGLE
Empty 0.0° 290
A to D
rmr2008-022-026_c Full 85° 80
TYPICAL - CONTINUITY TEST OF FUEL LEVEL SENSOR WIRING
1. Cluster connector
2. Fuel pump module connector

If resistance readings are as specified, refer to

THE FUEL LEVEL SENSOR BENCH TEST.
If resistance readings are not as specified, carry
out continuity test at DIC1-D connector pin. Re-
pair or replace wiring and connectors as required.
NOTE: The DIC1 connector is located between
the air inlet resonator and the instrument console.
With Analog Fuel Gauge
Measure for continuity of the wiring from the fuel
pump connector (FP) and the analog fuel gauge
connector (FG) as per following table. Refer to
WIRING DIAGRAM for details.

18 rmr2013-023
 Subsection XX (FUEL TANK AND FUEL PUMP)

rmr2013-023-002_b

TYPICAL
1. Fuel pressure regulator
2. Filter
3. Fuel return hose to fuel pump

rmr2011-082-005_a
Fuel Pressure Regulator Test
1. Full position
2. Empty position Refer to FUEL SYSTEM PRESSURE TEST in this
subsection for testing procedure.
If fuel level sensor fails bench test, replace the
fuel pump module. Fuel Pressure Regulator Replacement
For replacement of the fuel pressure regulator, re-
FUEL PRESSURE REGULATOR fer to FUEL RAIL REPLACEMENT in the ELEC-
The fuel pressure regulator is mounted to the fuel TRONIC FUEL INJECTION (EFI) subsection.
rail on the LH side of the throttle body.
The fuel pump pressure hose is connected to the EVAP PURGE VALVE
fuel rail on the RH side of the throttle body. It pro-
vides the full fuel pump pressure to both injector
fuel rails through an interconnecting port within
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.

rmr2013-023-001_d

TYPICAL
1. EVAP purge valve

EVAP Purge Valve Test Using B.U.D.S.

1. Remove RH side panels as required to access
the purge valve. Refer to the BODY subsection.
2. Turn ignition key ON.

rmr2013-023 19
Subsection XX (FUEL TANK AND FUEL PUMP)

3. Using B.U.D.S. software, activate the purge

valve as per following illustration.

rmr2008-021-070_a

TYPICAL

rmr2010-023-004_a If the solenoid does not function, replace it.

TYPICAL - PURGE VALVE ACTIVATION IN B.U.D.S. If the solenoid functions, carry out the EVAP
Step 1: Select Activation page tab
Step 2: Choose ECM page PURGE VALVE INPUT VOLTAGE TEST.
Step 3: Click on purge valve icon
EVAP Purge Valve Operational Test
You should feel the solenoid within the purge
valve operating. 1. Disconnect purge valve vacuum hose from the
throttle body.
If operation of the solenoid is felt when activated,
carry out the EVAP PURGE VALVE OPERATION
TEST.
If solenoid does not function, carry out the EVAP
PURGE VALVE SOLENOID TEST.
EVAP Purge Valve Solenoid Test
1. Disconnect the purge valve connector.
2. Connect small jumper wires to the purge valve
solenoid.
3. Momentarily connect the jumper wires to a re-
mote 12 Vdc battery.

rmr2013-023-003_a

TYPICAL
1. Purge valve vacuum hose at throttle body

2. Install the VACUUM/PRESSURE PUMP (P/N 529

021 800) on the vacuum hose.

20 rmr2013-023
 Subsection XX (FUEL TANK AND FUEL PUMP)

529021800

rmr2008-021-071_a

TYPICAL

5. Turn ignition key ON.

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. If it does
not, replace purge valve.

rmr2008-021-071

TYPICAL

3. Set pump to vacuum function.

4. Activate pump lever until vacuum reach the
specification. Air should not come through
the purge valve. Otherwise, replace the purge
valve.
EVAP PURGE VALVE VACUUM TEST
34.5 kPa (5 PSI) for 1 minute

rmr2008-021-071_b

TYPICAL

7. Remove the hand pump and reconnect the vac-

uum hose on the throttle body.
8. Install all removed parts in the reverse order of
removal.

EVAP Purge Valve Input Voltage Test

1. Disconnect the purge valve connector.
2. Turn ignition switch to ON.

rmr2013-023 21
Subsection XX (FUEL TANK AND FUEL PUMP)

3. Using a FLUKE 115 MULTIMETER (P/N 529 035 EVAP Purge Valve Input Circuit Test
868) set to Vdc, measure for input voltage at the (Continuity)
purge valve connector (EVAP) as per following 1. Remove main relay motor (R5) in LFB to re-
table. move power from the ECM, refer to POWER
DISTRIBUTION AND GROUNDS subsection.
2. Remove fuse F8 in LFB.
3. Disconnect the purge valve connector.
4. Set multimeter to and test for continuity of
the purge valve input circuit (12 Vdc) as per fol-
lowing table.
EVAP PURGE VALVE INPUT CIRCUIT
TEST (CONTINUITY)
EVAP PURGE
529035868 VALVE RESISTANCE
LFB
HARNESS @ 20°C (68°F)
EVAP PURGE VALVE INPUT VOLTAGE TEST CONNECTOR
PURGE VALVE SOLENOID Close to 0
(HARNESS SIDE) Pin 2 Pin D4
MEASUREMENT (continuity)
PROBE
Pin 2 (OG/GN) Battery ground Battery voltage

rmr2013-024-001_a

LFB

If continuity is not good, repair or replace wiring

rmr2008-021-070_b
TYPICAL
If input voltage is as specified, carry out the
PURGE VALVE CONTROL CIRCUIT TEST.
If input voltage is not as specified, check fuse F8.
NOTE: If fuse F8 is open, the starter solenoid will
not function either.
If fuse is good, carry out a PURGE VALVE INPUT
CIRCUIT TEST (CONTINUITY) in this subsection.
and connectors between fuse box and valve con-
nector.
If continuity is good, carry out the EVAP PURGE
VALVE CONTROL CIRCUIT TEST in this subsec-
tion.
EVAP Purge Valve Control Circuit Test
(Continuity)
1. Remove main relay motor (R5) in LFB to re-
move power from the ECM, refer to POWER
DISTRIBUTION AND GROUNDS subsection.
2. Disconnect “A” connector from the ECM and
connect it to the ECM ADAPTER TOOL (P/N 529
036 166).
3. Set multimeter to and test for continuity of
the purge valve control circuit (ground) as per
following table.

22 rmr2013-023
 Subsection XX (FUEL TANK AND FUEL PUMP)

EVAP PURGE VALVE CONTROL CIRCUIT TEST

EVAP PURGE
ECM
VALVE RESISTANCE
CONNECTOR
HARNESS @ 20°C (68°F)
“A”
CONNECTOR
Close to 0
Pin 1 M3
(continuity)

rmr2013-023-013_a

1. 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 TEST in this subsection.
2. Install purge valve with flow arrow pointing
away from the EVAP purge canister.

rmr2008-021-070_g

If ground circuit is faulty, repair/replace wiring/con-

nector.
4. Reinstall main relay motor (R5).

EVAP Purge Valve Replacement

EVAP Purge Valve Removal
1. Disconnect purge valve connector.
2. Remove Oetiker clamps securing hoses to
purge valve.
REQUIRED TOOL rmr2011-023-003_b

1. Purge valve location

OETIKER PLIERS (P/N 295 000 070)
3. Secure hoses to the purge valve using NEW
Oetiker clamps.
4. Reconnect purge valve connector.
5. Carry out a fuel system pressure test. Refer
to FUEL SYSTEM PRESSURE TEST in this sub-
section.

295000070

rmr2013-023 23
 Subsection XX (POWER DISTRIBUTION AND GROUNDS)

POWER DISTRIBUTION AND GROUNDS

GENERAL
POWER DISTRIBUTION DIAGRAM
Use the POWER DISTRIBUTION DIAGRAMS lo- Power Bus Bar
cated in the pocket on the back cover page of the The fuse boxes are single bus bar type which feed
manual. power to the main fuses (J-case type) through
CONNECTOR CODE DESCRIPTION their lower contact. Power comes either directly
from the battery or from the voltage regulator/rec-
ACC Accessories tifier through the FB in-line fuse.
ACS Adjustable controlled suspension
BLS Brake lights switch
CAN/US Canada/United States
CAPS Camshaft position sensor
CSS Compressor suspension sensor
CSV Clutch valve solenoid
CTG Coolant temperature gauge
D.E.S.S. Digitally encoded security system
rmr2013-024-002_b

DLC Diagnostic link connector FUSE BOX (LH AND RH)

1. Power bus bar
DPS Dynamic power steering
ECM Engine control module
Power Top Contacts
The top contacts distribute power to the sec-
FB Rectifier/regulator fuse ondary fuses (blade type) and relays, which in
FHGS Front heated grip switch turn, redistribute it to the subsystems or compo-
nents.
FLS Fog light switch
HAS Hood Actuator Switch
MSR Multifunction switch right
LFB Left fuse box
PBM Parking brake module
PBS Parking brake switch
PRS Pillion rider (passenger) switch
RFB Right fuse box
SAS Steering angle sensor rmr2013-024-200_a

FUSE BOX (LH AND RH)

TCM Transmission control module 1. Power top contacts
VCM Vehicle control module
WPM Windshield and parking brake module
YRS Yaw rate sensor

rmr2013-024 1
Subsection XX (POWER DISTRIBUTION AND GROUNDS)

POWER CABLES

rmo2013-003-032_c

1. Voltage regulator/rectifier fuse

LEFT FUSE BOX (LFB)

rmr2013-024-003_a

1. Battery
2. Jump start positive post
3. To starter solenoid
4. To LH fuse box
5. To RH fuse box
6. FB (Voltage regulator/Rectifier fuse)
7. To voltage regulator/rectifier

FUSES AND RELAYS LOCATION

There are 2 fuse boxes and they are located in the
front storage compartment.
Relays are located in both fuse boxes.
rmr2013-024-002_a

J-Case Fuse Identification (J1 to J5)

Direct battery power is supplied J1 to J5 fuses.
J-CASE
DESCRIPTION RATING
FUSE NO.
J1 VCM pump 40 A
J2 VCM valves 25 A
J3 DPS 40 A
J4 Main control 40 A
J5 Cooling fan 30 A
rmo2013-003-011_a

INSIDE FRONT STORAGE COMPARTMENT

1. Left fuse box
2. Right fuse box

The voltage regulator/rectifier 60A fuse (FB) is lo-

cated under the LH service cover in the front stor-
age compartment.

2 rmr2013-024
 Subsection XX (POWER DISTRIBUTION AND GROUNDS)

Blade Fuse Identification (F1 to F8) Relay Identification (R1 to R6)

NO. DESCRIPTION Direct battery power is supplied to R3, R4 and
Direct battery power: R5.
– Cluster (clock) NO. DESCRIPTION
F1 15 A
– D.E.S.S.
R1 Reverse actuator
– Diagnostic link connector (DLC)
Through ignition switch: R2 Pre-starting
– Steering angle sensor (SAS)
– Yaw rate sensor (YRS) R3 Cooling fan
F2 – Vehicle control module (VCM) 10 A R4 Main accessories
– Engine control module (ECM) R5 Main motor
– D.E.S.S.
– Pillion rider switch (PRS) R6 Not used
F3 NOT USED NA
Power from main acc relay (R4) RIGHT FUSE BOX (RFB)
F4 Through fuse: (some models) 20 A
– WPM/PBM
Power from main motor relay (R5)
F5 Through fuse: 5A
– ECM
Power from main motor relay (R5)
F6 Through fuse: 15 A
– Injectors / Coils
Power from main acc relay (R4)
Through fuse:
– Wake-up TCM rmr2013-024-002_a

– DLC
– DPS J-Case Fuse Identification (J1 to J5)
– Cluster Direct battery power is supplied J1 to J5 fuses.
F7 10 A
– Coolant temp gauge (some models)
J-CASE
– Fuel gauge (some models) DESCRIPTION RATING
FUSE NO.
– Front storage LED (some models)
– Hood actuator switch (some models) J1 Not used NA
– Illumination (gauges/switches) J2 Accessories 40 A
– DC acc plug relay (R6) (control) J3 TCM solenoids 20 A
Power from main motor relay (R5)
J4 LO headlamps 30 A
Through fuse:
– H02S J5 HI headlamps 20 A
– CAPS
F8 15 A
– Fuel pump
– EVAP
– Clutch solenoid valve
– Pre-starting relay (R2)

rmr2013-024 3
Subsection XX (POWER DISTRIBUTION AND GROUNDS)

Blade Fuse Identification (F1 to F8) NO. DESCRIPTION

R1 Hi headlamp
R2 Lo headlamp
R3 Load shedding
R4 Suspension (some models)
R5 Main headlamp
R6 DC Accessory plug (some models)

RELAYS
rmr2013-024-002_a

Relays
NO. DESCRIPTION
NOTE: The 4-pin relays can be inverted by 180° at
Direct battery power: installation.
– Ignition switch
Relay Activation
Through ignition switch:
F1 – Day lights 15 A RELAY ACTIVATION CONDITION
– Pilot lights Main motor
– Tail lights (Left fuse box
– License plate light - LFB)
Main When key ON
Direct battery power:
accessories
F2 – Brake light switch 10 A (Left fuse box
– Hazard switch - LFB)
Direct battery power (some models): When engine speed
F3 15 A
– Radio Load shedding reaches approx. 800 RPM
(Right fuse box AND
Direct battery power (some models):
F4 10 A - RFB) Battery voltage is higher
– Trailer than 11 Vdc.
Direct battery power:
F5 – Horn 20 A Relay Deactivation
– Load shedding relay (R3) RELAY DEACTIVATION CONDITION
Direct battery power (some models): Main motor
F6 10 A
– DC acc plug relay (R6) (contacts) (Left fuse box Approx. 40 minutes after key OFF
- LFB)
Direct battery power (some models): Main
F7 10 A
– Front/rear acc plugs (Left fuse box Approx. 30 seconds after key OFF
- LFB)
F8 NOT USED NA When engine speed is lower
Load shedding than approx. 800 RPM
DC PLUGS: FRONT/REAR ACCESSORY PLUGS (Right fuse OR
From factory: Powered when box - RFB) Battery voltage is lower
key ON (Vkey) through F6 than 11 Vdc

Customization: Always powered (Vbat); remove

fuse at F6 location and install at F7 location

Relay Identification (R1 to R6)

Direct battery power is supplied to R1, R2, R3
and R5.

4 rmr2013-024
 Subsection XX (POWER DISTRIBUTION AND GROUNDS)

Relay Pin Identification LOAD SHEDDING RELAY

(R3) PIN IDENTIFICATION
MAIN RELAY MOTOR (R5) PIN IDENTIFICATION
(RIGHT FUSE BOX - RFB)
(LEFT FUSE BOX - LFB)
FUSE
FUSE
FUNCTION BOX CONDITION
FUNCTION BOX CONDITION
PIN
PIN
Direct battery power
12 V input Direct battery power 12 V input
C6 86
at winding From J4 at winding
From J2, then F5
Grounded by ECM B,
Grounded by Cluster, pin 1
pin H2 with Key ON
Control D4 Control 85 when engine reaches approx.
Turns OFF approx. 40 minutes
800 RPM
after key OFF
Direct battery power
12 V input Direct battery power 12 V input
C4 30
at contacts From J4 at contacts
From J2, then F5
12 V See POWER DISTRIBUTION
D6 See POWER DISTRIBUTION
output DIAGRAM 12 V output 87
DIAGRAM
MAIN RELAY ACCESSORIES
(R4) PIN IDENTIFICATION
(LEFT FUSE BOX - LFB)
FUSE BOX PIN IDENTIFICATION
FUSE
FUNCTION BOX CONDITION
PIN
Direct battery power
12 V input
C8
at winding
From J4
Grounded by ECM B,
pin J2 with Key ON
Control D7
Turns OFF approx. 30
seconds after key OFF
Direct battery power
12 V input rmr2013-024-300_a
C7
at contacts
From J4 LH AND RH FUSE BOXES
12 V See POWER DISTRIBUTION
D8
output DIAGRAM

rmr2013-024 5
Subsection XX (POWER DISTRIBUTION AND GROUNDS)

GROUND CABLES

rmr2013-024-006_a

ENGINE GROUND — LH SIDE OF ENGINE, UNDERNEATH

IGNITION COILS
1. Ignition coils
2. Engine ground
rmr2013-024-004_a

1. Battery
2. Jump start negative post
3. Frame ground
4. Engine ground
5. DPS ground (dynamic power steering)

GROUNDS
Ground Location

rmr2013-027-006_a

FUEL TANK GROUND — REAR RH SIDE

1. Fuel tank
2. Fuel tank ground

rmr2013-024-005_a

FRONT GROUNDS — LH FRONT SIDE OF FRAME, NEAR OIL

TANK
1. Oil tank
2. Frame grounds
3. From DPS (dynamic power steering)
4. From wiring harness
5. From engine
6. DPS (dynamic power steering) ground
7. Ignition coil ground
8. Ignition coil ground
9. To jump start negative post

6 rmr2013-024
 Subsection XX (WIRING HARNESS AND CONNECTORS)

WIRING HARNESS AND CONNECTORS

SERVICE TOOLS
Description Part Number Page
CRIMPING TOOL (HEAVY GAUGE WIRE) .................................... 529 035 730 ........................................... 14
CRIMPING TOOL (KOSTAL).......................................................... 529 035 909 ........................................... 11
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 8
ECM TERMINAL REMOVER 2.25................................................. 529 036 175 ............................................. 8
ECM TERMINAL REMOVER 3.36................................................. 529 036 174 ............................................. 8
KOSTAL DIE .................................................................................. 529 035 906 ........................................... 11

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
DELPHI TERMINAL EXTRACTOR ................................................. 12094429 ........................................... 10
TOOL ............................................................................................. AMP- ..................................... 11–12
755430-2

GENERAL
The illustrations 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
Ambient Air Pressure ant Temperature CIC Cargo Inter-connector
AAPTS
Sensor
CL Cluster
ANT Antenna (D.E.S.S.)
COIL Ignition Coil
ACS Adjustable Control Suspension
CSS Compressor Suspension Switch
AUX Audio Connector
CSV Clutch Solenoid Valve
BA Backup Actuator
CTG Coolant Temperature Gauge
BAT Battery
CTS Coolant Temperature Sensor
BLS Brake Light Switch
CES Clutch Switch CL Cluster
BSF Brake Fluid Level Sensor CPS Crankshaft Position Sensor
D2 Diode (starter solenoid)
BHL Bottom Headlight
D3 Diode (ground JT BK10, D3-C, D3-A)
BL Backup Light
DC Accessories 12 Vdc
BLS Brake Light Switch
BST Booster post
CAPS Camshaft Position Sensor
CB Citizen Band DIC Dashboard Inter-connector
CES Clutch Engage Switch
CHAS Ground (frame)

rmr2013-025 1
Subsection XX (WIRING HARNESS AND CONNECTORS)

ABBREVIATION DESCRIPTION HIC Harness Inter-Connector

DLC Diagnostic Link Connector
HL Headlight
HN Horn
HO2S
DPS Dynamic Power Steering Oxygen Sensor

HS Headset

ECM Engine Control Module INJ Injector

EOPS Engine Oil Pressure Switch IK Ignition Key Switch

ETA Electric Throttle Actuator KIC Ignition Key

EVAP EVAP Purge Valve KS Knock Sensor

FB Rectifier/regulator fuse
LBHL Right Bottom Headlight
FCS Front Storage Switch
LCS Left Case Switch
FG
Fuel Gauge LDL Left Daylight

FGS Fog Light Switch LED Front Case LED

FHS Front Heated Grip Switch LHL Left Headlight

FL Fog Light LFB Left Fuse Box

FLF Front Left Flasher LPS Low Brake Pressure Switch

FLH Front Left Heated Grip LRHL Left/Right Headlight

FLS Left Tail Light

Front Left Speaker LTL (Brake, position and turn signal
lights)
FP Fuel Pump MAPS Manifold Absolute Pressure Sensor
FPL MOT Ground (engine)
Front Position Lights

FRF Front Right Flasher

FRH Front Right Heated Grip
FRS MSL
Front Right Speaker Left Multifunction Switch

FSA Front Storage Actuator MSR Right Multifunction Switch

FSS Front Storage Switch
GBPS Gearbox Position Sensor
PBM
GND Ground
Parking Brake Module

PBS Parking Brake Switch

GPS
GPS (global positioning system) PIC
Panel Inter-Connector
GSC Gear Solenoid Connector
PL License Plate Light
HA Hood Actuator
PRC Passenger Radio Control
HBS Parking Brake Light Switch

2 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

PRS Pillion Rider Switch VCM Vehicle Control Module

Pressure and Temperature Sensor VIM Vehicle Immobilizer Module
PTS
Connector (AAPTS) (theft protection device)
R1, R4, R5 Resistor (compressor suspension switch) VR Voltage Regulator
RBHL Right Bottom Headlight VSS
RCF Cooling Fan (right) Vehicle Wheel Speed Sensor
RCS Right Case Switch
RDL Right Daylight WM
Adjustable Windshield Motor
RDO1 Radio
RFB Right Fuse Box WPM Windshield and Parking Brake Module

RHL Right Headlight YRS Yaw Rate Sensor

RHS Rear Heated Grip Control

RLF Rear Left Flasher
RLH Rear Left Heated Grip
RLS
Rear Left Speaker

RRF Rear Right Flasher

RRH Rear Right Heated Grip
RRS
Rear Right Speaker

Right Tail Light

RTL (Brake, position and turn signal
lights)
SAS Steering Angle Sensor
SH Shutter (HI/LO beam)
SM Starter Motor
SPK Spark plug
SPS Suspension Position Sensor
SRS Suspension Release Sensor
SRV Suspension Release Valve
STS Starter Solenoid

TANK Ground (fuel tank)

TAS Throttle Accelerator Sensor
TCM Transmission Control Module
TCS Top Case Switch
TIC Transmission Control Module (interface)
TL Tail Light
TPS Throttle Position Sensor

rmr2013-025 3
Subsection XX (WIRING HARNESS AND CONNECTORS)

PROCEDURES
WIRING HARNESS
Wiring Harness Replacement
The wiring harness is routed through the center of
the SST frame.

rdd2011-001-025

Begin by taping all the connectors together flat

and lined up behind one another.

rdd2011-001-023

It exits through the bottom rear of the SST frame.

rdd2011-001-026_a

1. Upper frame member opening

Leave the pull through loop that is incorporated

into the harness exposed.

rdd2011-001-024

All these connectors need to be pulled through

the frame.

rdd2011-001-027

4 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

Snake a pull wire through the frame and loop it 1

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.

F18Z0LA 2
TYPICAL
1. Flat screwdriver
2. Deutsch connectors

rdd2011-001-028

DEUTSCH CONNECTOR
Deutsch Connector Identification
The Deutcsh connectors are easily identified by
the orange secondary lock inserted in front of the
female terminals.

F18Z0NA 2 1
3 1
TYPICAL
1. Deutsch connectors
2. Press release button

Deutsch Terminal Replacement

NOTICE Do not apply dielectric grease on ter-
minal inside connector.
3
2 To remove terminals from connector, proceed as
4 follows:
F00H1CA
– Using a long nose pliers, pull out the lock.
1. Male connector
2. Female connector
3. Secondary lock (orange)
4. 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.

rmr2013-025 5
Subsection XX (WIRING HARNESS AND CONNECTORS)

V01G0QA 1
TYPICAL — FEMALE CONNECTOR
V01G0OA 1 1. Retaining tab

TYPICAL — FEMALE CONNECTOR To install:

1. 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.
6. After all required terminals have been inserted,
the lock must be installed.

1 1
V01G0PA 1
TYPICAL — MALE CONNECTOR
1. Male lock

NOTE: Before extraction, push wire forward to re-

lieve pressure on retaining tab.
1. Insert a 4.8 mm (.189 in) wide screwdriver F04H6LA
blade inside the front of the terminal cavity.
TYPICAL
2. Pry back the retaining tab while gently pulling 1. Wire identification numbers
wire back until terminal is removed.
MOLEX CONNECTOR (ECM)
There are two 48-pinconnectors on the ECM.

6 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

CONNECTOR
CONNECTION
IDENTIFICATION
A Engine wiring harness
B Vehicle wiring harness

Do not apply any lubricant product to the pins of

the connector on the ECM.

smr2009-045-012_a

Pull out connector.

smr2009-027-005

ECM CONNECTORS

MOLEX Connector Removal

To reach ECM connector, refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.
Push and hold the locking tab of the desired con-
nector.

smr2009-045-013_a

MOLEX Connector Installation

Fully open connector lock.

smr2009-045-011_a

Rotate connector lock until it stops.

smr2009-045-013_b

Install connector to ECM.

Rotate connector lock until it snaps locked.

rmr2013-025 7
Subsection XX (WIRING HARNESS AND CONNECTORS)

NOTICE 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

(Harness Connector)
To remove a signal terminal from ECM harness
connector, use the ECM TERMINAL REMOVER 2.25
(P/N 529 036 175). To remove a power terminal,
use the ECM TERMINAL REMOVER 3.36 (P/N 529
036 174).

smr2009-045-011_b

1. Locked here

MOLEX Connector Probing

The most recommended and safest method to
probe ECM connector terminals is to use the ECM
ADAPTER TOOL (P/N 529 036 166). This tool will
prevent deforming or enlarging terminals which
would lead to bad ECM terminal contact creating 529036175

intermittent or permanent problems.

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.
smr2009-045-025_a

Insert tool to unlock terminal.

vmr2008-139-016_a

TYPICAL
1. ECM connector
2. ECM adapter

8 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

smr2009-045-026_a

1. Unlock here

vmr2006-032-001_a

TYPICAL – GAUGE CONNECTOR

Packard Connector Terminal

Replacement
Push on both tabs to remove retainer.

smr2009-045-027_a

WARNING
Before terminal installation, ensure all ter-
minals are properly crimped on wires. After
rmr2008-078-053_a
plugging connectors, ensure they are prop-
TYPICAL – TCM CONNECTOR
erly fastened. 1. Retainer
2. Tab (one on each side)

PACKARD CONNECTOR (TCM
AND GAUGE)
Packard Connector Removal
Firmly push down tab and hold to unlock connec-
tor while pulling it out.
Cut locking tie securing connector housing to har-
ness.
Open housing by lifting 3 tabs.

rmr2008-078-054_a

TYPICAL – TCM CONNECTOR

1. Tabs

rmr2013-025 9
Subsection XX (WIRING HARNESS AND CONNECTORS)

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.

smr2009-045-014_a

1. Unlock terminal here

A32E3XA

TYPICAL
1. Lift and hold plastic lock
2. Lift to unlock and push out smr2009-045-015_a

WARNING
Before terminal installation, ensure all ter-
minals are properly crimped on wires. After
plugging connectors, ensure they are prop-
erly fastened.
WARNING
Before terminal installation, ensure all ter-
minals are properly crimped on wires. After
plugging connectors, ensure they are prop-
erly fastened.

DELPHI CONNECTORS (DPS) AMP MULTILOCK CONNECTOR

Delphi Connector Terminal Connector Disassembly (Male
Replacement Housing)
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
required.

A32Z01A

10 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

Insert TOOL (P/N AMP-755430-2) under lock and

twist to lift it.

1
A32Z05A 1
FEMALE HOUSING — CUT-AWAY
1. Lock

Terminal Crimping (Multilock and AMP

8-circuits)
To crimp a new connector terminal, use the
A32Z02A
CRIMPING TOOL (KOSTAL) (P/N 529 035 909) and
the KOSTAL DIE (P/N 529 035 906).
MALE HOUSING — CUT-AWAY
1. Lock

Female terminals can be removed from housing

with sharp head pin.

Connector Disassembly (Female

Housing)
529035909

CRIMPING TOOL

To properly crimp the wires, strictly follow this pro-

cedure.
Strip the wire to a maximum of 3 mm (1/8 in).

A
A32E2QA

TYPICAL
A. 3 mm (1/8 in) max.

A32Z04A
Position wire in terminal.
Squeeze the terminal tabs with your fingers to
Insert TOOL (P/N AMP-755430-2) under lock and temporarily retain terminal in place.
twist to lift it.

rmr2013-025 11
Subsection XX (WIRING HARNESS AND CONNECTORS)

A33Z04A 1
1. Lock
A32E3YA

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.

A33Z05A 1
AMP 8-CIRCUIT CONNECTOR — CUT-AWAY
1. Tab

Terminal Crimping
Refer to TERMINAL CRIMPING (MULTILOCK
A32E3ZA
AND AMP 8-CIRCUITS) for procedure.
1. Top of terminal tabs
2. Align tabs with pliers edge
DELPHI CONNECTOR (VCM)
Crimp terminal. Ensure no tiny wire goes out of
terminal. This might cause strange problems of
VCM Connector Removal
the electrical system. WARNING
VCM motor and valves are continuously
AMP CONNECTOR (8-CIRCUIT) powered from battery. Always disconnect
Connector Disassembly the battery prior to disconnecting VCM con-
nector.
Pry housing to release lock.

NOTICE Improper connector handling may

lead to breakage.
Slide out the RED locking device.

12 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

VCM Connector Installation

Ensure lock lever it fully opened.

rmr2013-025-230_a

1. RED locking device

Pull the locking lever.

rmr2013-025-232_a

1. Lock lever fully opened

Position the connector on the ECM.

Pivot lock lever to the end of its stroke.
Fully slide the RED locking device to secure the
locking lever.

rmr2013-025-231_a

1. Locking lever

Pivot lock lever until it reaches the end of its

stroke.

rmr2013-025-230_b

rmr2013-025-232_a

1. Lock lever fully opened

Pull out connector.

rmr2013-025 13
Subsection XX (WIRING HARNESS AND CONNECTORS)

VCM Connector Disassembly

A32E2RA

INSTALLATION OF TERMINAL

Follow the instructions provided with the CRIMP-

ING TOOL (HEAVY GAUGE WIRE) (P/N 529 035 730)
to select the proper position of the tool.

rmr2013-025-233_a

Step 1: Cut locking ties

Step 2: Slide down cover
Step 3: Unlock cover here (both sides) 529035730
Step 4: Lift up cover
NOTE: Different wires require different crimp pli-
Use an appropriate terminal extraction tool to un- ers settings, so make sure to follow the instruc-
lock and push terminal out. tion supplied with the tool.

BATTERY CABLE TERMINAL

Terminal Installation
Carefully strip the wire approximately to 13 mm
1
(1/2 in) in length, using a wire stripping tool or
sharp blade/knife.

2
A A32E2SA

A32E2QA
POSITIONING THE CRIMP PLIERS
Step 1: Press
A. 13 mm (1/2 in) Step 2: Rotate

NOTE: Make sure not to cut wire strands while After positioning the crimp pliers, crimp the termi-
stripping the wire. nal already installed on wire.
Install the appropriate terminal on the wire ac-
cording to the requirement. Refer to appropriate
PARTS CATALOG.

14 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

A32E2TA

CRIMPING OF WIRE

A32E2UA

PROPERLY CRIMPED WIRE

To verify, if the wire is properly crimped, apply

some pulling force on wire and the terminal at the
same time from both directions.
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.

rmr2013-025 15

IGNITION SYSTEM
SERVICE TOOLS
Description
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 2, 8
SERVICE PRODUCTS
Description
HEAT-SINK PASTE P12.................................................................. 420 897 186 ........................................... 10
GENERAL
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed, must be
replaced (e.g.: 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.
WARNING
Never check for engine ignition spark from
an open coil and/or spark plug as spark may
cause potential fuel vapors to ignite. Always
use an approved spark tester.
SYSTEM DESCRIPTION
The engine management system (EMS) controls
the ignition system as well as many other engine
related functions. It can detect many abnormali-
ties including an open or short circuit in the pri-
mary winding of the ignition coils as well as its as-
sociated circuits.
The battery supplies power to the primary side of
the ignition coils through a relay while the ECM
completes the circuit to each coil primary winding
by switching it to ground at the appropriate mo-
ment.
With the primary coil circuits switched ON and
OFF by the ECM, the secondary coil circuits sup-
ply the high energy to fire the spark plugs as re-
quired for proper engine operation.
Ignition Timing
Ignition timing is not adjustable.
rmr2013-026
Subsection XX (IGNITION SYSTEM)
Part Number Page
Part Number Page
The ECM is programmed with data (ignition map-
pings) that it uses to provide optimum ignition tim-
ing.
It receives signals from a variety of sensors that
tell it what the engine is doing and what are the
operating conditions. It compares all the data it
receives with the ignition mappings and uses it
to control the ignition spark timing, duration and
firing order to ensure optimum engine operation.
The crankshaft position sensor (CPS), the man-
ifold absolute pressure sensor (MAPS) and the
throttle position sensor (TPS) are the primary
sensors used to control the ignition timing.
Engine RPM Limiter
The ECM will limit the maximum engine speed by
cutting off ignition spark and fuel at a predeter-
mined engine RPM.
ENGINE SPEED LIMITATION
9500 RPM
TROUBLESHOOTING
It is good practice to check for fault codes using
B.U.D.S. as a first troubleshooting step. Refer to
DIAGNOSTIC AND FAULT CODES subsection.
Refer to POWER DISTRIBUTION AND GROUNDS
for fuses and relays information.
Always refer to the WIRING DIAGRAM when
troubleshooting an electrical circuit.
NOTE: Install a battery charger on jump start
posts in front storage compartment for any tests
that involve a prolonged "key ON" period. If bat-
tery voltage gets too low, some accessories are
shut off by the ECM and test results can be al-
tered.
NOTICE Never force a multimeter probe into
an electrical terminal.
1
Subsection XX (IGNITION SYSTEM)

TROUBLESHOOTING 4. Carry out an IGNITION SWITCH OUTPUT VOLT-

GUIDELINES AGE TEST (TO ECM).

Lights or Gauge Do not Come on Ignition Switch Output Voltage Test

when the Ignition Switch is Turned ON (to ECM)
1. Check battery and cables condition. 1. To gain access to the ECM connector, refer
2. Carry out an IGNITION SWITCH OPERATION to ECM LOCATION ACCESS in ELECTRONIC
TEST. See procedure in this subsection. FUEL INJECTION (EFI) subsection. .
2. Disconnect ECM connector "B". For connector
Misfires or no Ignition Spark on One identification, refer to WIRING HARNESS AND
or both Cylinders CONNECTOR subsection.
1. Check fuse F6 in LH fuse box. REQUIRED TOOL
2. Check spark plug(s), refer to SPARK PLUGS in
this subsection. ECM ADAPTER TOOL
3. Check spark plug cable(s), refer to SPARK (P/N 529 036 166)
PLUGS CABLES in this subsection.
4. Carry out an ignition coil test with B.U.D.S. See
3. Connect adapter on ECM connector "B".
IGNITION COILS in this subsection.
4. Set multimeter to Vdc.
PROCEDURES 5. Turn ignition switch ON.
NOTE: Because of lights and accessories current
IGNITION SWITCH consumption, a slight battery voltage drop is nor-
mal.
Ignition Switch Operation Test
6. Measure voltage as per table.
Turn ignition switch ON. The following should
come on:
– Multifunction gauge (assuming it works)
– LH and RH marker lights
– License plate light
– Taillight.
If Nothing Came ON, Check the Following in
this Order:
1. TheJ4 main fuse in LH fuse box
2. Fuses F1 and F2 in LH fuse box (both must be
smr2009-030-010_d
blown for complete quick test failure).
Check voltage at J4 fuse input terminal. IGNITION SWITCH OUTPUT VOLTAGE
If there is no voltage, check for an open circuit be- TEST (TO ECM)
tween battery and rear fuse box. TEST PROBES VOLTAGE
If there is voltage, check for an open circuit be- ECM connector
tween J4 fuse and fuses F1 and F2 in LH fuse box. Ground Battery voltage
"B" pin A2
If Lights Came ON but the Multifunction If voltage is adequate, check ECM input voltage
Gauge did not, check the Following in this
Order: from main relay motor (R5) and ECM ground
circuits, refer to ELECTRONIC FUEL INJECTION
1. Fuse F2 in LH fuse box. (EFI).
2. Check main relay motor (R5) and related cir- If there is no voltage, isolate the open section of
cuits, refer to POWER DISTRIBUTION AND the circuit:
GROUNDS subsection. – Between J4 fuse and F2 fuse in LH fuse box
3. Multifunction gauge connector, and associated – Between F2 fuse and ignition switch pin A
circuits – Between ignition switch pin G and ECM.
2 rmr2013-026
 Subsection XX (IGNITION SYSTEM)

If no wire is open, carry out an IGNITION SWITCH IGNITION SWITCH CONTINUITY TEST
CONTINUITY TEST.
IGNITION SW IGNITION SW
NOTE: Use B.U.D.S. to reset fault codes gener- TEST PROBES
OFF ON
ated when voltage check was carried out with
ECM adapter. A – G Infinite (OL) Close to 0
B – F Infinite (OL) Close to 0
Ignition Switch Continuity Test
M – I Close to 0 Infinite (OL)
IGNITION SWITCH CIRCUIT FUNCTIONS
Any other pin
PINS CIRCUIT FUNCTIONS Infinite (OL) Infinite (OL)
combinations
A – G Ignition Any pin to
Infinite (OL) Infinite (OL)
battery ground
B – F Lights
M – I Ignition circuit to ground The following gives the circuit functions through
ignition switch:
Remove the ignition switch (refer to IGNITION If you do not obtain the above resistance values,
SWITCH REMOVAL). replace the ignition switch.
Set multimeter to . NOTE: Replace ignition switch and D.E.S.S. mod-
Probe switch contacts as per table below and note ule as a unit.
resistance values.
Ignition Switch Removal
ST/RS Models
Refer to BODY and STEERING SYSTEM subsec-
tions and:
– Remove RH front panel
– Remove dashboard panel
– Detach handlebar lower cover
– Detach handlebar upper cover
– Remove handlebar central cover
Unhook latch cables (seat and front storage com-
partment).

rmr2008-023-503_a

rmr2008-023-006

TYPICAL

Slide ignition switch protector downward.

rmr2013-026 3
Subsection XX (IGNITION SYSTEM)

rmr2013-026-013_a
rmr2008-023-007_b
SEVERAL PARTS REMOVED FOR CLARITY PURPOSE ONLY
TYPICAL 1. YRS
2. D.E.S.S. antenna connector
Disconnect ignition switch main connector.
Remove ignition switch retaining screws.

rmr2008-023-008_a

TYPICAL
rmr2008-023-009
Disconnect ignition switch D.E.S.S. antenna con- TYPICAL
nector. It is located underneath the yaw rate sen-
sor (YRS). Refer to VEHICLE STABILITY SYSTEM Remove ignition key.
(VSS) subsection for procedures to gain access to Raise ignition switch and hold in this position.
the YRS connector.
Turn ignition switch top cover counterclockwise to
unlock.
Pull out top cover.

4 rmr2013-026
 Subsection XX (IGNITION SYSTEM)

rmr2010-026-002_c

4. Disconnect ignition switch main connector (at

rmr2008-023-010_a
switch).
TYPICAL 5. Disconnect ignition switch antenna D.E.S.S.
connector. It is located above the D.E.S.S.
Remove ignition switch. module. Refer to the DIGITALLY ENCODED
RT Models SECURITY SYSTEM (D.E.S.S.) subsection for
procedures to gain access to the connector.
1. Remove console module, refer to BODY sub-
section.
2. Unhook latch cables (seat and front storage
compartment) and glove box lock cable.

rmr2013-029-002_c

1. D.E.S.S. module
rmr2010-026-002_b 2. D.E.S.S. antenna connector
1. Latch and lock cables
6. Remove ignition switch retaining screws.
3. Cut locking tie and slide ignition switch protec-
tor downwards.

rmr2010-026-004_a

1. Retaining screws

rmr2013-026 5
Subsection XX (IGNITION SYSTEM)

7. Remove ignition key.

8. Raise ignition switch and hold in this position.
9. Turn ignition switch top cover counterclockwise
to unlock.
10. Pull out top cover.

rmr2010-026-002_a

TYPICAL — RT MODELS
1. RH SIDE: To seat
2. CENTER: to glove box
3. LH SIDE: To front storage compartment

IGNITION COILS
Ignition Coil Access
Remove the LH middle side panel. Refer to BODY
subsection:
rmr2008-023-010_a

TYPICAL
Step 1: Raise ignition switch
Step 2: Turn top cover
Step 3: Remove top cover

11. Remove ignition switch.

Ignition Switch Installation

For installation, reverse removal procedures.
However, pay attention to the following.
NOTE: Program new keys before completing in-
stallation. Refer to DIGITALLY ENCODED SECU-
RITY SYSTEM (D.E.S.S.) subsection.
Install latch cables on switch as shown. rmr2010-026-001_a

TYPICAL
1. Ignition coil
2. Oil tank

rmr2008-023-011_a

TYPICAL— RS/ST MODELS

1. RH SIDE: To seat
2. LH SIDE: To front storage compartment

6 rmr2013-026
 Subsection XX (IGNITION SYSTEM)

rmr2013-026-001_a

1. Front ignition coil

2. Rear ignition coil

NOTE: Ensure each coil spark plug cable is con-

vmr2006-018-100
nected to the appropriate cylinder.
TYPICAL

Ignition 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.

rmr2008-062-001_a

1. To front cylinder spark plug

2. To rear cylinder spark plug

You should hear the spark occurring. If in doubt,

use an inductive spark tester.
NOTE: Keep in mind that even if there is a spark
during this static test, voltage requirement is
higher to produce a spark in the combustion
chamber when the engine is running. The igni-
tion coil may not be working properly in actual
operation. Replacing the ignition coil may be
rmr2011-024-006_b

1. Retaining nut
necessary as a test.
2. Ground cable If spark occur, check spark plugs and spark plugs
Tighten a NEW nut to specified torque. cables.
If there is no spark, carry out IGNITION COIL IN-
TIGHTENING TORQUE PUT VOLTAGE TEST.
Ignition coil retaining nut 10 N•m (89 lbf•in)
Ignition Coil Input Voltage Test
Ignition Coil Test with B.U.D.S. Disconnect the ignition coil input connector.
In B.U.D.S., select the Activation and ECM tabs. Turn ignition switch ON.
Energize the ignition coil for each spark plug alter- Using a multimeter set to Vdc, read voltage as fol-
nately by clicking on the coil illustration. lows.

rmr2013-026 7
Subsection XX (IGNITION SYSTEM)

IGNITION COIL INPUT VOLTAGE TEST Ignition Coil Control Circuit Continuity
Test
TEST PROBES VOLTAGE
1. Remove key from ignition switch.
Close to
Coil connector 2. Remove J4 fuse in LH fuse box.
Ground battery
pin 2
voltage 3. To gain access to the ECM connector, refer
to ECM LOCATION ACCESS in ELECTRONIC
FUEL INJECTION (EFI) subsection.
4. Disconnect ECM connector "A". For connector
identification, refer to WIRING HARNESS AND
CONNECTOR subsection.
REQUIRED TOOL

ECM ADAPTER TOOL

...
V (P/N 529 036 166)

5. Connect adapter on ECM connector "A".

6. Set multimeter to .
smr2005-057-016_a

TYPICAL
7. Measure resistance between ignition coil con-
nector and ECM connector as per following ta-
If battery voltage is read, carry out an IGNITION ble.
COIL RESISTANCE TEST.
If voltage is significantly lower than battery volt-
age, measure voltage as per table.
TEST PROBES VOLTAGE
LH fuse box, Close to
Battery
Fuse F6 input battery
ground
terminal voltage

rmr2010-026-007_a

IGNITION COIL GROUND CIRCUIT

CONTINUITY TEST
TEST PROBES RESISTANCE

rmr2013-024-002_c
Ignition coil ECM
connector connector "A" Close to 0
If voltage reaches fuse, check for an open circuit pin 1 pin M2
between fuse and coil connector. Ignition coil ECM
If voltage does not reach fuse, check the follow- connector connector "A" Close to 0
ing: pin 3 pin M1
– An open circuit between main relay motor (R5)
and fuse F6. If resistance readings are high or infinite, check for
an open circuit or parasitic resistance.
– Defective main relay motor (R5) or related cir-
cuits, refer to POWER DISTRIBUTION AND If resistance is close to 0 , try a new ECM.
GROUNDS subsection.

8 rmr2013-026
 Subsection XX (IGNITION SYSTEM)

Ignition Coil Resistance Test CABLE POSITION CABLE RESISTANCE

An ignition coil with good resistance measure- Front cylinder 5.11 to 8.72 k
ments can still be faulty. Voltage leak can occur
at high voltage levels which is not detectable with Rear cylinder 3.24 to 5.53 k
an ohmmeter. Replacing the ignition coil may be
necessary as a test. If cables do not meet specifications, replace ca-
bles.
Primary Windings
Disconnect the ignition coil connector. SPARK PLUGS
Using a multimeter, check resistance in primary Spark Plug Removal
windings as follows.
Refer to BODY subsection and remove panels on
both sides:
– Middle side panel
– Top side panel
– Front panel
Front Spark Plug Access (RH Side)
Refer to AIR INTAKE SYSTEM subsection and re-
move air filter cover.
Try removing cable and spark plug using:
– long nose pliers
– a ratchet
– an extension with a universal joint
rmr2008-023-518_a

RESISTANCE
TEST PROBES (IGNITION COIL)
@ 20°C (68°F)
Pin 2 Pin 1
0.3 to 0.6
Pin 2 Pin 3

If a resistance reading is not as specified, replace

the ignition coil.
If resistance readings are as specified, carry out an
IGNITION COIL CONTROL CIRCUIT CONTINUITY
TEST.
Secondary Windings
Due to the integrated diode, it is not possible to
measure the secondary windings resistance.
rmr2008-023-12_a

SPARK PLUG CABLES TYPICAL

Spark Plug Cable Resistance Test
Inspect each spark plug cable condition. If cable
ends, sheath (insulator) or contacts are in poor
condition, replace them.
If cables are in good condition, carry out a resis-
tance check as follows.
Disconnect each spark plug wire from the coil as-
sembly and spark plugs.
Measure each cable resistance and compare to
following chart.
If it cannot be done, remove air filter housing.
Removal
Unscrew the spark plug one turn.
Clean the spark plug and cylinder head with pres-
surized air, then completely remove spark plug.
Troubleshooting Fouled Spark Plug
Fouling of the spark plug is indicated by:
– Irregular running of the engine.
– Decreased engine speed due to misfiring.

rmr2013-026 9
Subsection XX (IGNITION SYSTEM)

– Reduced performance. SERVICE PRODUCT

– Increased fuel consumption.
HEAT-SINK PASTE P12 (P/N 420 897 186)
Possible causes:
– Loss of compression.
– Prolonged idling or low-speed riding.
– Clogged air filter.
– Incorrect fuel.
– Defective ignition system.
– Incorrect spark plug gap.
– Lubricating oil entering the combustion cham-
ber. vmr2008-024-002_a

The plug face of a fouled spark plug has either: 1. Heat-sink paste here
– A wet black deposit. Hand screw spark plugs into cylinder head.
– A black carbon fouling.

Spark Plug Analysis

1 2

A00E0AA 1 2 3
TYPICAL A00E0BA
1. Overheated (light grey, white)
2. Normal (light brown, brown) 1. Proper socket
3. Fouled (black, wet or dry, dark deposits, grey, melted coating) 2. Improper socket

The plug face (part of the plug projecting into the Use a spark plug socket and torque spark plugs to
combustion chamber) reveals the condition: specification.
– Of the engine.
TIGHTENING TORQUE
– Operating condition.
– Method of driving. Spark plug 19 N•m (168 lbf•in)
– Fuel mixture.
Therefore, inspect the spark plug at regular inter-
vals and to examine the plug face.

Spark Plug Gap Verification

Use a feeler gauge to check electrode gap.
SPARK PLUG GAP
SPARK PLUG TYPE GAP
0.7 mm to 0.8 mm
NGK KR8Bi (irridium)
(.028 in to .031 in)

Spark Plug Installation

Apply the recommended paste on the spark plug
threads and gasket to allow proper cooling of
spark plug.

10 rmr2013-026
 Subsection XX (CHARGING SYSTEM)

CHARGING SYSTEM
SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................................... 2

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
EXTECH AMMETER ..................................................................... model ........................................... 3
380941
NAPA ULTRA PRO BATTERY LOAD TESTER ............................... 95260 ........................................... 7

SERVICE PRODUCTS
Description Part Number Page
DIELECTRIC GREASE ................................................................... 293 550 004 ........................................... 8

GENERAL
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed, must be
replaced (e.g.: 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.

SYSTEM DESCRIPTION
The purpose of the charging system is to keep
the battery at a full state of charge and to provide
the electrical system with the required electrical
power for normal vehicle operation.
Magneto
The magneto is the primary source of electrical
power. It transforms a magnetic field into an al-
ternating current (AC).
The magneto has a 3 phase delta wound stator.
The magneto is capable of 52 amperes.
vmr2006-017-001
TYPICAL
Voltage Regulator/Rectifier
The voltage regulator/rectifier receives AC current
from the magneto and transforms it into direct cur-
rent (DC).
The direct current is then supplied to the battery
for charging and to the vehicles systems through
the RFB fuse (60 A).
The voltage regulator/rectifier limits voltage to
prevent damage to electrical components.

rmr2013-027 1
Subsection XX (CHARGING SYSTEM)

– Quickly measure battery voltage.

– Quickly measure output current from voltage
regulator/rectifier.

INSPECTION
CHARGING SYSTEM OUTPUT
DC Voltage Output Test
1. Open front storage compartment cover.
rmr2010-027-004 2. Remove LH service cover.
TYPICAL – VOLTAGE REGULATOR/RECTIFIER
3. Remove RED rubber protector from positive (+)
Battery terminal.
The battery supplies DC power to the electric
starter for cranking the engine. During engine
starting, it also supplies DC power to all the
electrical and electronic systems. At low engine
RPM operation and high current load conditions,
it supplements the magneto output if required,
and helps to maintain a steady system voltage.

Jump Start Posts

Located under the LH service cover in the front
storage compartment.

rmo2013-003-032_a

1. NEGATIVE (-) post

2. POSITIVE (+) post

4. Set the FLUKE 115 MULTIMETER (P/N 529 035

868) to Vdc scale.
5. Connect multimeter between the positive (+)
and negative (-) posts.
6. Read battery voltage.
STATIC BATTERY VOLTAGE
12.6 Vdc minimum
rmo2013-003-032_a

1. NEGATIVE (-) post

2. POSITIVE (+) post
TEST RESULTS
Terminal posts are connected to the battery posts.
VOLTAGE INDICATION WHAT TO DO
Convenient terminal posts provided to:
Completely charge
– Quickly jump start the engine. Lower than Bad state of
battery before
– Connect a battery charger or power pack: specification charge
continuing
• To charge battery. Above Superficial Carry out a test with
• To continuously supply the electrical system specification charge the engine running
for electrical tests, reflashing electronic mod-
ules etc. 7. Start engine.

2 rmr2013-027
 Subsection XX (CHARGING SYSTEM)

8. Load the electrical system by turning ON: NOTICE Use an inductive ammeter capable
– Headlights on high beam of measuring over 20 A.
– Heated grips to high. 1. Open front storage compartment cover.
During the test: 2. Remove LH service cover.
– do not turn the handlebar to avoid DPS current
3. Clamp an inductive ammeter such as the EX-
draw
TECH AMMETER (P/N MODEL 380941) over the
– do not activate any other accessories RFB fuse cable coming from the voltage regu-
– make sure the cooling fan does not turn ON lator/rectifier.
9. Read voltage.
Voltage should be within following specification.
DC VOLTAGE OUTPUT TEST
TEST ENGINE SPEED VOLTAGE
4000 RPM 13.0 - 14 Vdc

TEST RESULTS
VOLTAGE WHAT TO DO
Within Complete inspection with the DC
specification CURRENT OUTPUT TEST
Significantly
above Replace voltage regulator/rectifier rmr2013-027-001_a

specification OUTPUT DC CURRENT TEST

– The RED battery indicator light 4. Start engine.

will come on in the
Exceeds
multifunction gauge
16 Vdc
– The HIGH BATT VOLT fault
message will be displayed
Turn engine OFF and check the
following:
– Both connectors are properly
connected to voltage
regulator/rectifier
– RFB regulator/rectifier fuse (60 A).
Does not
Refer to POWER DISTRIBUTION
increase or
drops
AND GROUNDS subsection
– Connection condition at jump start
posts and battery posts.
– If connectors, fuse and connections
are good, carry out a VOLTAGE
REGULATOR/RECTIFIER WIRING
TEST (OUTPUT SIDE)
DC Current Output Test
This test should be carried out as a complement
to the DC voltage output test.
Test vehicle under normal operating loads:
– no additional accessories turned on
– do not turn handlebar to avoid DPS current draw
– make sure the cooling fan does not turn ON
5. Read current.
OUTPUT DC CURRENT TEST
TEST ENGINE SPEED CURRENT
4000 RPM Minimum 10 A
If current reading is significantly below specifica-
tion, do the following:
– Check stator wires (YELLOW) and terminals at
voltage regulator for damage.
– Test stator, refer to MAGNETO AND STARTER
subsection.
– Carry out VOLTAGE REGULATOR/RECTIFIER
WIRING TEST (OUTPUT SIDE) in this subsec-
tion.
NOTE: A current above specification indicates a
charging system working harder than expected
because of a weak battery or an electric device
turned ON.
TROUBLESHOOTING
It is good practice to check for fault codes using
the B.U.D.S. software as a first troubleshooting
step. Refer to DIAGNOSTIC AND FAULT CODES
subsection.

rmr2013-027 3
Subsection XX (CHARGING SYSTEM)

Refer to POWER DISTRIBUTION AND GROUNDS Repetitive Blown RFB Fuse

for fuses and relays information. The possible causes for a repetitively blown RFB
Always refer to the WIRING DIAGRAM when are:
troubleshooting an electrical circuit. – Voltage regulator/rectifier internal circuit
Install a battery charger on jump start posts for shorted to ground.
any tests that involve a prolonged "key ON" period. – DC output (RED) wire shorted to ground.
If battery voltage gets too low, some accessories Refer to VOLTAGE REGULATOR/RECTIFIER TEST
are shut off by the ECM and test results can be FOR REPETITIVE BLOWN RFB FUSE in this sub-
altered. section.
NOTICE Never force a multimeter probe into
an electrical terminal. PROCEDURES
TROUBLESHOOTING VOLTAGE REGULATOR/
GUIDELINES RECTIFIER
Weak or Discharged Battery Static Test
If the battery is weak or discharged, check the fol- Due to internal circuitry, there is no static test
lowing: available.
– High key off current draw.
• Normal current draw: 10 - 20 mA.
Voltage Regulator/Rectifier Wiring Test
(Output Side)
• First 40 minutes after key off: 350 - 500 mA
– D.E.S.S. fuse OR battery disconnected and re- 1. Remove the RH bottom plate.
connected without turning the ignition key ON.
– Check regulator/rectifier fuse (RFB) at jump
start posts.
– Check jump start post connections. Refer to
BATTERY in this subsection.
– Check battery and connections. Refer to BAT-
TERY in this subsection.
– Check items in LOW OR NO CHARGING SYS-
TEM VOLTAGE.
– Check charging current output, refer to IN-
SPECTION in this subsection.
Low or No Charging System Voltage
If charging system voltage is low, the engine may
be unstable, or stall.
rmr2013-027-005_a
Test the following items:
TYPICAL
– Regulator/rectifier fuse (RFB) at jump start 1. RH bottom plate
posts.
2. Disconnect the 2-wire connector on the voltage
– Charging system voltage, refer to INSPECTION
regulator/rectifier.
in this subsection.
– Test stator, refer to MAGNETO AND STARTER
subsection.
– Wiring and connections, refer to VOLTAGE
REGULATOR/RECTIFIER in this subsection.

4 rmr2013-027
 Subsection XX (CHARGING SYSTEM)

rmr2013-027-002_a rmr2013-027-002_a

RH SIDE VIEW — ON BOTTOM FRAME MEMBER RH SIDE VIEW — ON BOTTOM FRAME MEMBER
1. Regulator/rectifier 1. Regulator/rectifier
2. 2-wire connector 2. 2-wire connector

3. Set multimeter to Vdc. 2. Install a new fuse.

4. Connect multimeter as per following table to If the fuse still burns, check for a shorted wiring
test the DC output wire. or connector pins.
VOLTAGE DC OUTPUT WIRE TEST If fuse does not burn, replace regulator/rectifier.
PROBES VOLTAGE Voltage Regulator/Rectifier
Pin 1 Replacement
Chassis ground Battery voltage
(RED wire) The voltage regulator/rectifier is located on bot-
tom frame member in front of engine.
If voltage is NOT as specified, repair wire or con-
nector. 1. Remove the RH bottom plate.
If voltage is as specified, check ground wire as per
following table.
GROUND WIRE TEST
PROBES VOLTAGE
Pin 3 Pin 1
Battery voltage
(BLACK wire) (RED wire)

If voltage is NOT as specified, repair wire or con-

nector.
NOTE: A conventional test light can be used to
check wiring. It should light brightly indicating
there is no parasitic resistance in the circuits.

Voltage Regulator/Rectifier Test for

Repetitive Blown RFB Fuse rmr2013-027-005_a

1. Disconnect the voltage regulator/rectifier 1. RH bottom plate

2-wire connector.
2. Disconnect the two connectors attached to the
voltage regulator/rectifier.

rmr2013-027 5
Subsection XX (CHARGING SYSTEM)

BATTERY
Battery Information
These vehicles are equipped with a VRLA battery
(Valve Regulated Lead Acid).
It is a sealed, maintenance-free, non-spillable
type battery.
Refer to the battery manufacturer's instructions
for proper charging procedures.

Battery Voltage Test (No Load Applied)

NOTE: A voltage test is carried out on a battery
without discharging current. It is the simplest and
most commonly used. However, be aware that a
rmr2013-027-002_b voltage test can indicate that the battery is good
RH SIDE VIEW — ON BOTTOM FRAME MEMBER even though the battery does not have enough
1. Regulator/rectifier
2. Connectors power to crank the engine.
A voltage reading provides an instant indication of
3. Remove the regulator retaining screws. the state of charge of the battery, not of its current
output capacity. A load test gives a more accu-
rate indication of the battery condition.
If the battery has just received a charge, allow it to
rest for 1-2 hours before taking a voltage reading.
Set multimeter to Vdc and connect to battery ter-
minals.
BATTERY VOLTAGE TEST (NO LOAD)
FULLY CHARGED BATTERY VOLTAGE
12.6 Vdc minimum

NOTE: A battery that shows a voltage of 12.0 Vdc

is considered completely discharged and needs to
be recharged.

rmr2013-027-002_c Battery Load Test (Engine Cranking)

RH SIDE VIEW — ON BOTTOM FRAME MEMBER Battery must be fully charged, refer to BATTERY
1. Regulator/rectifier
2. Retaining screws VOLTAGE TEST (NO LOAD APPLIED).
4. Install the new regulator in the reverse order of 1. Set multimeter to Vdc and connect it to the bat-
removal. tery.
5. Torque voltage regulator/rectifier retaining 2. Measure battery voltage at rest.
screws to specification. 3. With the multimeter still connected, crank
engine with throttle fully open to initiate the
TIGHTENING TORQUE
"drown mode" to prevent engine from starting
7 N•m (62 lbf•in) while reading multimeter.

6. Carry out a voltage regulator/rectifier output WARNING

voltage test to confirm its proper operation. While using the drown mode, always release
7. Reinstall bottom plate. START button before throttle.

6 rmr2013-027
 Subsection XX (CHARGING SYSTEM)

BATTERY LOAD TEST

BATTERY VOLTAGE WHILE CRANKING
10 Vdc minimum

Assuming the starting system is in good condi-

tion, a battery voltage that drops below specifica-
tion suggests a worn-out or defective battery.
NOTE: Before replacing the battery, make sure
the charging system is in good condition.

Battery Load Test (Using a Battery

Load Tester) rmo2013-003-007_b

This is the best test to determine the battery 1. Remove screws

2. Battery access panel
condition.
Use a load testing device such as the NAPA ULTRA 3. Disconnect the BLACK (-) battery cable first.
PRO BATTERY LOAD TESTER (P/N 95260). It has a NOTICE Always disconnect the NEGATIVE (-)
500 A carbon pile adjustable load. cable first.
Battery must be fully charged.
4. Pull back the RED rubber protector on the posi-
1. If battery has just been recharged, allow battery tive (+) battery post, then disconnect the cable.
to rest for 1-2 hours.
5. Remove battery rubber band.
2. Follow battery load tester instructions.
6. Lift top plate.
3. Carry out a test as per table.
7. Pull out battery.
BATTERY LOAD TEST
TIME TO
LOAD MEASURE VOLTAGE
INTO TEST
150 A 5 seconds Minimum 10 Vdc

If battery voltage has dropped below specifica-

tion, replace battery.
NOTE: Note, before replacing the battery, make
sure the charging system is in good condition.

Battery Removal
1. Open front storage compartment.
2. Remove the battery access panel.
rmr2013-027-003_a

Step 1: Disconnect first

Step 2: Disconnect last
Step 3: Remove rubber band
Step 4: Lift top plate
Step 5: Pull out

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.
Rinse with clear water and dry thoroughly using
a clean cloth.

rmr2013-027 7
Subsection XX (CHARGING SYSTEM)

Apply a light coat of DIELECTRIC GREASE (P/N 293 5. Connect the BLACK (-) battery cable.
550 004) on terminals.

Battery Inspection
Visually inspect battery casing for cracks or any
other damage. If casing is damaged, replace bat-
tery and thoroughly clean battery rack with a wa-
ter and baking soda solution.
Inspect battery posts, connectors, battery rack,
battery holding strap and strap attachment points.

Battery Storage
It is not necessary to remove the battery during
vehicle storage but is recommended for long term
storage.
Recharge the battery once a month with an ap-
rmr2013-027-003_b
proved battery charger as per manufacturer's rec- Step 1: Install in rack
ommendations. Step 2: Secure in its slots
Step 3: Secure rubber band
Clean battery, battery rack and connections as re- Step 4: Connect first
quired, refer to BATTERY CLEANING in this sub- Step 5: Connect last
section. 6. Install battery access panel.
For other recommendations during storage, refer 7. Turn ignition key ON then OFF to prevent bat-
to the battery manufacturer's instructions. tery drain from the D.E.S.S. system.
Battery Installation Battery Main Ground Connection
1. Insert battery in its rack. Refer to POWER DISTRIBUTION AND GROUNDS
2. Install top plate. subsection for vehicle grounds location.
2.1 Align tabs of plate into its slots. Ensure all ground connections are clean, tight and
free of corrosion.

Jump Start Post Connections

Ensure cable connections are clean, tight and free
of corrosion.

rmr2013-027-004_a

1. Top plate
2. Plate tabs in slots

3. Install battery rubber band.

NOTICE Always connect RED (+) cable first
then BLACK (-) cable.
4. Connect the RED (+) battery cable. Position the
RED protective rubber boot over the contact.

8 rmr2013-027
 Subsection XX (STARTING SYSTEM)

STARTING SYSTEM
SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................................. 8

GENERAL – Transmission in neutral (or in gear with the

brake pedal depressed)
SYSTEM DESCRIPTION – D.E.S.S. recognizes the key
– Start button pressed in.
Starting System Operation
NOTE
SEQUENCE OF OPERATION
If the transmission was not in neutral when the
Start button sends a ground signal to the engine was shut off, the HCM (hydraulic control
1
ECM and pre-starting relay module) will automatically shift the transmission to
Pre-starting relay provides battery voltage neutral at the next engine start to allow engine
to the starter solenoid coil starting (if there is sufficient oil pressure).
2
ECM provides ground to the starter The parking brake state will not affect engine
solenoid coil ST1 terminal cranking.

If the start button is activated when engine speed

is above 1400 RPM, engine cranking will not be TROUBLESHOOTING
allowed. In other words, if the engine is running,
no cranking will take place. TROUBLESHOOTING TIPS
If the start switch is activated while the throttle is It is good practice to check for fault codes using
opened more than 60°, the engine will not be al- B.U.D.S.as a first troubleshooting step. Refer to
lowed to start but the starter will crank the engine COMMUNICATION TOOLS AND B.U.D.S. sub-
(engine drown mode). section.
Engine Cranking Conditions Refer to POWER DISTRIBUTION AND GROUNDS
for fuses and relays information.
SM5 Model
Always refer to the WIRING DIAGRAM when
The following conditions must be met to allow en- troubleshooting an electrical circuit.
gine cranking:
Install a battery charger on jump start posts in
– Ignition switch ON front storage compartment for any tests that
– Engine stop switch to RUN involve a prolonged "key ON" period. If battery
– Mode button pressed in once (safety message voltage gets too low, test results can be altered.
acknowledgement)
NOTICE Never force a multimeter probe into
– Transmission in neutral (or in gear with clutch
lever depressed) an electrical terminal.
– D.E.S.S. recognizes the key
– Start button pressed in.
STARTING SYSTEM
TROUBLESHOOTING
SE5 Model
If the gauge or lights do not come on when igni-
The following conditions must be met to allow en- tion switch is ON, refer to TROUBLESHOOTING
gine cranking: in IGNITION SYSTEM subsection.
– Ignition switch ON
If gauge and lights come ON with the ignition
– Engine stop switch to RUN switch ON and starter does not engage, start
– Mode button pressed in once (safety message your testing sequence by carrying out STARTER
acknowledgement) OPERATION TEST in this subsection.

rmr2013-028 1
Subsection XX (STARTING SYSTEM)

Refer to the following list for possible causes: WARNING

– F8 fuse While using the drown mode, always release
– Battery or connections (refer to CHARGING Start button before throttle.
SYSTEM)
– D2 diode The starter should rotate smoothly.
– Start button If the starter does not run smoothly, refer to the
– Engine stop switch MAGNETO AND STARTER subsection.
– Starter solenoid If the starter does not rotate or rotates slowly,
– Clutch engagement switch (SM5 model) carry out a STARTER INPUT VOLTAGE TEST.
– Gear position sensor (SM5 model)
– D.E.S.S. Starter Input Voltage Test
– Brake light switch (SE5 model if transmission 1. Refer to BODY and AIR INTAKE SYSTEM sub-
in gear) sections and remove:
– Electrical cables/connections – RH top side panel
– ECM. – Air filter cover
If fuse F8 continuously blows, isolate the follow- 2. Set multimeter to Vdc.
ing components to determine the source of the 3. Measure voltage as per table while cranking en-
short circuit: gine with the throttle fully open to initiate the
– Pre-starting relay "drown mode" to prevent engine from starting.
– Starter solenoid
– Heated oxygen sensors WARNING
– EVAP purge valve While using the drown mode, always release
– Fuel pump Start button before throttle.
– D2 diode
STARTER INPUT VOLTAGE TEST
– Clutch solenoid valve
RESULT
– Camshaft position sensor
TEST PROBES (WHILE PRESSING
– Reverse actuator relay (R1) START BUTTON)
On SM5 model: Battery
– If starter cranks only with the clutch lever de- Starter terminal
negative Battery voltage
(SM)
pressed, verify the GBPS (gearbox position sen- post
sor) and its circuits. Refer to GEARBOX sub-
section. NOTE: Battery voltage will drop and fluctuate
– If starter cranks only in neutral, carry out the with starter cranking load.
CLUTCH SWITCH CONTINUITY TEST in this
subsection.

PROCEDURES
ELECTRIC STARTER
Starter Operation Test
Before testing, make sure the battery is in good
condition and fully charged.
1. Apply parking brake.
2. Crank engine with throttle fully open to initiate
the "drown mode" to prevent engine from start-
ing. rmr2008-025-001_a

2 rmr2013-028
 Subsection XX (STARTING SYSTEM)

TEST RESULTS 2. Connect multimeter probes to the starter hous-

ing and battery negative post.
READING WHAT TO DO
3. Measure voltage drop as follows while cranking
Check Start button and Stop button engine with the throttle fully open to initiate the
No voltage
using B.U.D.S. "drown mode" to prevent engine from starting.
Carry out a STARTER CABLE
Voltage is low WARNING
VOLTAGE DROP TEST.
Make sure engine is not seized. While using the drown mode, always release
Voltage is If engine is not seized, carry out Start button before throttle.
good a GROUND CIRCUIT VOLTAGE
DROP TEST. STARTER GROUND CIRCUIT VOLTAGE
DROP TEST
Starter Cable Voltage Drop Test PROBES
RESULT (WHILE
This test confirms if there is parasitic resistance in STARTING)
the cable, solenoid or connections. Starter Battery
0.8 Vdc maximum
1. To access battery positive terminal, refer to housing negative post
STARTER SOLENOID ACCESS in this subsec-
tion. If voltage exceeds the specification, check ground
cables and connections from battery to front LH
2. Set multimeter to Vdc. side of engine.
3. Connect multimeter probes to the starter termi- If voltage is as per specification, test starter mo-
nal (SM) and battery positive post. tor, refer to MAGNETO AND STARTER subsec-
4. Measure voltage drop as follows while cranking tion.
engine with the throttle fully open to initiate the
"drown mode" to prevent engine from starting. Starter Replacement
If the starter has to be replaced, refer to the MAG-
WARNING NETO AND STARTER subsection.
While using the drown mode, always release
Start button before throttle. D2 DIODE (STARTER SOLENOID)
STARTER CABLE VOLTAGE DROP TEST D2 Diode Troubleshooting
RESULT (WHILE A defective D2 diode will result in the following
PROBES conditions.
STARTING)
Starter Shorted Diode
Battery
terminal 1 Vdc maximum Fuse F8 will blow continually.
positive post
(SM)
Open Diode
If voltage exceeds the specification, test voltage Diode will not provide protection to the sensitive
drop between the following points using the same electronic components. Malfunction or damage
method to determine what part of the circuit is at may occur.
fault:
– Battery positive post and starter solenoid STS3 D2 Diode Test
– Starter solenoid STS3 and STS4 Remove front cargo box. Refer to BODY subsec-
– Starter solenoid STS4 and starter terminal (SM). tion.
Replace cable or solenoid if necessary.
Diode D2 must be isolated from other parallel cir-
Starter Ground Circuit Voltage Drop cuits for proper testing.
Test – Turn ignition switch OFF.
– Disconnect ECM connector B. Refer to ELEC-
This test confirms if there is parasitic resistance in
TRONIC FUEL INJECTION (EFI) subsection.
the ground cables or connections.
– Disconnect small connectors on the starter so-
1. Set multimeter to Vdc. lenoid.
Set multimeter as shown.
rmr2013-028 3
Subsection XX (STARTING SYSTEM)

NOTE: It is important to install the BLACK multi- Diode Replacement

meter probe in the BLACK “com” connector of The diode (D2) is located in the main harness,
the multimeter and the RED probe in the RED con- above the starter solenoid junction harness.
nector for proper testing of diode polarity.

rmr2013-028-001_a

1. Main harness
vmr2006-020-005 2. Starter solenoid
3. Starter solenoid junction harness
4. Approximate diode D2 location
Test diode D2 as follows.
1. Open the harness protective sheath to access
the diode.
NOTICE Be very careful not to damage wire
insulation while opening protective sheath.

rmr2008-025-002

TYPICAL DIODE WITHIN HARNESS

rmr2013-028-030_a

SMALL CONNECTORS OF SOLENOID NOTE: When replacing the diode, always test the
new diode with the "diode check" on the multime-
D2 DIODE TEST ter, before installing it in the circuit.
SOLENOID STS1 STS2 2. Replace diode making sure to install it in the
HARNESS (YELLOW/ (VIOLET/ READING right direction. Use the "diode check" function
CONNECTOR PINK) BEIGE) of the multimeter and refer to the WIRING DI-
RD BK 0.5 V AGRAM.
TEST PROBES
BK RD Infinite OL NOTE: If the diode is installed in the reverse di-
rection, the starter solenoid will not function and
If results are not as specified, replace diode. fuse F8 will probably blow and open the circuit.

4 rmr2013-028
 Subsection XX (STARTING SYSTEM)

ENGINE STOP SWITCH START BUTTON

NOTE: The engine stop switch is located on the
RH multifunction switch housing.
Engine Stop Switch Test with B.U.D.S.
1. Connect the vehicle diagnostic connector to a
computer with the appropriate version of the
B.U.D.S. software.
2. Select the Read Data button.
3. Select the Monitoring and ECM tabs.
4. Place engine stop switch to RUN, then to STOP
and look at the Stop Button indicator.
Start Button Test with B.U.D.S.
1. Connect the vehicle diagnostic connector to a
computer with the appropriate version of the
B.U.D.S. software.
2. Select the Read Data button.
3. Select the Monitoring and ECM tabs.
4. Press the engine start button and look at the
Start Button indicator.

rmr2013-028-002_b

1. Monitoring tab
2. ECM tab
3. Start Button indicator
rmr2013-028-002_a

1. Monitoring tab TEST RESULTS

2. ECM tab
3. Stop Button indicator START BUTTON
INDICATOR IN WHAT TO DO
TEST RESULTS B.U.D.S.
STOP BUTTON The starting system
INDICATOR IN WHAT TO DO input side is functioning
B.U.D.S. normally (start button, ECM,
Comes ON while
Comes ON when wiring and connections).
The switch and wiring are start button is
switch is in RUN Make sure engine stop switch
good and the D.E.S.S. module pressed in
position tests good, then carry out a
gets the signal. Make sure PRE-STARTING RELAY QUICK
Comes OFF when Start button tests good, then TEST.
switch is in STOP carry out a PRE-STARTING
position RELAY QUICK TEST Does not come ON Check for an open circuit or
while start button defective switch, refer to
Check for an open circuit is pressed in WIRING DIAGRAM.
or defective Stop switch,
Does not change refer to WIRING DIAGRAM.
when switch is Keep in mind that one side PRE-STARTING RELAY
toggled ON and of the switch is connected
OFF to the D.E.S.S. module and Pre-Starting Relay Quick Test
a failure of this circuit will 1. Locate pre-starting relay in the LH fuse
disable starting. box, refer to POWER DISTRIBUTION AND
GROUNDS.
2. While carrying out a start, touch the relay. You
should feel it "click" when you press start but-
ton.
rmr2013-028 5
Subsection XX (STARTING SYSTEM)

If relay does not click, temporarily substitute relay If voltage is not as specified, check for an open
with a known good one and retest. circuit
– If it now works, replace relay. – Between LH fuse box pin B9 and RH multifunc-
– If it still does not work, carry out a PRE-START- tion switch MSR2-4
ING RELAY INPUT VOLTAGE TEST. – Between ECMB-C4 and RH multifunction
If relay clicks, carry out a STARTER SOLENOID IN- switch MSR2-4.
PUT VOLTAGE TEST.
STARTER SOLENOID
Pre-Starting Relay Input Voltage Test
Starter Solenoid Access
1. Remove pre-starting relay.
NOTE: The starter solenoid is mounted besides
2. Set multimeter to Vdc. the battery.
3. Turn ignition switch (key) ON. To access starter solenoid:
4. Read voltage as per table. – Open front storage compartment.
NOTE: Refer to POWER DISTRIBUTION AND – Remove battery access panel.
GROUNDS for LH fuse box pinout.
PRE-STARTING RELAY INPUT VOLTAGE TEST
TEST PROBES RESULT
LH fuse box
pin A9
Ground Battery voltage
LH fuse box
pin A10

If there is no voltage at any test, check for an open

circuit.
If voltage is as specified, carry out a PRE-START-
ING RELAY CONTROL CIRCUIT TEST.
rmo2013-003-007_b

Pre-Starting Relay Control Circuit Test 1. Screws

2. Battery access panel
1. Remove pre-starting relay.
2. Set multimeter to Vdc.
3. Turn ignition switch (key) ON.
4. Read voltage as per table.
NOTE: Refer to POWER DISTRIBUTION AND
GROUNDS for LH fuse box pinout.
5. Measure voltage while while pressing start but-
ton.
PRE-STARTING RELAY CONTROL CIRCUIT TEST
RESULT (WHILE
TEST PROBES PRESSING START
BUTTON)
LH fuse box Battery
Battery voltage
pin B9 positive post rmr2013-028-001_c

PARTS REMOVED FOR CLARITY

If voltage is as specified, the relay gets a proper
ground signal.
1. Battery
2. Starter solenoid
Starter Solenoid Input Voltage Test
1. Disconnect connector from solenoid as per ta-
ble and test voltage as follows.

6 rmr2013-028
 Subsection XX (STARTING SYSTEM)

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 (ST1 and ST2) from so-
lenoid.
RESULT
(WHILE With a multimeter, measure the primary winding
TEST PROBES PRESSING resistance as follows.
START
SOLENOID WINDING CONTINUITY TEST
BUTTON)
MEASUREMENT
Battery SOLENOID
ST2 (VT/BG) Battery voltage
negative post TERMINALS RESISTANCE
@ 20°C (68°F)
STS1 STS2 Approximately 5

rmr2008-025-011_a

If there is no voltage while starting, check for an

open circuit including pre-starting relay mechani-
cal contacts.
If voltage is as specified, carry out a STARTER SO- rmr2013-028-003_b
LENOID CONTROL CIRCUIT TEST.
Test for a stuck solenoid plunger as follows.
Starter Solenoid Control Circuit Test
SOLENOID CONTACTS CONTINUITY TEST
1. Disconnect connector from solenoid.
SOLENOID CONNECTOR MEASUREMENT
2. Use a 12 Vdc test light and probe as per table..
Battery Starter
IMPORTANT: Using a voltmeter could lead to Open circuit
terminal terminal
false results.
3. Observe test light while start button is pressed
in.
STARTER SOLENOID CONTROL CIRCUIT TEST
RESULT (WHILE
TEST PROBES PRESSING START
BUTTON)
Battery
Test light should
ST1 (YE/PK) positive
be bright
terminal

If test light does not turn on or is dimmed while

cranking, check for an open circuit.
If test light is bright, the solenoid gets a proper
ground signal. Carry out a STARTER SOLENOID
STATIC TEST: CONTINUITY.
rmr2013-028-003_a

rmr2013-028 7
Subsection XX (STARTING SYSTEM)

If any measurement is out of specification, re- If any test failed, switch is defective. Replace with
place solenoid. a new one.
Reconnect battery and starter solenoid terminals. If switch is good, test related wiring/connectors.

Starter Solenoid Removal Clutch Switch Removal

Refer to STARTER SOLENOID ACCESS. Remove clutch lever from handlebar, refer to
Disconnect the battery. CLUTCH subsection.
Remove the four electrical connections from the Push switch towards lever.
starter solenoid.
Remove the two mounting screws.

Starter Solenoid Installation

Install the new solenoid in the reverse order of the
removal procedure.
Carry out an engine start to validate that the new
solenoid functions.

CLUTCH SWITCH
SM5 Model rmr2008-028-032_a

Step 1: Push switch

Clutch Switch Continuity Test Lift switch to remove it.
Remove RH front panel to access clutch switch
connector. Refer to BODY subsection.
Disconnect clutch switch connector on RH side of
vehicle.

rmr2008-028-033_a

Step 2: Lift switch

Remove the console module, refer to BODY sub-

section.
Disconnect the clutch switch connector then re-
move the connector housing from the connector
support.

rmr2013-028-004_a
Clutch Switch Installation
1. Clutch switch connector Clutch switch installation is the reverse of the re-
moval procedure.
Using the FLUKE 115 MULTIMETER (P/N 529 035
868), probe connector pins as per table.
CLUTCH SWITCH CONTINUITY TEST
CLUTCH SWITCH RESISTANCE @
PIN
POSITION 20°C (68°F)
Lever fully depressed Below 3
A B
Released Infinite (OL)

8 rmr2013-028
 Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

DIGITALLY ENCODED SECURITY

SYSTEM (D.E.S.S.)
SERVICE TOOLS
Description Part Number Page
MASTER KEY ................................................................................ 529 036 106 ......................................... 2, 4

GENERAL SYSTEM OPERATION

When the ignition switch is turned to the ON
SYSTEM DESCRIPTION position, a microcircuit inside the key is activated
The D.E.S.S. system is an electronic anti-start sys- and transmits by radio wave a unique binary code
tem that allows engine starting only with a pro- to the antenna surrounding the ignition switch.
grammed key. The antenna, connected to the D.E.S.S. module,
sends the module an electric signal.
– If the D.E.S.S. module recognizes the ignition
key code, it sends a run signal to the ECM
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 60 seconds before the message dis-
plays).

TROUBLESHOOTING
ENGINE STOPS AFTER 2 MINUTES
RUNNING
1. D.E.S.S module is still in programming mode.
rmr2008-018-003_a
The 2nd key must be programmed within 2 min-
1. Ignition switch utes.
2. D.E.S.S. module
3. Ignition key with a ROM chip

The ignition key contains a ROM chip that includes

a digital type code.
The 2 keys that come with the roadster have been
programmed at the factory. Up to 4 keys can be
programmed on the roadster.

rmr2013-029 1
Subsection XX (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 key(s) and this
Replace part(s) 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 036 106). The second key must be programmed within
lost 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 – Engine will start, then stop after 2 minutes.
as detailed in PROGRAMMING KEYS
– When the ignition is turned OFF, current drain
WITH A NEW D.E.S.S. MODULE in
this subsection. will be higher than usual and the battery will
completely discharge within 1 - 2 weeks if the
Ignition 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 IGNITION SWITCH and will display a SUCCESS message. If the cluster
look for ADDITIONAL PROCEDURE does not display this message, the new key pro-
ONLY IF 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 SWITCH in 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
WITH A NEW IGNITION SWITCH in 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. one programmed functional key.
module Follow programming procedures
as detailed in PROGRAMMING KEYS NOTE: Additional keys to program must be precut
WITH A NEW D.E.S.S. MODULE in to the ignition switch.
this subsection. To add or reprogram a key, carry out the following
steps:
D.E.S.S. MODULE DIAGNOSIS 1. Insert an already programmed functional key
into the ignition switch.
Use the DIAGNOSTIC FLOW CHART located in
the 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. Press MODE button for 3 seconds.
5. Wait 5 seconds.
KEYS 6. Remove programmed key.
General Information on Programming 7. Insert MASTER KEY (P/N 529 036 106).
Keys NOTE: The master key is purposely “not cut” and
The D.E.S.S. module is programmed to recognize will not turn in the ignition switch.
the digital code in the key.
A master key is used to program keys.
The cluster will display guiding tips during key pro-
gramming.

2 rmr2013-029
 Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))
rmr2008-001_a
MASTER KEY
1. No notches
2. RED colored
8. Wait until the cluster displays MASTER.
9. Remove the master key.
10. Insert a key to program.
11. Turn ignition switch to ON.
12. Wait until cluster displays NEXT KEY.
13. Turn ignition switch to OFF.
14. Press MODE button for 3 seconds.
15. Remove key.
16. Insert next key to program.
17. Turn ignition switch to ON.
18. Wait until cluster displays NEXT KEY.
NOTE: If there are at least 2 keys programmed
and you do not wish to program more keys (4 ma-
ximum), leave the last programmed key in the ig-
nition switch. If you wish to program another key,
repeat the previous five steps.
19. Wait until cluster displays SUCCESS.
20. Turn ignition switch to OFF.
21. Remove key.
Key programming procedure is complete.
NOTE: When the maximum of 4 keys are pro-
grammed, the cluster will display SUCCESS.
Start engine and let run for more than 2 minutes.
If engine does not stop on its own after 2 minutes,
programming mode is complete.
Programming Keys with a New
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.
rmr2013-029
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 1st key to program into the ignition
switch.
2. Turn the ignition key to ON.
3. Wait until cluster displays NEXT KEY.
4. Turn ignition switch to OFF.
5. Remove key.
6. Insert the 2nd key to program.
NOTE: A new D.E.S.S. module will allow
programming of 2 keys initially. If you wish
to program more than 2 keys, refer to
ADDING/REPROGRAMMING KEYS after this
procedure is completed.
7. Turn ignition switch to ON.
8. Wait until cluster displays SUCCESS.
9. Turn ignition switch to OFF.
10. Remove key.
Key programming procedure is complete.
Start engine and let run for more than 2 minutes.
If engine does not stop on its own after 2 minutes,
programming mode is complete.
Programming Keys with a New
Ignition Switch
Guidelines
The following procedure describes how to pro-
gram keys when only the ignition switch has
been replaced.
NOTE: You must have at least the top portion of a
key from the old switch containing the electronic
chip. Otherwise, both the ignition switch and
D.E.S.S. module must be replaced.
Switch Preparation
Connect only the large ignition switch connector
to the NEW ignition switch at this time. The OLD
ignition switch D.E.S.S. antenna must remain con-
nected to the D.E.S.S. module.
3
Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

rmr2008-065-002_a
rmr2008-065-004_a
IGNITION SWITCH ASSEMBLY
1. 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. Ignition switch connector 2. Antenna wire connected to D.E.S.S. module connector

NOTE: The NEW ignition switch will be used to
power ON the vehicle but the OLD ignition key
and antenna must be used for recognition by the
D.E.S.S. module.
Additional Procedure Only if Broken Key
or Key Cannot Be Inserted in OLD Ignition
Switch
NOTE: Carefully pry off the D.E.S.S. antenna from
the top of the old switch assembly. It will be used
during the key programming procedure.
Key Programming Procedure
1. Insert the OLD programmed key into the OLD
ignition switch (or old antenna).
NOTE: If key is broken or if key can not be in-
serted in the old switch, refer to ADDITIONAL
PROCEDURE ONLY IF BROKEN KEY OR KEY
CANNOT BE INSERTED IN OLD IGNITION
SWITCH in this subsection.
2. Insert a NEW key in the NEW ignition switch.
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.

rmr2008-065-003_a

1. Antenna ring
2. Antenna locking pin (one 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-
nition key and master key to put the D.E.S.S. mod- rmr2008-001_a

ule into programming mode. MASTER KEY

1. 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.
4 rmr2013-029
 Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

9. Quickly disconnect the OLD D.E.S.S. antenna

and connect the NEW D.E.S.S. antenna to the
D.E.S.S. module.
NOTE: If too much time is used to switch the an-
tenna connectors, the programming may fail and
the procedure will have to be repeated from the
beginning.
10. Turn NEW ignition switch to ON.
11. Wait until cluster displays NEXT KEY.
12. Turn ignition switch to OFF.
13. Remove key.
14. Insert next key to program.
15. Turn ignition switch to ON. rmr2013-029-002_a

1. D.E.S.S. module
16. Wait until cluster displays NEXT KEY.
NOTE: If there are at least 2 keys programmed D.E.S.S. Module Replacement
and you do not wish to program more keys (4 ma- 1. Refer to BODY and remove front cargo module.
ximum), leave the last programmed key in the ig-
nition switch. Disconnect the D.E.S.S. module connectors.
17. Wait until cluster displays SUCCESS. Unscrew the D.E.S.S. module retaining screws.
18. Turn ignition switch to OFF.
19. Remove key.
Complete ignition switch installation.
Start engine and let run for more than 2 minutes.
If engine does not stop on its own after 2 minutes,
programming mode is complete.

D.E.S.S. MODULE

rmr2013-029-002_b

1. D.E.S.S. module
2. Connectors (3)
3. Retaining screws

Remove the D.E.S.S. module.

For installation, reverse the removal procedures.
Tighten retaining screws to specification.
TIGHTENING TORQUE
rmr2008-026-004 7 N•m (62 lbf•in)
The D.E.S.S. module is located above battery, be-
NOTICE Do not apply any dielectric grease in
hind front storage compartment.
the D.E.S.S. module connectors.
Program a minimum of 2 keys into the new mod-
ule. See PROGRAMMING KEYS WITH A NEW
D.E.S.S. MODULE in this subsection.

rmr2013-029 5
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

LIGHTS, GAUGE AND ACCESSORIES

SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ...... 32, 37–38, 41–44, 48–49,
51, 54, 56–57, 59–62
SPANNER TOOL ........................................................................... 529 036 223 ........................................... 68

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 71

GENERAL SYSTEM DESCRIPTION

Refer to WIRING DIAGRAM INFORMATION sub- (LIGHTING SYSTEM)
section for diagnostic tips on troubleshooting
electrical problems.

WARNING
It is recommended to always disconnect the
battery when replacing any electrical compo-
nent. Always disconnect battery as specified,
BLACK (-) cable first. Do not place tools on
battery.

Clean threads before applying a threadlocker. Re-

fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedures.

WARNING
Torque wrench tightening specifications
must be strictly adhered to. Locking de- rmo2008-001-084_a
vices when removed, must be replaced (e.g.: TYPICAL NORTH AMERICAN MODELS
locking tabs, elastic stop nuts, self-locking 1. Turn signal light
2. Headlight
fasteners, cotter pins, etc.). 3. Position light

rmr2013-030 1
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmo2013-003-027_b

LIGHTS LOCATION — FRONT OF VEHICLE

1. Turn signal light
2. Headlight
rmo2008-002-003_a 3. Position light
TYPICAL - EUROPEAN MODELS
1. Turn signal light
2. Headlights — high beam
3. Headlights — low beam
4. Position light

rmo2013-003-049_a

LIGHTS LOCATION — REAR OF VEHICLE

1. Taillight/brake light
2. Turn signal light
3. License plate light

rmo2008-001-088_a

TYPICAL - RS AND ST MODELS

1. Taillight/brake light
2. Turn signal light
3. License plate light

rmo2010-001-075_a

NORTH AMERICAN MODELS

1. Headlights
2. Auxiliary lights (not shown)
3. Position lights

2 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

HIGH BEAM is selected, the shutter in both units

is powered and the top of the light beam is un-
blocked.
NOTE: With no power applied to the shutter so-
lenoid, the shutter is in the closed or low beam
position.
European Models
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.

Auxiliary Lights
rmo2010-001-304_a The auxiliary lights are located in the front panels
EUROPEAN MODELS on each side of the vehicle, where the low beams
1. Headlights — high beam
2. Headlights — low beam take place on European models.
3. Position lights
The auxiliary lights are powered through the
LOAD SHEDDING relay, then through the auxil-
iary light switch.

Turn Signal Lights

rmo2010-001-047_d
ALL MODELS
1. License plate light
2. Backup lights
3. Taillights/Brake lights
4. Turn signals
Headlights
The headlights automatically come ON when the
engine is started and reaches 800 RPM, and go
OFF automatically 20 seconds after engine shut
down.
The headlight beam selector switch is located in
the left multifunction switch. It is a Hall Effect
switch, not a contact switch. The switch cannot
be checked with an ohmmeter, it must be tested
live, by back-probing.
North American Models
The high and low beams are incorporated into a
single unit (one each side) equipped with a shut-
ter. When LOW beam is selected, the shutter
in both units is closed and the top of the light
beam is blocked. When HIGH beam or FLASH
The signals are conventional bulbs at rear and
LEDs at front.
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.
The turn signals will turn off automatically in the
following conditions:
1. After the vehicle has made a turn, the mul-
tifunction gauge is programmed to turn the
signals off, after a certain amount of degrees
of steering has been made and then returned
to center. The multifunction gauge receives
a CAN signal from the SAS (Steering Angle
Sensor) to determine when the turn has been
initiated.
NOTE: The turn signals turn off automatically af-
ter a normal turn, however after a shallow turn or
lane change they may have to be turned off man-
ually.
2. If turn signals are left ON, they will automati-
cally turn off after 30 seconds while the vehicle
is moving.
NOTE: If the vehicle did not move, they will stay
ON until selected OFF, or until the ignition key is
switched OFF.

rmr2013-030 3
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

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 rmr2010-030-006_a

hazard lights. TYPICAL

NOTE: When hazard warning lights are activated
at key OFF, they will be deactivated at key ON.
Taillight/Brake Light
This vehicle is equipped with two taillights that
use LED (Light Emitting Diodes) for illumination.
Nine LED's are always lit when the ignition key is
turned ON and acts as a rear position (or parking)
light. Those nine LED's plus a second set of three
LED's are lit at a higher intensity when used for
the brake light function.
Internal circuitry inside of the taillight housing
causes the intensity to increase when the brakes
are applied.
1. BLS (brake light switch)
Position Lights/License Plate Light
Position Lights
This vehicle is equipped with two marker lights
located on top of each front fender.
The two position lights (or marker lights) come
ON when the ignition switch is ON. They receive
power from the ignition switch and will remain on
as long as the ignition switch is left ON.
License Plate Light
Receives power from the ignition switch is ON
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.

rmr2010-030-005

TAILLIGHT

Power for the taillights comes from the ignition

switch. When ignition switch is ON, the following
lights turn on.
– Taillights
– Front position lights
– License plate light
– Front day lights.
Power for the brake light comes from the BLS
(Brake Light Switch) located on the brake pedal as-
sembly at the master cylinder.

4 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

MULTIFUNCTION GAUGE CLUSTER (RS BASE MODEL)

The multifunction gauge cluster includes gauges (speedometer, tachometer, engine temperature, fuel
level), indicator lamps and a user selectable digital display.

Description

1 9 2

3
3
8 7 6 5 4
rmo2013-001-015_b

1) Analog Speedometer
Measures vehicle speed in kilometers or miles per hour. To change units, refer to SETTING METRIC/IM-
PERIAL UNIT.
2) Analog Tachometer (RPM)
Measures engine revolutions per minute (RPM). Multiply by 1000 to obtain actual revolutions.
3) Indicator Lamps
Indicator lamps will inform you of various conditions or problems.
An indicator lamp can flash alone or in combination with another lamp.
The digital display provides a brief description for some of the conditions or problems indicated by lamps.
INDICATOR LAMPS (NORMAL OPERATION)
MAIN DIGITAL
INDICATOR LAMP(S) DESCRIPTION
DISPLAY
All indicator lamps are activated when
All indicator
On None ignition switch is set to ON and the
lamps
engine is not started.
Flashing PARK BRAKE Parking brake engaged.
SE5 model: The ignition switch is OFF
! Flashing + Beeper None
and the parking brake is not engaged.
Always engage the parking brake when
parking the vehicle.

N On None Gearbox in neutral position.

rmr2013-030 5
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

INDICATOR LAMPS (NORMAL OPERATION)

MAIN DIGITAL
INDICATOR LAMP(S) DESCRIPTION
DISPLAY

R Flashing None Gearbox in reverse position.

On None Headlights in the HIGH beam position.

Flashing None VSS intervention occurs.

Turn signal or hazard warning lights

Flashing None
flashing.

For indicator lamps (malfunctions), refer to INDICATOR LAMPS (MALFUNCTION) in DIAGNOSTIC AND
FAULT CODES.
4) Main Digital Display
Displays useful real-time information to the rider.
For display function informations, refer to DIGITAL DISPLAY INFORMATION.
5) Fuel Level
Bar gauge that continuously indicates the amount of fuel left in the fuel tank.
6) Secondary Digital Display
Displays useful real time information to the rider. For display function informations, refer to DIGITAL DIS-
PLAY INFORMATION.
7) Gearbox Position
Displays the selected gearbox position.
8) Engine Temperature
Bar gauge that continuously indicates the engine coolant temperature.
9) Digital Speedometer
In addition of the analog type speedometer, vehicle speed can also be indicated via this display.
Speed can be displayed in kilometers (Km/h) or miles per hour (MPH). To change units, refer to SETTING
METRIC/IMPERIAL UNITS.
Startup and Shutdown
Any time the ignition switch is set to ON after having been in the OFF position for five minutes or more,
the main digital display will scroll the following message:
– BEFORE OPERATING READ THE SAFETY CARD ABOVE THEN PRESS MODE BUTTON.
NOTE: Acknowledge this message to allow engine starting.

Digital Display Information

WARNING
Do not adjust the display while riding. You could lose control.

Main Display Functions

Pressing the SET button on the RECC will scroll through the different functions.

6 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

FUNCTION SEQUENCE INFORMATION DISPLAYED

XX °C (Celsius)
Outside temperature
XX °F (Fahrenheit)
Tachometer (revolutions per minutes) XXXX RPM

Secondary Display Functions

Pressing the MODE button on the RECC will scroll through the different functions.
FUNCTION SEQUENCE INFORMATION DISPLAYED
XX:XX (24:00 time base)
Clock
XX:XX A or P (12:00 AM/PM time base)
Cumulative distance odometer XXXXX.X Km or mi
Trip distance — odometer A (TRIP A) XXXXX.X Km or mi
Trip distance — odometer B (TRIP B) XXXXX.X Km or mi
Trip time chronometer (HrTRIP) XXXXX.X
Engine time chronometer (Hr) XXXXX.X
Date (Month - Day) XX-XX Month and Day

To reset any trip functions, push and hold the MODE button for three seconds.

Display Settings
Setting Metric/Imperial Units
1. Push and hold SET button on the RECC for three seconds.
2. Push _down arrow_ to select KM, push up arrow to select MI.
Setting Clock
1. Press MODE button to select clock display.
2. Push and hold MODE button for three seconds.
3. Press down arrow to select 12:00 AM PM or up arrow to select 24:00 time base.
4. If 12:00 AM PM time base is selected, AM PM is displayed in upper LCD.Press up or down arrow to
select A (AM) or P (PM).
5. Press on the right arrow to display Hr in upper LCD. The hour number flashes in the lower LCD. Press
up or down arrow to select the applicable hour value.
6. Press on the right arrow to display Min in upper LCD. The minute number flashes in the lower LCD.
Press up or down arrow to select the applicable minute value.
7. When completed, press the right arrow to exit the menu.
NOTE: You can always return to previous selection using the left arrow.
Setting Language
The gauge display language can be changed. Refer to an authorized Can-Am roadster dealer for language
availability and setup the gauge to your preference.

MULTIFUNCTION GAUGE (RS-S MODEL)

WARNING
Watching or using the multifunction gauge or the infotainment center can distract the driver from
the operation of the vehicle. Always keep on observing the traffic and make sure the surrounding
is clear and safe before doing so.

rmr2013-030 7
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

The multifunction gauge includes analog gauges (speedometer and tachometer), indicator lamps and an
infotainment center with a digital screen.

Description

rmr2013-030-051_a

1) Analog Speedometer
Displays vehicle speed in kilometers (km/h) or miles per hour (MPH). To change units, refer to PREFER-
ENCES SCREEN.
2) Analog Tachometer (RPM)
Displays engine revolutions per minute (RPM). Multiply by 1000 to obtain actual revolutions.
3) Indicator Lamps
Indicator lamps will inform you of various conditions or problems.

8 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

INDICATOR LAMPS (NORMAL OPERATION)

INDICATOR LAMP(S) MAIN SCREEN DESCRIPTION
All indicator Temporarily all indicator lamps are activated when
On None
lamps ignition switch is ON and the engine is not started
Flashing None Parking brake engaged

! Flashing +
None
SE5 model: The ignition switch is OFF and the parking
brake is not engaged. Always engage the parking
Beeper
brake when parking the vehicle

N On None Gearbox in neutral position

R Flashing None Gearbox in reverse position

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.
Flashing None Left and right side indicator lights flash at
the same time: hazard warning lights

For indicator lamps (malfunctions), refer to INDICATOR LAMPS (MALFUNCTION) in DIAGNOSTIC AND
FAULT CODES.
4) Digital Display
Displays useful real-time information to the rider and is used as an interface for the infotainment center.
The display will use a light color when the ambient light is bright and will automatically change to a darker
color when the ambient light is dusky.
For a complete description of the digital display, refer to DIGITAL DISPLAY DESCRIPTION.
Refer to MULTIFUNCTION GAUGE STARTUP INFORMATION in this subsection to digital display infor-
mation.

rmr2013-030 9
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

MULTIFUNCTION GAUGE (ST MODELS)

WARNING
Watching or using the multifunction gauge or the infotainment center can distract the driver from
the operation of the vehicle. Always keep on observing the traffic and make sure the surrounding
is clear and safe before doing so.

The multifunction gauge includes analog gauges (speedometer and tachometer), indicator lamps and an
infotainment center with a digital screen.

Multifunction Gauge Description

rmr2013-030-051_a

1) Analog Speedometer
Displays vehicle speed in kilometers (km/h) or miles per hour (MPH). To change units, refer to PREFER-
ENCES SCREEN.
2) Analog Tachometer (RPM)
Displays engine revolutions per minute (RPM). Multiply by 1000 to obtain actual revolutions.

3) Indicator Lamps
Indicator lamps will inform you of various conditions or problems.
INDICATOR LAMPS (NORMAL OPERATION)
INDICATOR LAMP(S) MAIN SCREEN 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
SE5 model: The ignition switch is OFF and
! Flashing +
None
the parking brake is not engaged. Always
Beeper engage the parking brake when parking the
vehicle

N On None Gearbox in neutral position

R Flashing None Gearbox in reverse position

On None Headlights in the HIGH beam position

10 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

INDICATOR LAMPS (NORMAL OPERATION)

INDICATOR LAMP(S) MAIN SCREEN DESCRIPTION

Flashing None VSS intervention occurs

Left side turn signal.

Left and right side indicator lights
Flashing None
flash at the same time: hazard warning
lights
Right side turn signal.
Left and right side indicator lights
Flashing None
flash at the same time: hazard warning
lights

For indicator lamps (malfunctions), refer to INDICATOR LAMPS (MALFUNCTION) in DIAGNOSTIC AND
FAULT CODES.
4) Digital Display
Displays useful real-time information to the rider and is used as an interface for the infotainment center.
The display will use a light color when the ambient light is bright and will automatically change to a darker
color when the ambient light is dusky.
For a complete description of the digital display, refer to DIGITAL DISPLAY DESCRIPTION.
Refer to MULTIFUNCTION GAUGE STARTUP INFORMATION in this subsection to digital display infor-
mation.

SYSTEM DESCRIPTION (MULTIFUNCTION GAUGE) (RT MODELS)

Multifunction Gauge Operation
WARNING
Watching or using the multifunction gauge or the infotainment center can distract the driver from
the operation of the vehicle. Always keep on observing the traffic and make sure the surrounding
is clear and safe before doing so.

The multifunction gauge includes analog speedometer and tachometer, indicator lamps and an infotain-
ment center with a digital screen.
In addition, the gauge itself is a module. Through CAN (Controller Area Network) it is in constant commu-
nication 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.
For more information on CAN refer to the CONTROLLER AREA NETWORK (CAN) subsection.

rmr2013-030 11
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmr2013-030-051_a

TYPICAL
1. Analog speedometer
2. Analog tachometer (RPM)
3. Indicator lamps
4. Digital display

1) Analog Speedometer
Displays vehicle speed in kilometers (km/h) or miles per hour (MPH). To change units, refer to PREFER-
ENCES SCREEN or use B.U.D.S.
2) Analog Tachometer (RPM)
Displays engine revolutions per minute (RPM). Multiply by 1000 to obtain actual revolutions.
3) Indicator Lamps and Messages
Indicator lamps inform of various conditions or problems.
An indicator lamp can be on or flash alone or in combination with another lamp.
The digital display provides a brief description for some of the conditions or problems in conjunction with
an indicator lamp.
The message displayed is large and colored.

rmr2011-079-005_a

1. Large colored message

After a moment, the message will stop being displayed. An icon will appear in the lower central portion
of the digital display instead.

12 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmr2011-079-006_a

1. Icon

The following table lists the indicator lamps during normal operation.
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

! Flashing +
None
SE5 model: The ignition switch is OFF and the
parking brake is not engaged. Always engage
Beeper
the parking brake when parking the vehicle

N On None Gearbox in neutral position

R On None Gearbox in reverse position

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.
Flashing None Left and side indicator lights flash at
the same time: hazard warning lights

For indicator lamps (malfunctions), refer to INDICATOR LAMPS (MALFUNCTION) in DIAGNOSTIC AND
FAULT CODES.

rmr2013-030 13
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

4) Digital Display
Displays useful real-time information to the rider and is used as an interface for the infotainment center.
For a complete description of the digital display, refer to DIGITAL DISPLAY DESCRIPTION.
Important information messages can also be displayed, refer to MESSAGES IN MULTIFUNCTION
GAUGE.
Multifunction Gauge Startup Information
A self test is initiated every time the ignition key is turned on. The default riding screen will turn on and
indicator lights will turn on for a moment. This allows the operator to validate that all indicators are work-
ing properly.
Anytime the ignition switch is turned ON after having been in the OFF position for 5 minutes or more,
the digital display will show the following message:
– BEFORE OPERATING READ THE SAFETY CARD ABOVE THEN PRESS MODE BUTTON.
Press the MODE button to acknowledge this message to allow engine starting.

Digital Display Description

The display is divided in several areas as follows.

1 2 3

4 5 9 6 7 8
rmo2010-001-015_cen

1. Category icons
2. Ambient temperature
3. Clock
4. Gearbox position
5. Cruise control status
6. Trip meter
7. CB communication status (optional)
8. Odometer
9. Main screen

1) Category Icons
There are 5 selectable category icons. Each icon is linked to a different screen. See table below.

14 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

CATEGORY ICON CATEGORY ICON SCREEN

Default riding

Audio (option package)

CB (optional)

Trip meter

Preferences (only available when vehicle is stopped,

except for the trailer mode)

For a complete description, refer to CATEGORY ICON SCREEN DESCRIPTION.

You can navigate through the category icons to select several functions and to change certain settings
using the RECC (Roadster Electronic Command Center).
2) Ambient Temperature
The ambient air temperature is displayed in °C or °F. To change units, refer to PREFERENCES SCREEN.
3) Clock
The current time is displayed in 24h or am/pm format. To change the format, refer to PREFERENCES
SCREEN.
4) Gearbox Position
Displays the selected gearbox position.
5) Cruise Control Status
Displays ON when the cruise control is turned on but not set to any speed.
Displays SET when the cruise control is in operation and a speed has been set.
Displays OFF when the cruise control is not in use.
6) Trip Meter
Time. distance travelled and average speed since the last reset. Two trip meters are available and they
are identified as "A and "B". To change units, refer to PREFERENCES SCREEN.
7) CB Communication Status (Optional)
Displays wether the CB (citizens' band) is receiving (RX) or transmitting (TX).
8) Odometer
Total distance travelled in kilometers or miles since the delivery from the factory. To change units, refer
to PREFERENCES SCREEN.
9) Main Screen
The main screen is the area where the most information is displayed. The display will change when nav-
igating through the available gauge functions.

rmr2013-030 15
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmo2010-001-015_en

DEFAULT RIDING SCREEN SHOWN

Automatic Digital Display Dimming

The multifunction gauge contains a photo sensor. In low light conditions the display will automatically
change to the nighttime viewing screen.

rmr2010-030-001

DIMMED DISPLAY FOR LOW LIGHT CONDITIONS

Navigating in the Digital Display

We recommend you practice selecting some functions on the infotainment center before getting on the
road. You will get used to them and they will be easier to use on the road.
Use the RECC (Roadster Electronic Command Center) to control the display functions.

16 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmo2010-001-020_a

1. 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 to the next available icon. When an icon is selected, its related screen
will appear.
NOTE: The audio or CB icons are skipped when the vehicle is not equipped with these features. The
Preferences screen is skipped when vehicle is above 5 km/h (3 MPH), except for the SE5 model for the
towing mode.

rmo2010-001-015_ben

1. Category icons
2. Default riding icon selected

When the selection is on the last icon, it will then move to the first icon when the MODE button will be
pressed.
In some screens, vertical or horizontal arrows are visible. This indicates that you have to use the
LEFT/RIGHT button to change the setting enclosed by the horizontal arrows and to use the UP/DOWN
button to change the setting enclosed by the vertical arrows.
Pressing an arrow button repeatedly on single or double arrows will move one selection at a time.
Holding an arrow button on a double arrow will move to the end or beginning of the selection.
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.

rmr2013-030 17
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

2
1

rmo2010-001-022_cen

1. Use the UP/DOWN button to select the vertical arrows

2. Use the LEFT/RIGHT button to select the horizontal arrows

When an item is selected, this sets the item to the current value.
After acknowledging the initial safety message at gauge startup, or after a few seconds elapsed in any
other screen without pressing any RECC button, the display will automatically return to the default riding
screen.

Category Icon Screen Description

Default Riding Screen

1 2

4 5
rmo2010-001-401_aen

DEFAULT RIDING SCREEN

1. Engine coolant temperature (option package)
2. Fuel level (option package)
3. Digital speedometer
4. Engine speed (not factory set)
5. Radio preset or radio frequency (not factory set)

1) Engine Coolant Temperature (except models with Separate Analog Gauges):

Bar gauge that continuously indicates the engine coolant temperature.
NOTE: On models with a separate analog engine coolant temperature gauge, the bar gauge is not dis-
played in the digital display.
2) Fuel Level (except models with Separate Analog 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:
18 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

Displays vehicle speed in kilometers (km/h) or miles per hour (MPH). To change units, refer to PREFER-
ENCES SCREEN.
4) Engine Speed:
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 frequency.
NOTE: This is not a default function. To activate this function, refer to PREFERENCES SCREEN.
Audio Screen (Option)
This screen is only available when an audio system is installed.
The audio screen will appear with its last configuration.

rmo2010-001-022_ben

1. Current selected audio device

Repeatedly pressing the SET button will display the available audio devices in this order: FM, AM, WX
(weather channel), iPOD or AUX and XM (satellite radio).
AUDIO SYSTEM ENABLING
Ignition switch ON
Press MODE button for 3 seconds immediately after ignition switch is turned OFF

AUDIO SYSTEM DISABLING

Ignition switch ON, then OFF
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.

rmr2013-030 19
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

Radio (FM, AM, WX, XM)

1 3

2 4

rmo2010-001-022_aen

FM RADIO SHOWN
1. Current selected band
2. Station number preset
3. Current station
4. Volume level

Press the LEFT/RIGHT button to select the desired preset radio station.
Press and hold the LEFT/RIGHT button for more than one second to SEEK the next available radio station.
The radio will remain tuned to that station.
Press the SET button and hold for more than one second to enter the setup screen.
In the setup screen, press the LEFT/RIGHT button to tune the radio frequency in increments of 0.2.
NOTE: When a frequency is already recorded in a preset, its preset number will appear.
To record up to 15 station presets:
Press the DOWN button to record the actual frequency to the preset number displayed.
NOTE: While riding, the radio station will be automatically recorded to the next available preset number.
If all preset numbers are already used, the preset number 15 will be over written.

rmo2010-001-027_aen

TYPICAL
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

While riding, the available functions are:

– Audio volume

20 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

– Mute and seek (XM radio) functions

– Radio preset functions (selection and storing).
iPOD or AUX
When a MP3 player is connected to the vehicle audio connector (option package), the AUX screen will
appear. It will play as set at the time of the connection. Only the volume control will be available for this
type of player.
When an iPOD is connected to the vehicle iPOD connector (option package) the iPOD screen will appear.

rmr2011-079-011_en

TYPICAL iPOD SCREEN

Press the LEFT/RIGHT button to change the song in the current folder.
Press and hold the LEFT/RIGHT button for more than one second to change the playlist if the playlist
item is selected, to change the artist if the artist item is selected and to change the album if the album
item is selected.
While riding, the available functions are:
– Audio volume and mute
– Previous or next song selection (iPod)
– Artist, album or playlist selection (iPod).
CB Screen (Optional)
This screen is only available when a CB is installed.
NOTE: The CB screen will appear whenever the PTT (push to talk) button is pressed whatever the screen
that was displayed.

rmr2013-030 21
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

1 2 3 4 5 6

rmo2010-001-023_aen

1. Current channel
2. CB communication status: RX (receiving), TX (transmitting) and OFF
3. Squelch adjustment
4. Volume adjustment
5. Intercom volume adjustment (i-com)
6. Voice activation sensitivity adjustment (vox)

Use the LEFT/RIGHT buttons to select the item to change (channel, squelch, headset volume, intercom
volume and voice activation sensitivity).
Use the UP/DOWN buttons to set a value.
Press and hold the DOWN button for more than one second to set the item to its lowest value.
Trip Meter Screen

1 2 3

rmo2010-001-024_aen

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 desired trip meter.

Press the UP button to pause or resume the selected trip meter.
Press the DOWN button to reset the selected trip meter.

22 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

Preferences Screen

rmr2010-030-058_aen

1. 1st column: Main category

2. 2nd column: Secondary category or item
3. 3rd column: Unit or setting

This screen is only available when vehicle is stopped.

NOTE: On SE5 model, the trailer mode in the PREFERENCES SCREEN is available while riding.
Use the LEFT/RIGHT button to select the desired column.
Within a column, use the UP/DOWN button to select the desired item. If more items are available to the
next right column, use the RIGHT button to select the column then use again the UP/DOWN button to
select the desired item. Continue using this pattern to reach the desired item.
When an item is selected, this sets the item to the current value. You may then go to any screen, the
value will be kept.
NOTE: When in the 2nd or 3rd column, you can go back to the column at the left using the LEFT button.
NOTE: When the units are changed they will be changed on both the analog and the digital displays. The
units will be used for the odometer and both trip meters.

rmr2013-030 23
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)
SYSTEM DESCRIPTION (REAR
STORAGE COMPARTMENT)
The storage compartment storage cover states
(open or closed) are monitored by the multifunc-
tion gauge.
Rear Storage Compartment Switch
Operation
If a side or top compartment is left open, a warn-
ing will be set on the multifunction gauge indicat-
ing a compartment is open.
The storage compartment indicator switches
work through one suspension up/down switch
circuit.
When the suspension switch is in the FREE (not
activated) position, the circuit wire is connected
through the switches to the multifunction gauge.
Each compartment has a small micro-switch on
the latch mechanism. When a compartment is
opened, the micro-switch closes and connects a
gauge pin to the ground through a 1.5 k resistor.
The multifunction gauge internal circuitry mon-
itors the voltage drop forced by either an ACS
switch or compartment switch position.
SYSTEM DESCRIPTION (LEFT
MULTIFUNCTION SWITCH)
Left Multifunction Switch Operation
The left multifunction switch contains the follow-
ing:
– MODE button
– SET button
– TURN SIGNAL switch
– WINDSHIELD UP/DOWN switch
– HEADLIGHT beam selector switch
– HORN switch
– REVERSE button
– PTT (Push To Talk) switch (For CB)
– RECC (Roadster Electronic Command Center)
– SE5 shift UP/DOWN switch (SE5 models only).
The left multifunction switch contains a module
that converts certain switch inputs to CAN (Con-
troller Area Network) protocol. The CAN signal
generated by the module in the switch is sent
via the CAN HI and CAN LO wires to various
modules to perform specific functions.
The MODE and SET CAN signals are received by
the multifunction gauge.
24
The THUMB UP, THUMB DOWN, THUMB RIGHT,
THUMB LEFT CAN signals are received by the
multifunction gauge and the radio module.
The REVERSE button signal is received by the
TCM (SE5 equipped models) and the multifunc-
tion gauge.
The PTT (Push To Talk) signals are received by the
radio and sent to the CB module (option).
The WINDSHIELD UP/DOWN signals are re-
ceived by the WPM (Windshield and Parking
Brake) module.
The turn signal switch signals are received by the
multifunction gauge.
In addition, commands from the cruise control
switch (part of the RIGHT multifunction switch)
are sent to the LEFT multifunction switch, con-
verted to CAN and sent to the ECM.
The only contact switch in the left multifunction
switch is the HORN switch. It supplies a ground
to the horn directly through the switch.
The left multifunction switch is powered by the
multifunction gauge. It is powered at the same
time as the radio.
SYSTEM DESCRIPTION (CRUISE
CONTROL)
Cruise Control Operation
The cruise control is operated in conjunction with
the ETC (Electronic Throttle Control). The ECM
(Engine Control Module) uses various inputs to
calculate the position of the ETC in order to regu-
late the vehicles speed.
The cruise switch, located on the right multi-
function switch, contains momentary contact
switches that are normally open. When activated
the switch contacts close. When closed the
signals from the cruise switch for ON, SET, or RE-
SUME are sent to the left multifunction switch.
The left multifunction switch contains a module
that converts the signals into CAN (Controller
Area Network) protocol. The converted CAN in-
formation is then transmitted via the CAN HI and
CAN LO wires to the ECM.
Also, the VCM (Vehicle Control Module) wheel
speed sensor information is converted into CAN
by the VCM. The ECM uses this information to
determine vehicle speed.
Given all the input information, the ECM can send
the appropriate electrical signals to the ETC and
accurately control vehicle speed.
rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)
An electrical signal directly from the BLS (Brake
Light Switch) to the ECM is one method used to
disengage the cruise control. Other methods to
disengage the cruise control and give back throttle
control to the operator include:
– Squeezing the clutch lever or if a clutch slippage
occurs (SM5 models).
– Initiating a gear change (SE5 models).
– Any vehicle stability system intervention.
SYSTEM DESCRIPTION (AUDIO
AND COMMUNICATION
SYSTEMS)
Audio and Communication Systems
Operation
The radio module is located underneath the rear
right radio control panel. The radio module is in
communication via CAN (Controller Area Network)
protocol with the multifunction gauge. The multi-
function gauge displays the radio functions. Op-
eration of radio controls is done via CAN with the
RECC (Roadster Electronic Command Center) lo-
cated in the left hand multifunction switch. The
radio is equipped with AM, FM and WX (weather
channels). Optionally the radio can be linked with
additional audio equipment such as CB, XM (Satel-
lite radio), i-POD and comes with an auxiliary input
jack to connect an accessory such as a CD player.
NOTE: Some infotainment features have prece-
dence over the others.
Passenger Radio Control Switch
The passenger radio control buttons contains a
series of 4 diodes for the volume up and down
switches, and another 4 diodes for the channel
up and down switches.
NOTE: Only affect rear headset volume when CB
is installed.
Each diode (in circuit) drops approximately 0.5 Vdc
when conducting electricity. The combination of
diodes in which the current passes (depending on
the what button is depressed) establish different
voltage levels sent to the radio.
The radio senses and interprets the different volt-
age levels as signals that tell it which switch is ac-
tivated.
rmr2013-030
TROUBLESHOOTING
DIAGNOSTIC TIPS
IMPORTANT: When solving an electrical problem,
the first thing to do is to check the battery condi-
tion as well as its cables and connections.
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,
not only test results can be altered, but the vehi-
cle electrical system may not operate normally.
Pay attention to ground wires. They could be-
come loose or corroded which causes them to
act as an additional load in a circuit, dropping
voltage and reducing current to components.
Some components may be grounded through
their outer casing and mounted hardware. This
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-
lems resulting from one of these causes.
NOTICE 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
or terminals.
MULTIFUNCTION GAUGE
TROUBLESHOOTING
GAUGE FUNCTIONS INOPERATIVE OR
WORKING INTERMITTENTLY
1. Power supply or ground problem
- Check power supply and ground circuits.
25
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

TURN SIGNAL LIGHT

TROUBLESHOOTING TIP
All 2013 Models Except RT Models
TURN SIGNAL LIGHTS FLASHES TWICE
AS FAST WHEN THE TURN SIGNAL
SWITCH IS ACTIVATED
1. The “International” option may not properly
be set in Vehicle Configuration page within rmo2010-001-007_b

B.U.D.S. TYPICAL - RT MODEL SHOWN

A. 10 m (33 ft)
- Set the “International” option as described in
ECM REPLACEMENT within ELECTRONIC FUEL
INJECTION (EFI) subsection.
- Carry on the usual troubleshooting.
90°
PROCEDURES
HEADLIGHTS
Headlights Aiming Verification
North American Models rmo2010-001-008_a

1. If applicable, set the rear suspension air pres- TYPICAL - RT MODEL SHOWN
sure to 0 kPa (0 PSI) using the schrader valve lo-
cated under the seat. Trace 2 lines parallel to the ground on the test sur-
face as follows:
LINES ON THE TEST SURFACE (RS MODELS
EXCEPT AUSTRALIA)
Line A 700 mm (27-1/2 in) above ground
Line B 610 mm (24 in) above ground

LINES ON THE TEST SURFACE (RS

MODELS - AUSTRALIA)
Line A 464 mm (18-1/2 in) above ground
Line B 374 mm (14-3/4 in) above ground

LINES ON THE TEST SURFACE (ST MODELS)

Line A 794 mm (31-1/4 in) above ground
rmo2010-001-056_a Line B 704 mm (27-3/4 in) above ground
TYPICAL
1. Schrader valve
LINES ON THE TEST SURFACE - RT MODEL
2. Position the vehicle in front of a test surface as Line A 732 mm (28.8 in) above ground
shown.
Line B 642 mm (25.3 in) above ground

3. Have a person of at least 91 kg (200 lb) taking

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.

26 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

1 A

B
rmo2008-027-101_b

HEADLIGHT REFLECTION ON TEST SURFACE - RS MODELS

EXCEPT AUSTRALIA
1. Focus point
A. 700 mm (27-1/2 in) above ground
B. 610 mm (24 in) above ground

1 A

rmo2010-001-056_a

B TYPICAL
1. Schrader valve
rmr2013-030-052_a

HEADLIGHT REFLECTION ON TEST SURFACE - RS MODELS
AUSTRALIA
1. Focus point
A. 464 mm (18-1/2 in) above ground
B. 374 mm (14-3/4 in) above ground
2. Position the vehicle in front of a test surface as
shown.
3. Have a person of at least 91 kg (200 lb) taking
place on the driver's seat.

1 A

B
rmo2008-027-101_b

HEADLIGHT REFLECTION ON TEST SURFACE - ST MODELS

1. Focus point
A. 794 mm (31-1/4 in) above ground
B. 704 mm (27-3/4 in) above ground

rmo2010-001-007_b
2 TYPICAL - RT MODEL SHOWN
A. 10 m (33 ft)

1 B A 90°

rmo2013-030-015_a

TYPICAL HEADLIGHT REFLECTION ON TEST SURFACE

1. Ground
2. Focus point
A. 732 mm (28.8 in) above ground
B. 642 mm (25.3 in) above ground
rmo2010-001-008_a

European Models TYPICAL - RT MODEL SHOWN

NOTE: This verification is valid for either left-hand Trace 2 lines parallel to the ground on the test sur-
or right-hand traffic regulations. face as follows:
Low Beam
1. If applicable, set the rear suspension air pres-
sure to 0 kPa (0 PSI) using the schrader valve lo-
cated under the seat.

rmr2013-030 27
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

LINES ON THE TEST SURFACE (RS MODELS 1 A

EXCEPT AUSTRALIA)
Line A 464 mm (18-1/4 in) above ground
Line B 374 mm (14-3/4 in) above ground B
rmo2008-027-101_b
LINES ON THE TEST SURFACE (RS HEADLIGHT REFLECTION ON TEST SURFACE - ST MODELS
MODELS - AUSTRALIA) 1. Focus point
A. 464 mm (18-1/4 in) above ground
Line A 464 mm (18-1/4 in) above ground B. 374 mm (14-3/4 in) above ground

Line B 374 mm (14-3/4 in) above ground

2
LINES ON THE TEST SURFACE (ST MODELS)
Line A 464 mm (18-1/4 in) above ground
Line B 374 mm (14-3/4 in) above ground
1 B A
LINES ON THE TEST SURFACE (RT MODELS)
Line A 515 mm (20.3 in) above ground
rmo2013-030-015_a

Line B 415 mm (16.3 in) above ground TYPICAL HEADLIGHT REFLECTION ON TEST SURFACE - RT
MODELS
1. Ground
4. Select low beam. 2. Focus point
5. Beam aiming is correct when the focus point A. 515 mm (20.3 in) above ground
B. 415 mm (16.3 in) above ground
(brightest spot) of the headlight reflection is
within the marks. High Beam
1. Follow steps 1 and 2 of the low beam verifica-
1 A tion procedure.
2. Trace 2 lines parallel to the ground on the test
surface as follows:
B LINES ON THE TEST SURFACE (RS MODELS
rmo2008-027-101_b EXCEPT AUSTRALIA)
HEADLIGHT REFLECTION ON TEST SURFACE - RS MODELS Line A 828 mm (32-19/32 in) above ground
EXCEPT AUSTRALIA
1. Focus point
Line B 738 mm (29-1/16 in) above ground
A. 464 mm (18-1/4 in) above ground
B. 374 mm (14-3/4 in) above ground
LINES ON THE TEST SURFACE (RS
MODELS - AUSTRALIA)
1 A
Line A 828 mm (32-19/32 in) above ground
Line B 738 mm (29-1/16 in) above ground

B LINES ON THE TEST SURFACE ( ST MODELS)

rmr2013-030-052_a
Line A 894 mm (32-13/64 in) above ground
HEADLIGHT REFLECTION ON TEST SURFACE - RS MODELS
AUSTRALIA Line B 804 mm (32 in) above ground
1. Focus point
A. 464 mm (18-1/2 in) above ground
B. 374 mm (14-3/4 in) above ground LINES ON THE TEST SURFACE (RT MODELS)
Line A 850 mm (33.5 in) above ground
Line B 800 mm (31.5 in) above ground

Select high beam.

Beam aiming is correct when the focus point
(brightest spot) of the headlight reflection is
within the marks.
28 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

1 A Upper Headlight Units

RS Models
Turn adjustment screws to adjust beam height.
Adjust both headlights evenly.
B
rmr2013-030-053_a

HEADLIGHT REFLECTION ON TEST SURFACE — HIGH BEAM -

RS MODELS EXCEPT AUSTRALIA
1. Focus point
A. 828 mm (32-19/32 in) above ground
B. 738 mm (29-1/16 in) above ground

1 A

rmr2008-027-102_a

ADJUSTMENT SCREWS
B
rmr2013-030-053_a
ST Models
HEADLIGHT REFLECTION ON TEST SURFACE — HIGH BEAM To adjust headlight beam, insert a Phillips #4
- RS MODELS - AUSTRALIA
1. Focus point screwdriver and use it to turn the adjustment
A. 828 mm (32-19/32 in) above ground knobs. Ajust both headlights evenly.
B. 738 mm (29-1/16 in) above ground
NOTICE Make sure to use a Phillips #4 to
avoid damaging adjustment mechanism.
1 A

B
rmr2013-030-053_a

HEADLIGHT REFLECTION ON TEST SURFACE — HIGH BEAM

- ST MODELS
1. Focus point
A. 894 mm (32-13/64 in) above ground
B. 804 mm (32 in) above ground

rmo2013-001-011_a

1. Adjustment screw
1 B A
RT Models
rmo2013-030-015_a To adjust headlight beam, turn the adjustment
TYPICAL HEADLIGHT REFLECTION ON TEST SURFACE - RT knob. Adjust both headlights evenly.
MODELS
1. Ground
2. Focus point
A. 850 mm (33.5 in) above ground
B. 800 mm (31.5 in) above ground

Headlights Aiming Adjustment

1. Remove both middle side panels. Refer to
BODY subsection.

rmr2013-030 29
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmr2011-079-001_a rmr2011-079-002_a

RH SIDE SHOWN RH SIDE SHOWN

1. Adjustment knob "HB" 1. Adjustment knob "LB"

HEADLIGHT BEAM ADJUSTMENT HEADLIGHT BEAM ADJUSTMENT

Raise beam Turn knob clockwise Raise beam Turn knob clockwise
Lower beam Turn knob counterclockwise Lower beam Turn knob counterclockwise

Lower Headlight Units (European Models Only) Beam Selector Switch Test with
RS and ST Models B.U.D.S.
Insert a long Philips screwdriver into air duct to 1. In B.U.D.S., select Monitoring and Cluster
reach the adjustment screws. tabs.
2. Monitor the High Beam indicator in the Switch
Inputs field.

rmr2008-027-106_a

TYPICAL
1. Air duct rmr2011-079-003_a
2. Screwdriver
1. High Beam indicator
Turn adjustment screws to adjust beam height.
Adjust both headlights evenly. If the indicator turns ON when high beam is se-
lected, an input signal in sent to the gauge.
RT Models If the indicator does not turn ON when high beam
1. To adjust headlight beam, turn the adjustment is selected, check switch and wiring continuity.
knob. Adjust both headlights evenly.
Headlight Wire Identification
HEADLIGHT RELAY (R5)
FUNCTION PIN COLOR
12 volt input from fuse R5
C4 OG/BK
(headlights power)

30 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

HEADLIGHT RELAY (R5) HEADLIGHT RELAY VOLTAGE TEST

FUNCTION PIN COLOR VOLTAGE
TEST PROBES CONDITION
(DC)
12 volt input from fuse R5
C6 OG/BK
(relay winding input) Close to
C6 to chassis
At all times battery
12 volt output to HI ground
D6 BN/VT voltage
beam relay (R1)
Close to
12 Volt output to LO beam D5 YE/WH C4 to chassis
At all times battery
ground
Relay winding ground (from voltage
D4 GN/RD
beam selector switch)
Close to
D6 to positive Engine
battery
HEADLIGHT HI BEAM RELAY (R1) battery connection running
voltage
FUNCTION PIN COLOR
If results are as specified, try a new relay.
12 volt input from headlight
relay (R56) (relay winding A12 BN/VT If results are not as specified, repair wiring/con-
input) nectors.
12 volt output to HI NOTE: Note the ground signal to pin D6 is pro-
B12 GY vided by the ECM. If circuit is correct and the
beam circuit
ground signal does not reach the relay, try a new
HEADLIGHT LO BEAM RELAY (R2) ECM.
FUNCTION PIN COLOR HI/LO Headlight Relay Voltage Test
12 volt input from headlight 1. Make sure R5 of LH fuse box is in good condi-
relay (R5) (relay winding A10 YE/WH tion and powered.
input)
2. Check for voltage at the RFB, HI (R1) and LO
12 volt output to LO (R2) headlight relays location using the follow-
B10 GN/BG
beam circuit ing chart.
HEADLIGHT BEAM SELECTOR SWITCH HIAND LO HEADLIGHT RELAYS VOLTAGE TEST
FUNCTION PIN COLOR VOLTAGE
TEST PROBES CONDITION
(DC)
From headlights HI/LO
MSL2-2 GN/RD
beam relay (R5) winding Close to
A10 (R2)to chassis
At all times battery
ground
voltage
Headlight Circuit Protection
Close to
CONDITION CIRCUIT PROTECTION A9 (R2) to chassis Engine
battery
ground running
Supplied at all times R5 of RFB voltage
Engine
Close to
Headlight Relay Voltage Test B12 to chassis running and
battery
ground High beam
1. Make sure R5 of RFB is in good condition and voltage
selected
powered.
2. Check for voltage at the RFB, headlight relay If results are as specified, try a new relay.
(R5) location using the following table: If results are not as specified, check headlights re-
lay (R5) repair wiring/connectors.
NOTE: Note the ground signal to pin B12 is pro-
vided by the beam selector switch. If circuit is
correct and the ground signal does not reach the
relay, carry out HEADLIGHT BEAM SELECTOR
SWITCH TEST.

rmr2013-030 31
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

Headlight Voltage Test

1. To test for voltage at the headlight bulb and or
shutter solenoid, disconnect the headlight con-
nector, refer to HEADLIGHT REPLACEMENT in
this subsection.
2. Test for power at the headlight connector as per
the following chart:
3. Start engine.
HEADLIGHT VOLTAGE TEST
HEADLIGHT
BEAM
TEST PROBES SELECTOR RESULT
SWITCH
POSITION rmr2010-030-002_a

1. MSL2 connector
Close to 2. MSL3 connector
Pin 1 to pin 4 Low beam
battery voltage
HEADLIGHT BEAM SELECTOR SWITCH TESTING
Pin 1 to chassis Close to
Low beam SWITCH SWITCH
ground battery voltage RESULT
CONNECTOR POSITION
Pin 4 to
Low beam or Close to Connector MSL2 Close to
positive battery
high beam battery voltage pin 2 to chassis Low beam battery
connection
ground voltage
Close to
Pin 3 to pin 4 High beam Connector MSL2 High beam
battery voltage Close to
pin 2 to chassis or flash high
Pin 3 to chassis Close to 0.45 Vdc
High beam ground beam
ground battery voltage
If the headlight beam selector switch test is within
If there is no voltage at pin 1 in the low beam po- specification, however the high beam relay volt-
sition, check the headlight and HI/LO headlight re- age test failed, test the continuity between left
lays. multifunction connector MSL2-2 and relay termi-
If there is no voltage at pin 3 in the high beam nal D4.
position, check the HI/LO headlight relay. If the test is not to specification perform the LEFT
If voltage is within specification from pin 1 to MULTIFUNCTION SWITCH VOLTAGE TEST in this
pin 4, however the headlight does not illuminate, subsection.
replace the headlight bulb.
If voltage is within specification from pin 3 to pin 4,
Headlights Bulb Replacement - RS
however the high beam shutter does not function, Models
replace the high beam shutter. North American Models
Headlight Beam Selector Switch Test To replace a headlight bulb, first remove the mul-
tifunction gauge to access the back of the light
NOTE: Due to the electronic circuitry of the head- assembly. Refer to MULTIFUNCTION GAUGE
light beam selector switch, it must be tested us- (CLUSTER) in this section.
ing a voltmeter while headlights are ON.
Pull out the housing cap on the back of the head-
1. Remove the left side acoustic panel. Refer to light.
BODY subsection.
2. Back probe connector terminal with an appro-
priate tool and test with the FLUKE 115 MULTI-
METER (P/N 529 035 868) as indicated.
3. Turn ignition switch ON.

32 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)
rmo2008-001-123_a
1. Housing cap
Turn the connector counterclockwise to remove it
from the housing.
rmo2008-001-124_a
1. Bulb housing
2. Bulb retaining clip
Remove the bulb by releasing both clips with a
small flat head screwdriver.
Install the new bulb by clipping it to the connector.
NOTICE Never touch glass portion of a halo-
gen bulb with bare fingers, it shortens its oper-
ating life. If glass is touched, clean it with iso-
propyl alcohol which will not leave a film on
the bulb.
Install the connector in the housing and put the
housing cap on.
Install the multifunction gauge, refer to MULTI-
FUNCTION GAUGE (CLUSTER) in this section.
European Models
High Beams
To replace a headlight bulb, first remove the mul-
tifunction gauge to access the back of the light
assembly. Refer to MULTIFUNCTION GAUGE
(CLUSTER) in this section.
rmr2013-030
Locate defective bulb, then turn it counterclock-
wise to release it from the bulb housing.
rmo2008-002-007_a
RH SHOWN
1. Bulb
Release tabs then pull bulb off connector by its
base.
rmo2008-002-008_a
1. Bulb connector
2. Tabs
Install a new bulb on the connector.
NOTICE Never touch the glass portion of a
halogen bulb with bare fingers, it shortens its
operating life. If glass is touched, clean it with
isopropyl alcohol which will not leave a film on
the bulb.
Install connector on headlight housing, turn clock-
wise to secure.
Install the multifunction gauge, start engine and
confirm lights operation.
Low Beams
Refer to body and remove the front panel.
Release tabs and disconnect bulb connector.
33
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmo2008-002-005_a

1. Bulb connector rmo2013-003-042_a

2. Tabs
1. Screws
Turn bulb counterclockwise to release, then re- 2. Remove the four screws and the gauge contour
move bulb from light housing. panel.

rmo2013-003-039_a
rmo2008-002-006_a
1. Screws
ROTATE TO RELEASE
3. Manually disengage the gauge from the con-
Reinstall removed parts in the reverse order of sole by pushing down on the tabs.
their removal.
NOTICE Never touch glass portion of a halo-
gen bulb with bare fingers, it shortens its oper-
ating life. If glass is touched, clean it with iso-
propyl alcohol which will not leave a film on
the bulb.
NOTICE Do not overtighten panel screws.
Any deformation of the panel around a screw
is an indication that it is too tight. You may
damage the panel.
Confirm that the lights operation. rmo2013-003-016_a

Headlight Bulb Replacement - ST

Models
1. Remove the four screws and the upper panel.

34 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

mmo2013-004-036_c

rmo2013-003-015_a Step 1: Push both sides

1. Tabs
4. Disconnect electrical connector.
5. Remove the applicable rubber boot.
Step 2: Push down to release
Step 3: Release both sides
1. Retaining clip
7. Pull bulb and replace. Properly reinstall parts.
NOTICE Never touch glass portion of halo-
gen bulb with bare fingers, it shortens its
operating life. If glass is touched, clean it with
isopropyl alcohol and a clean cloth.

Headlight Bulb Replacement - RT

Models
1. Remove the top side panel.
2. Remove the upper retaining screws from front
fascia.

rmo2013-003-031_a

1. Electrical connector
2. Rubber boot rmr2010-038-022_a

1. Upper retaining screw

6. Press and pull both sides of the retaining clip at
the same time to release it from bulb support. 3. Remove middle retaining screws from front fas-
cia.

rmr2013-030 35
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmr2010-038-023_a
rmo2010-001-076_a
1. Middle retaining screw
1. Retaining screws
4. Remove lower retaining screws and washers
from front fascia. 8. Pull tabs apart the to unlock cover.

rmr2010-038-024_a

1. Lower retaining screw

5. Remove front fascia. rmo2010-001-077_a

1. Headlight cover
6. Remove adjustment cable retaining nut. 2. Pull tabs apart

9. Pull cover out.

10. Disconnect the bulb connector.

rmr2011-079-001_b

1. Adjustment cable retaining nut

rmo2010-001-078_a
7. Remove from headlight the 4 retaining screws. 1. Unplug connector

11. Turn the bulb counterclockwise to unlock it.

36 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

LIGHTS
FUNCTION PIN COLOR
12 volt input from auxiliary
3 GY/GN
lights switch
Ground 7 BK

Headlight Circuit Protection

CONDITION CIRCUIT PROTECTION
Supplied at all times F5 of RFB

Auxiliary Light Voltage Test at

rmo2010-001-079_a

1. Turn counterclockwise
Auxiliary Light Connector
1. Make sure F5 of RFB is in good condition and
12. Pull bulb out. powered.
13. Insert the new bulb into its socket then turn 2. Remove the middle side panel. Refer to BODY
clockwise to lock it in position. subsection.
NOTICE Never put your fingers on a new 3. Disconnect the auxiliary light connector to be
halogen bulb. This would shorten its life. tested.
4. Start engine.
5. Check for voltage at the auxiliary light connector
as per the following chart using the FLUKE 115
MULTIMETER (P/N 529 035 868).
AUXILIARY LIGHTS VOLTAGE TEST AT
AUXILIARY LIGHT CONNECTOR
AUXILIARY LIGHT SWITCH
RESULT
CONNECTOR POSITION
Close to
Pin 2 to pin 3 Switch ON battery
voltage
Close to
Pin 3 to chassis
Switch ON battery
ground
rmo2010-001-079_b
voltage
1. Turn clockwise Close to
Pin 2 to positive
Switch OFF battery
14. Plug connector to the bulb. battery connection
voltage
15. Reinstall headlight cover and remaining parts
in the reverse order of the removal. If the auxiliary light voltage testing is within spec-
ification, replace the auxiliary light bulb. Refer to
AUXILIARY LIGHTS (OPTION AUXILIARY LIGHT BULB REPLACEMENT in this
subsection.
PACKAGE)
If there is no voltage at pin 3 with the headlight
Auxiliary Lights Wire Identification switch ON, perform the AUXILIARY LIGHT VOLT-
AUXILIARY LIGHT SWITCH AGE TEST AT SWITCH.
If result at pin 2 is not as specified, repair ground
FUNCTION PIN COLOR
circuit.
12 volt input from load
2 GN/GY
shedding relay Auxiliary Light Voltage Test at Switch
12 volt output to lights 3 GY/GN 1. Make sure F5 of RFB is in good condition and
powered.
rmr2013-030 37
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

2. Remove the central panel to access the back of Insert your hand through the opening above the
the auxiliary light switch. Refer to BODY sub- upper arm of front suspension.
section.
3. Perform the test at the back of the auxiliary light
switch with the switch connected.
4. Start engine.
5. Perform the test with the FLUKE 115 MULTIME-
TER (P/N 529 035 868) using the following illus-
tration and chart.

rmo2010-001-071_a

1. Auxiliary light
2. Access to the auxiliary light bulb

Pull tabs apart to unlock cover.

rmr2010-30-040_a

BACK OF AUXILIARY LIGHT CONNECTOR (PIN-OUT)

AUXILIARY LIGHTS VOLTAGE TESTING

AT SWITCH
AUXILIARY
SWITCH
LIGHTS SWITCH RESULTS
POSITION
CONNECTOR
Close to
Pin 2 to chassis
Any battery
ground
voltage rmo2010-001-072_a

1. Auxiliary light cover

Close to 2. Pull tabs apart
Pin 3 to chassis
Switch ON battery
ground
voltage Pull cover out.
Disconnect bulb connector.
If there is voltage at pin 2 to but no voltage at pin 3
when the switch is ON, replace the auxiliary lights
switch.
If there is no voltage from pin 2 to chassis ground,
test load shedding relay. Refer to POWER DISTRI-
BUTION AND GROUNDS subsection.
If there is voltage at pin 3, check the continuity
from pin 3 of the auxiliary lights switch and pin 3 of
the auxiliary light connector. Repair the wires/con-
nectors as necessary.

Auxiliary Light Bulb Replacement

Remove the middle side panel.
Clean the back area of auxiliary light.
rmo2010-001-073_a

1. Unplugged connector

38 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

Turn bulb counterclockwise to unlock it.

rmr2010-30-038_a

FRONT LEFT BUMPER COVER AIR DUCT

1. Screws
2. Plastic rivets
rmo2010-001-074_a

1. Turn counterclockwise 3. Remove the 3 screws at the bottom inside of

the front panel.
Pull bulb out.
NOTICE Never put your fingers on a new
halogen bulb. This would shorten the bulb
life.
Insert the new bulb into its socket then turn clock-
wise to lock it in position.

rmr2010-30-044_a

INSIDE OF LEFT FRONT PANEL

1. Screws

4. Remove the 3 plastic rivets from the top of the

front panel.

rmo2010-001-074_b

1. Turn clockwise

Plug connector to the bulb.

Reinstall auxiliary light cover and middle side panel
in the reverse order of the removal.

Auxiliary light Removal

1. Remove the front cargo module. Refer to
BODY subsection.
2. Remove the 6 plastic rivets and the 2 screws
from the front bumper cover air duct.

rmr2013-030 39
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

8. Remove the top rear securing screw retaining

the auxiliary light assembly.

rmr2010-30-045_a

TOP OF THE LEFT FRONT PANEL

1. Plastic rivets

5. Carefully remove the front panel. rmr2010-30-049_a

6. Remove the 2 front screws retaining the auxil- 1. Top rear screw
iary light assembly. 9. Carefully remove the auxiliary light assembly.

Auxiliary Light Installation

Installation of the auxiliary light is the reverse of
removal procedures. Pay specific attention to all
torque values, refer to BODY subsection.

LICENSE PLATE LIGHT

License Plate Light Wire Identification
IGNITION SWITCH
FUNCTION PIN COLOR
12 volt from F1 of RFB B RD/YE
rmr2010-30-047_a

AUXILIARY LIGHT 12 volt output to

F OG
1. Screws license plate lights
7. Remove the rear screw retaining the auxiliary LIGHTS
light assembly.
FUNCTION PIN COLOR
12 volt input from
1 OG
ignition switch
Ground 2 BK

License Plate Light Circuit Protection

CONDITION CIRCUIT PROTECTION
Supplied at all times F5 of RFB

rmr2010-30-048_a

1. Rear screw

40 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

Licence Plate Light Test Licence Plate Light Bulb Replacement -

1. Remove the licence plate light. Refer to LI- RT Models
CENCE PLATE LIGHT BULB REPLACEMENT 1. Remove the lens screws with a Phillips head
in this subsection. screwdriver.
2. Perform the test on the licence plate light as per
the following chart with the FLUKE 115 MULTI-
METER (P/N 529 035 868).
LICENCE PLATE LIGHT TEST
LICENCE IGNITION
PLATE LIGHT SWITCH RESULT
CONNECTOR POSITION
Close to
Pin 1 to pin 2 ON battery
voltage
Close to
Pin 1 to chassis
ON battery
ground
voltage
Close to rmo2010-001-080_a
Pin 2 to positive
Any battery 1. License plate lens screws
battery connection
voltage
2. Pull lens out.
If the test is within specification, replace the li- 3. Remove the bulb by pulling it off.
cence plate light bulb. Refer to LICENCE PLATE
LIGHT BULB REPLACEMENT in this subsection.
If results are not as specified, check wiring/con-
nectors.

Licence Plate Light Bulb Replacement -

RS and ST Models
Remove lens.

rmo2010-001-081_a

1. Pull out

4. Install the new bulb by pushing it in.

5. Reinstall the lens.
rmo2008-001-090_a

TYPICAL
1. Lens screw, license plate

Remove the bulb by pushing it in and turning coun-

terclockwise.
Install the new bulb by pushing it in and turning
clockwise.
Reinstall lens and confirm light operation.

rmr2013-030 41
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

TURN SIGNAL LIGHTS/HAZARD Front Turn Signal Test

WARNING LIGHTS 1. Remove the front mirror assembly of the turn
signal to be tested. Refer to BODY.
Turn Signal Lights/Hazard Warning
Wire Identification 2. Perform the following test at the front turn sig-
nal connector using the FLUKE 115 MULTIMETER
CLUSTER (P/N 529 035 868).
FUNCTION PIN COLOR 3. Turn ignition on and activate turn signal switch
on the vehicle side to be tested.
CAN HI 24 WH/BG
FRONT TURN SIGNAL TEST
CAN LO 23 WH/BK
PROBE RESULTS
Output to LH turn
4 GY/PK
signal/hazard lights Pin 1 Pin 2 Pulsing 8 to 12 Vdc
Output to RH turn Pin 1 Chassis ground Pulsing 8 to 12 Vdc
5 BN/YE
signal/hazard lights
Positive
Pin 2 battery Close to battery voltage
LIGHTS
connection
FUNCTION PIN COLOR
If results are as specified, replace turn signal.
LH rear turn
signal/hazard 12 volt 4 GY/PK If there is no voltage at pin 1, carry out TURN SIG-
input (from cluster) NAL SWITCH TEST WITH B.U.D.S. in this subsec-
RH rear turn
tion.
signal/hazard 12 volt 4 BN/YE If result at pin 2 is not as specified, repair ground
input (from cluster) circuit.
LH rear taillight
assembly ground
5 BK Rear Turn Signal Test
1. Remove the rear taillight to be tested. Refer
RH rear taillight
assembly ground
5 BK to TAILLIGHT/BRAKE LIGHT REPLACEMENT
in this subsection.
LH front turn
signal/hazard 12 volt 1 GY/PK
2. Perform the following test at the rear taillight
input (from cluster) connector using the FLUKE 115 MULTIMETER
(P/N 529 035 868).
RH front turn
signal/hazard 12 volt 1 BN/YE 3. Turn ignition ON and activate turn signal switch
input (from cluster) on vehicle side to be tested.
LH front turn REAR TURN SIGNAL TEST
2 BK
signal/hazard ground PROBE RESULTS
RH front turn Pin 4 Pin 5 Pulsing 8 to 12 Vdc
2 BK
signal/hazard ground
Pin 4 Chassis ground Pulsing 8 to 12 Vdc
Turn Signal Lights/Hazard Warning Positive
Circuit Protection Pin 5 battery Close to battery voltage
connection
CIRCUIT
CIRCUIT CONDITION
PROTECTION If results are as specified, replace turn signal bulb.
Supplied at all If there is no voltage at pin 4, carry out TURN SIG-
Turn signals F1 of RFB
times NAL SWITCH TEST WITH B.U.D.S. in this subsec-
Hazard Supplied at all tion.
F2 of RFB
Warning times If result at pin 5 is not as specified, repair ground
circuit.

42 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

Turn Signal Wire Continuity Test

1. Remove the multifunction gauge. Refer to
MULTIFUNCTION GAUGE in this subsection.
2. Perform the following test between the turn
signal connector and the multifunction gauge
connector using the FLUKE 115 MULTIMETER
(P/N 529 035 868).
FLASHER WIRE CONTINUITY TEST
MULTIFUNCTION
TURN SIGNAL
GAUGE RESULTS rmr2011-079-003_b
CONNECTOR
CONNECTOR 1. Flasher L and Flasher R indicators
Left front turn Close to If the indicator turns ON when the correspond-
Pin 4
signal pin 1 0.2
ing turn signal is selected, the switch is good and
Left rear turn
Pin 4
Close to the gauge receives the signal. Carry out the TURN
signal pin 4 0.2 SIGNAL WIRE CONTINUITY TEST in this subsec-
Right front turn Close to tion.
Pin 5
signal pin 1 0.2 If the indicator does not turn ON when the corre-
Right rear turn Close to
sponding turn signal is selected, replace switch.
Pin 5
signal pin 4 0.2
HAZARD WARNING LIGHTS
If all the turn signal tests and the turn signal SWITCH
switch test with B.U.D.S. are satisfactory, replace
the multifunction gauge. Hazard Warning Lights Switch Test
If result is not as specified, repair defective circuit. with B.U.D.S.
1. In B.U.D.S., select Monitoring and Cluster
Front Turn Signal Replacement tabs.
Remove mirror, refer to BODY subsection. 2. Monitor the Hazard indicator in the Switch In-
Replace turn signal. puts field.

Rear Turn Signal Bulb Replacement

If the rear turn signal bulbs require replacement,
refer to TAILLIGHT/BRAKE LIGHT REPLACE-
MENT in this subsection.

TURN SIGNAL SWITCH

Turn Signal Switch Test with B.U.D.S.
1. In B.U.D.S., select Monitoring and Cluster
tabs.
2. Monitor the Flasher L and Flasher R indicators rmr2011-030-001_c

in the Switch Inputs field. 1. Hazard indicator

If the indicator turns ON when the hazard warning

lights are on, an input signal is sent to the gauge.
If the indicator does not turn ON, check wiring
continuity and carry out HAZARD WARNING
LIGHTS SWITCH TEST AT GAUGE CONNECTOR.

rmr2013-030 43
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

Hazard Warning Lights Switch Test at Back-probe the connector with the appropriate
Gauge Connector tool using the FLUKE 115 MULTIMETER (P/N 529
035 868).
Before proceeding with this test, inspect the 10 A
fuse F5 in the RH fuse box. 2. Turn the ignition switch ON.
If the turn signals function, however the hazard 3. Perform the test using the following chart:
warning switch does not function, perform the fol- HAZARD WARNING LIGHTS SWITCH TEST AT
lowing test. RH MULTIFUNCTION SWITCH CONNECTOR
1. Remove the multifunction gauge, refer to MUL-
SWITCH
TIFUNCTION GAUGE in this subsection. TEST PROBES
POSITION
RESULTS
2. Perform the following test at the multifunction
Close to
gauge connector. Pin 6 to chassis
Any battery
ground
HAZARD WARNING LIGHTS SWITCH TEST voltage
AT GAUGE CONNECTOR Close to
Pin 1 to chassis
SWITCH Any battery
TEST PROBES RESULT ground
CONDITION voltage
Close to Pin 2 to chassis
Pin 10 and chassis OFF Close to 0 Vdc
Activated battery ground
ground
voltage Pin 2 to chassis
ON 11 to 12 Vdc
ground
If test is within specification, replace the multi-
function gauge. If all tests are within specification, check the con-
If test is not within specification, perform the tinuity from the MSR2 connector to pin 10 of the
HAZARD WARNING SWITCH TEST AT RH MUL- multifunction gauge connector and repair as nec-
TIFUNCTION SWITCH CONNECTOR. essary.
If there is no voltage at pin 6, check the continuity
Hazard Warning Lights Switch Test at from pin 6 of the MSR2 connector to pin G of the
RH Multifunction Switch Connector ignition switch and repair as necessary.
This test is performed at the MSR2 connector. If there is no voltage at pin 1, check continuity be-
tween fuse F2 and pin 1. Repair as necessary.
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 F7 of RFB B RD/YE
12 volt output to lights F OG

rmr2010-030-004
BRAKE SWITCH
MSR2 CONNECTOR FUNCTION PIN COLOR
1. Remove the left hand acoustic panel, refer to 12 volt input from F2
1 RD/OG
BODY subsection. of RH fuse box
NOTE: The hazard switch is an Hall Effect switch. 12 volt output to lights 2 WH
It must be tested using a voltmeter while circuit is
ON.

44 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

LIGHTS
FUNCTION PIN COLOR
LH taillight 12 volt
input (from ignition 2 OG
switch)
RH taillight 12 volt
input (from ignition 2 OG
switch)
LH brake light 12
volt input (from brake 1 WH
light switch)
RH brake light 12 rmr2010-030-007

volt input (from brake 1 WH TAILLIGHT CONNECTOR

light switch)
TAILLIGHT/BRAKE LIGHT TEST
LH rear taillight
5 BK TAILLIGHT SWITCH
assembly ground RESULTS
CONNECTOR CONDITIONS
RH rear taillight
5 BK Close to
assembly ground Pin 2 to chassis Ignition
battery
ground switch ON
voltage
Taillight/Brake Light Circuit Protection
Close to
Pin 1 to chassis
CIRCUIT Brake applied battery
CIRCUIT CONDITION ground
PROTECTION voltage
Supplied at Close to
Taillights F1 (RFB) Pin 5 to positive
all times Any battery
battery connection
voltage
Supplied at
Brake lights F2 (RFB)
all times
If there is no voltage at pin 2 of the taillight con-
nector, check continuity from taillight connector to
Taillight/Brake Light Test pin F of the ignition switch. Repair as necessary.
If no lights function check the 30 A fuse J4 in the If there is no voltage at pin 1 of the taillight con-
RFB. nector, check for voltage at the brake light switch.
1. If taillight, position and licence lights are inop- Perform also the BRAKE LIGHT SWITCH TEST.
erative, check if F2 of RFB is in good condition Refer to BRAKES subsection.
and powered. If result at pin 5 is not as specified, repair ground
2. Remove taillight to be tested. circuit.
3. Perform the following test at the taillight con- Taillight/Brake Light Bulb Replacement
nector using the following illustration and chart.
- RS and ST Models
Remove the lower tail cover by unscrewing 7 Torx
screws as indicated below.

rmr2013-030 45
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmo2008-001-114_a rmo2008-001-117_a

LOWER TAIL COVER 1. Remove Torx screw

1. 7 Torx screws location
Turn the connector counterclockwise and remove
Partially remove right rear side panel by removing it from the light assembly.
the 2 plastic rivets under the seat as indicated be-
low.

rmo2008-001-115_a

1. 2 plastic rivets under the seat

rmo2008-001-118_a

Disconnect right turn signal housing connectors. 1. Turn connector clockwise to remove

Remove the Torx screw behind the lens as indi-
cated below.
Remove the bulb by pushing it in and turning coun-
terclockwise.
Install the new bulb by pushing it in and turning
clockwise.
Reinstall the parts in the reverse order of their re-
moval.
NOTE: When installing right rear side panel, con-
nect the turn signal housing connectors by match-
ing the wire colors.

Taillight/Brake Light Replacement - RT

Models
NOTE: If a LEDs in the taillight or brake light fail,
rmo2008-001-116_a the entire taillight must be replaced.
1. Remove Torx screw 1. Open the top storage compartment.
Remove the Torx screw beside the lens under the 2. Open the side storage compartments.
rear tip as indicated below. 3. Remove the 8 retaining screws from the rear
panel.

46 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

8. Insert the new bulb into its socket then turn

clockwise to lock it in position.

rmo2010-001-082_a

1. Rear panel
2. Retaining screws

4. Pull out panel.

rmo2010-001-084_b

1. Turn clockwise

9. Plug connector to the bulb.

10. Reinstall rear panel in the reverse order of the
removal.

POSITION LIGHTS
Position Lights Wire Identification
IGNITION SWITCH
FUNCTION PIN COLOR
12 volt from F1 of RFB B RD/YE
12 volt output to lights F OG
rmo2010-001-083
LIGHTS
5. Unplug connector. FUNCTION PIN COLOR
6. Turn the bulb counterclockwise to unlock it.
LH position 12 volt
input (from ignition 1 OG
switch)
RH position 12 volt
input (from ignition 1 OG
switch)
LH rear position
2 BK
light ground
RH rear position
2 BK
light ground

Position Lights Circuit Protection

CONDITION CIRCUIT PROTECTION

rmo2010-001-084_a
Supplied at all times F1 of RFB
1. Turn counterclockwise

7. Pull bulb out.

rmr2013-030 47
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

Position Lights Test

1. If taillight, position and licence lights are inop-
erative, check if F1 of RH fuse box is in good
condition and powered.
2. Remove the position light bulb. Refer to PO-
SITION LIGHTS BULB REPLACEMENT in 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
POSITION LIGHT rmo2008-003-001_a
SWITCH RESULTS
CONNECTOR
POSITION Lift the front portion of lens with your thumb or a
Close to small screwdriver to release.
Pin 1 to pin 2 Switch ON battery
voltage
Close to
Pin 1 to chassis
Switch ON battery
ground
voltage
Close to
Pin 2 to positive
Any battery
battery connection
voltage

If the test is within specification, replace the posi-

tion light bulb. Refer to POSITION LIGHTS BULB
REPLACEMENT in this subsection.
If there is no voltage at pin 1, check continuity
from pin F of the ignition switch connector to pin 1 rmo2008-003-002_a

of the position light connector. Repair wire as nec-

essary. Turn the lens clockwise and remove it from the
bulb holder.
If result at pin 2 is not as specified, repair ground
circuit.

Position Lights Replacement RS-S, ST

LTD and RT LTD Models
Refer to BODY and remove front fender.
Install new position light.
Installation is the reverse of removal.

Position Lights Bulb Replacement RS

and RT Base Models rmo2008-001-086_a

Push the lens upwards and towards the rear of 1. Turn clockwise
fender.
Pull out the bulb from the holder as indicated be-
low.

48 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

2. Perform the following test at the rear taillight

connector using the FLUKE 115 MULTIMETER
(P/N 529 035 868).
3. Turn ignition on and put vehicle in reverse.
BACK UP LIGHTS TEST
PROBE RESULTS
Pin 3 Pin 5 Close to 12 Vdc
Chassis
Pin 3 Close to 12 Vdc
ground
rmo2008-001-087_a

1. Pull out bulb Positive

Pin 5 battery Close to 12 Vdc
Insert a new bulb in the holder. connection
Reinstall the parts in the reverse order of their re-
moval. If the test from pin 3 to pin 5 is within specifica-
tion, replace the back up light bulb.
Test the lights by turning the ignition to ON.
If the test from pin 3 to chassis ground is not
within specification, perform the BACK UP
BACK UP LIGHTS LIGHTS WIRE CONTINUITY TEST on defec-
Back Up Lights Type tive circuit.
Back up lights are light bulbs located in the rear If result at pin 5 is not as specified, repair ground
taillights. circuit.

Back Up Lights Wire Identification Back Up Lights Wire Continuity Test

CLUSTER
FUNCTION PIN COLOR
CAN HI 24 WH/BG
CAN LO 23 WH/BK
Output to lights 7 PK/BG
LIGHTS
FUNCTION PIN COLOR
LH back-up 12 volt
3 PK/BG
input (from cluster)
RH back-up 12 volt
3 PK/BG
input (from cluster)
LH rear taillight
5 BK
assembly ground
RH rear taillight
5 BK
assembly ground
Back Up Lights Circuit Protection
CONDITION CIRCUIT PROTECTION
Supplied at all times F1 (RFB)
1. Remove the multifunction gauge. Refer to
MULTIFUNCTION GAUGE in this subsection.
2. Perform the following test between the turn
signal connector and the multifunction gauge
connector using the FLUKE 115 MULTIMETER
(P/N 529 035 868).
BACK UP LIGHTS WIRE CONTINUITY TEST
MULTIFUNCTION
TAILLIGHT
GAUGE RESULT
CONNECTOR
CONNECTOR
Close to
Pin 1 (LH or RH) Pin 7
0.2
If all back up lights tests are within specifications,
replace the multifunction gauge.
Back Up Lights Bulb Replacement
The procedure to replace the back up lights is al-
most the same as the procedure to replace the
rear turn signal bulbs or tail light. Refer to TAIL-
LIGHT/BRAKE LIGHT REPLACEMENT in this sub-
section

Back Up Lights Test

1. Remove the rear taillight to be tested. Refer to
TAILLIGHT/BRAKE LIGHT in this subsection.
rmr2013-030 49
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

MULTIFUNCTION GAUGE Multifunction Gauge Test Using

B.U.D.S.
Multifunction Gauge (Cluster) Wire
Identification Connect vehicle to the latest applicable B.U.D.S.
version. Refer to COMMUNICATION TOOLS
MULTIFUNCTION GAUGE (CLUSTER) AND B.U.D.S. subsection.
FUNCTION PIN COLOR In B.U.D.S., select the Activation and Cluster
tabs.
Load shedding relay
1 YE/LT BU Click on the WOW Test button.
ground
Analog coolant
temperature gauge (CTG) 2 BG/BK
signal
12 volt output to LH turn
4 GY/PK
signal lights
12 volt output to RH turn
5 BN/YE
signal lights
To VIM (D.E.S.S.) 6 YE/BN
2 volt output to back-up
7 PK/BG
lights
12 volt input from main
8 OG/RD
relay 2
rmr2010-030-013_a
12 volt input from F1 ACTIVATION PAGE, CLUSTER TAB
9 RD/YE
(RFB) 1. WOW Test button

12 volt input from hazard All indications will come and stay ON so that you
10 YE/GY
switch can verify each indication.
Ground 11 BK NOTE: The WOW Test only tests the gauge Ana-
CTG and FG ground 12 BK/VT log displays, LEDs, and LCD. It does not test the
actual circuit functions related to each indication.
ACS position sensor
13 LT BU/YE
signal Multifunction Gauge Power Test
Analog fuel level gauge If the multifunction gauge is inoperative, first
15 BU
(FG) signal check for fault codes with B.U.D.S., record all
HI beam indicator input 16 GY faults then erase them. Reactivate the electrical
system and recheck for faults. If any fault code
Parking brake switch input 17 GN/WH appears, perform service actions required. Re-
ACS release solenoid fer to COMMUNICATION TOOLS AND B.U.D.S.
18 LT BU/RD
signal subsection.
ACS relay ground 19 LT BU/OG 1. Remove multifunction gauge.
ACS switch supply 20 PK/GY 2. Perform testing at multifunction gauge connec-
tor as per following illustration and tables.
ACS position sensor
21 YE/WH
supply
Radio and LH
multifunction switch 22 LT GN/PK
(headlights)
CAN LO 23 WH/BK
CAN HI 24 WH/BG

50 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

MULTIFUNCTION GAUGE GROUND TEST

WITH MULTIMETER
TEST PROBES OHMS ( )
Multifunction Chassis
Close to .2
connector pin 11 ground

MULTIFUNCTION GAUGE GROUND TEST

WITH TEST LIGHT
TEST PROBES TEST LIGHT
rmr2010-030-014_a Positive
Multifunction
MULTIFUNCTION GAUGE CONNECTOR (PIN-OUT) battery Bright light
connector pin 11
connection
3. Perform the multifunction gauge power tests
with the FLUKE 115 MULTIMETER (P/N 529 035 If the ground at pin 11 is not within specification,
868) set to Vdc and then with a test light. check the related circuit.
MULTIFUNCTION GAUGE POWER TEST If the ground tested to specification, continue
WITH MULTIMETER with the MULTIFUNCTION GAUGE CAN WIRE
TEST.
IGNITION VOLTAGE
TEST PROBES
POSITION DC
Multifunction Gauge CAN Wire Test
Multifunction Close to 1. Remove the right side service panel. Refer to
Chassis
connector Any battery
pin 9
ground
voltage
BODY subsection.
2. Perform the multifunction gauge CAN wire test
Multifunction Close to with the FLUKE 115 MULTIMETER (P/N 529 035
Chassis
connector ON battery
ground 868) set to the OHMS. Perform the test be-
pin 8 voltage
tween the multifunction gauge connector and
MULTIFUNCTION GAUGE POWER TEST the DLC (Diagnostic Link Connector) located
WITH TEST LIGHT underneath the right side service panel.
IGNITION TEST MULTIFUNCTION GAUGE CAN WIRE TEST
TEST PROBES
POSITION LIGHT
TEST PROBES OHMS ( )
Multifunction
Chassis Bright Multifunction DLC (Diagnostic
connector Any Close to
ground light connector pin 24 Link Connector)
pin 9 0.2
(CAN HI) connector pin 1
Multifunction
Chassis Bright Multifunction DLC (Diagnostic
connector ON Close to
ground light connector pin 23 Link Connector)
pin 8 0.2
(CAN LO) connector pin 2
If there is no power at pin 9, check fuse F1 and
If the CAN wire verification test fails, check the
the related circuit.
related circuit.
If there is no power at pin 8, check accessory (R4)
If the multifunction gauge functions, however
and the related circuit.
there is a suspected communication problem with
If the power test is within specification, continue another component, perform this test between
with the MULTIFUNCTION GAUGE GROUND the multifunction gauge and that component.
TEST.
If the multifunction gauge power, ground and
Multifunction Gauge Ground Test CAN verification tests are all to specifications and
the multifunction gauge is inoperative, replace
Perform the multifunction gauge ground tests the multifunction gauge.
with the FLUKE 115 MULTIMETER (P/N 529 035 868)
set to OHMS and then with a test light. Multifunction Gauge Removal
1. Remove the left and right side mirrors. Refer to
BODY subsection.

rmr2013-030 51
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)
2. Remove the 4 gauge trim retaining screws.
rmr2010-030-009_a
1. Gauge trim retaining screws
3. To release the 2 side retaining tabs on the back
of the gauge trim, insert a screwdriver into
the opening at the top of the mirror mounts as
shown in the illustration. Then slide the screw-
driver up the guide ramp and release the tab
while gently pulling on the side of the gauge
trim.
rmr2010-030-010_a
RELEASING GAUGE TRIM TAB
1. Opening for guide ramp
52
rmr2010-030-011_a
RELEASING GAUGE TRIM TAB - TOP COVER REMOVED FOR
CLARITY
1. Guide ramp
2. Gauge trim retaining tab
4. Steer handlebar completely to the left.
5. Remove gauge trim by lifting the lower section
first.
NOTE: If equipped with the optional analog tem-
perature and fuel gauges, disconnect the gauge
connectors.
6. Release the 2 tabs at the top of the multifunc-
tion gauge by pulling down on the tab with a
screwdriver. Insert a finger at the side of the
multifunction gauge while the tab is down and
pull the gauge out of its mount.
rmr2010-030-012_a
RELEASING MULTI FUNCTION GAUGE
1. Multifunction gauge retaining tab
2. Pull down with screwdriver
7. Disconnect the gauge connector and remove
the gauge.
Multifunction Gauge Installation
1. Install connector on multifunction gauge.
rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

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 lbf•in).
5. Install both side mirrors refer to BODY subsec-
tion.
NOTE: If a new gauge is installed, refer to MUL-
TIFUNCTION GAUGE REPLACEMENT in this sub-
section and match the gauge to the ECM. rmr2011-079-007_a

6. Start vehicle engine and test gauge functions. 1. Cluster Units

Multifunction Gauge Replacement NOTE: The units of measurement may also be

NOTE: If the multifunction gauge is replaced, the
engine may not start because of the security ex-
change coding. The gauge must be matched to
the ECM for the vehicle to start.
Connect vehicle to B.U.D.S. Refer to COMMUNI-
CATION TOOLS AND B.U.D.S. subsection.
Once connected, you will see a message similar
to the following illustration.
set using the MODE and SET buttons on the
RECC on the left hand multifunction switch. Re-
fer to the PREFERENCES SCREEN in CATEGORY
ICON SCREEN DESCRIPTION located in this
subsection.
The SPS (Suspension Position Sensor) must be re-
set with B.U.D.S. Refer to REAR SUSPENSION
subsection for the complete reset procedure.
Select the Faults tab and see if there are any
active fault codes. If the faults have all been
corrected, clear the occurred faults displayed and
start vehicle.
Finally, make sure the multifunction gauge func-
tions properly and that all settings and indications
are within parameters.

ANALOG COOLANT
vmr2006-020-058_aen
TEMPERATURE GAUGE
Make sure you have the right type and gauge
model for the vehicle you are working on before
Analog Coolant Temperature Sensor
answering Yes, otherwise it will not function Wire Identification
properly. Select Yes to continue. ANALOG COOLANT TEMPERATURE GAUGE
Once the gauge has been matched to the ECM, FUNCTION PIN COLOR
you will need to set the units of measurement,
miles or kilometers. 12 volt input from CTG1-P OG/RD
accessory (R4) CTG2 OG/RD
In B.U.D.S., select Read Data.
Select Setting and Cluster tabs and select the de- Signal from multifunction
CTG1-S BG/BK
sired unit. gauge
Ground CTG1-G BK/VT

rmr2013-030 53
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

ANALOG FUEL GAUGE 1.3 CAN circuits between the querying mod-
ule and the missing module (continuity,
Analog Fuel Gauge Sensor Wire short between CAN LO and HI circuits,
Identification short to power or ground).
ANALOG FUEL GAUGE
Left Multifunction Switch Test with
FUNCTION PIN COLOR B.U.D.S.
12 volt input from FG1-P OG/RD 1. In B.U.D.S., select the Monitoring and ACC
accessory (R4) FG2 OG/RD tabs.
2. Monitor the MSL Group Box of the screen
To fuel level sensor FG1-S BU
while activating the following buttons:
Ground FG1-G BK/VT – Mode
– Set
LEFT MULTIFUNCTION SWITCH – Thumb Up
– Thumb Down
Left Multifunction Switch Wire – Thumb Right
Identification
– Thumb Left
LEFT MULTIFUNCTION SWITCH – Push To Talk.
FUNCTION PIN COLOR
Hi beam (relay winding
MSL2-2 GN/RD
ground signal)
12 volt input MSL2-1 OG/RD
CAN LO MSL3-2 WH/BK
CAN HI MSL3-3 WH/BG
MSL1-2 GN
MSL1-3 BN
Cruise control switch
MSL1-4 WH
MSL1-1 BN/BK rmr2011-079-004_a

1. MSL Group Box

Ground MSL2-4 BK
Horn MSL2-6 BN/GY
If the indicators turn ON while pressing the but-
tons, the switch is good.
Ground (horn) MSL2-5 BK
If the indicators do not turn ON in B.U.D.S. con-
tinue with the left multifunction switch voltage
Left Multifunction Switch Circuit test.
Protection
Left Multifunction Switch Voltage Test
CONDITION CIRCUIT PROTECTION
This test can be carried out using a test light. A
Supplied at all times J4 (LFB) dim test light indicates a possible parasitic resis-
tance in the tested circuit.
CAN Communication Test for Left 1. Remove the left acoustic panel, refer to BODY
Multifunction Switch subsection.
1. Ensure the module is powered. Referring to 2. Turn ignition switch ON position.
the WIRING DIAGRAM, check the following.
3. Perform these tests on the left multifunction
1.1 Power and ground circuits switch connector as per following charts using
1.2 Terminals (bad contact, out of shape, bro- the FLUKE 115 MULTIMETER (P/N 529 035 868).
ken)

54 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

LEFT MULTIFUNCTION SWITCH VOLTAGE

TEST WITH MULTIMETER
TEST PROBES VOLTAGE DC
Close to
MSL2 connector Chassis
battery
pin 1 ground
voltage

If voltage is to specification carry out the LEFT

MULTIFUNCTION SWITCH GROUND TEST.
If voltage is not to specification perform LEFT
MULTIFUNCTION SWITCH ACTIVATION WIRE
CONTINUITY TEST.
Left Multifunction Switch Activation rmr2010-030-002_a
Wire Continuity Test 1. MSL2 connector
2. MSL3 connector
1. Remove the multifunction gauge.
2. Check continuity as follows: MULTIFUNCTION SWITCH CAN WIRE TEST
LEFT MULTIFUNCTION SWITCH ACTIVATION TEST PROBES OHMS ( )
WIRE CONTINUITY TEST
DLC
(CAN HI)
LEFT (Diagnostic
MULTIFUNCTION multifunction
MULTIFUNCTION Link Close to 0.2
GAUGE RESULT switch connector
GAUGE Connector)
CONNECTOR MSL3 pin 3
CONNECTOR pin 1
MSL2 Connector Close to DLC
Pin 22 (CAN LO)
pin 1 0.1 (Diagnostic
multifunction
Link Close to 0.2
switch connector
If the continuity test passes and none of the LH Connector)
MSL3 pin 2
multifunction switch functions operate, replace pin 2
the multifunction gauge.
If the CAN wire test fails, repair related circuit.
If continuity test fails, repair defective circuit.
If the multifunction switch functions, however
Left Multifunction Switch Ground Test there is a suspected communication problem with
another component, perform this test between
1. Check voltage as follows: the multifunction switch and that component.
LEFT MULTIFUNCTION SWITCH VOLTAGE If the multifunction switch power, ground and
TEST WITH MULTIMETER CAN verification tests all pass and the multifunc-
TEST PROBES VOLTAGE DC tion switch is inoperative, replace the multifunc-
tion switch.
MSL2 connector Chassis
Close to .1
pin 4 ground
FRONT HEATED GRIPS
If the test is not to specification repair circuit.
Front Heated Grips Wire Identification
If the test is to specification continue with LEFT
MULTIFUNCTION SWITCH CAN WIRE TEST. HEATING ELEMENTS
FUNCTION PIN COLOR
Left Multifunction Switch CAN Wire
HI intensity 1 LT GN/WH
Test
1. Check continuity as follows: LO intensity 2 LT GN/BU
Ground 3 BK

rmr2013-030 55
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

HEATED GRIPS SWITCH If test is within specification, perform the FRONT

HEATED GRIP VOLTAGE TEST.
FUNCTION PIN COLOR
If the test is not within specification, perform test
To heating element (LO) 1 LT GN/BU at front heated grip. Refer to STEERING SYSTEM
12 volt input (from load subsection for access to heated grip connectors.
2 LT GN/GY
shedding relay) NOTE: One open grip heating element will give
To heating element (HI) 3 LT GN/WH an higher ohm reading about double the normal
specification.
Switch illumination ground 7 BG/BN
Switch illumination 12 volt Front Heated Grip Voltage Test
8 OG/RD
input (from main relay 2) 1. Remove the central panel to access the back of
the heated grip switch. Refer to BODY subsec-
Front Heated Grips Circuit Protection tion.
CONDITION CIRCUIT PROTECTION 2. Perform the test at the back of the heated grip
switch with the switch connected.
Through load
R3 (RFB) 3. Perform the test with the FLUKE 115 MULTIME-
shedding relay
TER (P/N 529 035 868) using the following illus-
tration and chart.
Front Heated Grip Resistance Test
4. Turn ignition switch to ON position and start en-
1. Remove the central panel to access the back of gine.
the heated grip switch. Refer to BODY subsec-
tion. FRONT HEATED GRIP VOLTAGE TEST
(AT SWITCH CONNECTOR)
2. Perform the test at the back of the heated grip
switch with the switch disconnected. SWITCH
TEST PROBES RESULTS
POSITION
3. Perform the test with the FLUKE 115 MULTIME-
TER (P/N 529 035 868) using the following illus- Pin 2 to chassis Close to
ANY
tration and chart. ground battery voltage
Pin 1 to chassis LOW Close to
ground intensity battery voltage
Pin 3 to chassis HIGH Close to
ground intensity battery voltage

If there is no voltage at pin 2, check fuse R3

and load shedding relay operation. Refer to the
POWER DISTRIBUTION AND GROUNDS sub-
section.
If there is voltage at pin 2 but no voltage at pin 1 in
the low intensity position, replace the heated grip
switch.
If there is voltage at pin 2 but no voltage at pin 3
in the high intensity position, replace the heated
rmr2010-030-042_a
grip switch.
HEATED GRIP SWITCH (PIN-OUT)

FRONT HEATED GRIP RESISTANCE TEST

(AT SWITCH CONNECTOR)
TEST PROBES RESULTS
Pin 1 to pin 3 Close to 10.9
Pin 1 to chassis ground Close to 6.7
Pin 3 to chassis ground Close to 4.5

56 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

PASSENGER HEATED GRIP If there is no continuity from BK wire to chassis

SWITCH ground, check the ground wire and repair as nec-
essary.
Passenger Heated Grips Wire
Identification Passenger Heated Grip Element
Resistance Test
SWITCH
1. Remove the right or left rear switch panels to
FUNCTION PIN COLOR access the rear grip connector.
12 volt input A LT GN/GY 2. Perform the test with the FLUKE 115 MULTIME-
Heating element ground TER (P/N 529 035 868) using the following table.
B LT BU/PK
(pulsed) PASSENGER HEATED GRIP ELEMENT
Ground C BK RESISTANCE TEST
TEST PROBES RESULTS
Passenger Heated Grips Switch Circuit PIN 1 to PIN 2 of either
Protection 8 to 10
grip element
CONDITION CIRCUIT PROTECTION
If the resistance of either grip element is not
Through load within specification, replace the defective grip.
R3 (RFB)
shedding relay
If the resistance is within specification and the
voltage and ground to the switch are also good,
Passenger Heated Grip Switch Test replace the passenger rear heated grip switch.
1. Remove the battery panel and switch as-
sembly. Refer to PASSENGER HEATED GRIP Passenger Heated Grip Switch
SWITCH REMOVAL in this subsection. Removal
2. Turn ignition switch to ON position and start en- 1. Refer to BODY subsection and remove the fol-
gine. lowing:
3. Perform the test with the FLUKE 115 MULTIME- – Left middle side panel
TER (P/N 529 035 868) using the following table. – Left top side panel
– Left rear side panel.
PASSENGER HEATED GRIP SWITCH TEST
(AT SWITCH CONNECTOR) 2. Remove left screws for battery panel and
switch assembly.
TEST PROBES RESULTS
3. Disconnect PRS (Pillion Rider Switch) connec-
Close to battery tor.
LT BU/PK to BK wires
voltage
Close to battery
LT GN/GY to BK wires
voltage
LT GN/GY wire to chassis Close to battery
ground voltage
BK wire to chassis ground Close to 0.2

If test is to specification, proceed with the passen-

ger heated grip element resistance test.
If there is no voltage from the LT GN/GY wire
to chassis ground, check the circuit for fuse F8
and load shedding relay operation. Refer to the
POWER DISTRIBUTION AND GROUNDS sub-
section.
If there is no voltage from the LT BU/PK wire rmr2010-030-015

to chassis ground, proceed with the passenger

heated grip element resistance test. 4. Disconnect passenger heated grip switch con-
nector.

rmr2013-030 57
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

RADIO MODULE
FUNCTION PIN COLOR
CAN HI RDO1-16 WH/BG
CAN LO RDO1-17 WH/BK
RDO1-11 OG/GY
RDO1-12 BK/BU
RDO1-13 BK/GY
To iPOD
RDO1-22 BK/VT
connector
RDO1-23 LT BU/BN
RDO1-24 LT GN/BN
rmr2010-030-016
RDO1-25 OG/BN
5. Depress the three tabs on the switch and re- RDO2-9 WH/BK
move from battery panel.
RDO2-2 WH/BG
RDO2-3 GY/BK
RDO2-1 BU/GY
RDO2-4 BG/LT GN
RDO2-11 GY/LT BU
To CB connector
RDO2-5 BU/LT GN
RDO2-10 GY/BK
RDO2-8 BU/GY
RDO2-13 LT BU/WH

rmr2010-030-017
RDO2-6 GY/WH
RDO2-12 BU/BN
Passenger Heated Grip Switch
Installation 12 volt
input from
Reinstall the passenger heated grip switch in the RDO1-33 LT GN/PK
multifunction
reverse order of removal. gauge
RDO1-21 WH/LT GN
RADIO MODULE Passenger radio
RDO1-14 WH/LT BU
control
Radio Module Wire Identification RDO1-15 BU/LT BU
RADIO MODULE RDO1-30 BK
FUNCTION PIN COLOR BK
Ground RDO1-31
RDO1-6 LT GN/BK BK
RDO1-32
RDO1-7 BN/LT BU
To GPS Front left RDO1-3 PK/BK
RDO1-8 RD/LT GN speaker
connector
RDO1-2 PK
RDO1-9 LT GN/BG
Front right RDO1-10 BN/LT GN
RDO1-34 LT GN/YE
speaker RDO1-1 LT GN
RDO1-27
12 volt input Rear right RDO1-26 VT/BK
RDO1-28 LT GN/RD
from F6 speaker RDO1-18 VT
RDO1-29

58 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

RADIO MODULE
FUNCTION PIN COLOR

Rear left RDO1-5 GN/BK

speaker RDO1-4 GN
RDO2-15 WH/GN
RDO2-21 WH/BN
RDO2-16 GY/BK
RDO2-14 BU/GY
RDO2-23 LT BU/BU

XM satellite RDO2-17 GY/YE

rmr2010-030-021
radio connector RDO2-24 LT GN/GN
4. Test the radio voltage power at the at the radio
RDO2-22 GY/BK connector as per following tables and illustra-
RDO2-20 BU/GY tion using FLUKE 115 MULTIMETER (P/N 529 035
868).
RDO2-19 LT GN/LT BU
RDO2-25 GN/VT
RDO2-18 GN/PK

Radio Module Circuit Protection

CONDITION CIRCUIT PROTECTION
Supplied at all times F3 (RFB)

Radio Tests Guidelines

Make sure F6 of RH fuse box is in good condition
and powered before beginning any voltage test.
The following voltage tests can be carried out us-
ing a test light. A dim test light indicates a possi- rmr2010-030-022_a
ble parasitic resistance in the tested circuit. RADIO CONNECTOR PIN-OUT
To access the radio connector, refer to RADIO RE-
MOVAL in this subsection. RADIO CONSTANT POWER CIRCUIT
VOLTAGE TEST
Radio Constant Power Voltage Test TEST PROBES VOLTAGE DC
1. Refer to BODY subsection and remove the fol- Close to battery
lowing: Pin 27 Chassis ground
voltage
– Right middle side panel
Close to battery
– Right top side panel Pin 28 Chassis ground
voltage
– Right rear side panel.
Close to battery
2. Remove right radio control panel and switch as- Pin 29 Chassis ground
voltage
sembly.
3. Disconnect radio connector. If voltage is within specification, carry out RADIO
ACTIVATION POWER VOLTAGE TEST.
If voltage is not within specification, carry out RA-
DIO CONSTANT POWER CIRCUIT CONTINUITY
TEST.

rmr2013-030 59
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

Radio Activation Power Voltage Test
1. Turn ignition switch to the RUN position.
2. Perform the following test with the FLUKE 115
MULTIMETER (P/N 529 035 868) and a test light.
If the continuity test passes and none of the left
hand multifunction switch functions operate, re-
place the multifunction gauge.
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
Close to battery
following table.
Pin 33 Chassis ground
voltage RADIO GROUND CIRCUIT TEST

If voltage is within specification, carry out RADIO TEST PROBES RESULT

GROUND CIRCUIT TEST. Chassis
Pin 30 Close to 0.1
If voltage is not within specification, perform RA- ground
DIO ACTIVATION POWER CIRCUIT CONTINUITY Chassis
TEST. Pin 31 Close to 0.1
ground

Radio Constant Power Circuit Chassis

Pin 32 Close to 0.1
ground
Continuity Test
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
wire verification test.
RADIO RH FUSE
RESULTS 1. To access the radio connector, refer to RADIO
CONNECTOR BOX (RFB)
REMOVAL in this subsection.
Pin 27 Pin B6 Close to 0.1
2. Remove the right front service panel to access
Pin 28 Pin B6 Close to 0.1 the DLC connector. Refer to BODY subsection.
Pin 29 Pin B6 Close to 0.1 RADIO CAN WIRE VERIFICATION TEST
If continuity test fails, repair defective circuit. TEST PROBES OHMS ( )
DLC
Radio Activation Power Circuit (CAN HI) radio
(Diagnostic
Continuity Test connector Close to 0.2
Link Connector)
pin 16
1. Remove the multifunction gauge. connector pin 1
2. Test the radio activation voltage power continu- DLC
(CAN LO) radio
ity with multimeter between the multifunction (Diagnostic
connector Close to 0.2
gauge connector and the radio connector as per Link Connector)
pin 17
the following table. connector pin 2

RADIO POWER CIRCUIT CONTINUITY TEST If the test is not within specification, check and
(ACTIVATION VOLTAGE) repair the wire as necessary.
MULTIFUNCTION
RADIO
GAUGE RESULT Radio Removal
CONNECTOR
CONNECTOR 1. Refer to BODY subsection and remove the fol-
Close to lowing:
Pin 33 Pin 22 – Right middle side panel
0.1
– Right top 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.

60 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)
2. Remove right radio control panel and switch
assembly. Refer to PASSENGER RADIO CON-
TROL REMOVAL in this subsection.
3. Disconnect antenna connector.
rmr2010-030-019
4. Disconnect radio connector.
rmr2010-030-021
5. Remove the four screws securing the radio.
rmr2010-030-020_a
1. Screws
Radio Installation
Reinstall the radio in the reverse order of removal.
rmr2013-030
NOTICE Make sure to add dielectric grease in
the antenna connector and make it point down-
ward to prevent water infiltration.
PASSENGER RADIO CONTROL
SWITCHES
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-
DIO REMOVAL for access to the connector.
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
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.
vmr2006-020-005
4. Test the passenger radio control switch at the
radio connector as per following tables.
61
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

PASSENGER RADIO CONTROL VOLUME PASSENGER RADIO CONTROL CHANNEL

SWITCH TEST (AT RADIO CONNECTOR) SWITCH TEST (AT SWITCH)
SWITCH FLUKE GAUGE SWITCH FLUKE
VOLTAGE SWITCH PIN VOLTAGE
POSITION 115 CONNECTOR POSITION 115

Switch RD lead Pin 14 Approx. Channel RD lead Pin C

Approx.
released 2 Vdc down
BK lead Pin 21 BK lead Pin A 1.1 Vdc
depressed
Volume RD lead Pin 14
Approx. Channel RD lead Pin C
up Approx.
BK lead Pin 21 1.1 Vdc up
depressed BK lead Pin A 1.6 Vdc
depressed
Volume BK lead Pin 17
Approx.
down
1.6 Vdc
If the test is not within specification at the switch,
depressed RD lead Pin 18 replace the switch.
If the test is good at the switch but not at the ra-
PASSENGER RADIO CONTROL CHANNEL
SWITCH TEST (AT RADIO CONNECTOR)
dio connector, check the continuity of the wires
between the passenger radio control switch and
SWITCH FLUKE GAUGE the radio connector.
VOLTAGE
POSITION 115 CONNECTOR
If any reading is significantly different than speci-
Switch RD lead Pin 15 Approx. fied, carry out the same test at the switch connec-
released BK lead Pin 21 2 Vdc tor, refer to the wiring diagram. If you obtain the
same results, replace the switch assembly.
Channel RD lead Pin 15
Approx. If voltages measured on the switch at the radio
down
BK lead Pin 21 1.1 Vdc connector are as specified (or very close to it), the
depressed
switches and the wiring harness are good. The
Channel RD lead Pin 15 fault may be within the radio.
Approx.
up
BK lead Pin 21 1.6 Vdc NOTE: The test results given for the diode switch
depressed
were obtained with a FLUKE 115 MULTIMETER
If the test at the radio connector are not within (P/N 529 035 868). If a different multimeter is
specification, perform the test at the passenger used, the test result may not be accurate unless
radio control switch per following tables: the multimeter has a minimum resistance range
of 12 Mega ohms. Ensure to check the specifica-
PASSENGER RADIO CONTROL VOLUME tion of the multimeter being used.
SWITCH TEST (AT SWITCH)
SWITCH FLUKE Passenger Radio Control Switch
SWITCH PIN VOLTAGE
POSITION 115 Removal
Switch RD lead Pin B Approx. 1. Refer to BODY subsection and remove the fol-
released 2 Vdc lowing:
BK lead Pin A
– Right middle side panel
Volume RD lead Pin B – Right top side panel
Approx.
up
BK lead Pin A 1.1 Vdc – Right rear side panel.
depressed
Volume RD lead Pin A 2. Remove 2 screws for radio control panel and
Approx. switch assembly.
down
BK lead Pin B 1.6 Vdc
depressed

PASSENGER RADIO CONTROL CHANNEL

SWITCH TEST (AT SWITCH)
SWITCH FLUKE
SWITCH PIN VOLTAGE
POSITION 115

Switch RD lead Pin C Approx.

released BK lead Pin A 2 Vdc

62 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

SPEAKERS
Speaker Resistance Test
1. Refer to BODY subsection and remove the fol-
lowing:
– Right middle side panel
– Right top side panel
– Right rear side panel.
2. Remove right radio control panel and switch as-
sembly.
rmr2010-030-018_a 3. Disconnect radio connector.
PASSENGER RADIO CONTROL PANEL
1. Screws

3. Disconnect passenger radio control switch con-

nector.

rmr2010-030-021

4. Test the Passenger speaker resistance at the

radio connector as per following table:
SPEAKER TESTING (AT RADIO CONNECTOR)
rmr2010-030-016

GAUGE
4. Depress the three tabs on the switch and re- SPEAKER OHMS ( )
CONNECTOR
move from switch panel.
Front left Pin 3
3.2 to 4.3
speaker Pin 2
Front right Pin 10
3.2 to 4.3
speaker Pin 1
Right rear Pin 26
3.2 to 4.3
speaker Pin 28
Right left Pin 5
3.2 to 4.3
speaker Pin 4

If the resistance values of the speakers is within

rmr2010-030-017
Passenger Radio Control Installation
Reinstall the passenger radio control switch in the
reverse order of removal.
specification, perform the SPEAKER INPUT VOLT-
AGE TEST.
If the resistance of one speaker is bad, check the
resistance at the speaker terminals:
– If good, check the continuity of the wires to the
radio connector and repair as necessary.
– If bad, replace the speaker.

rmr2013-030 63
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

Speaker Input Voltage Test

1. Access the correct speaker terminals. Refer to
the appropriate speaker removal procedure.
2. Test the speaker with the connectors con-
nected to the speaker with a multimeter set to
Vac as per the following chart and illustration.
NOTE: The voltage reading at half volume should
be pulsing and will vary with the radio station and
volume intensity.

rmr2010-030-023_a

1. Screws

3. Remove 4 screws on the rear of top storage

compartment.

rmr2010-030-043_a

TESTING VAC AT THE SPEAKER TERMINALS

SPEAKER INPUT VOLTAGE TEST

TEST ONE HALF
NO VOLUME
PROBES VOLUME
Speaker .300 Vac to rmr2010-030-024_a
.000 Vac
Terminals 1.3 Vac 1. Screws

If the AC voltage test is good at the speaker ter-
minals, replace the speaker.
If 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.
4. Carefully pull back and upward on rear panel to
remove from vehicle.
5. Remove the antenna mast (if necessary).
6. Remove 3 screws inside the top rear storage
compartment securing the speaker and arm
rest assembly.

64 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmr2010-030-027_a

rmr2010-030-025_a 10. Remove the speaker front cover screw under

1. Screws the side the cover.
7. Carefully remove the speaker and arm rest as-
sembly.
NOTE: If the SPEAKER INPUT VOLTAGE TEST is
to be performed, proceed with that test now. If
the speaker is to be replaced, continue with this
procedure.
8. Remove the 3 speaker side cover screws on
the outside of the cover.

rmr2010-030-028_a

1. Screw

11. Remove the speaker front cover screw under

the side of the cover.
12. Remove the speaker front cover screw on the
inside of the speaker assembly.

rmr2010-030-026_a

1. Screws

9. Carefully lift the edge of the side cover and slide

the 3 hooks on the side speaker cover out of
position.

rmr2010-030-029_a

1. Screw

13. Remove the front speaker cover.

rmr2013-030 65
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

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
arm rest assembly.
rmr2010-038-053_a

1. 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.

rmr2010-030-030_a

1. Groove
2. Lip

Front Speaker Removal

1. Remove the multifunction gauge. Refer to
MULTIFUNCTION GAUGE REMOVAL in this
subsection.
2. Remove windshield and windshield support to-
gether. Refer to WINDSHIELD SUPPORT in the
BODY subsection. rmr2010-030-050_a

3. Remove front fascia. Refer to FRONT FASCIA TYPICAL

in the BODY subsection.
4. Remove WPM module from it support. Refer
to WINDSHIELD MODULE (WPM) in the BODY
subsection.
5. Slightly lift WPM module upwards.
6. Disconnect WPM module connector.
1. Screw
10. Remove the central panel. Refer to BODY
subsection.
11. Remove the 2 screws for the multifunction
mount under the central panel.

66 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmr2010-030-051_a rmr2010-030-053_a

TYPICAL 1. Screws
1. Screw
15. Disconnect the speaker connector and re-
12. Remove the 2 side multifunction gauge mount move the speaker from the vehicle.
screws.
Front Speaker Installation
Reinstall the front speaker in the reverse order of
removal.

AUXILIARY AUDIO IN JACK

Auxiliary Audio in Jack Test
1. Refer to BODY subsection and remove the fol-
lowing:
– Right middle side panel
– Right top side panel
– Right rear side panel.
2. Remove right radio control panel and switch as-
sembly.
rmr2010-030-052_a

1. Screw
3. Disconnect radio connector.

13. Slide the multifunction gauge mount up and

remove from the vehicle.
14. Remove the 4 speaker screws.

rmr2010-030-021

rmr2013-030 67
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

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.
AUXILIARY
RADIO AUDIO
RESULTS
CONNECTOR IN JACK rmr2010-030-032_a

CONNECTOR AUXILIARY AUDIO INPUT CABLE

1. Contact with radio connector terminal 11
Pin 11 Pin A Close to 0.1 2. Contact with radio connector terminal 13
3. Contact with radio connector terminal 12
Pin 12 Pin B Close to 0.1
If the continuity is not within specification, replace
Pin 13 Pin C Close to 0.1 the 3.5 mm audio input cable.
Pin 22 Pin D Close to 0.1
Auxiliary Audio in Jack Removal and
Pin 23 Pin E Close to 0.1
Installation
Pin 24 Pin F Close to 0.1 Use the SPANNER TOOL (P/N 529 036 223) to re-
Pin 25 Pin G Close to 0.1 move and install auxiliary jack retaining nut.

529036223

ANTENNA
rmr2010-030-031_a

A. Contact with radio connector pin 11

Antenna Removal
B. Contact with radio connector pin 12
C. Contact with radio connector pin 13 ST Ltd Model
D. Contact with radio connector pin 22
E. Contact with radio connector pin 23 1. Remove antenna from antenna mount.
F. Contact with radio connector pin 24
G. Contact with radio connector pin 25

If continuity test fails, repair defective circuit.

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 Tip contact area Close to 0.1
rmr2013-030-005_a
Center contact
Pin 12 Close to 0.1 1. Antenna
area
Rear contact 2. Remove lower tail cover. Refer to BODY sec-
Pin 13 Close to 0.1 tion.
area

68 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

3. Remove antenna mount.

rmr2013-030-007_a

1. Antenna mount retaining nut

2. Antenna signal wire rmr2010-030-024_a
3. M5 washer
4. M10 washer 1. Screws

RT Models 4. Carefully pull back and upward on rear panel to

remove from vehicle.
1. Open top and both side storage component
covers. 5. Remove the antenna boot and mast.
2. Remove 2 screws at the top rear of each side
storage compartment.

rmr2010-030-033

ANTENNA BOOT
rmr2010-030-023_a

1. Screws

3. Remove 4 screws on the rear of top storage

compartment.

rmr2010-030-034

ANTENNA MAST

rmr2013-030 69
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

6. Remove 3 screws inside the top rear storage

compartment securing the speaker and arm
rest assembly.

rmr2010-030-027_a

10. Remove the antenna signal wire nut from the

stud and remove the signal wire.

rmr2010-030-025_a

1. 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.

rmr2010-030-035_a

1. Antenna mount bolt

2. Ground strap screw
3. Antenna signal wire nut

11. Remove the self threading screw through the

ground strap.
rmr2010-030-026_a
12. Remove the bolt securing the antenna mount.
1. 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.

70 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmr2010-030-030_a

1. Groove
2. Lip
rmr2010-030-036_a

ANTENNA MOUNT Pass the M6 lock washer (if applicable) on the an-
tenna threads.
Antenna Installation Apply a drop of LOCTITE 243 (BLUE) (P/N 293 800
ST Models 060) on the first antenna thread as shown.

Installation is the reverse of removal. However

pay attention to the following.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on the
first antenna thread.

rbg2010-007-002_a

TYPICAL
1. Drop of LOCTITE 243
2. M6 stainless steel lock washer (if applicable)

NOTICE Apply threadlocker only where

shown.
rmr2013-030-006_b

1. Drop of LOCTITE 243

HORN
RT Models
Horn Test
Installation is the reverse of removal. However
1. Make sure F5 of RH fuse box is in good condi-
pay attention to the following.
tion and powered.
Ensure to engage the groove at the inside edge
2. Remove the front cargo module, refer to BODY
of the speaker and arm rest assembly with the lip
subsection.
located near the rear of the seat.
3. Perform test at the 2 pin horn connector as per
NOTICE Failure to engage the groove onto the following chart.
the lip can result in damage to the speaker and
arm rest assembly.

rmr2013-030 71
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmr2010-030-037 rmr2010-030-038_a
HORN CONNECTOR LEFT FRONT BUMPER COVER AIR DUCT
1. Screws
HORN TEST AT 2 PIN HORN CONNECTOR 2. Plastic rivets

SWITCH 3. Remove the 3 screws at the bottom inside of

TEST PROBES RESULTS
POSITION the front panel.
Close to
Pin 1 Pin 2 ON battery
voltage
Close to
Chassis
Pin 2 Any battery
ground
voltage
positive Close to
Pin 1 battery ON battery
connection voltage

If the test is to specification, replace horn.

If there is no voltage at pin 2, check continuity
from fuse F5 to horn connector and repair as re-
quired.
I there is no ground to pin 1 with horn switch ac- rmr2010-030-044_a
tivated, proceed with horn switch testing. INSIDE OF LEFT FRONT PANEL
1. Screws
4. Remove left side acoustic panel to access left
multifunction switch connectors, refer to BODY 4. Remove the 3 plastic rivets from the top of the
subsection. left front panel.
5. Perform the horn switch test.

Horn Removal
1. Remove the front cargo module. Refer to
BODY subsection.
2. Remove the 6 plastic rivets and the 2 screws
from the left bumper cover air duct.

72 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

rmr2010-030-045_a rmr2010-030-002_a
TOP OF THE LEFT FRONT PANEL 1. MSL2 connector
1. Plastic rivets 2. MSL3 connector

5. Carefully remove the auxiliary light fascia. HORN SWITCH TEST

6. Disconnect the horn connectors. LEFT MULTIFUNCTION
SWITCH
7. Remove the retaining screw for the horn. SWITCH CONNECTOR RESULTS
POSITION
(MSL2)
Switch
Pin 5 to pin 6 OL
OFF
Switch Close to
Pin 5 to pin 6
ON 1

REAR STORAGE COMPARTMENT

SWITCHES
Rear Storage Compartment Switch
Test (at Gauge Connector)
1. Remove the multifunction gauge to access the
rmr2010-030-046_a gauge connector, refer to MULTIFUNCTION
HORN GAUGE REMOVAL in this subsection.
2. Set multimeter to and test as follows.
Horn Installation
Installation of the horn is the reverse of removal
procedures.

HORN SWITCH
Horn Switch Test
Perform the horn switch test at the MSL2 connec-
tor as per the following chart.

rmr2010-030-014_a

MULTIFUNCTION GAUGE CONNECTOR (PIN-OUT)

rmr2013-030 73
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

REAR STORAGE COMPARTMENT SWITCH FRONT STORAGE COMPARTMENT LIGHT

TEST (AT GAUGE CONNECTOR) VOLTAGE TEST
GAUGE REAR STORAGE RESULT
RESULTS
CONNECTOR COMPARTMENTS TEST PROBES (IGNITION
SWITCH ON)
Pin 20 to chassis
All closed OL
ground Light connector
Chassis Close to battery
pin 1
Pin 20 to chassis Any compartment Close to ground voltage
(vehicle side)
ground opened 1.5 k
If result is not as per specification, check the conti-
If the preceding test at the gauge connector is
nuity between pin 1 of the storage light connector
within specification, replace the multifunction
and pin 7 of the LH fuse box.
gauge.
If result is as per specification, carry out FRONT
If the reading is OL in all positions:
STORAGE COMPARTMENT LIGHT GROUND
– Check circuit continuity between the ACS TEST.
switch and storage compartment switches.
– Test ACS switch, refer to REAR SUSPENSION. Front Storage Compartment Light
If the reading is 1.5 k with all the compartments Ground Test
closed, perform the REAR STORAGE COMPART- 1. Remove the front storage compartment.
MENT SWITCH TEST (AT SWITCH CONNECTOR)
2. Set multimeter to and test as follows.
at each switch.
FRONT STORAGE COMPARTMENT LIGHT
Rear Storage Compartment Switch GROUND TEST
Test (at Switch Connector) COVER
TEST PROBES RESULT
1. Remove the left, right or rear panel as applica- POSITION
ble to access the a ppropriate switch as deter- Light Close to
mined in the previous test. Refer to BODY sub- Open
connector 0
section. pin 2 Chassis
2. Set multimeter to and test as follows. (storage ground
Closed compartment OL
REAR STORAGE COMPARTMENT SWITCH side)
TEST (AT SWITCH CONNECTOR)
STORAGE STORAGE If close to 0 regardless of the cover position,
SWITCH carry out FSS RESISTANCE TEST (FOR STORAGE
COMPARTMENT COMPARTMENT
CONNECTOR
CLOSED OPEN COMPARTMENT LIGHT).
Pin 1 to pin 2 OL Close to 1 If OL regardless of the cover position, check
circuit continuity and carry out FSS RESISTANCE
If the test is not within specification, replace the TEST (FOR STORAGE COMPARTMENT LIGHT).
switch. If result is as per specification, replace light.

FRONT STORAGE HOOD ACTUATOR (RT MODELS

COMPARTMENT LIGHT (RT ONLY)
MODELS)
Hood Actuator Voltage Test
Front Storage Compartment Light 1. Open the front storage compartment.
Voltage Test
2. Remove the right front service panel.
1. Remove the front storage compartment.
3. Disconnect the hood actuator.
2. Set multimeter to Vdc and test as follows.
4. Put ignition switch to the ON position
5. Activate the PBS switch.
6. Test the voltage with a multimeter on the vehi-
cle harness side.

74 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

HOOD ACTUATOR VOLTAGE TEST If there is voltage at pin 5 but no voltage to pin 4
with the switch activated, replace the PBS switch.
TEST PROBES RESULT
If the test is to specification, check the continuity
Chassis Close to battery from pin 4 of the PBS switch to pin 2 of the FCS
Pin 1
ground voltage connector and repair the wire as necessary.
If the voltage is to specification, check the conti-
nuity between hood actuator pin 2 and FSS pin 2. FRONT STORAGE SWITCH (FSS)
If the continuity is good, replace the hood actua- (RT MODELS)
tor. If the continuity is not good, repair the wire as
necessary. FSS Resistance Test (for Hood
Actuator)
If there is no voltage to pin 1 of the hood actuator
connector, continue with the PBS SWITCH FUNC- NOTE: The front storage compartment switch is
TIONAL TEST in this subsection. referred to as the front case opening switch in the
wiring diagram.
PBS SWITCH (HOOD ACTUATOR 1. Open the front storage compartment.
FUNCTION) (RT MODELS ONLY) 2. Remove the right front service panel.
3. Disconnect the FSS connector.
PBS Switch Functional Test
4. Set multimeter to and test as follows.
1. Remove the central panel. Refer to BODY sub-
section.

rmr2010-030-054_a
rmr2010-030-055_a
FSS CONNECTOR
PBS CONNECTOR (PIN-OUT) 1. Pin 1
2. Pin 2
3. Pin 3
Test condition:
– Ignition switch ON. FSS RESISTANCE TEST (FOR HOOD ACTUATOR)
PBS SWITCH SWITCH FUNCTIONAL TEST SWITCH
TEST PROBES RESULTS
POSITION
SWITCH
TEST PROBES RESULTS
POSITION Switch
Pin 1 to pin 2 Close to 0.2
CLOSED
PBS connector
Close to
pin 5 to Chassis Any
battery voltage If result is not as per specification, replace the
ground
front storage compartment switch.
PBS connector
pin 4 to Chassis
Switch Close to If the test is as per specification, carry out the FSS
activated battery voltage GROUND TEST.
ground
If both the FSS RESISTANCE TEST (FOR HOOD
If there is voltage at pin 5, check the continuity ACTUATOR) and the FSS GROUND TEST are as
between pin 5 of the PBS connector and: per specification, check continuity between pin 2
– Main relay R4 (LFB) and hood actuator.

rmr2013-030 75
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

FSS Resistance Test (for Storage

Compartment Light)
1. Open the front storage compartment.
2. Remove the right front service panel.
3. Disconnect the FSS connector.
4. Set multimeter to and test as follows.

rmr2010-030-054_a

FSS CONNECTOR
1. Pin 1
2. Pin 2
3. Pin 3

FSS GROUND TEST

TEST PROBES RESULT
Chassis
Pin 1 Close to 0.1
rmr2010-030-054_a ground
FSS CONNECTOR
1. Pin 1 If the test is not to specification, repair the wire as
2. Pin 2
3. Pin 3 necessary.

FSS RESISTANCE TEST CRUISE CONTROL SWITCH

(FOR STORAGE COMPARTMENT LIGHT)
SWITCH Cruise Control Switch Test with
TEST PROBES RESULTS B.U.D.S.
POSITION
Pin 1 to pin 3 Cover OPEN Close to 0.2 1. Connect B.U.D.S., refer to COMMUNICATION
TOOLS AND B.U.D.S. subsection.
If the test is not to specification, replace the front 2. In B.U.D.S., select Monitoring and ACC tabs.
storage compartment switch.
If the test is to specification, perform the FSS
GROUND TEST.
If both the FSS RESISTANCE TEST (FOR HOOD
ACTUATOR) and the FSS GROUND TEST are as
per specification, check continuity between pin 3
and storage compartment light.

FSS Ground Test

1. Open the front storage compartment.
2. Remove the right front service panel.
3. Disconnect the FSS.
4. Set multimeter to and test as follows.
rmr2010-030-039

MONITORING PAGE, ACC TAB

3. Monitor the MSR Group Box while activating

the following buttons:
– SET/DEC

76 rmr2013-030
 Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

– RES/ACCEL CRUISE CONTROL SWITCH TEST WITH

– Cruise ON. MULTIMETER
CRUISE
SWITCH
SWITCH RESULTS
POSITION
CONNECTOR
Cruise switch
OFF - RESUME
Pin 1 to pin 3 OL
Switch
Activated
Cruise switch
Pin 1 to pin 4 Close to 0.2
ON
Cruise switch
Pin 1 to pin 4 OL
OFF
rmr2011-079-004_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 CRUISE Central Panel Switches Illumination
CONTROL SWITCH 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.
BODY subsection.
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 RESULTS
POSITION
CONNECTOR
Cruise switch
ON - SET
Pin 1 to pin 2 Close to 0.2
Switch
Activated
Cruise switch rmr2010-030-055_a
OFF - SET CENTRAL PANEL SWITCH (PIN OUT)
Pin 1 to pin 2 OL
Switch
Activated CENTRAL PANEL SWITCHES ILLUMINATION
POWER TEST
Cruise switch
ON - RESUME TEST PROBES RESULT
Pin 1 to pin 3 Close to 0.2
Switch
Activated Chassis Close to battery
Pin 8
ground voltage

rmr2013-030 77
Subsection XX (LIGHTS, GAUGE AND ACCESSORIES)

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 SWITCHES ILLUMINATION
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
Pin 7
ground 8.25 k

If the test is within specification, replace the de-

fective central panel switch. Refer to BODY sub-
section.
If the test is not within specification, repair ground
circuit as necessary.

78 rmr2013-030
 Subsection XX (ELECTRONIC SHIFT SYSTEM (SE5))

ELECTRONIC SHIFT SYSTEM (SE5)

SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................................. 7

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
FLUKE RIGID BACK PROBES ....................................................... TP88 ............................................. 7

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.

rmo2010-001-036_b

TYPICAL - SE5 SWITCHES

1. Upshift
2. Downshift
3. Reverse

rmr2011-080-010_a

TYPICAL
1. Transmission control module (TCM)
2. Hydraulic control module (HCM)
3. SE5 switches (upshift, downshift, reverse)
4. Oil tank
5. Solenoid valves
6. Link rod between HCM and shifter

The transmission control module (TCM) manages

4 solenoid valves located on the hydraulic control
module (HCM) that control and activate the gear rmr2013-031-001_a
shifting process. TYPICAL
1. HCM
2. Clutch servo
3. Solenoid valves
4. 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.

rmr2013-031 1
Subsection XX (ELECTRONIC SHIFT SYSTEM (SE5))
rmr2013-031-050_a
TYPICAL
1. Centrifugal clutch
Auto Neutral
When engine is started and running, the gearbox
is automatically set to the neutral position.
The gearbox is not linked with the engine until the
engine speed is above approximately 2000 RPM
to engage the centrifugal clutch.
Shift from Neutral
The following conditions must be met so that a
gearshift can take place:
– Engine RPM is lower than 1800 RPM.
– Vehicle speed is lower than 3 km/h (2 MPH).
Upshift
When the gearshift selector is pushed (upshift)
and the vehicle is stopped, the TCM will immedi-
ately signal the corresponding solenoid valves on
the HCM to shift the gearbox up one gear if the
gearbox is in neutral or reverse.
When the vehicle is moving and the gearbox is
in 1st gear or above, a minimum RPM and speed
must be met to permit an upshift to take place.
Otherwise, no upshift is allowed until the required
RPM is reached.
If desired, the gearbox can remain in this gear until
engine reaches its rev-limited RPM.
If the gearbox is in 5th gear and the gearshift se-
lector is pushed (upshift), nothing will happen.
Downshift
When the gearshift selector is pulled (downshift),
the TCM will signal the corresponding solenoid
valves on the HCM to shift the gearbox down
one gear as long as it does not cause the engine
RPM to exceed preset parameters.
2 rmr2013-031
Reverse
To shift in reverse gear:
– Engine must be running.
– Vehicle must not be moving.
– Push the reverse button.
– Pull the gearshift selector (downshift).
If gearbox is in reverse gear and the gearshift se-
lector is pulled (downshift), nothing will happen.
Double Shift from 1st Gear or Reverse
When the gearshift selector is held for more than
1/3 second, a double shift will take place as fol-
lows:
– If gearbox is in 1st gear, the gearbox will shift to
the reverse gear (reverse button must be held
also).
– If gearbox is in reverse gear, the gearbox will
shift to the 1st gear.
Auto Downshift
When the following conditions are met, a down-
shift will automatically take place:
– Throttle is released.
– Vehicle decelerates.
– A predetermined RPM is reached.
– A predetermined vehicle speed is reached.
TCM Calibration Update
The new calibration offered can be easily com-
pared to a kick-down of an automatic transmission
car under load (or acceleration).
The new calibration recognizes an increase in load
in the identified rpm range and will initiate a down-
shift therefore increasing the rpm out of the risk
zone and giving the centrifugal clutch its full en-
gagement force to prevent slippage.
This calibration downshift will occur from 5th to
4th, 4th to 3rd, and 3rd to 2nd. A downshift from
2nd to 1st is less likely unless certain specific con-
ditions are met.
NOTE: This calibration will not affect the habitual
auto-downshift at 2200-2500 when throttle is re-
leased in normal mode and at 3300-3500 in trailer
mode.
If the load request that initiated a downshift is
maintained and an upshift is requested by the
driver, the unit will not upshift until the load re-
quest is released or rpms are higher than the
predetermined curve.
 Subsection XX (ELECTRONIC SHIFT SYSTEM (SE5))
This file can be added and removed using
B.U.D.S. by checking or unchecking the MY13
calibration box in the ECM/vehicle configuration
tab, "writing", data and following the instructions.
RPM Increase on Downshift
When a downshift is commanded, the TCM will
transmit a downshift signal through the CAN
BUS that is used by the engine control module
(ECM) to command the electric throttle actuator
(ETA) to momentarily "slightly" open the throttle
plates to increase engine RPM. This assists the
synchronization of engine RPM and rear wheel
speed without any required action by the opera-
tor. This also prevents the RPM from dropping
below centrifugal clutch engagement speed.
Vehicle Stop
When coming to a complete stop, after the gear-
box has shifted into first gear, the centrifugal
clutch will automatically disengage the engine
from the gearbox. This prevents stalling and
leaves the vehicle ready for its next acceleration
event.
TROUBLESHOOTING
Refer to POWER DISTRIBUTION AND GROUNDS
for fuses and relays information.
Always refer to the WIRING DIAGRAM when
troubleshooting an electrical circuit.
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,
test results can be altered.
NOTICE Never force a multimeter probe into
an electrical terminal.
TROUBLESHOOTING
GUIDELINES
This troubleshooting guideline should be used
jointly with the flow chart available in the pocket
located on the last page of this manual.
For any problem, start troubleshooting by:
– Checking fault codes using B.U.D.S.
– Checking oil level and condition. Engine and
HCM share the same oil. Oil type, level and
condition are very important.
NOTE: In doubt of the oil condition or type,
change oil and filters before further diagnosis.
rmr2013-031
Gearbox Does not Shift Into Gear (Up
or Down)
– Check battery condition, refer to CHARGING
SYSTEM.
– Carry out the TCM STATUS VALIDATION. Re-
fer to TRANSMISSION CONTROL MODULE
(TCM) in this subsection.
– Using B.U.D.S., check shifting system compo-
nents (shift switches, solenoid valves, TCM,
etc.).
– Carry out HCM oil pressure test, refer to HY-
DRAULIC CONTROL MODULE (SE5) subsec-
tion.
– Check hydraulic and mechanical components.
– Check if vehicle "creeps" at idle. If so, verify
clutch, refer to CLUTCH (SE5) subsection.
– Make sure the shift linkage is in good condition
and adjusted correctly, refer to HYDRAULIC
CONTROL MODULE (SE5) subsection.
– Check RPM profile in B.U.D.S. (History tab).
Gearbox may not shift every time if a lot of rid-
ing time is spent at less than 2500 RPM.
– Make sure the ground cable at ignition coil re-
taining nut is properly installed and in good con-
dition.
Erratic or Harsh Shifting
Carry out a CLUTCH ACTIVATION TEST, refer to
TEST WITH B.U.D.S. in this subsection.
Gearbox Does not Shift Into Reverse
Refer to REVERSE BUTTON TEST WITH B.U.D.S.
in the GEARBOX subsection.
TROUBLESHOOTING WITH
B.U.D.S.
B.U.D.S. provides useful features to troubleshoot
the gear shift system. Most are obvious. The oth-
ers are described here.
NOTE: Some items need the engine to be running
to be monitored in B.U.D.S. In this case, follow
the displayed instructions carefully.
Monitoring Page in B.U.D.S.
Clutch mod (%) is useful to acknowledge the
clutch modulation while shifting.
Outputs Section
Clutch/Shift Up/Shift Down Sol
– When ON, it indicates that the TCM sent the
command to activate the related solenoid.
3
Subsection XX (ELECTRONIC SHIFT SYSTEM (SE5))

Check TCM
– When ON, it indicates that a fault relative to the
TCM is active.
TCM Active
– When ON, it indicates that the TCM is working
to carry out the gear shifting.
– When OFF, it indicates that the TCM is OFF be-
cause of a TCM malfunction. No gear shift will
take place. Refer to TCM STATUS VERIFICA-
TION in this subsection.
BLS/Reverse (R)/Neutral (N)
– They indicate their status as seen by the TCM.
Switch Inputs Section
rmr2013-031-003_a
When a LED is ON, it indicates that the switch
1. Clutch cover cap
sends the signal.
NOTE: If oil is present when removing cap, check
Activation Page in B.U.D.S. the O-ring on the clutch piston nut and the clutch
Activation section allows the activation of the dif- piston seal. Replace as required.
ferent solenoids. Make sure TCM is operational. Refer to TCM STA-
Routine section allows to force an action such as TUS VERIFICATION in this subsection.
an upshift or downshift. For example, the Shift Select the Activation and the TCM tabs. Look at
up button will activate all the necessary solenoids, the Routine section.
in the proper sequence, required to carry out an
upshift. Start engine and let run at idle.
In B.U.D.S., click the Clutch activation button.
Test with B.U.D.S. Clutch piston should move outwards then return
Connect vehicle to B.U.D.S. approximately at the same speed.
NOTE: Make sure you have checked fault codes
and engine oil level prior to carrying the following
tests.
Clutch Activation Test
Refer to BODY and remove RH bottom rear side
panel.
Remove clutch cover cap.

rmr2008-078-050

PISTON — OUT

4 rmr2013-031
 Subsection XX (ELECTRONIC SHIFT SYSTEM (SE5))

rmr2008-078-051

PISTON — IN rmr2013-031-004_a

1. Shift shaft lever

If test is successful, carry out a CLUTCH ACTIVA-
TION AND MODULATION TEST below. If the shift shaft does not turn, disconnect its link-
If test failed, check the HCM oil pressure and age and try again to turn the shift shaft.
the clutch solenoids operation. Refer to HY- – If the shift shaft does not turn, proceed with
DRAULIC CONTROL MODULE (SE5) subsection. gearbox repair.
If the HCM oil pressure and solenoids test good, – If the shift shaft turns, inspect the shift linkage
check for clutch mechanical problems. Refer to and the HCM hydraulic piston.
CLUTCH (SE5) subsection.
Clutch Activation and Modulation Test
In B.U.D.S., click the Clutch activ + mod button.
Clutch piston should move outwards then return
slower than when it moved outwards. Other-
wise, check the clutch modulation solenoid oper-
ation. Refer to HYDRAULIC CONTROL MODULE
(SE5) subsection.
Shifting Test
If shift switches DELs turn ON in B.U.D.S. when
switches are pressed in but gearbox does not shift
gears, carry out the following:
Start engine.
rmr2008-078-008_a
Go in TCM under Activation. Look at the Routine TYPICAL - VIEW FROM BACK SIDE OF HCM
section. 1. Shift linkage
2. Hydraulic piston in HCM
Click ON the Upshift or Downshift button.
Gearbox should shift into selected gear. If not, try PROCEDURES
to manually shift gearbox through all gears as fol-
lows:
GEAR SHIFTING SWITCHES
Install a 13 mm wrench on the flat edges of the
shift shaft lever and use it to turn shift shaft. Gear Shifting Switches Test with
B.U.D.S.
Connect vehicle to B.U.D.S.
Make sure that both clutch and clutch modulation
solenoids and valves work. Refer to CLUTCH AC-
TIVATION TEST in this subsection.
Select the Monitoring and TCM tabs.
The LED status in the Switch Inputs section
should be as per following table.

rmr2013-031 5
Subsection XX (ELECTRONIC SHIFT SYSTEM (SE5))

If LED do not turn ON when button is pressed in,

refer to the WIRING DIAGRAM and check wiring
and switch continuity.

TRANSMISSION CONTROL
MODULE (TCM)
TCM Status Validation
Turn ignition key to ON.
rmr2011-031-002_a Ensure that fuel pump turns ON a few seconds.
1. Switch inputs LEDs Otherwise, check ECM power supply.
GEAR SHIFTING SWITCH INPUT LED STATUS Connect vehicle to B.U.D.S.
In the tool bar at the top of screen, click on Mod-
CONDITION
LED ule. TCM should be visible in the menu.
IDENTIFICATION SWITCH SWITCH
ACTIVATED RELEASED
Up or Down
ON OFF
Button
Free Up or Free
OFF ON
Down Button

If LEDs turn ON as specified, carry out the SHIFT-

ING TEST. Refer to TROUBLESHOOTING WITH
B.U.D.S. in this subsection.
If LEDs do not turn ON as specified, refer to rmr2008-078-024_a

WIRING DIAGRAM to check wiring and switch 1. TCM is visible

continuity.
REVERSE BUTTON
Reverse Button Test with B.U.D.S.
Connect vehicle to B.U.D.S.
Select the Monitoring and TCM tabs.
The Reverse Button LED in the Switch Inputs
section should be OFF when button is free and
should turn ON while pressing on it.
If not, the module is either not powered, defective
or unable to communicate via CAN.
If TCM module is visible, select Monitoring and
TCM tabs.
In the Outputs section, check if TCM active LED
is turned ON. Otherwise, turn ignition switch (key)
OFF, wait 30 seconds, then turn it ON. If LED still
does not turn ON, try a new TCM.

rmr2011-031-001_a

1. TCM active LED

rmr2011-031-002_b

1. Reverse Button LED

NOTE: Make sure there is no communication
problem code.
If LED turns ON at the appropriate moment, If TCM module is visible and active, carry out
carry out the SHIFTING TEST. Refer to TROU- GEAR SHIFTING SWITCHES TEST WITH B.U.D.S.
BLESHOOTING WITH B.U.D.S. in this subsection.
6 rmr2013-031
 Subsection XX (ELECTRONIC SHIFT SYSTEM (SE5))

If TCM module is not visible or active, carry out

TCM INPUT VOLTAGE TEST.
TCM Input Voltage Test
Check fuse F7 in LH fuse box and fuse J3 in RH
fuse box.
Refer to BODY and remove:
– LH upper side panel
– LH service cover.
Remove acoustic panel.

rmr2013-031-008_a

If voltage is not as specified, check wiring and

connectors between TCM and main relay 2. Re-
fer to WIRING DIAGRAM.
If voltage is good, carry out a TCM GROUND
TEST.
Clear fault codes.

TCM Ground Test

Use the FLUKE 115 MULTIMETER (P/N 529 035 868)
and FLUKE RIGID BACK PROBES (P/N TP88).
rmr2013-031-005_a
Set multimeter to VDC.
1. Frame
2. Acoustic panel Check ground as follows:
3. Retaining screw
1. Connect multimeter RED probe to a positive
Disconnect TCM connector. source such as the battery terminal of the
Use the FLUKE 115 MULTIMETER (P/N 529 035 868) starter solenoid.
and FLUKE RIGID BACK PROBES (P/N TP88). 2. Probe TCM connector pins with the BLACK
Set multimeter to Vdc. (COM) probe of the multimeter as follows.
Read voltage as follows. NOTICE To avoid damaging the connector,
probe only the terminal tip.
NOTICE To avoid damaging the connector,
probe only the terminal tip. TCM
BATTERY RESULT
CONNECTOR
TCM
BATTERY VOLTAGE Pin 10
CONNECTOR
Positive source Battery voltage
Pin 17 Pin 28
Ground Battery voltage
Pin 35

Turn ignition switch (key) ON.

TCM VOLTAGE
BATTERY
CONNECTOR (KEY ON)
Pin 4 Ground Battery voltage

rmr2013-031 7
Subsection XX (ELECTRONIC SHIFT SYSTEM (SE5))

Check CAN circuit continuity as per following ta-

ble:
TCM CAN CIRCUIT TEST
TEST PROBES RESULT
TCM
Close to
CAN High: DLC pin 1 connector
0
pin 19
TCM
Close to
CAN Low: DLC pin 2 connector
0
pin 1

If result is not as specified, repair wiring or con-

nector.
rmr2013-031-008_c
TCM Replacement
If ground circuits are not as specified, check
TCM Removal
wiring and connections between TCM and bat-
tery ground. Refer to BODY and remove LH upper side panel.
If ground circuits are as specified, try a new TCM. Remove acoustic panel.
Clear fault codes.

TCM Test for CAN Communication

1. Check for CAN fault codes using B.U.D.S.
2. Carry out TCM STATUS VALIDATION in this
subsection.
If TCM is powered but not visible in B.U.D.S.,
carry out the TCM CAN CIRCUIT TEST.
TCM CAN Circuit Test
1. Refer to BODY and remove:
– LH upper side panel
– Service covers.
2. Disconnect TCM connector.
rmr2013-031-005_a

1. Frame
2. Acoustic panel
3. Retaining screw

Disconnect TCM connector.

Remove TCM retaining screws.

rmr2013-031-006_a

1. TCM connector

3. Locate the diagnostic link connector (DLC).

8 rmr2013-031
 Subsection XX (ELECTRONIC SHIFT SYSTEM (SE5))

rmr2013-031-007_a

1. TCM
2. Frame

rmr2013-031-007_b

Pull out TCM.

TCM Installation
Reverse removal procedures.

rmr2013-031 9
 Subsection XX (DRIVE BELT AND REAR WHEEL)

DRIVE BELT AND REAR WHEEL

SERVICE TOOLS
Description Part Number Page
BELT TENSION METER ................................................................ 529 036 115 ............................................. 4
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ............................... 10, 12, 15
SOCKET SPANNER ....................................................................... 529 036 113 ........................................... 10

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON SEAL PULLER .............................................................. YA105 ........................................... 15

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 11
XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 11

rmr2013-032 1
Subsection XX (DRIVE BELT AND REAR WHEEL)

Front sprocket with flywheel

NEW
25 N•m
(18 lbf•ft)
NEW
125 N•m
(92 lbf•ft)

Engine
oil NEW
72.5 N•m
(53 lbf•ft)

NEW
NEW
72.5 N•m
(53 lbf•ft) NEW
20 N•m
(15 lbf•ft)
Loctite 243

NEW
NEW NEW NEW
XPS
synthetic
225 N•m grease
(166 lbf•ft)

XPS
synthetic grease

NEW = Component must be replaced when removed.

rmr2013-032-100_a

2 rmr2013-032
 Subsection XX (DRIVE BELT AND REAR WHEEL)

GENERAL WEAR CONDITION

REQUIRED
ACTION
During assembly/installation, use the torque val-
ues and service products as in the exploded Good condition None
views.
Hairline cracks Monitor condition
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE Minor chipping Monitor condition
APPLICATION at the beginning of this manual for
complete procedure. Opened cracks Replace belt

WARNING Hook wear Replace belt

Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.
NOTICE During installation, make sure every
part is free from old grease and dirt. This al-
lows for a clean reassembly and will avoid pre-
mature wear caused by dirt contamination.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
Road test vehicle at moderate speeds a few min-
utes to ensure normal operation following mainte-
nance or repair (proper drive belt tension and align-
ment, rear brake operates correctly, etc.).
PROCEDURES
DRIVE BELT
Drive Belt Inspection
Lift the rear of vehicle and install a jack under the
frame to support the rear of vehicle off the ground.
Remove the belt guard.
Inspect the full length of the belt. Inspect for the
following conditions:
Missing teeth Replace belt
Belt fabric worn, Replace belt
exposing internal
components
Stone damage Replace belt
NOTE: Hairline cracks do not require the replace-
ment of the belt, but must be monitored closely –
they may lead to opened cracks or missing teeth,
requiring belt replacement. Damage to the cen-
ter of belt will eventually require belt replacement,
but when cracks extend to the edge of belt, belt
failure is imminent.
When a drive belt is replaced, also replace the
sprockets to increase the longevity of the new
drive belt.
Drive Belt Tension Verification
NOTICE Always verify drive belt tension
with all parts at room temperature and the
rear wheel lifted of the ground.
1. Place vehicle on a level surface.
NOTE: The area must be protected against wind
and must have a low background noise.
2. Set transmission to NEUTRAL.
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.

rmr2013-032 3
Subsection XX (DRIVE BELT AND REAR WHEEL)

rmr2008-030-009
rmr2008-031-003
TYPICAL - LIFT BY THE FRAME
TYPICAL - SWING ARM ALIGNED WITH A SPOKE
4. To check the drive belt tension use the BELT
7. Position the sensor under the LH passenger
TENSION METER (P/N 529 036 115).
footrest and hold the sonic tension meter sen-
sor approximately 1 cm (1/2 in) from belt or
closer without touching the belt.

529036115

5. Enter the following specifications to program

the meter.
MASS WIDTH SPAN
8.4 g/m 28.0 mm/R 1028 mm rbs2010-006-001

8. Tap the belt to make the belt vibrate and note

rmr2008-031-002
SONIC TENSION METER DISPLAY
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.
the measurement.
9. Repeat step 8.
NOTE: The second value should be within ± 25 N.
If not, repeat measurements until tolerance is
met.
10. Repeat steps 6 to 9 for the 2 remaining wheel
spokes.
The average of the 3 obtained values (at the 3
spokes) must be within the following range:

4 rmr2013-032
 Subsection XX (DRIVE BELT AND REAR WHEEL)

DRIVE BELT TENSION Adjust tensioner screws as following:

(PARTS AT ROOM TEMPERATURE AND – Tighten screws 1/4 turn to increase belt ten-
REAR OF VEHICLE LIFTED) sion.
1050 N ± 150 N – Loosen screws 1/4 turn to decrease belt ten-
sion.
If the tension of drive belt is out of specification, NOTE: Always turn both tensioner screws evenly
adjust drive belt as per DRIVE BELT TENSION AD- to keep drive belt aligned.
JUSTMENT.
Drive Belt Tension Adjustment
Lift rear of vehicle using a floor jack until rear
wheel is off the ground.
NOTICE Place floor jack underneath frame
only.

rmr2013-032-002_a

1. Rear axle tensioner

2. Tensioner screw

Tighten rear axle nut enough to avoid rear axle

rmr2008-030-009
movement.
TYPICAL
Adjust drive belt tension as per specification, refer
Remove both rear axle caps. to DRIVE BELT TENSION VERIFICATION.
From RH side of vehicle, remove and discard cot- When recommended tension is obtained, torque
ter pin locking the rear axle nut. rear axle nut.
REAR AXLE NUT TIGHTENING TORQUE
225 N•m (166 lbf•ft)

Install a NEW cotter pin and both axle caps.

WARNING
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:
DRIVE BELT AND REAR SPROCKET
rmr2013-032-001_a
INTERNAL FLANGE GAP
REAR RH SIDE OF VEHICLE Minimum 1 mm (1/32 in)
1. Cotter pin
2. Rear axle nut
Maximum 5 mm (3/16 in)
Using a 36 mm socket, loosen rear axle nut.

rmr2013-032 5
Subsection XX (DRIVE BELT AND REAR WHEEL)

From RH side of vehicle, remove and discard cot-

ter pin locking the rear axle nut.

rmr2013-032-001_a

TYPICAL - REAR RH SIDE OF VEHICLE

1. Cotter pin
2. Rear axle nut

Using a 36 mm socket, loosen rear axle nut.

NOTE: Loosen axle nut just enough to slide wheel
rmo2008-001-027_a
using axle tensioner screws.
TYPICAL - BELT ALIGNMENT
1. Rear sprocket Adjust tensioner screws as follows:
2. Belt
3. Sprocket internal flange – If drive belt is on the outside edge of rear
4. Proper belt alignment sprocket, tighten the LH tensioner screw.
5. Belt exceeding external edge — realign belt
A. MIN. 1 mm (1/32 in) — MAX. 5 mm (3/16 in) – If drive belt is on the rear sprocket flange,
tighten the RH tensioner screw.
Drive Belt Alignment Procedure
Clear rear wheel area.
If drive belt needs to be aligned, proceed as fol-
lows. Ask somebody to start engine.
Lift rear of vehicle using a floor jack until rear Select first gear.
wheel is off the ground. Accelerate engine to turn rear wheel.
NOTICE Place the floor jack underneath WARNING
frame only.
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-
priate axle tensioner screw and recheck the align-
ment.
When alignment is good, check drive belt tension.
Refer to DRIVE BELT TENSION VERIFICATION.
rmr2008-030-009 Torque rear axle nut.
TYPICAL

Remove both axle caps.

6 rmr2013-032
 Subsection XX (DRIVE BELT AND REAR WHEEL)

REAR AXLE NUT TIGHTENING TORQUE
130 N•m (96 lbf•ft)
Install a NEW cotter pin and the both axle caps.
WARNING
Always install a NEW cotter pin on rear axle.
Remove belt tension, refer to DRIVE BELT TEN-
SION ADJUSTMENT and completely loosen ten-
sioner screws to remove belt from rear sprocket.
Remove shift lever from shift shaft.
Remove LH footrest support from vehicle by un-
screwing retaining screws.

Drive Belt Removal

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-
ximum drive belt life span.
Lift rear of vehicle by the frame until rear wheel
is off the ground.

rmr2013-032-004_a

RS AND ST MODELS
1. Typical - Footrest support retaining screws.

rmr2008-030-009

TYPICAL

Remove body parts as required to access to the

front sprocket. Refer to BODY subsection.
Remove belt guard from swing arm.

rmr2010-032-001_a

RT MODELS
1. Footrest support retaining screws.

rmr2013-032-003_a

TYPICAL
1. Belt guard

rmr2013-032 7
Subsection XX (DRIVE BELT AND REAR WHEEL)

NOTICE Do not remove flywheel from front

sprocket for the drive belt removal.

Drive Belt Installation

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 DRIVE BELT ALIGN-
MENT.
rmr2010-032-002_a Adjust drive belt tension. Refer to DRIVE BELT
RT MODELS TENSION ADJUSTMENT.
1. Footrest support retaining screws.
Install the shift lever and align its slot with the dot
Unscrew bolt securing LH lateral support to fuel on the end of shifter shaft.
tank.
Torque Allen screw securing shift lever on shifter
shaft.
SHIFT LEVER SCREW TIGHTENING TORQUE
19 N•m (168 lbf•in)

Make sure that gear shift lever works properly.

REAR WHEEL
Rear Wheel Removal
Place vehicle on a level surface.
rmr2008-031-010_a Remove the following body panels, refer to REAR
TYPICAL CARGO MODULE DISASSEMBLY in BODY sub-
1. Lateral support section.
2. Fuel tank
– Rear panel
Lift end of lateral support. – Rear fender.
Slide drive belt between lateral support and the Lift rear of vehicle by the frame until rear wheel
footrest support bracket. is off the ground.
Carefully slide drive belt between sprocket fly-
NOTICE Do not lift under rear shock ab-
wheel and shifter shaft.
sorber. Always lift by the frame. Refer to
illustration.

rmr2008-030-009

rmr2010-032-004
TYPICAL - LIFT BY THE FRAME
TYPICAL

8 rmr2013-032
 Subsection XX (DRIVE BELT AND REAR WHEEL)

Remove both axle caps.

From RH side of vehicle, remove and discard cot-
ter pin locking the rear axle nut.

rmr2013-032-001_b

1. Caliper screws

From the LH side of vehicle, support rear wheel

and remove the rear axle.
rmr2013-032-001_a

TYPICAL - REAR RH SIDE OF VEHICLE

1. Cotter pin
2. Rear axle nut

Using a 36 mm socket, loosen rear axle nut.

Loosen rear axle tensioner screws. Be careful not
to unscrew tensioner screws completely.

rmr2013-032-005_a

1. Rear axle

Remove drive belt from rear sprocket.

Remove wheel from vehicle.

Rear Wheel Disassembly

rmr2013-032-002_a
Remove the external spacer.
1. Rear axle tensioner
2. Screw

Remove and discard both caliper screws.

rmr2013-032 9
Subsection XX (DRIVE BELT AND REAR WHEEL)

rmr2013-032-006_a rmr2013-032-008_a

1. External spacer
2. Rear sprocket Remove wheel hub and spacer.
Remove REAR SPROCKET, see procedure in this Using the SOCKET SPANNER (P/N 529 036 113), un-
subsection. screw the wheel bearing nut.
Remove rear sprocket dampers.

529036113

rmr2013-032-007_a
1. Rear sprocket dampers
Unscrew wheel hub bolts.
rmr2008-031-019
Using the BLIND HOLE BEARING PULLER SET
(P/N 529 036 117), remove and discard wheel bear-
ing.

529036117

10 rmr2013-032
 Subsection XX (DRIVE BELT AND REAR WHEEL)

– Caliper support
– Wheel.
Insert the rear axle from the LH side.
On RH side, install a washer and the rear axle nut.
Pull rear wheel backward and tighten rear axle nut
slightly.
Using a ruler, measure the distance between
washer and the swing arm end.

rmr2008-031-021

Rear Wheel Inspection

Verify condition and wear of the following wheel
components:
– External spacer
– Seals
– O-ring (inside external spacer)
– O-ring (around nave)
– Rim.
Replace any components as required.
rmr2008-031-023

Rear Wheel Assembly Tighten rear adjuster screws to same length on

The assembly is the reverse of the disassembly both sides of swing arm.
procedure. However, pay attention to the follow- Align drive belt. Refer to DRIVE BELT ALIGN-
ing. MENT.
Install a NEW wheel bearing.
WARNING
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of wheel bearing nut. Always install a NEW cotter pin on rear axle.
Torque wheel bearing nut.
REAR SPROCKET
WHEEL BEARING NUT TIGHTENING TORQUE
20 N•m (15 lbf•ft)
Rear Sprocket Removal
Remove rear wheel. Refer to REAR WHEEL in
Install the rear sprocket and wheel hub on rear this subsection.
wheel. Refer to REAR SPROCKET and WHEEL Pull rear sprocket.
HUB.
Make sure rear sprocket spokes are aligned along
with rear wheel spokes.

Rear Wheel Installation

Install the rear caliper support. Refer to BRAKES
subsection.
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) on
rear axle.
Install the drive belt on rear sprocket. rmr2008-031-025_a

TYPICAL
Align holes of the following components: 1. Rear sprocket
– Swing arm
– Rear adjusters Rear Sprocket Inspection
Verify sprocket as follows:
– Sprocket teeth for wear.
rmr2013-032 11
Subsection XX (DRIVE BELT AND REAR WHEEL)

– Sprocket bearing turns smoothly and freely.

– Bearing spacer for wear.

529036117

Rear Sprocket Assembly

The assembly is the reverse of the disassembly
procedure. However, pay attention to the follow-
rmr2008-031-026_a
ing.
1. Bearing spacer
When installing the sprocket bearing, make sure
Replace components as required. to insert the bearing very straight to avoid damag-
ing sprocket hub and to press the bearing from its
Rear Sprocket Disassembly outer race.
Remove seal. Install the long side of bearing spacer inside rear
sprocket bearing.

rmr2008-031-027_a rmr2008-031-026_a

1. Seal 1. Long side of bearing spacer

Remove circlip. Rear Sprocket Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Check the gap between rear sprocket and rear
wheel.
REAR SPROCKET AND REAR WHEEL GAP
1.6 mm (1/16 in)

NOTE: If the gap is higher, remove the rear

sprocket and check the condition of the nave
O-ring.
rmr2008-031-028_a
Make sure rear sprocket spokes are aligned along
1. Circlip
with rear wheel spokes.

Using the BLIND HOLE BEARING PULLER SET

(P/N 529 036 117), remove and discard sprocket
bearing.

12 rmr2013-032
 Subsection XX (DRIVE BELT AND REAR WHEEL)

FRONT SPROCKET Front Sprocket Inspection

NOTICE Do not remove flywheel from front
sprocket for the inspection.
Inspect splines of main shaft for wear or other
damages. If necessary replace main shaft (gear-
box disassembly is required).
Check inner splines and teeth of sprocket for wear
or other damages. Replace sprocket as required.
Check inner flange of sprocket to ensure it is not
warped or worn out.

Front Sprocket Disassembly

NOTICE Remove flywheel from front
sprocket only if the sprocket needs to be
changed. If disassembly is required, make
sure to strictly follow assembly procedure.
rmr2011-032-005
Unscrew flywheel retaining screws from front
Front Sprocket Removal sprocket.

CAUTION Apply parking brake before re-

moving front sprocket to avoid vehicle move-
ment.
Remove body parts as required to access to the
front sprocket. Refer to BODY subsection.
Loosen drive belt tension. Refer to DRIVE BELT
in this subsection.
Remove and discard the front sprocket screw.
NOTICE Do not remove flywheel from front
sprocket for its removal. rmr2010-032-005_a

TYPICAL
1. Flywheel retaining screws
2. Flywheel
3. Front sprocket

Front Sprocket Assembly

Clean front sprocket threads using a metric tap
M8 x 1.25.
WARNING
To ensure good clamping of flywheel screws,
it is imperative to clean front sprocket threads
using a metric tap M8 x 1.25.
rmr2011-032-002_a

TYPICAL Install flywheel on front sprocket.

1. Front sprocket with flywheel
2. Sprocket screw Install NEW flywheel retaining screws (with
3. Washer
threads already coated with a self-locking prod-
Remove front sprocket from main shaft. uct).

rmr2013-032 13
Subsection XX (DRIVE BELT AND REAR WHEEL)

WHEEL HUB
Wheel Hub Removal
Remove rear wheel. Refer to REAR WHEEL in
this subsection.
Remove rear sprocket dampers.

rmr2011-032-003

Tighten flywheel retaining screws as per the fol-

lowing sequence.

WARNING
Make sure to install NEW flywheel screws
with threads already coated with a self-lock-
ing product. Screw must be torqued as
specified.

rmr2013-032-007_a

1. Rear sprocket dampers

Unscrew wheel hub bolts.

rmr2010-032-005_b

FLYWHEEL SCREW TIGHTENING TORQUE

25 N•m (18 lbf•ft)

Front Sprocket Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
rmr2013-032-008_a
Install a NEW front sprocket screw with threads
already coated with a self-locking product. Remove wheel hub and spacer.
WARNING Wheel Hub Bearing Replacement
Make sure to install a NEW sprocket screw Remove the wheel hub inner spacer.
with threads already coated with a self-lock-
ing product. Screw must be torqued as spec-
ified.

SPROCKET SCREW TIGHTENING TORQUE

125 N•m (92 lbf•ft)

14 rmr2013-032
 Subsection XX (DRIVE BELT AND REAR WHEEL)

rmr2008-067-002_a

1. Inner spacer
2. Wheel hub
rmr2013-032-010_a

Remove the outer spacer. 1. Seal

2. Wheel hub

Using the BLIND HOLE BEARING PULLER SET

(P/N 529 036 117), remove and discard sprocket
bearing.

529036117

rmr2013-032-009_a

1. Outer spacer
2. Wheel hub

Using a seal puller such as the SNAP-ON SEAL

PULLER (P/N YA105) or a screwdriver, drive the
seal out of the wheel hub.

rmr2008-067-005

Clean bearing area.

Install the NEW bearing, make sure to insert the
bearing very straight to avoid damaging wheel hub
and to press bearing from its outer race.
Install a NEW seal.

Wheel Hub Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
rmr2013-032 15
Subsection XX (DRIVE BELT AND REAR WHEEL)

When installing wheel hub, ensure inner spacer
is properly seated against both inner races (wheel
bearing and wheel hub bearing).
REAR TIRE
It is normal to see uneven wear on tire depending
on how the vehicle is driven and road conditions.
The rear tire center tread will wear unevenly de-
pending on if the vehicle is driven smoothly or ag-
gressively.

Rear Tire Inspection Recommended Tire

Check tire pressure. Check for air leaks (hissing WARNING
sound) caused by an ill-fitting rim or a faulty tire
valve. It is imperative to follow the proper MAX
LOAD RATING of the tire relating to the
Check tire for: model of vehicle serviced. Always check on
– Cuts the tire sidewall to ensure that the load rating
– Slits is in accordance with the following table.
– Cracks.
Check sides of tire for: REAR TIRE LOAD RATING
– Bumps MAX LOAD
MODEL DESIGNATION
– Bulges RATING
– Nails MC 225/50R15
Spyder RT 400 kg (882 lb)
– Other foreign objects. 76H
Check minimum tread depth by using the tread- NOTE: The Spyder RT uses a heavy duty rim with
wear indicators. Check in three locations across a load rating of 400 kg (882 lb) to match with the
the tire tread: tire. Always check the load rating on rim spoke
– Outer edge to ensure that the rim meets the proper specifica-
– Center tion.
– Inside edge.
The tread-wear indicators will appear across the
Rear Tire Replacement
treads that have been worn down to the minimum
tread depth. When at least one tread-wear indi-
WARNING
cator appears across the tread, have the tire re- The VSS on the vehicle has been calibrated
placed as soon as possible. to perform best with a tire of a specific size,
material, and tread pattern. Replacing the tire
with one not approved by BRP can cause the
VSS to be ineffective.

To replace the rear tire, do the following:

Remove rear wheel from vehicle. Refer to REAR
WHEEL in this subsection.
Using an automotive tire changer (rim clamp type),
remove the old tire and install the new one.
WARNING
The tire is only designed to rotate in one di-
rection. If a tire is mounted on the incorrect
side, you will have less traction and could
rmo2008-001-041_a
lose control.
TYPICAL
1. Tread-wear indicator
A. Appropriate tread depth
B. Minimum tread depth, replace tire

16 rmr2013-032
 Subsection XX (DRIVE BELT AND REAR WHEEL)

WARNING
It is imperative to follow the proper MAX
LOAD RATING 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 TIRE.

NOTE: Refer to manufacturer's instructions for

tire changer operation. rmr2008-030-029_a

Remove the old balancing masses from rim. Separate both sliding blocks.
Clean inner side of wheel with alcohol to remove
grease and dust.
Balance wheel using a wheel balancer.
See directive in table below depending which
wheel balancer type is used.
WHEEL BALANCER
Motorcycle type Do not remove wheel
balancer hub or wheel bearing
Automotive type Remove wheel hub and
balancer wheel bearing
rmr2008-030-030_a

NOTE: Refer to manufacturer's instructions for

wheel balancer operation. Unscrew nut completely.
Install the new balancing masses inside wheel.
Position them in the center of the flat inner sur-
face of the rim.
NOTICE Improperly positioned weights can
cause interference.
Install a NEW wheel bearing if it has been re-
moved.
Reinstall wheel. Refer to REAR WHEEL in this
subsection.
WARNING rmr2008-030-031_a

When installing a new tire, always observe Remove tensioner bolt with its washer.
a break-in period of 300 km (200 mi). During
this time, the tire and the VSS will not operate
at their maximum efficiency. You could lose
control and crash – use extra caution.

REAR WHEEL TENSIONER

Rear Wheel Tensioner Removal
Remove rear wheel. Refer to REAR WHEEL in
this subsection.
Pull tensioner out of swing arm end.
rmr2008-030-032_a

rmr2013-032 17
Subsection XX (DRIVE BELT AND REAR WHEEL)

Rear Wheel Tensioner Installation

Install nut into sliding blocks recesses.

rmr2008-030-033_a

1. Sliding blocks recesses

Insert tensioner into swing arm end.

Install and adjust all other removed parts.

18 rmr2013-032
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

VEHICLE STABILITY SYSTEM (VSS)

SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................... 8, 10–12, 14–15

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
FLUKE RIGID BACK PROBES ....................................................... TP88 ........................... 8, 12, 14–15

SERVICE PRODUCTS
Description Part Number Page
BRP HEAVY DUTY CLEANER ....................................................... 293 110 001 ........................................... 16

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
NOTICE Hoses, cables or locking ties re- as necessary.
moved during the procedure must be rein- Prevents the wheels to lock while
ABS
stalled as per factory standard. (Antilock
braking.
It reduces braking power to the
Braking
appropriate wheel by modulating
GENERAL System)
brake pressure as necessary.

SYSTEM DESCRIPTION EBD

Allows the distribution between
(Electronic
(FEATURES) Brake
front and rear brakes to be adjusted
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.

rmr2013-033 1
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

VSS SYSTEM DESCRIPTION

(Vehicle Stability
System) (COMPONENTS)
Vehicle Control Module (VCM)
VCM The Vehicle Control Module (VCM) is the heart
of the vehicle stability system (VSS). It contains
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)

rmr2008-019-018_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
rmr2013-033-002_a
brake point at the right foot, to provide the op-
1. Electronic module (2 microprocessors)
timal amount of hydraulic brake pressure on all 2. Hydraulic pump motor
three wheel's brake discs, under a multitude of 3. Solenoids and passageways
braking and road conditions. The result is maxi-
The VCM receives inputs from several sensors
mizing vehicle control while allowing the wheels
and performs calculations to cycle the pump and
to remain available to generate steering control
solenoids to apply or relieve hydraulic pressure to
force in response to the rider’s input.
or from the vehicle brake calipers. In addition the
Electronic Brake Distribution (EBD) VCM has the ability to send a signal to the ECM
to reduce engine torque if necessary.
The EBD allows the distribution between front
and rear brakes to be adjusted according to condi-
SAS
tions. Based on inputs from the various sensors, VSS 1 VSS 2
it achieves an efficient braking by reacting to ve-
hicle weigh transfer by reducing the rear braking
pressure as needed. VCM

LPS
Traction Control System (TCS)
The TCS optimizes rear wheel traction to help YRS
keep the vehicle on its intended course. It can
reduce engine torque if necessary. It may also BLS
apply brake on rear caliper if necessary.
The TCS will limit rear wheel spin and is throttle ECM
dependant. PRS
At WOT (throttle opening above 90%), TCS will OLS 1
allow rear wheel slip speed up to redline in first OLS 2
gear.
At lower throttle opening, TCS will manage rear VSS 4
wheel slip to allow maximum acceleration and rmr2011-082-002_a
control.
2 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

VSS Sensors

rmr2013-033-003_a

TYPICAL
1. Wheel speed sensor (rear)
2. Wheel speed sensors (front)
3. Vehicle control module (VCM)
4. Steering angle sensor (SAS)
5. Yaw rate sensor (YRS)
6. Pillion rider sensor (PRS)
7. Oil level sensors (BFS)
8. Brake light switch (BLS) and low pressure switch (LPS)

rmr2013-033 3
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

SENSOR VSS INPUTS/OUTPUTS

DESCRIPTION FUNCTION
ACRONYM
INPUT USAGE OUTPUT
Determines the
Wheel speed YRS
VSS1 speed of the LH
sensor # 1
front wheel. Longitudinal
Determines the acceleration
Wheel speed
VSS2 speed of the RH Lateral
sensor # 2 These sensor
front wheel. acceleration signals (or
– Modulate
Wheel speed VSS (3) parameters)
Determines the brake fluid
sensor # 3 are used by the
VSS3 speed of the rear Front brake VSS to perform pressure to
(bottom rear
wheel. pressure proper caliper.
sensor) computations
(inside and to then act – Engine torque
Determines the VCM) by providing the reduction.
Steering angle angle of the front proper output(s).
SAS SAS
sensor wheels in relation to
the vehicle. PRS
Measures lateral BLS thru
and longitudinal ECM
Yaw rate
YRS accelerations, as
sensor
rotation speed (yaw LPS These sensors
rate). are used to
monitor proper
Signals the VCM VSS system
when the PRS operation. They – Fault codes.
switch is depressed. OLS (2)
are not used
the VCM applies to perform
Pillion rider changes to the computations.
PRS
switch control parameters,
mainly to reduce
The YRS and SAS are input sensors that, in addi-
maximum allowed
lateral acceleration tion to monitoring, broadcast their values to the
and yaw. CAN bus to be used by other electronic modules.
Signals the ECM Yaw Rate Sensor (YRS)
that the vehicle The YRS is located on top of the frame, at the front
has begun braking. of vehicle.
Brake light
BLS The ECM then
switch
broadcasts the
signal to the VCM
via CAN bus.
Signals the VCM
in case of a low
Low pressure
LPS pressure situation in
switch
the braking hydraulic
system.
Signals the VCM
in the event of a
Brake fluid level low brake fluid level
OLS1
sensor # 1 in rear half of the
dual reservoir (front
brakes).
Will signal the VCM
in the event of a rmr2013-033-005_a

Brake fluid level low brake fluid level TYPICAL

OLS2 1. Yaw rate sensor (YRS)
sensor # 2 in front half of the
dual reservoir (rear
brakes).

4 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

The YRS measures lateral and longitudinal accel- Pillion Rider (Passenger) Switch (PRS)
eration as well as vehicle rotation rate.

Longitudinal
Acceleration
X axis

Vehicle rotation
YRS Lateral
Acceleration
Y axis

rmr2013-033-006_a

TYPICAL - BOTTOM VIEW OF SEAT, REAR LH SIDE

1. Pillion rider switch (PRS)
rmr2008-019-022_aen

The Pillion Rider Switch (PRS), located under the

This VCM input helps to determine the direction seat, detects the presence of a passenger and in-
and velocity in which the vehicle mass is actually forms the VCM.
traveling.
The center of gravity and weight is much affected
The VCM calculates the acceleration, deceleration by the presence of a passenger therefore, the VSS
and rotation of the vehicle. It determines the ve- behavior will change based on the addition of the
locity and direction, calculates the force (weight) second rider.
and adjusts the VCM parameters accordingly.
Wheel Speed Sensor (VSS)
Steering Angle Sensor (SAS)
The SAS is attached to the bottom of the steering
column shaft under the DPS.

rmr2013-033-007_a

FRONT WHEEL SPEED SENSOR

rmr2013-033-004_a

1. Steering angle sensor (SAS)

The SAS informs the VCM of the handlebar posi-

tion in relation to the chassis.
NOTE: To test, replace and reset the steering an-
gle sensor (SAS), refer to STEERING (DPS) AND
FRONT WHEELS subsection.
rmr2013-033 5
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

Brake Fluid Level Sensor (OLS)

rmr2013-033-001_a

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
wheel pass in front of the sensor. The output fre-
quency of the sensor is proportional to the wheel
rotation speed.
rmr2013-033-009_a
1. Brake fluid reservoir
2. Brake fluid level sensor (front brakes)
3. Brake fluid level sensor (rear brakes)
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
or an open circuit or short circuit in the brake fluid
level sensor (OLS) connections.
Brake Light Switch (BLS)
The brake light switch (BLS) is located close to the
master cylinder. It is activated by the brake pedal.

rmr2013-033-008_a

1. Extrusions on encoder wheel

2. 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.

rmr2013-033-010_a

1. Brake light switch

2. Low pressure switch

6 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))
The BLS turns on the brake lights and supplies
the ECM a signal that the operator is applying the
brakes. The ECM sends the message to the VCM
via CAN. This input is used notably to enable the
ABS and deactivate cruise control.
Low Pressure Switch (LPS)
The low pressure switch (LPS) is located close
to the master cylinder (see previous illustration in
Brake Light Switch (BLS)). It is also activated by
the brake pedal.
Under normal operation during a light to medium
braking, the brake lever does not activate the LPS
switch.
The switch is positioned so that it will be activated
only when a predefined stroke is reached. At this
point, the VSS checks the pressure in the system
and reacts accordingly.
If there is a loss of pressure (leak or air in the sys-
tem), the pedal would travel further than the pre-
defined stroke and activate the LPS switch. This
will inform the VCM of the low pressure condition.
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.
rmr2008-039-012
MONITORING TAB, VCM MODULE
TROUBLESHOOTING
Refer to POWER DISTRIBUTION AND GROUNDS
for fuses and relays information.
Always refer to the WIRING DIAGRAM when
troubleshooting an electrical circuit.
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,
the VSS shuts off, some accessories are shut off
by the ECM and test results can be altered.
NOTICE Never force a multimeter probe into
an electrical terminal.
rmr2013-033
TROUBLESHOOTING TIPS
If the vehicle is in limp home mode and the appli-
cable indicator lights remain ON in the multifunc-
tion gauge, the VSS does not work.
Start troubleshooting by checking fault codes us-
ing B.U.D.S. Make sure fuses 6 and 8 in rear fuse
box are good; follow the service actions in the
fault codes section. Refer to DIAGNOSTIC AND
FAULT CODES.
In B.U.D.S., the VCM will not show up in the
Module menu (top of screen) if the VCM does
not communicate through CAN bus. Refer to
VCM CAN RESISTOR TEST in this subsection.
Carry out the tests in this subsection according to
the fault codes informations. Refer to DIAGNOS-
TIC AND FAULT CODES subsection.
PROCEDURES
WARNING
The recommended tire pressure is critical
for optimal VSS operation. Use only recom-
mended tire dimensions and type.
YAW RATE SENSOR (YRS)
YRS Connector Access
To access the YRS connector, refer to BODY sub-
section and carry out the following;
– Open the seat.
– Remove console module.
rmr2013-033-005_a
TYPICAL
1. Yaw rate sensor (YRS)
YRS Input Voltage Test
1. Disconnect the YRS connector.
7
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

2. Use the FLUKE 115 MULTIMETER (P/N 529

035 868) and the FLUKE RIGID BACK PROBES
(P/N TP88).
3. Set multimeter to Vdc.
4. Turn ignition switch to ON.
5. Read voltage as follows.
YRS INPUT VOLTAGE TEST
rmr2013-033-011_b
PROBES RESULT
YRS connector If ground circuit is not good, check wiring from
Ground Battery voltage YRS connector to battery ground. Refer to
pin 4
WIRING DIAGRAM.
If continuity is good, check the CAN lines.

YRS CAN Line Test

1. Open front storage compartment cover.
2. Remove service cover.
3. Disconnect diagnostic link connector (DLC).
4. Read wiring resistance between diagnostic link
connector and YRS.
rmr2013-033-011_a

YRS CAN LINE TEST

If voltage is not good, check wiring and connec-
tors from battery through ignition switch to YRS CAN* PROBES RESULT
connector. Refer to WIRING DIAGRAM. Diagnostic
YRS
If voltage is good, carry out the YRS GROUND link
High connector
connector
CIRCUIT TEST that follows. pin 3
pin 1 Close
to 0
YRS Ground Circuit Test YRS
Diagnostic (continuity)
link
1. Use the FLUKE 115 MULTIMETER (P/N 529 Low connector
connector
035 868) and the FLUKE RIGID BACK PROBES pin 2
pin 2
(P/N TP88).
* CAN: Serial data communication
2. Set multimeter to Vdc.
3. Connect multimeter RED probe to a positive If continuity is not good, check wiring and connec-
source such as the battery terminal of the tors from diagnostic link connector (DLC) to YRS
starter solenoid. connector. Refer to WIRING DIAGRAM.
4. Probe pin 1 of the YRS connector with the If everything tested good, try a new YRS.
BLACK (COM) probe of the multimeter.
YRS GROUND CIRCUIT TEST
YRS Removal
1. Refer to BODY subsection and remove the fol-
PROBES RESULT lowing:
YRS connector – LH and RH upper side panels
Positive source Battery voltage
pin 1 – LH and RH acoustic panels.
2. Remove LH and RH fuel tank covers. Refer to
FUEL TANK AND FUEL PUMP subsection.
3. Remove YRS from frame.

8 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

YRS Installation PILLION RIDER (PASSENGER)

NOTICE The YRS is very fragile. Do not drop SWITCH (PRS)
or hit. Handle with care. Replace if dropped or PRS Location
damaged.
The PRS is located under the rear portion of the
Reverse removal procedure. However, pay atten- seat.
tion to the following. To access it, open the seat.
Position YRS as illustrated.

rmr2013-033-006_a

rmr2013-033-012_a TYPICAL - PRS UNDER SEAT

TYPICAL 1. Pillion rider switch (PRS)
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 ING SYSTEM subsection.
1. Place vehicle on a flat level surface.
2. Connect vehicle to applicable B.U.D.S. version.
3. In 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.

rmr2013-033-013_a

1. PRS connector
rmr2008-033-012_b

SETTING, VCM PRS Test with B.U.D.S.

1. Reset Longitudinal Offset button
1. Connect vehicle to applicable B.U.D.S. version.

rmr2013-033 9
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

2. In B.U.D.S., select the following:

– Monitoring page tab
– VCM page.
3. Have someone sit on the rear portion of the
seat (passenger position).
NOTE: The Pillion Rider switch light should
come ON in B.U.D.S.

rmr2008-033-016_a
rmr2008-033-015_b

MONITORING, VCM If voltage is not good, check wiring and connec-

1. Pillion Rider switch light
tors from battery through ignition switch to PRS
If the pillion rider switch light in B.U.D.S. does connector. Refer to WIRING DIAGRAM.
not come on as specified, carry out a PRS INPUT If voltage is good, carry out a PRS GROUND CIR-
VOLTAGE TEST. CUIT TEST.
4. Have the person leave the seat.
PRS Ground Circuit Test
NOTE: The pillion rider switch light should turn
OFF in B.U.D.S. 1. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and set it to Vdc.
PRS Input Voltage Test 2. Connect multimeter RED probe to a positive
1. Open seat. source such as the battery terminal of the
starter solenoid.
2. Disconnect PRS connector, refer to PRS CON-
NECTOR ACCESS. 3. Probe pin C of the PRS connector with the
BLACK (COM) probe of the multimeter.
3. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and set it to Vdc. PRS GROUND CIRCUIT TEST
4. Turn ignition switch to ON. PROBES RESULT
5. Read voltage as follows. PRS connector
Positive source Battery voltage
pin C
PRS INPUT VOLTAGE TEST
PROBES RESULT
PRS connector
Ground Battery voltage
pin A

rmr2008-033-016_d

10 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

If ground circuit is not good, check wiring from
PRS connector to VCM,refer to WIRING DIA-
GRAM. If no problem is found, carry out the VCM
GROUND CIRCUIT TEST, refer to VEHICLE CON-
TROL MODULE (VCM) in this subsection.
If ground circuit is good, carry out the PRS OUT-
PUT SIGNAL TEST that follows.
2. Disconnect the seat stay cylinder from the seat.
3. Open seat until a resistance is felt and support
in position.
4. Disconnect PRS connector. Access connector
through the hole in the battery cover.
5. Remove PRS retaining screws.

PRS Output Signal Test

1. Reconnect PRS connector and rotated it to the
horizontal position.
2. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and set it to Vdc.
3. Carefully insert the back probes in the PRS con-
nector as specified in the following table.
4. Turn ignition key to ON and read voltage as fol-
lows.
PRS OUTPUT SIGNAL TEST
PROBES CONDITION RESULT
No passenger
2.5 to
seated on rear
PRS PRS 4.14 Vdc rmr2013-033-006_b
position 1. PRS retaining screws
connector connector
pin B pin C Passenger
0.9 to PRS Installation
seated on rear
1.84 Vdc
position Reverse removal procedure.

WHEEL SPEED SENSOR (VSS)

rmr2011-082-004_a

TYPICAL - PRS OUTPUT SIGNAL TEST

1. PRS connector
2. Back probes

If voltage output is not good, replace PRS. rmr2013-033-007_a

If voltage output is good, carry out a CONTINUITY FRONT WHEEL SPEED SENSOR
TEST OF PRS SIGNAL WIRES to check wiring and
connectors between PRS sensor and VCM. Refer
to WIRING DIAGRAM for circuit details.

PRS Removal
1. Open seat.

rmr2013-033 11
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

If one of the sensor gauges does not respond to

wheel rotation, refer to VSS WIRING CONTINU-
ITY TEST.
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
035 868) and the FLUKE RIGID BACK PROBES
(P/N TP88).
4. Set multimeter to .
rmr2013-033-001_a 5. Measure wiring resistance as follows.
1. Rear wheel speed sensor
NOTICE To avoid damaging the connector,
Make sure that: probe only the terminal tip.
– Wheel sensors are securely fastened and un- VCM
damaged. SENSOR
SENSOR CONNECTOR MEASUREMENT
– Rear wheel speed sensor is properly adjusted. TERMINAL
PIN
– Front wheel sensor gap is the same (within 1 8
0.6 mm (.024 in) at 4 different places, 90° Front LH
apart. Otherwise, inspect components for 2 19
straightness and ensure wheels are properly 1 4
tightened. Close to 0
Front RH
2 16 (continuity)
VSS Test with B.U.D.S.
1 17
1. Connect vehicle to applicable B.U.D.S. ver- Rear
sion, refer to COMMUNICATION TOOLS AND 2 29
B.U.D.S. subsection.
If continuity test failed, repair wiring or
2. In B.U.D.S., select the following: connectors.
– Read Data button
If continuity test succeeded, try a new sensor.
– Monitoring page tab
If problem persists, try a new VCM.
– VCM page.
3. Lift each wheel one at a time and manually ro- VSS Adjustment (Rear Only)
tate wheel. 1. Lift rear of vehicle and support safely.
4. Look in B.U.D.S. to see if the corresponding 2. Rotate wheel to align a tooth of the encoder
sensor needle moves. wheel with the sensor.
3. Use a feeler gauge and measure the gap be-
tween the tooth and sensor.

rmr2011-082-001

Otherwise, perform the electrical tests.

12 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))
rmr2013-033-014_a
A. Gap
ENCODER WHEEL/SENSOR GAP
1.30 - 1.80 mm (.051 - .075 in)
Rotate wheel and repeat measurement at 4 differ-
ent places spaced of approximately 90° apart.
If measurement is out of specification, carry out
theVSS ADJUSTMENT PROCEDURE that fol-
lows.
NOTE: If gap measurement varies significantly
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
adding shims between the sensor and mounting
bracket.
1. Remove sensor retaining screw.
2. Remove sensor with spacer and shims.
3. Add or remove shims to obtain gap specifica-
tion.
4. Reinstall sensor and ensure the spacer is
against the sensor followed by the shim(s).
5. Tighten sensor retaining screw as specified.
WHEEL SPEED SENSOR
RETAINING SCREW TORQUE
10 N•m (89 lbf•in)
6. Lower vehicle to the ground.
7. Clear fault codes using B.U.D.S. as necessary.
rmr2013-033
VEHICLE CONTROL MODULE
(VCM)
rmr2013-033-015
TYPICAL
VCM Troubleshooting
A VCM failure is not likely to occur. These mod-
ules have proven to be very reliable. Prior to re-
placing a suspected VCM, take the following into
account.
The problem can be related to a hydraulic function,
check the following:
– Brake fluid level
– Brake line leaking, bent or pinched
– Brake caliper
– Master cylinder (including piston rod position).
The problem can be related to an electric function,
check the following:
– Fault codes
– VCM electrical connector. Refer to WIRING
HARNESS AND CONNECTORS subsection for
detailed information on the VCM connector
– Wiring harness condition.
NOTE: If pins or terminals are not clean, check
VCM harness connector seal condition and ensure
connector mechanism properly locks connector
seal against VCM.
Try disconnecting and reconnecting the VCM con-
nector to see if it “cures” the problem.
As a final test, try a new VCM without discon-
necting brake lines from the old VCM. Proceed as
follows:
IMPORTANT: Disconnecting brake lines would re-
quire the system bleeding.
1. Connect VCM connector to a new VCM.
13
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

2. Turn ignition switch ON. VCM Power Supply Pinout

NOTE: It is normal that some fault codes appear VCM CONNECTOR
at this time. FUNCTION
TERMINAL
3. If problem persists, the trouble is elsewhere. Power from ignition
28
4. If problem is now solved, the VCM in the vehi- switch
cle is faulty. Install the new VCM in the vehicle. Hydraulic pump power 1

WARNING Hydraulic valves power 25

Never ride a vehicle with a VCM temporarily Grounds 13 and 38
installed. Can high 26

VCM Connector Access Can low 14

WARNING
The VCM motor and valves are powered from
the battery when the key is to the ON posi-
tion. Always disconnect the battery prior to
disconnecting VCM connector.

Connector can be accessed from the front LH side

as illustrated.

rmr2013-033-017_a

VCM HARNESS CONNECTOR PINOUT

VCM Input Voltage Test

rmr2013-033-016_a
LH SIDE
1. VCM connector
2. Lower suspension arm
Refer to WIRING HARNESS AND CONNECTORS
subsection for procedures on how to disconnect
and reconnect the VCM connector.
NOTICE Follow procedures to avoid damage
to the connector housing and lock lever.
1. Refer to WIRING HARNESS AND CONNEC-
TORS subsection and disconnect VCM con-
nector.
2. Disconnect SAS connector.
3. Open the reusable locking tie that secure har-
ness to the chassis.
4. Gently pull VCM connector out of the chassis to
ease probing.
5. Use the FLUKE 115 MULTIMETER (P/N 529
035 868) and the FLUKE RIGID BACK PROBES
(P/N TP88).
6. Set multimeter to Vdc.
7. Turn ignition switch ON.
8. Test for input voltage as follows.
NOTICE To avoid damaging the connector,
probe only the tip of the terminal.
NOTE: Refer to VCM POWER SUPPLY PINOUT in
this subsection for pin identification.

14 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

VCM VCM
BATTERY VOLTAGE BATTERY VOLTAGE
CONNECTOR CONNECTOR
Pin 28 Ground Battery voltage Pin 13 Positive source
Battery voltage
Pin 38 Positive source

rmr2013-033-019_a

If voltage is not good, check wiring/connectors rmr2013-033-019_b

from battery through ignition switch to VCM har-
ness connector. Refer to WIRING DIAGRAM.
If voltage is good, test for input voltage as follows.
NOTE: Ignition switch can be either ON or OFF.
VCM
CONNECTOR
BATTERY VOLTAGE
Pin 1 Ground
Battery voltage
Pin 25 Ground
If voltage is not good, check wiring/connectors
from battery to VCM harness connector. Refer to
WIRING DIAGRAM.
If voltage is good, carry out the VCM GROUND
CIRCUIT TEST in this subsection.
VCM Ground Circuit Test
1. Use the FLUKE 115 MULTIMETER (P/N 529
035 868) and the FLUKE RIGID BACK PROBES
(P/N TP88).
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 pins 13, then 38 VCM connector with the
BLACK (COM) probe of the multimeter.
NOTE: Refer to VCM POWER SUPPLY PINOUT in
this subsection for pin identification.
If ground circuits are not good, check wiring from
VCM harness connector to chassis ground located
on the front part of the frame. Refer to WIRING
DIAGRAM.
If ground circuits are good, carry out the CAN LINE
RESISTOR TEST in this subsection.
VCM CAN Resistor Test
NOTE: The VCM contains a CAN line termination
resistor. If the resistor value is not correct, or the
resistor is open circuit, the VCM will not be able
to properly communicate with the other modules.
To check the CAN resistor within the VCM, carry
out the following steps.
1. Turn off ignition switch.
2. Open front storage compartment and remove
RH service cover.
3. Disconnect the ECM-B connector, refer to
ELECTRONIC FUEL INJECTION (EFI) subsec-
tion.
4. Measure VCM CAN resistor by probing at the
diagnostic link connector (DLC) as follows.
NOTICE To avoid damaging the connector,
probe only the terminal tip.

rmr2013-033 15
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

VCM CAN RESISTOR TEST NOTE: Before replacing the VCM, make sure
electrical and hydraulic systems are in good
DLC CONNECTOR MEASUREMENT condition, see VCM REPLACEMENT in this sub-
Pin 1 Pin 2 55 - 65 section.
1. Disconnect battery. Refer to CHARGING SYS-
If the resistance value is as specified, VCM CAN TEM subsection.
resistor and CAN lines are good. Replace VCM.
2. Refer to BODY subsection and remove the bot-
If the resistance value is NOT as specified, carry tom rear side panel.
out the VCM CAN LINE CONTINUITY TEST in this
subsection. 3. Disconnect longitudinal engine mount tie-rod at
both ends, then move it out of the way. Do not
5. Reconnect ECM connector. loosen adjuster lock nuts.
VCM CAN Line Continuity Test
Read wiring resistance between diagnostic link
connector and VCM.
NOTE: Refer to VCM POWER SUPPLY PINOUT in
this subsection for pin identification.
NOTICE To avoid damaging the connector,
probe only the terminal tip.
VCM CAN LINE TEST
CAN* PROBES RESULT
Diagnostic
VCM
link
High connector
connector
pin 26 Close
pin 1
to 0 rmr2013-006-001_a
Diagnostic (continuity)
VCM 1. Front longitudinal engine mount tie-rod end
link
Low connector
connector 4. Disconnect both steering inner tie-rod ends.
pin 14
pin 2
5. Using compressed air, clean:
* CAN: Serial data communication – The VCM and brake line fittings
If continuity is not good, check wiring and con- – The area around the VCM.
nectors from diagnostic link connector (DLC) to 6. Use BRP HEAVY DUTY CLEANER (P/N 293 110
VCM connector. Refer to applicable WIRING DI- 001) to thoroughly clean the parts. Blow com-
AGRAM. pressed air again and thoroughly dry the parts.
If everything tested good and VCM does not work, NOTE: Disconnect brake lines from the old VCM
try a new VCM. only just prior to installing the new VCM. The
shorter the time the brake lines are open, the
VCM Removal lesser the possibility of brake system contamina-
tion.
WARNING
7. Disconnect VCM connector.
Cleanliness is critical when working with the
VCM and brake lines. All precautions must be 8. Disconnect brake lines.
taken to prevent any foreign particle from en- 9. Remove VCM from frame.
tering the brake system. 10. Pull assembly out of position to dislodge
grommet.

16 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

5. Tighten steering tie-rod ends to 85 N•m

(63 lbf•ft).
6. Make sure the VCM connector is properly in-
stalled and locked.
7. Reset the YRS. Refer to YAW RATE SENSOR
(YRS) in this subsection.
8. Bleed the VCM, refer to VCM BLEEDING pro-
cedure that follows.

VCM Bleeding
WARNING
Brake bleeding must be performed to remove
any air trapped in the brake system. Refer to
rmr2013-033-020_a
BRAKES subsection.
TYPICAL

11. Pull grommet out of VCM support and pull out After bleeding, refer to DIAGNOSTIC AND FAULT
VCM towards the LH side of vehicle. Discard CODES and do the following:
grommet. – Check and clear fault codes.
– Clear LPS fault (if occurred).
VCM Installation – Reset SAS.
NOTE: Keep the protective plugs on new VCM – Reset VCM variant if VCM is used.
until brake line installation.
Reverse removal procedure. However, pay atten-
tion to the following:
Install NEW grommet.
1. Remove protective plugs from VCM brake line
ports.
2. Make sure to reinstall brake lines as illustrated.

rmr2013-033-021_a

1. To LH front brake caliper

2. To RH front brake caliper
3. To rear brake caliper

3. Tighten VCM mounting screws to 7 N•m

(62 lbf•in).
4. Tighten longitudinal engine mount tie-rod to
48 N•m (35 lbf•ft).
rmr2013-033 17
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

STEERING (DPS) AND FRONT WHEELS

SERVICE TOOLS
Description Part Number Page
ALIGNMENT BAR ......................................................................... 529 036 265 ............................................. 6
ALIGNMENT BAR ......................................................................... 529 036 266 ............................................. 6
BALL JOINT INSTALLER............................................................... 529 035 975 ........................................... 41
BEARING PUSHER/REMOVER ..................................................... 529 036 095 ........................................... 42
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................................... 30
MAGNET SOCKET ........................................................................ 529 036 178 ............................... 31, 36, 38
PITMAN ARM JIG ......................................................................... 529 036 225 ..................................... 36–37
PITMAN ARM LOCKING TOOL .................................................... 529 036 228 ......................................... 6, 9
PITMAN ARM PULLER ................................................................. 529 036 227 ........................................... 36
PITMAN ARM PUSHER ................................................................ 529 036 226 ........................................... 37

SERVICE PRODUCTS
Description Part Number Page
CABLE LUBRICANT ...................................................................... 293 600 041 ..................................... 17, 24
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 32
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ........................................... 37
XPS SYNTHETIC GREASE............................................................. 293 550 010 ............................... 28–29, 35

rmr2013-034 1
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

7 N•m
(62 lbf•in) RT-STD, RT-S, RT-LTD
38 N•m
(28 lbf•ft)
7 N•m
(62 lbf•in)
10 N•m 2.5 N•m
(89 lbf•in) (22 lbf•in)

2 N•m
(18 lbf•in)
XPS synthetic grease RS-STD, RS-S
10 N•m
(89 lbf•in)
25 N•m
(18 lbf•in)

NEW

XPS synthetic grease

XPS synthetic grease

43 N•m ST, ST-S, ST-LTD
(32 lbf•ft)
28 N•m
(21 lbf•ft) NEW
NEW 63 N•m
(46 lbf•ft)
NEW
Loctite 767
(antiseize lubricant)

NEW

63 N•m
(46 lbf•ft)

NEW = Component must be replaced when removed.

rmr2013-034-102_a

2 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

RT-LTD, ST-LTD

RS-S, ST-S

RS, ST

RT, RT-S

165 N•m
(122 lbf•ft)
NEW

105 N•m
(77 lbf•ft)

rmr2013-034-101_a

rmr2013-034 3
Subsection XX (STEERING (DPS) AND FRONT WHEELS)
GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed, must be
replaced (e.g.: locking tabs, elastic stop nuts,
cotter pins, etc.).
NOTICE Hoses, cables, or locking ties re-
moved during procedure must be reinstalled
as per factory standards.
SYSTEM DESCRIPTION
(FEATURES)
The Dynamic Power Steering (DPS) provides
a computer controlled, variable power assist,
achieved by an electric motor to optimize the
amount of steering input required by the rider.
rmr2010-034-002 _a
1. Dynamic power steering (DPS)
The DPS uses the following parameters:
– Battery voltage
– Engine RPM
– Vehicle speed
– Torque sensor
– Steering angle sensor.
The amount of steering assist provided is depen-
dent on the handlebar effort (steering torque),
steering angle and the vehicle speed.
4 rmr2013-034
The greater the handlebar effort (steering torque),
the greater the assist will be.
The slower the vehicle speed, the greater the as-
sist will be.
When the vehicle is operated in reverse, power
steering assist will decrease as vehicle speed in-
creases.
NOTE: If available electrical power is limited due
to low battery amperage or excessive electrical
system loads that reduce available voltage to the
DPS, steering assist will be reduced.
SYSTEM DESCRIPTION
(COMPONENTS)
DPS Unit
The DPS unit is a self contained unit that includes
the steering gear, the DPS module, the DPS mo-
tor, the steering angle sensor and the torque sen-
sor.
rmr2008-019-016_a
TYPICAL - DPS UNIT
1. DPS motor
2. Steering angle sensor
3. DPS module and torque angle sensor (internal)
The DPS module provides amperage to the motor.
The amount and duration of that amperage is de-
termined by the inputs to the DPS module.
The direction in which the motor turns is changed
by reversing the polarity of the electrical power
applied to the motor.
The DPS motor does not "spin", but rather turns in
very small increments based on the amount, du-
ration, and polarity of the DC power delivered by
the DPS module.
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

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. rmr2008-019-023_a

TYPICAL - STEERING ANGLE SENSOR

Steering Torque Sensor
The SAS determines the angle of the front wheels
in relation to the fore and aft centerline of the ve-
hicle. It provides a direct reading to the DPS and
VCM of the handlebar position in relation to the
vehicle.

SENSOR RESET
When adjusting or replacing the following parts or
sensors, the steering angle sensor and/or steering
torque sensor must be reset (re-zero) for proper
steering and VSS system operation.

rmr2008-019-017

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. Inside 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.

rmr2013-034 5
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

PART ADJUSTED OR HARDWARE

WHAT TO DO
REPLACED
An alignment bar: A 183 cm (6 ft)
– DPS unit carpenters level or equivalent straight
– Steering column edge such as a 2" x 2" square tubing.
The length is important to make proper
– Steering column measurements.
support
– Pitman arm 2 steel spacer bars: flat bars of 127 mm (5 in) x
– Tie rod 1. Carry out an SAS 25 mm (1 in) x 6 mm (1/4 in). Drill hole of 8 mm
RESET (5/16 in)diameter, 9 mm (.354 in) from the end of the
– Tie rod end bar
2. Carry out a TORQUE
– Knuckle SENSOR RESET
– Wheel bearing 2 Jack stands
– Ball joint 2 M8 X 130 mm long bolt with 2 washers and 2 nuts
– Front suspension arm 6 M18 elastic stop nuts or equivalent spacers
(lower/upper)
– Steering alignment
Procedure
– Steering Angle Sensor Carry out an SAS RESET
1. Place vehicle on a level surface.
(SAS)
2. Apply the parking brake.
3. Remove front storage compartment.
ADJUSTMENT
4. Lift the front of vehicle.
STEERING ALIGNMENT 5. Properly support vehicle on frame extension us-
VERIFICATION ing jack stands.

Required Items WARNING

SERVICE TOOLS Make sure the vehicle is securely supported
and stable.
The PITMAN ARM LOCKING TOOL (P/N 529 036
228)
A computer with the latest version of the applicable
B.U.D.S. software
ALIGNMENT BAR (P/N 529 036 265) for RS and ST
Models (quantity = 2)
ALIGNMENT BAR (P/N 529 036 266) for RT Models
(quantity = 2)

SHOP TOOLS
2 C-clamps or locking pliers (for attaching alignment
bar to spacer bars)
A magnetic dot laser (avoid using line lasers due
to lack of precision)
A measuring tape
Open end wrenches rmr2013-034-301_a

INSTALL JACK STANDS TO THESE LOCATIONS

6. Disconnect front fender position light.

7. Remove each front fender.

6 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

rmr2013-034-030_a rmr2008-028-002_a

1. Retaining bolts securing fender support to wheel TYPICAL

1. Lug nuts
2. M18 elastic stop nuts (as spacers)
8. Remove the front wheels.
9. Remove shocks and install appropriate align- 11. On RT models
ment bars. 11.1 Remove retaining nut from side panel
support.

rmr2013-034-073_c
rmr2013-034-014_a
REMOVE SHOCK AND REPLACE WITH ALIGNMENT BARS
1. Retaining nut
NOTE: Use previously removed nuts during 11.2 Remove side panel support to access
shock removal to install alignment bars. Finger push nut.
tighten nuts.
NOTE: Using the proper alignment bars for each
model is critical to obtaining a proper alignment.
10. Secure both brake discs to wheel hubs using
lug nuts and spacers (M18 elastic stop nuts).

rmr2013-034-015_a

1. Push nut

rmr2013-034 7
Subsection XX (STEERING (DPS) AND FRONT WHEELS)
11.3 Remove push nut, retaining screw and
washer.
NOTE: This push nut is used for factory op-
erations only and does not need to be rein-
stalled.
12. Remove plastic rivets securing bottom plate to
vehicle.
rmr2013-034-012_a
LH SIDE SHOWN
1. Plastic Rivets (All models)
2. Lower plastic rivets (RT Models only)
rmr2013-034-013_a
RH SIDE SHOWN
1. Plastic rivets (All models)
2. Lower plastic rivets (RT Models only)
13. Gently pull on bottom plate to unclip it from
sub frame bar.
8 rmr2013-034
rmr2013-034-300_a
1. Sub frame bar
2. Bottom plates
14. Using an M8 bolt with proper length, from the
right side assemble the bolt with a washer
and the space bar, pass the bolt through the
frame where both plastic rivets were previ-
ously removed, to the left side and secure
with washer and nut.
rmr2013-034-307_a
LH SIDE SHOWN
1. Nut
2. Space bar
NOTICE To avoid damaging the brake lines,
ensure the nut and washer are behind the
brake lines before passing the bolt through the
frame.
NOTE: Ensure spacers are straight (vertical) to
avoid erroneous measurements.
15. Install the second spacer bar where the other
plastic rivets were removed.
16. Mark alignment bar at its center.
17. 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).
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

rmr2013-034-305_a

TYPICAL - PARTS REMOVED FOR CLARITY

1. DPS unit
2. Pitman arm locking tool
3. Pitman arm
rbs2010-016-024_b

FRAME TOP VIEW

1. Imaginary line between front axles
2. Edge of frame
3. Alignment bar

18. Ensure alignment bar is parallel with the frame

(left/right) by visually inspecting from the front.
Adjust bar and clamps as required.
19. 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.
NOTE: The reference points must be the same on
each side.
rmr2011-034-013_a

1. Pitman arm locking tool

2. Pitman arm
3. C-clamp pliers
4. DPS unit

21. Finger tighten the locking tool screws.

NOTICE Do not overtighten. Overtightening
screws can cause damage to the DPS housing.
22. Measure the handlebar position again to make
sure it did not move during pitman arm locking
tool installation.
23. Install the magnetic laser on a brake disc.
rmr2011-083-001_a

1. Handlebar extremity
2. Fixed point at rear

MAXIMUM DIFFERENCE BETWEEN

MEASUREMENTS
3 mm (1/8 in)

20. Install the PITMAN ARM LOCKING TOOL

(P/N 529 036 228).
20.1 Place the locking tool over the pitman
arm.
20.2 Secure locking tool on the pitman arm us-
ing a C-clamp or locking pliers.

rmr2013-034 9
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

NOTE: Measuring tape must be held perpendicu-

lar to the alignment bar to obtain a precise mea-
surement. Move the tape end back and forth in
the laser light until the shortest distance is read.
When the shortest distance is read, the tape is
perpendicular to the bar. Note the lowest mea-
surement.
26. Starting from one side, measure both front
and rear then go to the other side and take
the same measurements. Note these mea-
surements in the appropriate spaces in the
alignment reference chart.

rmr2013-034-016_a

TYPICAL
1. Magnetic laser level

24. In order to increase the precision of your mea-

surement follow the next steps to align the
laser dot at the correct height of your align-
ment bar.
24.1 From the front, measure the height of the
top end of your alignment bar from the
ground. rmr2013-034-304_a

TYPICAL - FRONT MEASUREMENT SHOWN

24.2 Move your tape in front of the laser and 1. End of alignment bar
move the laser to match the appropriate 2. Laser line
height. F. Front distance

rmr2013-034-303_a

rmr2013-034-304_b TYPICAL - REAR MEASUREMENT SHOWN

1. End of alignment bar 1. Rear end of alignment bar
2. Laser line 2. Laser line
R. Rear distance
24.3 You will need to repeat this procedure
when taking the rear measurements. 27. Refer to the following chart for alignment
specification.
25. Starting on one side, measure front and rear
distances between alignment bar and laser
level line. Retake measurements 3 times
while rotating disc 1/3 of a turn. This step
is to compensate for any minor disc brake
warpage.
IMPORTANT: Measure at the ends of the align-
ment bar. Failure to measure from the end of the
bar will reduce the accuracy of this procedure.

10 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

ALIGNMENT VERIFICATION
Measurements LH RH Customer:
F1 (Front 1) Unit VIN:
F2 (Front 2) Unit Mileage:
F3 (Front 3) Technician:
Front Avg
(F1+F2+FR3)
____________
3
R1 (Rear 1)
R2 (Rear 2)
R3 (Rear 3)
Rear Avg
(R1+R2+R3)
___________
3
Difference
(Rear Avg -
Front Avg)
Alignment
(LH Diff + RH
Diff)

Alignment
Verification All models Alignment = 0 mm ± 5 mm (0 in ± .2 in)
Specification

NOTE: If
alignment
is within
specification,
no alignment
needed.

If alignment
is NOT within
specification,
proceed
with steering
alignment.

rmr2013-034 11
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

STEERING ALIGNMENT
STEERING ALIGNMENT PROCEDURE
SPECIFICATION
All models

Rear distance - Front

distance = 0 mm ± .5 mm
(0 in ± .02 in) Each side is
independent and
in reference to the
alignment bar.
rmr2013-034-010_a
1. Hold the tie-rod with an open end wrench (on TYPICAL
the flat portions of the tie rod) and loosen the 1. Tie-rod
lock nut at each tie-rod end. 2. Tie-rod lock nut (one per tie-rod end)

2. To set alignment of each wheel: 3. Ensure each tie-rod end is perpendicular (90°)
2.1 Adjust the tie-rod length by turning it until to its stud after lock nuts are tightened.
proper alignment specification is obtained.
NOTE: For the left side inner nut, use a
18 mm (11/16 in) crow-foot with an exten-
sion to loosen the lock nut. Be careful not
to bend or move the VCM brake lines.
NOTICE Be careful not to scratch the tie-
rod. Electrical tape may be used to protect
tie-rod.
2.2 Torque outer tie-rod lock nut to spec.
2.3 Torque the inner tie-rod lock nut to specifi-
cation after, it is not necessary to hold the
tie-rod at this point, simply twist the tie-rod
in the direction you are tightening the lock
nut.
TIGHTENING TORQUE rbs2010-016-25_a

Tie-rod lock nut 34 N•m (25 lbf•ft) TYPICAL

1. Tie rod end housing
2. Stud

4. Recheck alignment.
5. Carry out the following, see procedures in this
subsection prior to reassembling vehicle:
– SAS RESET
– TORQUE SENSOR RESET.
NOTE: Do not remove the PITMAN ARM LOCK-
ING TOOL, it is required for the SAS reset.
6. Reinstall all removed parts. However pay atten-
tion to the following.
TIGHTENING TORQUE
Shock retaining nut 48 N•m (35 lbf•ft)

12 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

SAS RESET
Make sure tire pressure is as specified.
COLD TIRE PRESSURE RECOMMENDATION
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.) rmr2010-034-014_a

STEERING ANGLE SENSOR RESET

in front of the vehicle.
– By pushing the rear of the vehicle, move the
vehicle forward (approximately 3 m to 6 m
(10 ft to 20 ft)) to confirm that wheels are
straight. The vehicle should roll straight with-
out veering off to the right or left.
– Repeat until wheels are straight ahead.
Step 1: Choose Setting tab
Step 2: Select VCM tab
Step 3: Click on Reset Steering Angle button
TORQUE SENSOR RESET
If steering alignment has just been done, remove
pitman arm locking tool.
1. Place the handlebar as straight as possible.
NOTE: Make sure there is nothing resting on,
pulling or touching handlebars.
2. Connect vehicle to the applicable B.U.D.S. soft-
ware, refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection.
3. Select the Setting and DPS tabs.
NOTE: If the "0 torque" is difficult to obtain and re-
peat, inspect steering system for excessive fric-
tion (ball joints and tie-rod ends).

rbg2010-006-006_a

1. Start and stop engine 5 times.

2. Without moving vehicle or handlebar or sitting
on vehicle, connect vehicle to the appropriate
B.U.D.S. software, refer to COMMUNICATION
TOOLS AND B.U.D.S. subsection.
rmr2011-034-006_b
3. Select the Setting and VCM tabs. 1. 0 Torque
4. Click on the Reset Steering Angle button.
4. Click on Reset Torque Offset button.

rmr2013-034 13
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

TROUBLESHOOTING jectory, the VCM will compare these values for a

short distance then generate several codes and
DPS STRATEGY ACCORDING TO set the vehicle in limp home mode.
FAULTS To resolve this, the wheels must be positioned ab-
solutely straight while the SAS is reset. Refer to
FAULT DPS BEHAVIOR SAS RESET in this subsection.
SAS (steering If fault code C0051 reappears SAS reset proce-
angle sensor) dure has been strictly followed, the SAS should
YRS (yaw rate Limp home mode is set. be replaced.
sensor)
VSS
FAULT CODE P0551 FOLLOWING
NEW DPS INSTALLATION
ECM fault
(GBPS) Limp home mode is set. Fault code P0551 may become active following a
DPS reflash if a torque sensor reset was not done.
DPS
Reflash DPS unit and proceed with a torque sen-
When battery voltage is lower than sor reset.
11.5 V, steering assist will gradually
Low battery
decrease. If battery voltage is
voltage PROCEDURES
below 8 Vdc, no steering assist will
be available.
FRONT WHEELS
NOTE: Steering assist will resume on restart if
there are no more active fault codes. Front Wheel Removal
1. Place the vehicle on a level surface.
FAULT CODE C0051 AFTER DPS 2. Apply parking brake.
REPLACEMENT OR SAS RESET 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.

CAUTION Do not hold the front wheel

spoke while attempting to spin the front wheel
rdd2011-001-001 as your fingers may be caught between the
wheel and the brake caliper.
Fault code C0051 may become active and other
fault codes "occurred" if front wheels were not Front Wheel Installation
straight during SAS reset. 1. The installation is the reverse of the removal
NOTE: Depending on riding conditions, it may procedure.
take up to 50 km to trip this fault code after a SAS 2. Tighten wheel lug nuts to 105 N•m (77 lbf•ft).
reset.
Although all the codes relate to the SAS, the FRONT TIRES
C0051 code has triggered the others.
The C0051 code is triggered by a discrepancy be- Front Tire Inspection
tween the SAS (steering angle sensor) and the 1. Check tire pressure. Check for air leaks (hissing
YRS (yaw rate sensor). sound) caused by a puncture, an ill-fitting rim, or
If the vehicle is moving straight ahead and SAS a faulty tire valve.
data shows a steering angle of ± 2.0° or more 2. Check tire for:
while the YRS shows a 0 degree (straight) tra- – Cuts
– Slits
– Cracks.

14 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)
3. Check sides of tire for:
– Bumps
– Bulges
– Nails
– Other foreign objects.
4. Check for minimum tread depth by using the
tread-wear indicators. Check in three locations
across the tire's tread:
– Outer edge
– Center
– Inside edge.
The tread-wear indicators will appear across the
treads that have been worn down to the minimum
tread depth. When at least one tread-wear indi-
cator appears across the tread, have the tire re-
placed as soon as possible.
rmo2008-001-041_a
1. Tread-wear indicator
A. Appropriate tread depth
B. Minimum tread depth, replace tire
It is normal to see uneven wear on tires depend-
ing on how the vehicle is driven and road condi-
tions. The front tires outer or inner tread edges
will wear unevenly depending on if the vehicle is
driven smoothly or aggressively.
Front Tire Rotation
Rotate front tires when tread depth reaches 4 mm
(5/32 in). This will maximize tire life.
WARNING
The tires are designed to rotate only in one
direction. Do not switch the left and right
front wheels. The tires must be dismounted
from the wheels for tire rotation. If a tire is
mounted on the incorrect side, you will have
less traction and could lose control.
rmr2013-034
Front Tire Replacement
WARNING
The VSS on the vehicle has been calibrated
to perform best with a tire of a specific size,
material, and tread pattern. Replacing a tire
with one not approved by BRP can cause the
VSS to be ineffective.
To replace a front tire, carry out the following
steps:
1. Remove front wheel from the vehicle. Refer to
FRONT WHEELS in this subsection.
2. Using an automotive tire changer (rim clamp
type), remove the old tire and install the new
one.
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
tire changer operation.
3. Remove the old balancing weight(s) from the
rim.
4. Clean the inner side of wheel with alcohol to
remove grease and dust.
5. Balance wheel using a wheel balancer.
NOTE: Refer to manufacturer's instructions for
wheel balancer operation.
6. Install new balancing weight(s) inside wheel.
Position them in the center of the flat inner sur-
face of the rim.
NOTICE Improperly positioned weights can
cause interference with the lower ball joint
stud.
7. Reinstall wheel. Refer to FRONT WHEELS in
this subsection.
WARNING
When installing new tires, always observe
a break-in period of 300 km (200 mi). During
this time, the tires and the VSS will not oper-
ate at their maximum efficiency. You could
lose control and crash – use extra caution.
15
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

HANDLEBAR GRIP
NOTE: This vehicle uses heated handlebar grips.
The LH grip may be replaced on its own however,
the RH grip must be replaced with the throttle
handle assembly, that includes the TAS (throttle
accelerator sensor).

LH Handlebar Grip Removal

1. Remove handlebar end cap retaining screw,
and remove end cap from handlebar.
rmr2013-034-034_a

TYPICAL
1. Retaining screws
2. Tube retaining clamp
3. Handlebar tube

5. Remove the heated grip wire harness from the

retaining clip in the handlebar.

rmr2013-034-041_a

TYPICAL
1. End cap retaining screw
2. Handlebar end cap
3. Heated grip
4. Grip retaining screws (2)

2. Slightly pull back the raised shoulder of the rub-

ber grip near LH multifunction switch, and re-
move the two grip retaining screws.

rmr2013-034-035_a

LH HANDLEBAR, LOWER COVER REMOVED

1. Handlebar
2. Multifunction switch
3. Retaining clip

6. Remove the required body parts to access elec-

trical connectors for the heated grip. Refer to
BODY subsection.
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.
7. Disconnect the LH heated grip connector.
rmr2013-034-036_a

1. Grip retaining screws (2)

3. Remove the lower cover under the LH handle-

bar.
4. Remove the handlebar tube clamp and remove
the tube from the handlebar.

16 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

LH Handlebar Grip Installation

1. 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-
vided in 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).
2. Position the grip on the handlebar tube with the
heater wires properly aligned with the groove in
rmr2013-034-037_a the handlebar tube.
1. LH heated grip connector
2. RH heated grip connector

8. Cut the locking-tie that secures the wire har-

ness at the front of the upper frame member.
9. Attach a string of approximately 1.25 m (4 ft) to
the wire harness to help feed the wires on the
new grip through the upper frame member, and
rubber seal under handlebar.
10. Pull the wire harness up to the handlebar.
11. Untie the feed string from the wire harness.
12. Remove the connector housing from the rmr2010-034-009_a
heated grip wiring. SM5 MODEL ILLUSTRATED, CLUTCH LEVER INSTALLED
13. As you pull the grip off the handlebar, feed 1. Groove for heater wiring
the grip electrical wires through the handlebar 3. Carefully insert the heated grip over the tube
tube. and simultaneously pull the wire harness
NOTE: To facilitate removal of the wire harness through the groove provided in the tube.
from handlebar tube, spray a light coat of CABLE 4. Push the heated grip in until the retaining screw
LUBRICANT (P/N 293 600 041) in the groove pro-
holes in the grip align with the holes in the han-
vided in the handlebar tube. Align the connector dlebar tube.
pins end to end to route them through the multi-
function switch housing and clutch lever housing 5. Install the two grip retaining screws. Torque
(SM5 only). It is not necessary to remove the mul- screws to 2.5 N•m (22 lbf•in).
tifunction switch and clutch lever housings from 6. Install the handlebar grip cap and torque retain-
the handlebar tube. ing screw to 7 N•m (62 lbf•in).

rmr2013-034-041_a

1. Cap retaining screw

2. Handlebar end cap
rmr2013-034-039_a 3. Heated grip
TYPICAL - LH HEATED GRIP WIRE ROUTING 4. Grip retaining screws (2)
1. LH multifunction switch (cover removed)
2. Brake lever housing (SM5 only)

rmr2013-034 17
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

7. Install the handlebar tube on the handlebar and

finger tighten retaining screws at this time.
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.

rmr2010-034-017_a

1. Multifunction switch to handlebar contact

9. Torque the tube retaining clamp to 10 N•m

(89 lbf•in).
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.
rmr2010-034-016_a

TYPICAL
1. Location pin in retaining clamp
2. Oblong location hole in handlebar tube

rmr2010-034-035_a

TYPICAL - HANDLEBAR TUBE CLAMP

1. Torque screws indicated by this arrow first
rmr2013-034-042_a

1. Notch facing alignment pin
8. Push the handlebar tube in until the multifunc-
tion switch makes contact with the handlebar.
10. Attach the feed string to the heated grip wire
harness.
11. Using the feed string, pull the wires through
the upper frame member.
12. Install heater wires in the connector housing
as per following table.

18 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

LH FRONT HEATED GRIP WIRE CONNECTIONS

WIRE PIN NUMBER
Light green/white pin 1 (FLH-1)
Light green/blue pin 2 (FLH-2)
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. Insert the heated grip and multifunction
switch harnesses in the retaining clip pro-
vided in the handlebar. rmr2013-034-035_b

1. Handlebar tube
15. Install the LH handlebar cover. Apply 1 N•m 2. Retaining clamp
(9 lbf•in) to the 4 retaining screws. 3. Handlebar

16. Install a new locking-tie to secure wire har-
ness at front of upper frame member.
17. Install console, refer to BODY subsection.
18. Start engine and test heated grip for proper
operation.
19. Install all removed body parts, refer to BODY
subsection.
MULTIFUNCTION SWITCH (LH)
LH Multifunction Switch Removal
1. Remove the screws that secure the multifunc-
tion switch cover.
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
the handlebar tube to mark the position of the
clutch lever housing. It will be used to properly
reposition the clutch lever housing on the han-
dlebar tube for installation.

rmr2010-034-018_a

1. Ink reference line (clutch housing position)

2. Handlebar tube
3. Clutch housing
4. Clutch master cylinder
5. LH multifunction switch

rmr2011-083-003_a
TYPICAL
1. Cover to switch retaining screws
2. Cover to handlebar retaining screw (if applicable)
2. Separate the cover from the multifunction
switch housing.
3. Remove the lower cover on the LH handlebar.
4. Remove the handlebar tube from the handlebar
by removing its retaining clamp.
7. Remove the clutch housing from the handlebar
tube.
All Models
8. Remove the multifunction switch housing from
the handlebar tube.
NOTE: If replacing multifunction switch assem-
bly, continue with the following steps.

rmr2013-034 19
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

9. Remove the console assembly for access to

the multifunction switch connectors. Refer to
BODY subsection.
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.

rmr2010-034-019 _a

TYPICAL - LH MULTIFUNCTION SWITCH COVER

1. Alignment pin

rmr2010-034-010_a

1. Connector location for LH multifunction switch

11. Attach a string of approximately 1.25 m (4 ft)

to the wire harness to help feed the new wires
though.
12. Remove the multifunction switch wire har-
ness from the upper frame member leaving
the feed string in its place.
rmr2013-034-035_c

LH Multifunction Switch Installation 1. Handlebar hole

The installation is the reverse of the removal pro-
4. Install the multifunction switch cover.
cedure. However, pay attention to the following
items. NOTICE When installing the multifunction
1. Slide the multifunction switch housing onto the switch cover, ensure its alignment pin (or
handlebar tube. screw hole protuberance) is inserted in the
hole provided in the handlebar tube. Ensure
SM5 Model wire harness exits the switch housing through
2. Position clutch lever housing on the handlebar the opening provided in the cover.
tube using the reference line, and install its re-
taining clamp. 5. Torque retaining screws to 1 N•m (9 lbf•in) in
the following sequence:
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.

20 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

12. Install all removed body parts, refer to the

BODY subsection.

MULTIFUNCTION SWITCH (RH)

RH Multifunction Switch Removal
1. Remove the retaining screws from the RH mul-
tifunction switch cover.

rmr2011-083-003_b

TYPICAL - RETAINING SCREWS TIGHTENING SEQUENCE

6. Attach the feed string to the wire harness and

carefully pull the wires though the upper frame
member.
NOTICE Ensure proper routing of wire har-
ness through the handlebar and upper frame
member to prevent pinching, chaffing or other
wire damage. rmr2011-083-003_a

TYPICAL
7. Secured harness in the retaining clip within the 1. Cover to switch retaining screws
handlebar. 2. Cover to handlebar retaining screw (if applicable)

2. Remove the multifunction switch cover.

3. Remove the RH handlebar cover.
4. Remove the 2 screws that secure the multi-
function switch housing to the throttle handle.

rmr2013-034-035_a

1. Handlebar
2. LH multifunction switch
3. Harness retaining clip

8. Secure wiring harness to the front frame mem-

ber using a locking-tie as per factory specifica-
tion.
rmr2013-034-044_a
9. Ensure wire harness does not hinder handlebar
1. Throttle handle
movement by turning handlebar in both direc- 2. RH multifunction switch housing
tions. 3. Retaining screws (2) for the multifunction switch housing

10. Install console, refer to BODY section. 5. Remove the multifunction switch housing from
11. Test multifunction switch controls for proper the throttle handle, and its wiring harness from
operation of applicable systems. the retaining clip within the handlebar.

rmr2013-034 21
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

NOTE: If replacing multifunction switch assem-

bly, carry on with following steps.
6. Remove the console assembly for access to
the multifunction switch connector. Refer to
BODY subsection.
7. Disconnect the RH multifunction switch con-
nector.

rmr2010-034-024_a

1. Throttle handle location pin

rmr2010-034-010_a

1. Connector location for RH multifunction switch

8. Cut the locking-tie that secures the wiring har-

ness at the front of the upper frame member.
9. Attach a string of approximately 1.25 m (4 ft) to rmr2010-034-027_a
the wire harness to help feed the new wires 1. Location hole in multifunction switch housing
though the upper frame member.
10. Remove the harness from the frame and han- 2. Install the two screws that retain the multi-
dlebar leaving the feed string in its place. function switch housing to the throttle handle.
Torque screws to 1 N•m (9 lbf•in).
RH Multifunction Switch Installation
Installation is the reverse of the removal proce-
dure. However, pay attention to the following.
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 housing that
must be inserted in a hole provided in the multi-
function switch housing.

rmr2013-034-044_b

1. Throttle handle
2. RH multifunction switch housing
3. Switch housing retaining screws (2)

3. Hold multifunction switch cover over the switch

housing.

22 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)
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.
rmr2013-034-045_a
1. Location hole for multifunction switch in handlebar tube
NOTE: When the multifunction switch housing is
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.
rmr2010-034-026_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 (9 lbf•in)
NOTICE When installing the multifunction
switch cover, torque the lower retaining screw
first. Ensure wire harness exits the switch
housing through the opening provided.
rmr2013-034
rmr2011-083-003_b
TYPICAL - RETAINING SCREWS TIGHTENING SEQUENCE
6. Carefully rotate throttle handle through its full
range of motion, then release to ensure proper
operation.
WARNING
Always test throttle handle operation. Throt-
tle handle must rotate smoothly and without
restriction through it full range of motion,
and return freely to its idle position when
released.
If throttle does operate smoothly without restric-
tion, or does not return freely to idle position, re-
fer to THROTTLE HANDLE INSTALLATION in this
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.
NOTICE 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
using a locking-tie.
9. Reconnect the multifunction switch connector.
10. Install the handlebar cover and torque screws
to 1 N•m (9 lbf•in).
11. Ensure wiring harness does not hinder handle-
bar movement by turning handlebar in both di-
rections.
12. Install the console, refer to BODY subsection.
13. Test multifunction switch controls for proper
operation of applicable systems.
23
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

14. Install all removed body parts, refer to the 5. Remove the console assembly for access to
BODY subsection. the heated grip connector and the TAS con-
nector (Throttle Accelerator Sensor). Refer to
THROTTLE HANDLE BODY subsection.
6. Disconnect the RH heated grip.
Throttle Handle Removal
1. Remove the RH multifunction switch from the
throttle handle. Refer to RH MULTIFUNCTION
SWITCH REMOVAL in this subsection.
2. To remove throttle handle, remove the items
listed in the following illustration.

rmr2013-034-037_a

1. LH heated grip connector

2. RH heated grip connector

7. Disconnect the TAS connector.

rmr2010-034-028_a

TYPICAL - RH THROTTLE HANDLE REMOVAL

1. End cap screw
2. throttle handle return spring
3. Return spring sleeve
4. End cap

3. Remove the RH handlebar tube retaining clamp

and remove the tube from the handlebar.

rmr2010-034-010_a

1. TAS connector location

8. Cut the locking-tie that secures the wiring har-

ness at the front of the upper frame member.
9. Attach a string of approximately 1.25 m (4 ft) to
rmr2010-034-022_a
the wire harness to help feed the new wires
TYPICAL
1. Harness retaining clip though.
2. RH multifunction switch
3. RH handlebar tube 10. Remove the harness from the handlebar and
4. Handlebar tube clamp frame leaving the feed string in its place.
4. Pull the heated grip wiring from the groove in Throttle Handle Installation
the handlebar tube as you remove the throttle
handle from the handlebar tube. 1. Spray a light coat of CABLE LUBRICANT (P/N 293
600 041) in the groove provided in the handlebar
NOTE: If replacing throttle handle, carry on with tube for the heated grip wiring harness.
the following steps.
2. Align the throttle handle and heated grip wire
harness with the groove in the handlebar tube.

24 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

3. As you slide the throttle handle on the han-

dlebar tube, carefully pull the wire harness
through the groove in the handlebar tube.
4. Ensure heated grip wiring is properly positioned
in line and in the groove provided in the handle-
bar tube.
WARNING
Ensure heated grip wiring is not wrapped
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.

rmr2010-034-029_a

1. Hole in throttle handle

2. Slot in handlebar

6. Insert the plastic sleeve in the throttle return

spring, then insert the spring and sleeve in the
throttle handle.

rmr2010-034-023_a

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
slot at the end of the handlebar tube.

rmr2010-034-030_a

1. Plastic sleeve
2. Return spring

NOTE: A small hole inside the throttle handle is

provided for inserting the pointed end of the re-
turn spring, and a slot is provided in the handlebar
tube for anchoring the folded end of the spring.

rmr2013-034 25
Subsection XX (STEERING (DPS) AND FRONT WHEELS)
rmr2010-034-031_a
1. Pointed end of spring in hole (not visible)
2. Folded end of spring in handlebar tube slot
7. As you hold the throttle handle steady, install
the handlebar end cap to hold the assembly
in place. Torque retaining screw to 1 N•m
(9 lbf•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 MULTIFUNCTION SWITCH
INSTALLATION in this subsection.
10. Carefully rotate the throttle handle a few times
through its full range of motion to ensure it
turns freely.
WARNING
Always test throttle handle operation. Throt-
tle handle must rotate smoothly and without
restriction through it full range of motion,
and return freely to its idle position when
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.
26
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.
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.
12. Secure harness in the retaining clip within the
handlebar, and at the front of the upper frame
using a locking-tie.
13. Reconnect the heated grip and TAS connec-
tors to the vehicle harness.
14. Install the handlebar cover and torque screws
to 1 N•m (9 lbf•in).
15. Ensure wire harness does not hinder handle-
bar movement by turning handlebar in both di-
rections.
16. Install the console, refer to BODY subsection.
17. Install all removed body parts, refer to the
BODY subsection.
18. Start vehicle and test for proper operation of
throttle and heated grip.
HANDLEBAR
Handlebar Removal
1. Remove the LH and RH handlebar covers.
2. Remove the clamps that secure both LH and
RH handlebar tubes to the handlebar, and re-
move the wiring harnesses (LH and RH) from
the retaining clips.
NOTE: This removes all controls from the handle-
bar without disassembling or disconnecting them.
rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

rmr2013-034-035_a

TYPICAL - LH SE5 MODEL ILLUSTRATED rmr2010-034-016_a

1. Handlebar tube retaining clamp
2. Wiring harness retaining clip TYPICAL - LH SIDE ILLUSTRATED
1. Location pin in retaining clamp
2. Oblong location hole in handlebar tube
3. Remove the ignition switch from the handlebar,
refer to IGNITION SYSTEM subsection.
4. Remove and discard the 4 handlebar retaining
screws.

Handlebar Installation
Installation is the reverse of the removal proce-
dure however, pay attention to the following.
1. Install handlebar using NEW retaining screws.
Torque screws to 38 N•m (28 lbf•ft).
2. Install ignition switch, refer to IGNITION SYS-
TEM subsection.
3. Torque the screws retaining the central handle-
bar cover to 3.5 N•m (31 lbf•in).
4. Install the LH and RH handlebar tubes loosely.
rmr2013-034-042_a
NOTE: A pin in the handlebar tube retaining clamp TYPICAL - LH SIDE ILLUSTRATED
inserts in an oblong location hole provided in the 1. Notch facing alignment pin
handlebar tube. The tube clamp is installed with
the notch on its perimeter in line with a pin on the 5. Push handlebar grip inwards until the multifunc-
handlebar (LH and RH are opposite). tion switch housing touches the handlebar.

rmr2010-034-017_a

TYPICAL - LH SIDE ILLUSTRATED RH SIMILAR

1. Multifunction switch to handlebar contact

rmr2013-034 27
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

6. Torque the tube retaining clamp screws to

10 N•m (89 lbf•in).
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.

rmr2013-034-058_a

DPS UNIT
1. Lower steering column pinch bolt

4. Remove the 4 screws that secure the steering

column support assembly to the frame.

rmr2010-034-035_a

TYPICAL - LH HANDLEBAR TUBE CLAMP, 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.
8. Install the handlebar covers and torque retain-
ing screws to 1 N•m (9 lbf•in).
rmr2010-034-033_a
9. Install all other removed parts, refer to applica-
1. Steering column support
ble subsection. 2. Screws (4)

STEERING COLUMN 5. Pull the steering column out through top of

Steering Column Removal
1. Remove handlebar, refer to HANDLEBAR RE-
MOVAL 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.
frame.
Steering Column Installation
Installation is the reverse of the removal however,
pay attention to the following.
1. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
on steering column splines at lower U-joint.
2. Insert steering column in the frame.
3. Index and insert the steering column splines
onto the DPS shaft splines.
4. Install lower U-joint pinch bolt using a NEW
elastic nut. Torque nut to 31 N•m (23 lbf•ft).
5. Align 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 N•m (18 lbf•ft).

28 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)
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.
rmr2010-034-033_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.
Steering Column Support Removal
1. Remove the steering column assembly from
the vehicle. Refer to STEERING COLUMN
REMOVAL procedure in this subsection.
2. Push up on the bellows just bellow the steering
column support to expose the upper steering
column pinch bolt.
3. Remove the pinch bolt that secures the upper
steering column U-joint to the upper steering
column shaft.
4. Remove the bellows from the steering column
support.
5. Remove the O-ring from the splines of the up-
per steering column. Discard the O-ring.
6. Pull the upper steering column shaft out of the
column support.
Steering Column Support Installation
1. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
to the bushing contact points on the upper
steering column shaft and on the splines of the
lower steering column U-joints.
rmr2013-034
2. Insert the upper steering column shaft in the
column support.
3. Insert a NEW O-ring at the top of the splines on
the upper steering column shaft.
4. Insert the bellows over the bottom end of the
steering support. Do not install the locking-tie
at this time.
5. Index and push the lower steering column onto
the splines of the upper steering column shaft
until the pinch bolt can be inserted through the
grooved portion of the shaft.
6. Install a NEW elastic nut on the pinch bolt and
torque nut to 31 N•m (23 lbf•ft).
7. Position the bellows with the raised shoulder
on the steering column support inside the
groove provided within the small end of the
bellows.
rmr2013-034-057_a
1. Lower steering column shaft
2. Upper U-joint pinch bolt
3. O-ring
4. Raised shoulder on steering column (bellows not illustrated)
8. Install a locking-tie on the grooved portion to
properly secure the bellows.
9. Install the steering column, refer to STEERING
COLUMN INSTALLATION in this subsection.
10. Install the handlebar and controls, refer to
HANDLEBAR in this subsection.
11. Install the ignition switch, refer to IGNITION
system subsection.
12. Install all other removed parts, refer to applica-
ble subsection.
13. Perform the steering angle reset. Refer to
STEERING ANGLE SENSOR in this subsec-
tion.
14. Perform the torque offset reset. Refer to
TORQUE OFFSET RESET in this subsection.
29
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

STEERING ANGLE SENSOR SAS CAN Communication Link (CAN)

(SAS) Continuity Test
1. Disconnect steering angle sensor connector.
First, check for fault codes using the latest appli-
cable B.U.D.S. software. 2. Disconnect the vehicle diagnostic connector.
Before replacing the SAS, check the following. 3. Set a FLUKE 115 MULTIMETER (P/N 529 035 868)
to selection and test SAS CAN bus wire con-
SAS Input Voltage and Ground Test tinuity as per following table.
Disconnect SAS connector.
Turn ignition switch ON.

529035868

MULTIMETER PROBE RESISTANCE @

POSITIONS 20°C (68°F)
SAS connector (pin 3) and
rmr2013-034-056_a
diagnostic connector (pin 1)
TYPICAL - BOTTOM OF DPS UNIT
1. SAS
2. SAS connector

MULTIMETER PROBE VOLTAGE

POSITIONS (KEY ON)
SAS connector (pin 1) and
battery ground
Less than 1
SAS connector (pin 4) and
diagnostic connector (pin 2)

Battery voltage
SAS connector (pin 2) and
battery + terminal

Resistance is out of specification — Check wires

and connector pins. Repair and reset fault codes.
Resistance is good — Replace the steering angle
sensor and reset fault codes.

No voltage — Check wires and connector pins. SAS Removal

Replace or repair defective parts and reset fault 1. Remove the front storage compartment. Refer
codes. to BODY subsection.
Battery voltage measured — Check SAS commu- 2. Remove screws retaining the SAS support to
nication link (CAN). DPS.

30 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

529036178

NOTICE The SAS magnet is a sensitive and

fragile part. Do not to drop it on a hard surface.
rmr2013-034-055_a Do not place it directly on metallic parts. If the
TYPICAL SAS magnet is dropped, knocked, or place on a
1. RH SAS support screw metallic surface, replace it with a new one even
if it appears in a good condition.
3. Disconnect the SAS connector.
5. Remove and discard the seal.

rmr2013-034-055_b

TYPICAL
1. LH SAS support screw rmr2008-028-058_a

2. SAS connector TYPICAL

1. Magnet
4. Remove SAS from its support. 2. Seal
3. Pitman arm

SAS Inspection
Inspect SAS support for cracks or other damages.
Replace if necessary.
Inspect the magnet for cracks or other damages.
Replace as required.

SAS Installation
1. Install a NEW seal.
2. Install the magnet and tighten it to 2 N•m
(18 lbf•in) using the MAGNET SOCKET (P/N 529
036 178).
rmr2008-028-057_a

1. SAS
2. SAS support

Remove magnet from the DPS shaft.

MAGNET REMOVAL
MAGNET SOCKET
Required tool
(P/N 529 036 178)
529036178

rmr2013-034 31
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

3. Clean the magnet using a clean rag to remove

any metallic particle.
4. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of sensor support screw threads.
5. Tighten SAS support screws to 10 N•m
(89 lbf•in).
6. Install all other parts removed, refer to applica-
ble subsection.
Reset SAS, see procedure in this subsection.

DPS UNIT rmr2008-028-090_a

1. DPS main power connector

DPS Unit Troubleshooting 2.
3.
DPS
DPS
control connector
motor connector
Check for fault codes using the latest applicable 4. DPS ground
B.U.D.S. software.
2. Set multimeter to Vdc.
DPS Unit Fuse Inspection 3. Test for DPS motor circuit as per following ta-
Check MF5 (40 A) DPS motor fuse located in the ble.
rear fuse box under seat. Replace as required. MULTIMETER PROBE
VOLTAGE
POSITIONS
DPS power connector (DPS2
pin A) and battery ground

Battery voltage
DPS ground and battery
rmo2010-001-108_a + terminal
FUSE LOCATIONS, REAR FUSE BOX
DPS motor fuse (MF5)

The 12 Vdc DPS control power comes from fuse

F3 (25 A) through MAIN Relay 2 (R3), both located
in the front fuse box. This fuse supplies power
to several systems including the multifunction
gauge (cluster). If the cluster is powered, the
fuse is good.
DPS Unit Circuit Test (Main Power)
1. Disconnect DPS main power connector.
No voltage — Check fuse MF5 (40 A). If good,
check wires and connector pins. Replace or repair
defective parts and reset fault codes.
Voltage — Carry out a DPS CIRCUIT TEST (CON-
TROL POWER).
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.

32 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

MULTIMETER PROBE If resistance is good. Replace the DPS unit and re-
VOLTAGE set fault codes using the latest applicable B.U.D.S.
POSITIONS
software.
DPS control connector (DPS1
pin A) and battery ground
DPS Unit Removal
1. Open seat and remove 40 A MF5 DPS motor
Battery voltage fuse.

CAUTION The DPS motor fuse must be

If there is no voltage, check wires and connector
pins. Replace or repair defective parts and reset
fault codes.
If there is voltage. Carry out a CONTINUITY TEST
OF DPS UNIT COMMUNICATION LINK (CAN).
removed to avoid any accidental DPS move-
ment during its installation.
2. Remove the front storage compartment and
console. Refer to the BODY subsection.
3. Remove the steering support mounting
screws.
4. Remove the DPS unit ground wire.

Continuity Test of DPS Unit

Communication Link (CAN)
Make sure DPS is powered by carrying out DPS
UNIT CIRCUIT TEST (CONTROL POWER) in this
subsection.
1. Set multimeter to selection.
2. Disconnect DPS control connector.
3. Disconnect the vehicle diagnostic connector.
4. Test DPS CAN bus wire continuity as per follow-
ing table.
rmr2013-034-052_a
MULTIMETER PROBE RESISTANCE @
POSITIONS 20°C (68°F) 1. Ground wire on DPS unit

DPS control connector (pin C) 5. Remove the LH speed sensor connector.

and diagnostic connector (pin 1) 6. Disconnect the DPS unit power connector.

Below 1
DPS control connector (pin D)
and diagnostic connector (pin 2)

rmr2013-034-053_a

1. LH speed sensor connector

2. DPS unit power connector

If resistance is out of specification. Check wires 7. Remove the RH speed sensor connector from
and connector pins. Repair and reset fault codes. its mounting bracket.

rmr2013-034 33
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

8. Disconnect the DPS unit control and motor con-

nectors.

rmr2013-034-050_a

1. Steering angle sensor support

2. Pitman arm
3. DPS unit

rmr2013-034-054_a 12. Pull the steering column up sufficiently to dis-

1. RH speed sensor connector
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.
connect it from the DPS unit shaft.
NOTE: Some models may have shims of
0.25 mm (.01 in) installed between DPS unit
and frame. Note the shims location and quantity
at each screw prior to removing DPS unit. These
shims must be reinstalled at the same place.

rmr2013-034-066_a

1. Lower steering column U-joint

2. Pinch bolt
rmr2013-034-051_a

10. Disconnect the steering angle sensor (SAS) MANY PARTS REMOVED FOR CLARITY
1. DPS unit
connector. 2. Front member of frame
3. Shims location
11. Remove both tie-rod ends from pitman arm.

rbg2010-006-014

DPS SHIMS

34 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

13. Remove screws securing DPS unit to frame. STEERING COLUMN SUPPORT RETAINING
SCREWS TIGHTENING TORQUE
24 N•m (18 lbf•ft)

5. Reconnect the DPS unit connectors.

6. Reinstall the DPS ground wire.
GROUND WIRE RETAINING SCREW
TIGHTENING TORQUE
10 N•m ± 2 N•m (89 lbf•in ± 18 lbf•in)

7. Install the LH and RH speed sensor connectors

on their mounting brackets.
8. Install the SAS and magnet, refer to SAS IN-
rmr2013-034-049_a

1. DPS screws
STALLATION in this subsection.
9. Reinstall tie-rod ends to pitman arm using NEW
14. Pull upwards on the DPS unit to remove it nuts.
from the frame.
TIE-ROD ENDS RETAINING NUTS
15. If replacing the DPS unit, remove the SAS and TIGHTENING TORQUE
magnet from the DPS shaft, refer to SAS RE-
MOVAL in this subsection. 62.5 N•m ± 7.5 N•m (46 lbf•ft ± 6 lbf•ft)

DPS Unit Installation 10. Reinstall MF5 40 A DPS motor fuse.

NOTE: DPS, if replaced, must applicable to the 11. Install all other removed parts, refer to applica-
vehicle model. ble subsection.
1. Install the SAS on its support using NEW nuts. 12. Roll vehicle back and forth on a level surface
to make sure the wheels are in a straight line.
SAS BOLTS TIGHTENING TORQUE
13. Carry out TORQUE SENSOR RESET, see pro-
4.5 N•m ± 0.5 N•m (40 lbf•in ± 4 lbf•in) cedure in this subsection.
2. Install DPS unit on frame.
PITMAN ARM
2.1 Apply XPS SYNTHETIC GREASE (P/N 293 550
010) on DPS input shaft splines. Pitman Arm Removal
2.2 Position DPS unit in frame. Remove DPS unit. Refer to DPS UNIT in this sub-
section.
2.3 Index and insert steering column splines
on DPS input shaft splines. Remove the steering angle sensor (SAS) support
from DPS unit.
2.4 Install all previously removed shims at the
proper location.
2.5 Secure DPS units using NEW screws.
DPS RETAINING SCREWS TIGHTENING TORQUE
28 N•m ± 2 N•m (21 lbf•ft ± 1 lbf•ft)

3. Install pinch bolt at lower end of steering col-

umn using a NEW elastic nut.
LOWER STEERING COLUMN NUT
TIGHTENING TORQUE
rmr2008-028-068_a
31 N•m (23 lbf•ft)
1. SAS support screws
4. Install steering column support retaining Remove magnet from the DPS shaft.
screws.

rmr2013-034 35
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

MAGNET REMOVAL PITMAN ARM REMOVAL

MAGNET SOCKET PITMAN ARM JIG
Required tool
(P/N 529 036 178) (P/N 529 036 225)
Required tools
PITMAN ARM PULLER
(P/N 529 036 227)

529036178

NOTICE The magnet is a sensitive and fragile

part. Do not drop it on a hard surface and do
not place it directly on metallic parts. If mag-
net is dropped, knocked or place on a metallic
surface, replace it with a new one even if it ap-
529036225
pears in a good condition.
Remove and discard the seal.

529036227
rmr2008-028-069_a

1. Magnet Place the jig in a vise.

2. Seal
Position the DPS input shaft in the jig bottom hole.
Unscrew pitman arm nut and washer.

rmr2008-028-071_a

1. Pitman arm nut

rmr2011-034-007_a
2. Washer
3. Pitman arm 1. DPS input shaft
2. Jig bottom hole
Remove the pitman arm from the DPS shaft.
Lean the jig screw tip on the DPS output shaft.

36 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

Pitman Arm Installation

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 529 036 225)
Required tools
PITMAN ARM PUSHER
(P/N 529 036 226)

rmr2011-034-008_a

1. Jig screw tip

2. DPS output shaft

Install the puller over the pitman arm and the jig
thrust bearing.

529036225

rmr2011-034-009_a

1. Thrust bearing
2. Puller
3. Pitman arm

Pull pitman arm off the DPS output shaft by turn- 529036226

ing the thrust bearing. Hold the jig screw.

Place the jig in a vise.
Position the DPS input shaft in the jig bottom hole.

rmr2011-034-010

rmr2013-034 37
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

Install a NEW seal.

Install the magnet using the MAGNET SOCKET
(P/N 529 036 178) and tighten it to 2 N•m
(18 lbf•in).

529036178

rmr2011-034-007_a

1. DPS input shaft

Clean the magnet using a clean rag to remove any
2. Jig bottom hole metallic particle.
Install the pusher between the jig screw tip and Install all other removed parts.
pitman arm. Carry out STEERING ALIGNMENT, see procedure
in this subsection.

TIE-ROD
Tie-Rod Removal
1. Remove wheel, see procedure in this subsec-
tion.
2. At pitman arm and knuckle, remove:
– Cotter pin (discard)
– Tie-rod end nut
– Hardened washers.
rmr2011-034-011_a

1. Jig screw tip

2. Pusher
3. Pitman arm

Turn the jig screw to push the pitman arm on the

DPS output shaft until it stops.

rmr2013-034-048_a

AT KNUCKLE
1. Tie-rod end nut
2. Hardened washers
3. Knuckle

3. Remove tie-rod from the vehicle.

Tie-Rod Inspection
rmr2011-034-012 Inspect tie-rod ends for wear or excessive play. If
excessive, replace tie-rod end.
Install washer and nut.
Tighten nut to 62 N•m (46 lbf•ft).

38 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

Tie-Rod Installation 2. Apply parking brake.

1. For the installation, reverse the removal proce- 3. Loosen wheel lug nuts.
dure. However, pay attention to the following. 4. Lift the front of vehicle on jack-stands.
5. Remove wheel, see procedure in this subsec-
tion.
6. Remove brake disc and encoder wheel. Refer
to BRAKE SYSTEM subsection.
rmr2013-034-067_a
7. Remove wheel speed sensor retaining screw.
MAXIMUM LENGTH
1. Pitman arm side
2. Knuckle side
A. 620 mm ± 50 mm (24.5 in ± 2 in)

TIE-ROD
Maximum length - 620 mm ± 50 mm
dimension “A” (24.5 in ± 2 in)

rmr2013-034-047_a

1. Wheel speed sensor

2. Wheel speed sensor screw

rmr2008-028-016_a
8. Unscrew fender supports.
1. Pitman arm side
2. Knuckle side
B. 12 mm (.47 in)

TIE-ROD
Unengaged threads -
12 mm (.47 in)
dimension “B”*
* Dimension “B” to be approximately equal upon
assembly.

2. Tighten tie-rod lock nuts finger tight. rmr2008-028-018_a

1. Fender supports
3. Install tie-rod on steering knuckle. Follow instal-
lation sequence as depicted in exploded view. 9. Remove tie-rod end from knuckle, refer to TIE-
4. Torque tie-rod retaining nut to 63 N•m ROD in this subsection.
(46 lbf•ft).
5. Install NEW cotter pins. Both ends of cotter
pins must be folded around nut.
6. Tighten tie-rod end lock nuts to 34 N•m
(25 lbf•ft).
7. Carry out STEERING ALIGNMENT, see proce-
dure in this subsection.

KNUCKLE
Knuckle Removal
1. Place vehicle on a level surface.
rmr2013-034 39
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

WHEEL HUB
Wheel Hub Removal
1. Remove KNUCKLE, see procedure in this sub-
section.
2. Remove knuckle cap from knuckle.

rmr2008-028-019_a

1. Tie-rod end
2. Knuckle

10. Remove upper ball joint support retaining

screws.

rmr2013-034-059_a

1. Knuckle cap

3. Remove cotter pin and wheel nut from knuckle.

rmr2013-041-008_a

1. Ball joint support screws

11. Remove wheel hub and wheel bearing only if

necessary.

Knuckle Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
1. Tighten upper and lower ball joint nuts to rmr2013-034-060_a
82 N•m (60 lbf•ft). 1. Cotter pin
2. Wheel nut
2. Install NEW cotter pins. Both ends of cotter
pins must be folded around nut around nut. 4. Using a press, remove wheel hub from knuckle.
3. Install tie-rod ends as described in TIE-ROD in Support the knuckle properly to avoid damaging
this subsection. it.
4. Carry out STEERING ALIGNMENT, see proce-
dure in this subsection.

40 rmr2013-034
 Subsection XX (STEERING (DPS) AND FRONT WHEELS)

rmr2013-034-065_a

1. Wheel hub
2. Knuckle
3. Bearing inner race support
rmr2013-034-062_a

1. Install press here 2. Before pressing wheel hub, ensure it is per-

2. Wheel hub fectly aligned.
3. Knuckle
4. Support to avoid damaging
NOTICE If the wheel hub is not aligned,
5. Wheel bearing must be replaced every time wheel bearing will be damaged and its re-
wheel hub is removed. Refer to WHEEL BEAR- placement necessary.
INGS in this subsection.
3. Install the knuckle and all other removed parts.
6. If the bearing inner race remains on the wheel
hub shaft, use a press and a bearing separator
to remove it.
WHEEL BEARINGS
Wheel Bearing Inspection
1. Lift and support the front of vehicle on jack-
stands.
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.
If there is any play or roughness of rotation, re-
place the wheel bearing.
NOTE: First, check if ball joints are loose. If nec-
essary repair all defective parts before checking
the wheel bearing condition. Be careful not to
mistake play in a ball joint for a bad wheel bearing.
rmr2013-034-064_a

1. Install bearing inner race support here Wheel Bearing Removal

2. Knuckle
1. Remove WHEEL HUB. See procedure in this
Wheel Hub Installation subsection.
1. Press the wheel hub into the bearing using the 2. Remove the circlip retaining the wheel bearing
BALL JOINT INSTALLER (P/N 529 035 975) as a in the knuckle.
support. This tool will support the bearing inner
race during wheel hub installation.

rmr2013-034 41
Subsection XX (STEERING (DPS) AND FRONT WHEELS)

7. Carry out the steering angle sensor reset. Refer

to SAS RESET in this subsection.
8. Carry out the torque offset reset. Refer to
TORQUE SENSOR RESET in this subsection.

rmr2013-034-063_a

1. Circlip

3. Press out the wheel bearing.

REQUIRED TOOL
Wheel bearing BEARING PUSHER/REMOVER
removal (P/N 529 036 095)

529036095

NOTICE Support the knuckle properly to

avoid damaging it.

Wheel Bearing Installation

1. Leave the NEW bearing to cool to ease instal-
lation.
BEARING COOLING
In freezer 30 minutes minimum

2. Clean all grease from outer and inner surfaces

of knuckle.
3. Heat knuckle in an oven.
KNUCKLE HEATING
100°C (212°F) 30 minutes maximum

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.

42 rmr2013-034
 Subsection XX (FRONT SUSPENSION)

FRONT SUSPENSION
SERVICE TOOLS
Description Part Number Page
BALL JOINT INSTALLER............................................................... 529 035 975 ............................................. 9
BALL JOINT REMOVER SUPPORT .............................................. 529 036 121 ......................................... 7, 9
REAR WHEEL BEARING PUSHER ............................................... 529 036 246 ............................................. 9
SPRING COMPRESSOR ............................................................... 529 036 184 ............................................. 4

SERVICE PRODUCTS
Description Part Number Page
XPS SYNTHETIC GREASE............................................................. 293 550 010 ............................................. 3

rmr2013-041 1
Subsection XX (FRONT SUSPENSION)

Upper suspension arm Lower suspension arm

RH side RH side

3 N•m
3 N•m (27 lbf•in)
(27 lbf•in)
XPS synthetic grease
XPS synthetic grease

64 N•m
(47 lbf•ft)
2.0 N•m
(18 lbf•in)

64 N•m
(47 lbf•ft)
2.0 N•m
(18 lbf•in)

RS-S 48 N•m RS, ST, RT 48 N•m

(35 lbf•ft) (35 lbf•ft)

48 N•m
(35 lbf•ft) 48 N•m 25 N•m
(35 lbf•ft) (18 lbf•ft)

7.5 N•m
(66 lbf•in)

NEW = Component must be replaced when removed.

rmr2013-041-100_a

2 rmr2013-041
 Subsection XX (FRONT SUSPENSION)

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced. rmo2012-001-001_a

SPYDER RS-S
1. Spring preload adjustment ring
2. Lock ring
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled 3. Lock the assembly by tightening the lock ring
as per factory standards. against the preload ring.
TORQUE
ADJUSTMENT
Lock ring 10 N•m (89 lbf•in)
SPRING PRELOAD ADJUSTMENT
(RS-S MODELS) MAINTENANCE
WARNING SUSPENSION LUBRICATION
Adjust both springs to the same load. Un-
Place vehicle on a level surface.
even adjustment can cause poor handling,
loss of stability and loss of control. Apply parking brake.
Loosen wheel lug nuts.
Verification conditions: Lift the front of the vehicle.
– Vehicle on a level surface
Secure vehicle on jack stands.
– Normal cargo load
Remove wheel.
– Rider and passenger taking place on the vehi-
cle. Lubricate suspension arms. There are two grease
fittings per arm.
Measure the distance between the upper and
lower shock absorber mounting bolts. SERVICE PRODUCT
RECOMMENDED PRELOAD XPS SYNTHETIC GREASE (P/N 293 550 010)
420 mm (16-17/32 in)
(rider+passenger+cargo)

To adjust:
1. Loosen the lock ring.
2. Bring the preload ring to the recommended set-
ting.

rmr2013-041 3
Subsection XX (FRONT SUSPENSION)

rmr2013-041-002_a rmr2013-041-005_a

UPPER ARM FRONT CARGO MODULE REMOVED FOR CLARITY

1. Grease fittings 1. Shock absorber bolts

Remove shock absorber from vehicle.

Shock Absorber Disassembly

Remove spring from the shock absorber.
REQUIRED TOOL
SPRING COMPRESSOR (P/N 529 036 184)

529036184

rmr2013-041-003_a

LOWER ARM
Position the shock absorber in the tool and install
1. Grease fittings the spring compressor hooks.

PROCEDURES
SHOCK ABSORBER
Shock Absorber Removal
Remove body parts as required to access to the
shock absorber. Refer to BODY subsection.
Lift the front of vehicle.
mmr2010-033-012_a

Unscrew shock absorber bolts. 1. Spring compressor hooks

Tighten the spring compressor tool screw until

the spring is sufficiently compressed to remove
spring stopper.
Release the spring compressor tool screw.
Remove spring from shock absorber.

4 rmr2013-041

Shock Absorber Inspection
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.
– Seizing or binding condition except at extreme
end of either stroke.
– Oil leakage.
– A gurgling noise, after completing one full com-
pression and extension stroke.
Check piston rod for excessive wear or pitting.
Inspect the spring for damage. Replace if neces-
sary.
On both ends, check the bushings for excessive
wear or other damages.
Replace shock absorber or spring if any faults are
present.
Shock Absorber Assembly and
Installation
For assembly and installation, reverse the disas-
sembly and removal procedures.
AIR DEFLECTOR (UPPER ARM)
Air Deflector Removal
Remove body parts as required to access to the
air deflector. Refer to BODY subsection.
Underneath suspension arm, remove air deflector
screws.
rmr2013-041-007_a
rmr2013-041
Subsection XX (FRONT SUSPENSION)
Remove the upper shock absorber bolt.
rmr2013-041-004_a
1. Upper shock absorber bolt
Detach flexible brake hose and speed sensor wire
from air deflector.
Remove the air deflector.
Air Deflector Installation
The installation is the reverse of the removal pro-
cedure.
UPPER SUSPENSION ARM
Upper Suspension Arm Inspection
Check upper suspension arms for bending or
other damage. Replace suspension arms if nec-
essary.
Move upper 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
pivot bushings and sleeves for wear or damages.
Replace bushings and/or sleeves if necessary.
Upper Suspension Arm Removal
Place vehicle on a level surface.
Apply parking brake.
Remove front cargo module. Refer to BODY sub-
section.
Loosen wheel lug nuts.
Lift the front of the vehicle.
Secure vehicle on jack stands.
Remove wheel.
Remove brake disc and encoder wheel. Refer to
BRAKES subsection.
5
Subsection XX (FRONT SUSPENSION)

Remove screws securing the air deflector on up-

per suspension arm.

rmr2013-041-012_a

1. Upper suspension arm bolts

rmr2013-041-007_a
Remove the upper suspension arm without its air
Remove screws securing the upper ball joint sup- deflector.
port.
Upper Suspension Arm Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Perform STEERING ALIGNMENT. Refer to
STEERING (DPS) AND FRONT WHEELS.
Lubricate upper suspension arm. Refer to MAIN-
TENANCE in this subsection.

UPPER BALL JOINT

Upper Ball Joint Inspection
Inspect ball joint end for damage. Ensure it is
moving freely without play. Replace ball joints as
required.

rmr2013-041-008_d Upper Ball Joint Removal

1. Upper ball joint support screws
Remove upper screw retaining oil cooler air duct
(LH side) or radiator air duct (RH side).
Remove the UPPER SUSPENSION ARM, see pro-
cedure in this subsection.
Remove circlip securing ball joint to suspension
arm.

rmr2013-041-009_a

LH SIDE SHOWN
1. Oil cooler air duct
2. Screw to remove
rmr2008-029-015

Unscrew upper suspension arm bolts. Press ball joint out of the upper suspension arm.

6 rmr2013-041
 Subsection XX (FRONT SUSPENSION)

REQUIRED TOOL Move lower suspension arm from side to side and
up and down. There should be no noticeable play
BALL JOINT REMOVER SUPPORT in bushings.
(P/N 529 036 121)
If necessary, remove suspension arm and inspect
pivot bushings and sleeves for wear or damages.
Upper Ball Joint Installation Replace bushings and/or sleeves if necessary.
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. Lower Suspension Arm Removal
Press ball joint into the suspension arm. Place vehicle on a level surface.
BALL JOINT NUT TORQUE Apply parking brake.
48 N•m (35 lbf•ft) Remove front cargo module. Refer to BODY sub-
section.
Install circlip. Loosen wheel lug nuts.
Lift the front of the vehicle.
AIR DEFLECTOR (LOWER ARM) Remove wheel.
Air Deflector Removal Remove brake disc and encoder wheel. Refer to
Underneath suspension arm, remove air deflector BRAKES subsection.
screws. Unscrew ball joint nut.
Remove the lower shock absorber bolt.

rmr2013-041-006_a

UNDERNEATH LH LOWER SUSPENSION ARM

1. Air deflector screws rmr2013-041-008_b
2. Air deflector 1. Lower shock absorber bolt
3. Suspension arm

Remove the air deflector. Underneath lower suspension arm, remove stabi-
lizer bar bolt.
Air Deflector Installation
The installation is the reverse of the removal pro-
cedure.

LOWER SUSPENSION ARM

Lower Suspension Arm Inspection
Check lower suspension arms for bending or
other damage. Replace suspension arms if nec-
essary.
rmr2013-041-010_a

1. Lower suspension arm

2. Stabilizer bar

rmr2013-041 7
Subsection XX (FRONT SUSPENSION)

Unscrew lower suspension arm bolts.

rbg2013-003-001

rmr2013-041-003_a

1. Lower suspension arm bolts

Remove the lower suspension arm with its air de-

flector.
Turn suspension arm upside down and remove
the air deflector.

Lower Suspension Arm Installation

rbg2013-003-002
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. 3. Remove the RH front wheel.
Tighten ball joint nut to specification.
BALL JOINT NUT TORQUE
48 N•m (35 lbf•ft)

Perform STEERING ALIGNMENT. Refer to

STEERING (DPS) AND FRONT WHEELS.
Lubricate lower suspension arm. Refer to MAIN-
TENANCE in this subsection.

LOWER BALL JOINT

Lower Ball Joint Inspection rbg2013-003-003

Inspect ball joint end for damage. Ensure it is

moving freely without play. Replace ball joints as 4. Remove the lower ball joint retaining bolt and
required. discard elastic nut.

Lower Ball Joint Removal

1. Place the vehicle on a level surface and apply
parking brake.
2. Lift the front of vehicle.

8 rmr2013-041
 Subsection XX (FRONT SUSPENSION)

rbg2013-003-004_a

1. Ball joint retaining bolt location

rbg2013-003-006

5. Lift up the upper suspension arm. 6.3 Tighten C-clamp and press the ball joint out
of the suspension arm.

Lower Ball Joint Installation

1. Install the new lower ball joint.
1.1 Using electrical tape, secure a REAR
WHEEL BEARING PUSHER (P/N 529 036
246) to the top section of the BALL JOINT
INSTALLER (P/N 529 035 975).
1.2 Install the C-clamp, the ball joint installer,
the rear wheel bearing pusher and the
socket of 35 mm (1-3/8 in) as shown.

rbg2013-003-005

NOTE: Properly secure the suspension arm to

keep it out of the way during the procedure.
6. Remove the lower ball joint.
6.1 Using electrical tape, secure a REAR
WHEEL BEARING PUSHER (P/N 529 036
246) to the bottom of the BALL JOINT RE-
MOVER SUPPORT (P/N 529 036 121).
6.2 Install the C-clamp, the ball joint remover
support and the rear wheel bearing pusher
on lower ball joint as shown.
NOTE: Fixed portion of C-clamp must be in-
stalled on moving part of ball joint to stabilize
it during removal.

rbg2013-003-007

rmr2013-041 9
Subsection XX (FRONT SUSPENSION)

1.3 Tighten C-clamp and press the ball joint Pivot Bushings Installation
into lower suspension arm. The installation is the reverse of the removal pro-
NOTICE Always push on the ball joint edge, cedure.
never on center surface.
STABILIZER BAR
2. Lower upper suspension arm and secure
knuckle to lower suspension arm using a new Stabilizer Bar Removal
M10 elastic nut. Remove front cargo module. Refer to BODY sub-
TIGHTENING TORQUE section.
M10 elastic nut 48 N•m (35 lbf•ft) Unscrew stabilizer bar from link rods.

3. Reinstall wheel.
TIGHTENING TORQUE
Wheel lug nuts 105 N•m (77 lbf•ft)

PIVOT BUSHINGS
rmr2013-041-013_a
NOTE: The following procedure is the same for all
TYPICAL
suspension arms. 1. Stabilizer bar
2. Link rods
Pivot Bushings Removal
Turn stabilizer bar downward.
Remove appropriate suspension arm. Refer to
UPPER SUSPENSION ARM or LOWER SUSPEN- Remove stabilizer bar bushings.
SION ARM in this subsection.
Remove sleeve from pivot bushings.

rmr2008-029-027_a

1. Sleeve
2. Pivot bushings

Using a punch, remove pivot bushings.

rmr2013-041-014_a

TYPICAL
1. Stabilizer bar bushing
2. Remove these bolts
3. Stabilizer bar

Remove stabilizer bar from vehicle.

Stabilizer Bar Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
rmr2008-029-028_a

1. Pivot bushings Before installing stabilizer bar, verify if all ball joints
of link rods move smoothly and freely. Replace
link rod if necessary.

10 rmr2013-041
 Subsection XX (FRONT SUSPENSION)

Check stabilizer bar bushings for cracks or other

damages. Replace if necessary.
Install all other removed parts.

LINK ROD
Link Rod Removal
Lift the front of vehicle.
Remove the air deflector from lower suspension
arm.

rmr2013-041-015_a

TYPICAL - LH SIDE SHOWN

1. Air deflector

Unscrew the bolts securing link rods.

rmr2013-041-016_a

LH SIDE SHOWN
1. Link rod bolts
2. Lower suspension arm
3. Stabilizer bar

Link Rod Installation

The installation is the reverse of the removal pro-
cedure.

rmr2013-041 11
 Subsection XX (REAR SUSPENSION (RS AND ST SERIES))

REAR SUSPENSION (RS AND ST

SERIES)
SERVICE TOOLS
Description Part Number Page
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ............................................. 7
SPRING COMPRESSOR ............................................................... 529 036 184 ............................................. 3

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 648 (GREEN) .................................................................. 619 600 012 ............................................. 8
XPS SYNTHETIC GREASE............................................................. 293 550 010 ............................................. 7

rmr2011-035 1
Subsection XX (REAR SUSPENSION (RS AND ST SERIES))

48 N•m
(35 lbf•ft)

NEW

150 N•m
(111 lbf•ft)

NEW
150 N•m
XPS synthetic (111 lbf•ft)
grease

NEW = Component must be replaced when removed.

rmr2013-043-100_a

2 rmr2011-035
 Subsection XX (REAR SUSPENSION (RS AND ST SERIES))

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING
Torque wrench tightening specifications
must be strictly adhered to. rmr2008-030-010_a

Locking devices when removed (e.g.: locking TYPICAL

1. Shock absorber
tabs, elastic stop nuts, cotter pins, etc.) must 2. Upper bracket
be replaced with new ones.
Remove the shock absorber lower bolt.
Remove rear shock absorber from vehicle.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled Shock Absorber Disassembly
as per factory standards. Remove spring from the shock absorber.
PROCEDURES REQUIRED TOOL
SPRING COMPRESSOR (P/N 529 036 184)
SHOCK ABSORBER
Shock Absorber Removal
Unlatch and lift seat.
Remove rear body assembly. Refer to BODY sub-
section.
Remove the shock absorber upper bolt. 529036184

Install a jack under the rear portion of frame.

Position the shock absorber in the tool and install
the spring compressor hooks.

mmr2010-033-012_a

1. Spring compressor hooks

rmr2008-030-009

TYPICAL Tighten the spring compressor tool screw until

Lift the vehicle until the shock absorber can be re- the spring is sufficiently compressed to remove
moved from upper bracket. spring stopper.
Release the spring compressor tool screw.
Remove spring from shock absorber.

Shock Absorber Inspection

Examine shock for leaks.

rmr2011-035 3
Subsection XX (REAR SUSPENSION (RS AND ST SERIES))

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.
– Seizing or binding condition except at extreme
end of either stroke.
– Oil leakage. rmr2013-043-050_a

– A gurgling noise, after completing one full com-
pression and extension stroke.
Replace if any faults are present.
Shock Absorber Assembly
The assembly is the reverse of the disassembly
procedure. However, pay attention to the follow-
ing.
Position cam on position 1.
Align the center of cam adjuster between the po-
sition 1 and position 7.
When installing spring stopper and cap, make
sure to install opening at 180°.
TYPICAL - PARTS REMOVED FOR CLARITY
1. Lower bracket hole
2. Anchoring hole
Tighten shock absorber retaining bolts to specifi-
cation.
SHOCK ABSORBER RETAINING BOLTS TORQUE
48 N•m (35 lbf•ft)
Adjust spring preload if required. Refer to SPRING
PRELOAD ADJUSTMENT in this subsection.
SWING ARM
Swing Arm Removal
Place vehicle on a level surface.
Lift the rear of the vehicle.
Install a jack stand under frame.

rmr2008-030-014_a

1. Stopper opening
2. Cap opening

Shock Absorber Installation rmr2008-030-009

TYPYCAL
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. Refer to BODY subsection and remove:
Install shock absorber as follows: – Rear body assembly
– Ensure that cam is adjusted on position 1 then – Lower side panels
position shock absorber cam adjuster pointing – Belt guard.
towards RH side.
Remove cable protector from swing arm.

4 rmr2011-035
 Subsection XX (REAR SUSPENSION (RS AND ST SERIES))

rmr2008-030-023_a

LH SIDE FENDER SUPPORT

rmr2013-035-014_a

1. Cables protector Move rear fender supports aside.

2. Cables protector retaining screws
From underneath swing arm, remove parking
brake cable fastener.
Remove rear wheel. Refer to DRIVE BELT AND
REAR WHEEL subsection.
Remove shock absorber lower bolt.

rmr2013-035-015_a

UNDERNEATH SWING ARM

1. Parking brake cable fastener

Remove screws securing rear fender supports to

swing arm.
rmr2013-043-001_a

1. Shock absorber lower bolt

1. Remove rear cargo module. Refer to BODY

subsection.
2. Remove belt guard from swing arm.

rmr2008-030-022_a

RH SIDE FENDER SUPPORT

rmr2011-035 5
Subsection XX (REAR SUSPENSION (RS AND ST SERIES))

rmr2013-035-015_a

1. Parking brake cable fasteners

6. Remove and discard both caliper screws.

rmr2010-036-026_a

1. Belt guard

3. Remove muffler from swing arm.

rmr2013-035-013_a

1. Caliper screws

7. Place vehicle on a level surface.

8. Lift the rear of the vehicle.
rmr2013-008-213_a
9. Install a jack stand under frame.
1. Muffler 10. Remove rear wheel. Refer to DRIVE BELT
AND REAR WHEEL subsection.
4. Remove cables protector from swing arm.
11. Unscrew shock absorber lower bolt.

rmr2008-030-024_a

1. Shock absorber lower bolt

rmr2013-035-014_a
12. Remove swing arm flange bolts.
1. Cables protector
2. Cables protector retaining screws

5. From underneath swing arm, remove parking

brake cable fastener.

6 rmr2011-035
 Subsection XX (REAR SUSPENSION (RS AND ST SERIES))

rmr2013-035-008_a rmr2013-035-010_a

1. LH flange bolt CROSS SECTION OF FRAME AND SWING ARM (RIGHT SIDE)
2. Swing arm axle 1. Swing arm axle
2. Spacer
3. Frame
4. Swing arm bearings
5. Swing arm

14. Remove the swing arm.

Swing Arm Inspection

Check swing arm for cracks, bending or other
damages.
Check if bearings turn smoothly and freely.
Replace all damaged parts.

Swing Arm Disassembly

Using the BLIND HOLE BEARING PULLER SET
(P/N 529 036 117), remove swing arm bearings.
rmr2013-035-007_a

1. RH flange bolt

13. Using a longer bolt, position it in threads and

push to extract the swing arm axle.

529036117

Discard bearings and sleeves.

Swing Arm Assembly

1. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
on NEW sleeves.
2. Using a an appropriate bearing installer, install
NEW bearings, spacers and sleeves.

Swing Arm Installation

1. Position swing arm into place.

rmr2011-035 7
Subsection XX (REAR SUSPENSION (RS AND ST SERIES))

2. Apply LOCTITE 648 (GREEN) (P/N 619 600 012) on 10. Install all other removed parts.
threads of LH flange bolt.
3. Install LH flange bolt into swing arm axle.

rmr2013-035-008_a

1. LH flange bolt
2. Swing arm axle

4. From the LH side, insert the swing arm axle

assembly into position.
5. Apply LOCTITE 648 (GREEN) (P/N 619 600 012) on
threads of RH swing arm axle bolt.
6. Install RH flange bolt onto assembly.

rmr2013-035-007_a

1. RH flange bolt

7. Torque swing arm flange bolts to specification.

SWING ARM FLANGE BOLT TORQUE
55 N•m (41 lbf•ft)

8. Move swing arm up and down. The swing arm

must move freely and smoothly.
9. Install NEW caliper screws.

8 rmr2011-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

REAR SUSPENSION (RT SERIES)

SERVICE TOOLS
Description Part Number Page
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ........................................... 23
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 8, 13, 16
SPRING COMPRESSOR ............................................................... 529 036 184 ........................................... 19

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 24
LOCTITE 592 (PIPE SEALANT) ..................................................... 293 800 018 ........................................... 16
XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 23

rmr2013-035 1
Subsection XX (REAR SUSPENSION (RT SERIES))

System without Loctite 592

pipe sealant 48 N•m
compressor (35 lbf•ft)
13 N•m
(115 lbf•in)

Loctite 592
pipe sealant

7 N•m
(62 lbf•in)

5 N•m
(44 lbf•in)
7 N•m
(62 lbf•in) 7 N•m
(62 lbf•in)

7 N•m
(62 lbf•in)
NEW

55 N•m
(41 lbf•ft)

7 N•m
(62 lbf•in)
NEW
55 N•m
XPS synthetic (41 lbf•ft)
grease

NEW = Component must be replaced when removed.

rmr2013-035-100_a

2 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))
GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.
CAUTION The ACS suspension system
may be under high pressure (up to 7 bar
(100 PSI)). Release air pressure prior to work-
ing on the system. Refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING.
CAUTION Always wear safety goggles
when working with pressurized air system.
NOTICE Do not exceed 7 bar (100 PSI) in the
system. This might damage the air suspension
system.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
NOTE: Install a battery charger on battery termi-
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
ACS System Without Compressor
(Manual Adjustment)
The ACS suspension is manually adjustable using
a conventional air compressor and a pressure
gauge. This system is equipped with an air spring
mounted on the swing arm and located in front
of the shock absorber.
The air spring is connected directly to an air hose
with a pneumatic valve, as a result, adjusting the
air pressure is as easy as inflating a tire.
NOTE: When adjusting the pressure, do not put
your weight on the vehicle and do not load cargo
in the storage compartment.
rmr2013-035
ACS System with Compressor
(Remote Adjustment)
This system allows the suspension to be adjusted
electronically using a dedicated button. The sys-
tem can be adjusted on the fly to suit rider prefer-
ences and automatically keeps vehicle level con-
stant with changing rider weight or load applied.
To achieve this, an air spring is used in conjunction
with the following components:
– ACS air compressor
– ACS position sensor
– ACS solenoid valve
– ACS relay (R4)
– ACS switch.
When the suspension button is pressed, the re-
quested setting is sent to the multifunction gauge.
Depending on the rider adjustment, the multifunc-
tion gauge will request a pressure increase in the
air spring using the compressor or a pressure re-
lease using the solenoid valve. The position sen-
sor mounted on the swing arm monitors the vehi-
cle level to ensure proper ride height.
The highlighted bar on the multifunction gauge in-
dicates the actual setting. Pressing the switch will
move the bar up or down one at a time.
The multifunction gauge indicates suspension set-
ting as follows.
1
rmo2010-001-400_ben
1. Actual setting
To change the ACS setting, press ACS switch un-
til the requested setting is displayed in the multi-
function gauge.
3
Subsection XX (REAR SUSPENSION (RT SERIES))

3. Wait until the system is completely empty of

air.
NOTE: Make 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
rmo2010-001-038_i
1. Remove the rear side panels. Refer to BODY
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 (10 PSI) to 7 bar (100 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

WARNING
MINIMUM PRESSURE 10 PSI / 70 kPa
Do not exceed recommended pressure by 10 PSI / 70 kPa
PASSENGER + CARGO (lb /kg)
LOAD
0 100/45 150/70 200/90 250/115
Lb/Kg PSI/kPa PSI/kPa PSI/kPa PSI/kPa PSI/kPa
DRIVER

150/70 20/135 40/275 50/345 60/415 70/485 rmo2010-001-056_a

200/90 30/205 50/345 60/415 70/485 80/555 TYPICAL

250/115 40/275 60/415 70/485 80/555 90/625 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)
1 (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)
– ACS manifold (if applicable).
Releasing Air Pressure in System for
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.

4 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

rbs2010-017-002_a
rbs2010-017-001_a
SYSTEM WITHOUT COMPRESSOR
SYSTEM WITH 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
1 mm - 2 mm (.039 in - .079 in).
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)

rmr2013-035 5
Subsection XX (REAR SUSPENSION (RT SERIES))
NOTE: This kit includes the air spring and the 90°
fitting.
TROUBLESHOOTING
DIAGNOSTIC TIPS
Before any troubleshooting operations on ACS
system, it is important to check the fault codes
using B.U.D.S. to properly diagnose the problem.
Refer to DIAGNOSTIC AND FAULT CODES sub-
section.
ACS Does Not Work and No Fault
Code Is Set
If the ACS system (system with compressor) is
not working, make sure the required option is se-
lected in B.U.D.S. Otherwise, the ACS system will
not work and no fault code will be set.
1. Connect and start B.U.D.S. to check the Ad-
justable Controlled Suspension option.
rmr2011-085-001_a
SETTING AND ACC TABS
1. Adjustable Controlled Suspension
2. With/Without ACS option
NOTE: If the option is checked in B.U.D.S. and
the vehicle is not equipped with the ACS system,
false fault code(s) will be set.
Error Code "MANUAL" Displayed in
Gauge
The error code MANUAL can appear on the mul-
tifunction gauge for different reasons that are not
necessarily related to a failure of the ACS system.
rmo2011-001-004_a
TYPICAL
1. Error code MANUAL
6 rmr2013-035
If the Error Code Appears Momentarily
If the error code appears momentarily on the mul-
tifunction gauge, it indicates a disparity between
the requested and the actual suspension settings.
To deactivate the error code, turn the ignition key
to OFF position then wait a few seconds.
NOTE: Ensure that vehicle maximal load capacity
is not exceeded.
If the Error Code Remains Active
If the error code remains active each time that the
ACS switch is pressed, refer to TROUBLESHOOT-
ING GUIDELINES.
TROUBLESHOOTING
GUIDELINES
ERROR CODE "MANUAL" REMAINS
ACTIVE IN GAUGE
1. Leak in the ACS system.
- Check ACS system to detect leak, refer to ACS
SYSTEM LEAK TEST.
2. Faulty ACS position sensor or wiring. (Refer to
ACS POSITION SENSOR for testing).
- Check ACS position sensor signal circuit continu-
ity.
- Check ACS position sensor input voltage.
- Check ACS position sensor ground circuit conti-
nuity.
- Perform the ACS position sensor reset with
B.U.D.S.
3. Damaged position sensor.
- Check ACS position sensor for damage, refer to
ACS POSITION SENSOR INSPECTION.
REQUESTED SETTING DISPLAY DOES
NOT CHANGE IN GAUGE
1. Faulty ACS Switch (CSS) or wiring.
- Check ACS switch continuity, refer to ACS
SWITCH.
- Check ACS switch control circuit, refer to ACS
SWITCH.
SUSPENSION SETTING CAN NOT BE
CHANGED ON VEHICLE
1. Make sure the following requirements are met:
- Engine is started.
- Parking brake is released.
- Gearbox in gear (first or reverse).
- Rear storage compartments are closed.
 Subsection XX (REAR SUSPENSION (RT SERIES))

2. Damaged fuse.
- Check F5 fuse in RH fuse box (RFB), refer to
POWER DISTRIBUTION AND GROUNDS sub-
section.
3. Damaged relay.
- Check R3 relay (load shedding relay), refer to
POWER DISTRIBUTION AND GROUNDS sub-
section.
- Check R4 relay (ACS relay), refer to ACS RELAY
(R4).
4. Faulty multifunction gauge control circuits.
- Check multifunction gauge control circuit continu-
ity to ACS relay (R4) to (PIN-19).
- Check multifunction gauge control circuit continu-
ity to ACS solenoid valve (PIN-18).
5. Faulty ACS compressor or wiring.
- Carry out an ACS COMPRESSOR OPERATION rmr2011-085-002_a
TEST. Step 1: Select Monitoring
Step 2: Select ACC
6. Faulty ACS solenoid valve or wiring.
- Carry out an ACS SOLENOID VALVE OPERATION 4. Start engine and release parking brake.
TEST. 5. Let vehicle run at idle in 1st gear.
6. Press ACS adjustment switch on vehicle.
TROUBLESHOOTING WITH
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. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection.
2. Select Monitoring page.
3. Select ACC folder.
rmo2010-001-038_i

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
WIRING DIAGRAM.

rmr2013-035 7
Subsection XX (REAR SUSPENSION (RT SERIES))

ACS Position Sensor Location ACS Position Sensor Input Voltage

The ACS position sensor is located on the LH side Test
of the vehicle near the shock absorber. 1. Remove rear cargo module. Refer to BODY
subsection.
2. Disconnect position sensor connector.

rmr2010-036-004_a

SOME PARTS REMOVED FOR CLARITY PURPOSE

1. ACS position sensor

ACS Position Sensor Signal Circuit rmr2010-036-009_a

Continuity Test 1. Position sensor connector

1. Remove rear cargo module. Refer to BODY 3. Set the FLUKE 115 MULTIMETER (P/N 529 035
subsection. 868) to Vdc.
2. Disconnect position sensor connector. 4. Start engine and release parking brake.
5. Let vehicle run at idle in 1st gear.
6. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin 5 (YL/WH)
Battery voltage (± 5 Vdc)
Battery negative (-) post

ACS Position Sensor Ground Circuit

Continuity Test
1. Remove rear cargo module. Refer to BODY
rmr2010-036-009_a
subsection.
1. Position sensor connector 2. Disconnect position sensor connector.
3. Remove multifunction gauge from vehicle. Re-
fer to LIGHTS, GAUGE AND ACCESSORIES
subsection.
4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
5. Measure resistance as per the following table.
TEST PROBES RESISTANCE
Gauge connector
pin 13 (LT BU/YL)
Close to 0
Position sensor connector
pin 4 (LT BU/YL) rmr2010-036-009_a

1. Position sensor connector

3. Set the FLUKE 115 MULTIMETER (P/N 529 035

868) to Vdc.

8 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

4. Start engine and release parking brake. NOTE: Check battery voltage before performing
5. Let vehicle run at idle in 1st 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
Pin 1 (BK) Battery voltage 1. From LH side of vehicle, insert the short block
Battery positive (+) post (± 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
REQUIRED TOOLS
2 blocks of wood (typically 10 x 10 cm (4 x 4 in))
Short block: 110 mm (4-7/16 in)
Long block: 150 mm (5-7/8 in)

Vehicle Preparation
1. Park vehicle on a level surface.
2. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection. rbg2010-007-008_a

LH SIDE OF THE VEHICLE SHOWN

3. Inflate rear tire to 193 kPa (28 PSI).
4. Safely lift the vehicle.
5. Turn ignition key to ON.
6. Connect vehicle to B.U.D.S. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection.
7. Click the Setting tab.
8. Click the ACC tab at the bottom of the screen.
NOTE: Ensure the check box With/Without ACS
is checked.
1. Front of vehicle
2. Catalytic converter
2. Lower vehicle until it rests on block.
3. Place approximately 95 kg (210 lb) on passen-
ger seat.
4. Manually lift or push down the rear of vehicle
until rear screw of the footrest support is at the
specified distance from the ground.
DISTANCE FROM THE GROUND FOR
LOW POSITION RESET
355 mm ± 3 mm (14 in ± 1/8 in)

rbg2010-007-007_c

LOW POSITION FOR SENSOR RESET

1. Short block
A. See table
rbg2011-011-001_a

1. 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.

rmr2013-035 9
Subsection XX (REAR SUSPENSION (RT SERIES))

rbg2011-011-001_c rbg2011-011-001_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.
– These values must NEVER be used to adjust
or confirm the position of the ACS position
sensor.
– Do not try to match these values on other
vehicles.
7. Replace the short block with the long block.
8. Manually lift or push down the rear of vehicle vmr2006-012-100_ben

until rear screw of the footrest support is at the

specified distance from the ground.
DISTANCE FROM THE GROUND FOR
HIGH POSITION RESET
400 mm ± 3 mm (15-25/32 in ± 1/8 in)
12. Remove weight and wood block from vehicle.
13. Lower vehicle to the ground.
14. Turn the ignition key to OFF position then wait
a few seconds.
15. Start engine and release parking brake.
16. Let vehicle run at idle in 1st 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-
rbg2010-007-007_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.

10 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

4. Detach link rod from position sensor by remov-

ing upper bolt and nut.

rbs2010-012-001

CORRECT ORIENTATION

rmr2010-036-010_a

1. 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

INCORRECT 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 RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove body parts as required to access to the rmr2010-036-011_a

position sensor. Refer to BODY 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 ACS POSITION SENSOR RESET (WITH
B.U.D.S.).

ACS SOLENOID VALVE

The ACS solenoid valve is identified SRS in the
WIRING DIAGRAM.
ACS Solenoid Valve Location
rmr2010-036-009_a
The ACS solenoid valve is located on the RH side
1. Position sensor connector
of the vehicle near the shock absorber.
rmr2013-035 11
Subsection XX (REAR SUSPENSION (RT SERIES))
rmr2013-035-001_a
SOME PARTS REMOVED FOR CLARITY PURPOSE
1. ACS solenoid valve
ACS Solenoid Valve Operation Test
1. Manually adjust air suspension pressure to
6 bar (87 PSI).
2. Remove body parts as required to access to the
ACS solenoid valve. Refer to BODY subsection.
3. Disconnect solenoid valve connector.
rmr2013-035-002_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.
6. Verify that air exits from side port to confirm
proper solenoid operation.
12
rmr2013-035-001_a
SOME PARTS REMOVED FOR CLARITY PURPOSE
1. Side port
If air exits from side port:
– Check input voltage at solenoid valve (PIN-1),
refer to the WIRING DIAGRAM.
– Check ground circuit continuity at solenoid
valve (PIN-2), refer to the WIRING DIAGRAM.
– Check connector and terminal condition.
If no air exits from side port:
– Replace ACS solenoid valve.
ACS Solenoid Valve Replacement
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove body parts as required to access to the
ACS solenoid valve. Refer to BODY subsection.
3. Disconnect solenoid valve connector.
rmr2013-035-002_a
1. Solenoid valve connector
rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

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.

rmr2013-035-012_b

FRONT FUSES BLOCK

1. ACS suspension relay (R4)
2. Fuse F5

ACS Relay Continuity Test

1. Remove relay (R4), refer toACS RELAY LOCA-
rmr2013-035-003_a TION.
1. Air fittings 2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
5. Remove ACS manifold retaining screws.
3. Measure resistance as per the following table.
TEST PROBES RESISTANCE
Terminal 30
Open (OL)
Terminal 87

4. Apply 12 volts on terminals 86 and 85.

5. Measure resistance again as per the following
table.
TEST PROBES RESISTANCE
Terminal 30
Close to 0
rmr2010-036-014_a Terminal 87
1. ACS manifold retaining screws
If results are not as per the previous tables, re-
6. Remove ACS manifold from vehicle. place relay.
7. Unscrew ACS solenoid valve from ACS mani-
fold. ACS Relay Input Voltage Test
8. Install a new solenoid valve as the reverse of 1. Remove relay (R4), refer to ACS RELAY LOCA-
removal procedure. TION.
9. Check the air system for leakage, refer to ACS 2. Set the FLUKE 115 MULTIMETER (P/N 529 035
SYSTEM LEAK TEST. 868) to Vdc.
3. Start engine and release parking brake.
ACS RELAY (R4) 4. Let vehicle run at idle in 1st gear.
ACS Relay and Fuse Location 5. Measure voltage as per the following tables.
ACS relay (R4) and fuse F5 are located in the RH
fuse block (RFB), inside the front storage compart-
ment.
rmr2013-035 13
Subsection XX (REAR SUSPENSION (RT SERIES))

TEST PROBES VOLTAGE ACS Compressor Operation Test

Fuse box pin C7 NOTICE Do not power the compressor di-
(LIGHT GN/GY) Battery voltage rectly with the battery for more than 10 sec-
(± 12 Vdc) onds. Apply voltage quickly to ensure that
Battery negative (-) post
the compressor will not over pressurize the
TEST PROBES VOLTAGE ACS system. Respect a 1 minute cool down
between tests.
Fuse box pin C8
(LIGHT GN/GY) Battery voltage 1. Release air pressure, refer to RELEASING AIR
(± 12 Vdc) PRESSURE IN SYSTEM FOR SERVICING in this
Battery negative (-) post
subsection.
If voltage is not as specified: 2. Remove body parts as required to access to the
– Check fuse F5, refer to POWER DISTRIBU- compressor. Refer to BODY subsection.
TION AND GROUNDS. 3. Disconnect compressor connector.
– Check relay R3 (load shedding relay), refer to
POWER DISTRIBUTION AND GROUNDS.
– Check wiring continuity, refer to the WIRING
DIAGRAM.
– Check connector and terminal condition.

ACS COMPRESSOR
ACS Compressor Location
The ACS compressor is located on the RH side of
the vehicle near the shock absorber.

rmr2010-036-015_a

1. Compressor connector

4. Connect compressor connector pin 2 (ORANGE

wire) to a 20 A suitable fuse jumper and then
directly to the positive battery post.
5. Connect compressor connector pin 1 (BLACK
wire) directly to the negative battery post.
6. Verify if compressor works properly.
If compressor does not work:
– Replace compressor.
If compressor works:
– Check relay R4, refer to ACS RELAY (R4) in this
rmr2013-035-004_a
subsection.
SOME PARTS REMOVED FOR CLARITY PURPOSE
1. ACS compressor If the fault is not found after having carried out the
previous tests:
– Check input voltage at compressor (PIN-2), re-
fer to the WIRING DIAGRAM.
– Check ground circuit continuity at compressor
(PIN-1), refer to the WIRING DIAGRAM.
– Check connector and terminal condition.

14 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

ACS Compressor Removal

1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove body parts as required to access to the
compressor. Refer to BODY subsection.
3. Disconnect compressor connector.

rmr2013-035-011_a

1. Retaining collar
2. Bolts

6. Open retaining collar then remove compressor.

7. Remove compressor rubber.

rmr2010-036-015_a

1. Compressor connector

4. Disconnect compressor pneumatic hose from

manifold as follows:
4.1 Push fitting ring toward ACS manifold.
4.2 Hold ring in place.
4.3 Pull air hose.

rmr2010-036-018_a

1. Compressor rubber

8. Unscrew check valve and fitting from compres-

sor.

rmr2013-035-005_a

1. Compressor pneumatic hose

5. Remove bolts and nuts from compressor retain-

ing collar.
rmr2011-085-003_a

1. Check valve
2. Fitting

rmr2013-035 15
Subsection XX (REAR SUSPENSION (RT SERIES))

ACS Compressor Installation If switch does not work to UP and DWN position,
The installation procedure is the reverse of re- check control circuit continuity as follows.
moval procedure, however pay attention to the ACS SWITCH COMMON CONTROL CIRCUIT
following.
TEST PROBES RESISTANCE
Apply LOCTITE 592 (PIPE SEALANT) (P/N 293 800
018) on check valve and fitting threads. Multifunction gauge
pin-20 Close to 0
Check the air system for leakage, refer to ACS
SYSTEM LEAK TEST. ACS switch pin-6

ACS SWITCH COMMON CONTROL CIRCUIT

ACS SWITCH
TEST PROBES RESISTANCE
The ACS switch is identified CSS in the wiring di-
agram. Multifunction gauge
pin-20 Close to 0
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
TEST PROBES RESISTANCE
ACS switch pin-5
Close to 825
Main ground

If switch does not work to DWN position only,

check control circuit continuity as follows.
ACS SWITCH DOWN POSITION CONTROL
rmr2010-036-102_a
CIRCUIT
1. ACS switch TEST PROBES RESISTANCE
2. ACS switch connector
3. Central panel ACS switch pin-1
Close to 18.2 K
ACS Switch Continuity Test Main ground
Set the FLUKE 115 MULTIMETER (P/N 529 035 868)
to . ACS Switch Replacement
Check ACS switch continuity as follows. Remove central panel. Refer to BODY subsec-
tion.
ACS SWITCH
PIN RESISTANCE Remove ACS switch from console by pushing re-
POSITION
taining tabs.
Firmly pushed to UP 2 5
Released (FREE) 2 3 Close to 0
Firmly pushed to DWN 2 1

If switch is defective, replace it with a new one.

If switch is correct, carry out the ACS SWITCH
CONTROL CIRCUIT TEST.
ACS Switch Control Circuit Test
Set the FLUKE 115 MULTIMETER (P/N 529 035 868)
to . rmr2010-036-102_a

Check ACS switch control circuits as follows. 1. ACS switch

2. ACS switch connector
3. Central panel

16 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

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.

rmr2010-036-010_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.

rmr2013-035-006_a

SOME PARTS REMOVED FOR CLARITY PURPOSE

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 RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove body parts as required to access to the
ACS air spring. Refer to BODY subsection. rmr2013-035-006_b

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.

rmr2013-035 17
Subsection XX (REAR SUSPENSION (RT SERIES))

rmr2008-030-009

TYPICAL

7. From underneath swing arm, remove air spring rmr2010-036-024_a

lower retaining screw. 10. Remove the following components from air
spring:
– ACS position sensor
– Pneumatic fitting
– Air spring plate retaining nut
– Air spring plate.

rmr2010-036-022_a

1. Lower retaining screw

8. Remove air spring upper retaining screws on

both side.

rmr2010-036-025_a

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.
Tighten air spring retaining screws to specifica-
tion.
AIR SPRING SCREWS TORQUE
rmr2010-036-023_a
7 N•m (62 lbf•in)
1. Upper retaining screw
Tighten air spring retaining nut to specification.
9. Carefully push down air spring then remove it
from vehicle frame. AIR SPRING RETAINING NUT
7 N•m (62 lbf•in)

18 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

Check the air system for leakage, refer to ACS

SYSTEM LEAK TEST.

SHOCK ABSORBER
Shock Absorber Removal
NOTICE Always detach link rod from position
sensor before servicing the rear suspension
(on applicable models).
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this rmr2008-030-010_a

subsection.
2. Remove body parts as required to access to the
shock absorber. Refer to BODY subsection.
3. Detach link rod from position sensor by remov-
ing upper bolt and nut (on applicable models).
TYPICAL
1. Shock absorber
2. Upper bracket
7. Remove the shock absorber lower bolt.
8. Remove rear shock absorber from vehicle.
Shock Absorber Disassembly
Remove spring from the shock absorber.
REQUIRED TOOL
SPRING COMPRESSOR (P/N 529 036 184)

529036184

Position the shock absorber in the tool and install

rmr2010-036-010_a the spring compressor hooks.
1. Link rod upper bolt

4. Remove the shock absorber upper bolt.

5. Install a jack under the rear portion of frame.

mmr2010-033-012_a

1. Spring compressor hooks

Tighten the spring compressor tool screw until

the spring is sufficiently compressed to remove
spring stopper.
Release the spring compressor tool screw.
rmr2008-030-009 Remove spring from shock absorber.
TYPICAL

6. Lift the vehicle until the shock absorber can be

removed from upper bracket.

rmr2013-035 19
Subsection XX (REAR SUSPENSION (RT SERIES))

Shock Absorber Inspection

Shock Absorber Removed from Vehicle
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
rmr2008-030-014_a
denote a defective shock:
TYPICAL
– A very weak rebound. 1. Stopper opening
2. Cap opening
– A skip or a hang back when reversing stroke at
mid travel. Shock Absorber Installation
– Seizing or binding condition except at extreme
end of either stroke. The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
– Oil leakage.
– A gurgling noise, after completing one full com- ACS System with Compressor
pression and extension stroke. NOTICE In order to avoid damaging ACS po-
Replace if any faults are present. sition sensor:
Shock Absorber Installed on Vehicle – Ensure that the air pressure is released into
ACS system.
Manually adjust air suspension pressure to
2 bar ± 0.2 bar (30 PSI ± 3 PSI). – Do not lift the rear of vehicle too high.
From the rear, press down the vehicle as much Carefully lift the rear of vehicle and monitor the
as possible and release it to let suspension return alignment of the bottom of the shock absorber
upward. (anchoring hole) with the bottom of the lower
If the suspension bounces freely or returns too brackets.
quickly:
– Remove and inspect shock absorber.

Shock Absorber Assembly

The assembly is the reverse of the disassembly
procedure. However, pay attention to the follow-
ing.
When installing spring stopper and cap, make
sure to install opening at 180°.

rbs2010-012-010_a

TYPICAL
1. Lower bracket hole
2. Anchoring hole

20 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

SHOCK ABSORBER BOLTS TORQUE

48 N•m (35 lbf•ft)

SWING ARM
Swing Arm Removal
NOTICE Always detach link rod from position
sensor before servicing the rear suspension
(on applicable models).
rbs2010-012-004_a

INCORRECT SHOCK ABSORBER ALIGNMENT

1. Lower bracket hole
Prior to installing ACS position sensor, ensure that
sensor lever orientation is correct.
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove rear cargo module. Refer to BODY
subsection.
3. Remove belt guard from swing arm.

rbs2010-012-001

CORRECT ORIENTATION

rmr2010-036-026_a

1. Belt guard

4. Remove muffler from swing arm.

rbs2010-012-002_a

INCORRECT ORIENTATION

Tighten link rod on position sensor to specifica-

tion.
LINK ROD RETAINING NUT TORQUE
7 N•m (62 lbf•in)

Tighten shock absorber retaining bolts to specifi-

cation. rmr2013-008-213_a

1. Muffler

rmr2013-035 21
Subsection XX (REAR SUSPENSION (RT SERIES))

5. Detach ACS position sensor link rod from swing

arm by removing lower bolt and nut (on applica-
ble models).

rmr2013-035-013_a

1. Caliper screws

9. From underneath swing arm, remove air spring

rmr2010-036-028_a
lower retaining screw.
1. Link rod lower bolt

6. Remove cables protector from swing arm.

rmr2010-036-032_a

rmr2013-035-014_a TYPICAL
1. Lower retaining screw
1. Cables protector
2. Cables protector retaining screws
10. Place vehicle on a level surface.
7. From underneath swing arm, remove parking 11. Lift the rear of the vehicle.
brake cable fastener.
12. Install a jack stand under frame.
13. Remove rear wheel. Refer to DRIVE BELT
AND REAR WHEEL subsection.
14. Unscrew shock absorber lower bolt.

rmr2013-035-015_a

1. Parking brake cable fasteners

8. Remove and discard both caliper screws.

rmr2008-030-024_a

1. Shock absorber lower bolt

22 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

15. Remove swing arm flange bolts.

rmr2013-035-010_a

CROSS SECTION OF FRAME AND SWING ARM (RIGHT SIDE)

1. Swing arm axle
rmr2013-035-008_a 2. Spacer
3. Frame
1. LH flange bolt 4. Swing arm bearings
2. Swing arm axle 5. Swing arm

17. Remove the swing arm.

Swing Arm Inspection

Check swing arm for cracks, bending or other
damages.
Check if bearings turn smoothly and freely.
Replace all damaged parts.

Swing Arm Disassembly

Using the BLIND HOLE BEARING PULLER SET
(P/N 529 036 117), remove swing arm bearings,
spacers and sleeves.

rmr2013-035-007_a

1. RH flange bolt

16. Using a longer bolt, position it in threads and

push to extract the swing arm axle.

529036117

Discard bearings and sleeves.

Swing Arm Assembly

1. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
on NEW sleeves.
2. Using a an appropriate bearing installer, install
NEW bearings, spacers and sleeves.

rmr2013-035 23
Subsection XX (REAR SUSPENSION (RT SERIES))

Swing Arm Installation
1. Position swing arm into place.
2. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of LH flange bolt.
3. Install LH flange bolt into swing arm axle.
8. Move swing arm up and down. The swing arm
must move freely and smoothly.
9. Install NEW caliper screws.
10. Install all other removed parts.

rmr2013-035-008_a

1. LH flange bolt
2. Swing arm axle

4. From the LH side, insert the swing arm axle

assembly into position.
5. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of RH swing arm axle bolt.
6. Install RH flange bolt onto assembly.

rmr2013-035-007_a

1. RH flange bolt

7. Torque swing arm flange bolts to specification.

SWING ARM FLANGE BOLT TORQUE
55 N•m (41 lbf•ft)

24 rmr2013-035
 Subsection XX (BRAKES)

BRAKES
SERVICE TOOLS
Description Part Number Page
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ........................................... 20
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................................... 32–33
MASTER CYLINDER ROD ADJUSTER ......................................... 529 036 119 ........................................... 24

SERVICE PRODUCTS
Description Part Number Page
BRAKE FLUID................................................................................ 293 600 131 ............................................. 5
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 16

FRONT AND REAR BRAKES

25 N•m
NEW (18 lbf•ft)
68 N•m
(50 lbf•ft)
NEW

7N•m 11 N•m
(62 lbf•in) (97 lbf•in) 11 N•m
16 N•m (97 lbf•in)
(142 lbf•in)
NEW
7N•m 16 N•m
(62 lbf•in) (142 lbf•in) 25 N•m
(18 lbf•ft)

NEW
NEW
16 N•m
(142 lbf•in)
See NEW
installation NEW 68 N•m
procedure 105 N•m (50 lbf•ft)
(77 lbf•ft) NEW 28.5 N•m
NEW
85 N•m 4.5 N•m 4.5 N•m NEW (21 lbf•ft)
(63 lbf•ft) (40 lbf•in) (44 lbf•in) 25 N•m
(18 lbf•ft)
25 N•m
(18 lbf•ft)
NEW
NEW
105 N•m
(77 lbf•ft)
NEW = Component must be replaced when removed.
rmr2013-036-102_a

rmr2013-036 1
Subsection XX (BRAKES)

BRAKE PEDAL

ST-S SE5 ST SE5

ST-LTD SE5 ST SM5
ST-S SM5

RT SE5
RT SM5
RS SE5 RT-S SM5
RS SM5
RS-S SE5
RS-S SM5

NEW
RT-S SE5
RT LTD SE5

48 N•m
(35 lbf•ft)

NEW
NEW = Component must be replaced when removed.
rmr2013-036-105_a

2 rmr2013-036
 Subsection XX (BRAKES)

FRONT PARKING BRAKE PULLEY

ST and RT Models

12 N•m
(106 lbf•in)

5.5 N•m
(49 lbf•in)

5.5 N•m
(49 lbf•in)

rmr2013-036-100_a

rmr2013-036 3
Subsection XX (BRAKES)

FOOTREST RELEASE MECHANISM

ST-S and ST-LTD SE5 NEW

8 N•m
(71 lbf•in)
NEW

NEW
35N•m
(26 lbf•ft)

34N•m
(25 lbf•ft)

RT-S and RT-LTD SE5

NEW
8 N•m
NEW (71 lbf•in)

NEW
35N•m
(26 lbf•ft)
34N•m
(25 lbf•ft)

NEW = Component must be replaced when removed.

rmr2013-036-104_a

4 rmr2013-036
 Subsection XX (BRAKES)

GENERAL TASK WHAT TO DO

This subsection covers the maintenance and pro- Any brake part
1. Check/clear fault codes
cedures related to the braking system mechani- replacement that
involved bleeding 2. Clear LPS fault
cal components. For ABS related components, re-
fer to VEHICLE STABILITY SYSTEM (VSS) subsec-
tion. MAINTENANCE
During assembly/installation, use the torque val-
ues and service products as in the exploded BRAKE FLUID
views.
Clean threads before applying a threadlocker. Re- Recommended Brake Fluid
fer to SELF-LOCKING FASTENERS and LOCTITE Always use brake fluid meeting the specification
APPLICATION at the beginning of this manual for DOT 4 only such as BRAKE FLUID (P/N 293 600 131).
complete procedure.
WARNING
WARNING To avoid serious damage to the brake system:
Torque wrench tightening specifications – Use only DOT 4 brake fluid from a sealed
must be strictly adhered to. container.
Locking devices when removed (e.g.: locking – Use only a clean funnel when filling brake
tabs, elastic stop nuts, cotter pins, etc.) must fluid reservoir.
be replaced.
– Do not use brake fluid taken from old or
already opened containers.
WARNING – Do not mix different fluids for topping off.
Never use thread sealant or Teflon tape on
brake fittings or bleeders. Brake system dam- Brake Fluid Level Verification
age and failure may occurs.
Park the vehicle on a firm level surface.
WARNING Unlatch and lift seat.
Avoid brake system contamination. If re- Check brake fluid level in each reservoir, near the
quired, clean components prior to removal. back of the seat. They should both be above the
MIN. mark.

NOTICE Avoid spilling brake fluid on plastic,

rubber or painted parts. Protect these parts
with a rag when servicing brake system.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
NOTE: Install a battery charger on battery termi-
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.

FAULT CODES
rmr2013-036-002_a
If any bleeding is performed on the braking sys- TYPICAL
tem, it is important to reset the fault codes. Refer 1. Brake fluid reservoir
to DIAGNOSTIC AND FAULT CODES subsection.
WARNING
NOTE: B.U.D.S. software is used to perform the
reset. Clean filler caps before removing.

Add fluid as required. Do not overfill.

rmr2013-036 5
Subsection XX (BRAKES)

vmr2008-033-062_a

TYPICAL
1. Correct position
2. Wrong position

Close seat and ensure it is fully latched.

rmo2010-001-091_a
1. Brake fluid MAX. level mark
2. Brake fluid MIN. level mark
Brake Fluid Replacement
To replace brake fluid, perform the complete
brake bleeding sequence. Refer to BRAKE FLUID
BLEEDING PROCEDURE (COMPLETE SYSTEM)
below.
NOTE: Dispose brake fluid as per your local envi-
ronmental regulations.

Brake Fluid Bleeding Procedure

(Complete System)
General Guidelines
This procedure is divided in multiple tasks that
rmo2010-001-092_a must be completed in a specific order according
A. Operating range to the following table.
Prior to installing brake fluid reservoir caps: STEP TASK
– Check that V slit is in good condition. Perform manual bleeding procedure (left
1
– Ensure diaphragm are properly positioned. caliper, right caliper, rear caliper and VCM)
Perform B.U.D.S. bleeding procedure (front
2
circuit and rear circuit)
3 Validate the system pressure

Requirements for Task Completion

DESCRIPTION QTY
RECOMMENDED BRAKE 1.75 L
FLUID (1.85 qt (U.S. liq.))
40 cm (16 in) clear hose (3/16) 3
80 cm (31 in) clear hose (3/16) 1
Small locking ties 4
rbg2008-003-002_a
Locking ties 4
TYPICAL
1. V slit
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.

6 rmr2013-036

Vehicle Preparation
NOTE: Vehicle battery must be fully charge prior
to bleed brake system.
Remove body parts as required to access to the
following components. Refer to BODY subsec-
tion.
– Front left and right calipers
– Rear caliper
– VCM
– Brake fluid reservoir.
NOTICE Protect plastic, rubber or painted
parts with rags when servicing brake system.
Place vehicle on a level surface.
Loosen front wheel lug nuts.
Lift the front of the vehicle.
Secure front of vehicle on jack stands.
Level the vehicle by using a jack underneath the
rear shock absorber.
NOTE: To ensure that the vehicle is level, use the
bottom vehicle frame as a reference.
Remove front wheels.
Open seat.
Detach lift cylinder from seat.
Lift seat and unplug the pillion rider (passenger)
switch connector.
Cut locking ties securing brake hoses between
reservoir and master cylinder.
Remove reservoir caps.
Install a 40 cm (16 in) long clear hose onto:
– Left caliper bleeder
– Right caliper bleeder
– Rear caliper bleeder.
Secure all clear hose with small locking ties.
Fill clear hoses with brake fluid using a funnel (ap-
proximately 60 mm (2-1/2 in) long).
Locate VCM at the front of vehicle.
Install 80 cm (31 in) long clear hose onto VCM
bleeder.
rmr2013-036
Subsection XX (BRAKES)
rmr2013-036-005_a
1. VCM bleeder
Secure VCM clear hose with small locking tie.
Fill VCM clear hose with brake fluid using a funnel
(approximately 60 mm (2-1/2 in) long).
Manual Bleeding Procedure (Preliminary
Bleeding)
NOTE: Brake fluid reservoir must be kept full to
prevent air from being pumped into the system. If
a sequence is interrupted or a lack of fluid occurs,
start the sequence again.
1. Start bleeding system with left front caliper.
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: It 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.
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:
– Right front caliper
– Rear caliper
– VCM.
7
Subsection XX (BRAKES)
B.U.D.S. Bleeding Procedure (Final Bleeding)
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
B.U.D.S. BLEEDING
BLEEDER LOCATION
CIRCUIT
1: Left front caliper
Front circuit
2: Right front caliper
3: Rear caliper
Rear circuit
4: VCM
NOTE: Each sequence must be carried out with-
out interruption. Furthermore, brake fluid reser-
voir must be kept full to prevent air from being
pumped into the system. If a sequence is inter-
rupted or a lack of fluid occurs, start the sequence
again.
1. Connect B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE.
2. In B.U.D.S., select Read Data.
3. Select Setting folder then the VCM page.
4. Read and understand the procedure on screen
before beginning it.
5. Perform FRONT CIRCUIT BLEEDING and
REAR CIRCUIT BLEEDING inclusively. Follow
the instruction in B.U.D.S.
Reinstall caliper. Refer to CALIPER in this subsec-
tion.
Reinstall wheels on vehicle. Refer to STEER-
ING/FRONT WHEELS subsection for procedure.
Carry out the BRAKE SYSTEM PRESSURE VALI-
DATION as detailed in this subsection.
NOTICE Do not pump up the brake pedal re-
peatedly before doing the validation.
Vehicle Reassembly
Reinstall brake fluid reservoir on vehicle with the
hoses at their original location.
Secure brake fluid reservoir to 7 N•m (62 lbf•in).
Secure hoses with locking ties.
8 rmr2013-036
Install all removed BODY parts 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
(Rear Brake Only)
General Guidelines
This procedure is divided in multiple tasks that
must be completed in a specific order according
to the following table.
STEP TASK
Perform manual bleeding procedure
1
(rear caliper and VCM)
Perform B.U.D.S. bleeding procedure
2
(rear circuit)
3 Validate the system pressure
Requirements for Task Completion
Requirements are the same as for bleeding the
complete braking system. Refer to BRAKE FLUID
BLEEDING PROCEDURE (COMPLETE SYSTEM).
Vehicle Preparation
Remove body parts as required to access to the
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.
Lift seat and unplug the pillion rider (passenger)
switch connector.
Remove reservoir caps.
Install a 40 cm (16 in) long clear hose onto rear
caliper bleeder.
Secure all clear hose with small locking ties.
Fill clear hoses with brake fluid using a funnel (ap-
proximately 60 mm (2-1/2 in) long).
Locate VCM at the front of vehicle.
Install 80 cm (31 in) long clear hose onto VCM
bleeder.

rmr2013-036-005_a
1. VCM bleeder
Secure VCM clear hose with small locking tie.
Fill VCM clear hose with brake fluid using a funnel
(approximately 60 mm (2-1/2 in) long).
Manual Bleeding Procedure (Preliminary
Bleeding)
NOTE: Brake fluid reservoir must be kept full to
prevent air from being pumped into the system. If
a sequence is interrupted or a lack of fluid occurs,
start the sequence again.
1. Start bleeding system with rear caliper.
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: It 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.
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 VCM
bleeder.
B.U.D.S. Bleeding Procedure (Final Bleeding)
NOTE: The bleeding procedure is accomplished
FIRST by completing the manual bleeding proce-
dure as explained above.
rmr2013-036
Subsection XX (BRAKES)
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
Rear brake system
Rear circuit
bleeding
B.U.D.S. BLEEDING
BLEEDER LOCATION
CIRCUIT
3: Rear caliper
Rear circuit
4: VCM
NOTE: Each sequence must be carried out with-
out interruption. Furthermore, brake fluid reser-
voir must be kept full to prevent air from being
pumped into the system. If a sequence is inter-
rupted or a lack of fluid occurs, start the sequence
again.
1. Connect B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE.
2. In B.U.D.S., select Read Data.
3. Select Setting folder then the VCM page.
4. Read and understand the procedure on screen
before beginning it.
5. Perform REAR CIRCUIT BLEEDING. Follow
the instruction in B.U.D.S.
Carry out the BRAKE SYSTEM PRESSURE VALI-
DATION as detailed in this subsection.
NOTICE Do not pump up the brake pedal re-
peatedly before doing the validation.
Vehicle Reassembly
Reinstall brake fluid reservoir on vehicle with the
hoses at their original location.
Secure brake fluid reservoir to 7 N•m (62 lbf•in).
Secure hoses with locking ties.
Install all removed BODY parts 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
This procedure is divided in multiple tasks that
must be completed in a specific order according
to the following table.
9
Subsection XX (BRAKES)
STEP TASK
Perform manual bleeding procedure
1 NOTE: Brake fluid reservoir must be kept full to
(left caliper and right caliper)
Perform B.U.D.S. bleeding procedure
2
(front circuit)
3 Validate the system pressure
Requirements for Task Completion
Requirements are the same as for bleeding the
complete braking system. Refer to BRAKE FLUID
BLEEDING PROCEDURE (COMPLETE SYSTEM).
Vehicle Preparation
Remove body parts as required to access to the
following components. Refer to BODY subsec-
tion.
– Front left and right calipers
– Brake fluid reservoir.
Place vehicle on a level surface.
Apply parking brake.
Loosen front wheel lug nuts.
Secure front of vehicle on jack stands.
Level the vehicle by using a jack underneath the
rear shock absorber.
NOTE: To ensure that the vehicle is level, use the
bottom vehicle frame as a reference.
Remove front wheels.
NOTICE Never use any type of impact
wrench for lug nut removal and installation.
The use of impact wrench could damage the
bolts threads and nuts.
Open seat.
Detach lift cylinder from seat.
Lift seat and unplug the pillion rider (passenger)
switch connector.
Remove reservoir caps.
Install a 40 cm (16 in) long clear hose onto:
– Left caliper bleeder
– Right caliper bleeder.
Secure all clear hose with small locking ties.
Fill clear hoses with brake fluid using a funnel (ap-
proximately 60 mm (2-1/2 in) long).
10
Manual Bleeding Procedure (Preliminary
Bleeding)
prevent air from being pumped into the system. If
a sequence is interrupted or a lack of fluid occurs,
start the sequence again.
1. Start bleeding system with:
– Left front caliper
– Right front caliper.
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: It 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.
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.
B.U.D.S. Bleeding Procedure (Final Bleeding)
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
Front brake system
Front circuit
bleeding
B.U.D.S. BLEEDING
CIRCUIT
BLEEDER LOCATION
1: Left front caliper
Front circuit
2: Right front caliper
rmr2013-036

NOTE: Each sequence must be carried out with-
out interruption. Futhermore, brake fluid reser-
voir must be kept full to prevent air from being
pumped into the system. If a sequence is inter-
rupted or a lack of fluid occurs, start the sequence
again.
1. Connect B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE.
2. In B.U.D.S., select Read Data.
3. Select Setting folder then the VCM page.
4. Read and understand the procedure on screen
before beginning it.
5. Perform FRONT CIRCUIT BLEEDING. Follow
the instruction in B.U.D.S.
Reinstall caliper. Refer to CALIPER in this subsec-
tion.
Reinstall clip retaining hose on suspension arm
(one on each side).
Secure bolt to 11 N•m (97 lbf•in).
rmr2013-036-003_a
TYPICAL
1. Clip retaining hose
Reinstall wheels on vehicle. Refer to STEERING
(DPS) AND WHEELS for procedure.
Carry out the BRAKE SYSTEM PRESSURE VALI-
DATION as detailed in this subsection.
NOTICE Do not pump up the brake pedal re-
peatedly before doing the validation.
Vehicle Reassembly
Reinstall brake fluid reservoir on vehicle with the
hoses at their original location.
Secure brake fluid reservoir to 7 N•m (62 lbf•in).
Secure hoses with locking ties.
Install all removed BODY parts as the reverse of
the removal procedure.
rmr2013-036
Subsection XX (BRAKES)
Ride the vehicle and apply the brake a few times
to ensure the normal behavior of the vehicle.
INSPECTION
BRAKE SYSTEM PRESSURE
VALIDATION
NOTICE Do not pump up the brake pedal re-
peatedly before doing the validation.
In B.U.D.S., select Monitoring folder then the
VCM page.
Slowly depress the brake pedal (only once) until
you reach 3500 kPa (508 PSI) at the brake pres-
sure sensor.
Maintain the brake pedal in position.
Check the Low Pressure Switch button value on
the computer screen.
rmr2008-032-062_a
TYPICAL
1. Brake Pressure Sensor (PSI) value
2. Low Pressure Switch button
If Low Pressure Switch button is still off when
you reached the required pressure the validation
is successful.
If Low Pressure Switch button turns on before
reaching 3500 kPa (508 PSI), perform the follow-
ing additional steps:
Perform equivalent of 3 complete wheels rotation
(for the 3 wheels).
Slowly depress the brake pedal until Low Pres-
sure Switch button turns on.
Take note of the Brake Pressure Sensor (PSI)
value.
Perform equivalent of 3 complete wheels rotation
(for the 3 wheels).
Slowly depress the brake pedal until Low Pres-
sure Switch button turns on.
11
Subsection XX (BRAKES)

Take note of the Brake Pressure Sensor (PSI) PROCEDURES

value.
Perform equivalent of 3 complete wheels rotation CALIPER
(for the 3 wheels).
Caliper Removal
Slowly depress the brake pedal until Low Pres-
sure Switch button turns on. Front Caliper
Take note of the Brake Pressure Sensor (PSI) Place the vehicle on a level surface.
value. Apply parking brake.
Calculate the average of the 3 Brake Pressure Loosen wheel lug nuts.
Sensor (PSI) values previously noted.
Lift the front of vehicle.
If the average is EQUAL OR ABOVE 3500 kPa
(508 PSI), the brake system pressure is conform. Safely support the vehicle on jack stands.
Clear fault codes.
If the average is BELOW 3500 kPa (508 PSI), re-
peat BRAKE FLUID BLEEDING PROCEDURE with
the following deviation:
– Lift the rear of vehicle and adjust master cylin-
der on level.

TROUBLESHOOTING
TROUBLESHOOTING
GUIDELINES (PARKING BRAKE)
Before any troubleshooting operations on parking rmr2008-032-016

TYPICAL
brake system, it is important to check the fault
codes using B.U.D.S. to properly diagnose the Remove wheel.
problem. Refer to DIAGNOSTIC AND FAULT
CODES subsection. Remove and discard caliper screws.
NOTE: If the caliper is replaced, loosen brake
PARKING BRAKE DOES NOT WORK hose first. See procedure below. Otherwise,
1. Faulty WPM module or wiring.
omit the next steps concerning the brake hose.
- Check if windshield works properly.
- Carry out a WPM MODULE SIGNAL CIRCUIT
CONTINUITY TEST.
2. Faulty PBS switch or wiring.
- Carry out a PARKING BRAKE SWITCH TEST.
3. Faulty HBS switch or wiring.
- Carry out a PARKING BRAKE LIGHT SWITCH
TEST.
4. Faulty parking brake motor or wiring.
- Carry out a PARKING BRAKE MOTOR OPERA-
TION TEST.
5. Wrong parking brake cable adjustment.
- Carry out a PARKING BRAKE CABLE ADJUST-
MENT. rmr2013-036-009_b

TYPICAL
1. Caliper screws

NOTICE Do not let caliper hangs by the hose

and do not stretch or twist the hose.

12 rmr2013-036
 Subsection XX (BRAKES)

Install a drain pan under caliper to catch brake

fluid.
Loosen the Banjo fitting. Disconnect brake hose
and discard sealing washers.
Remove the caliper from the vehicle.
Rear Caliper
Place vehicle on a level surface.
Remove muffler from swing arm.
Remove parking brake cable from parking brake
support.
Remove retaining nut from parking brake ten-
sioner.
Remove parking brake cable tensioner and its rmr2013-036-011_a

spring. 1. Retaining clip

2. Retaining screw

Remove and discard caliper screws.

rmr2013-036-001_e

1. Parking brake cable

2. Parking brake support
3. Parking brake cable tensioner rmr2013-036-001_c

4. Parking brake tensioner retaining bolt 1. Caliper screws

5. Spring
NOTE: If the caliper is replaced, loosen brake
Remove parking brake support from caliper sup- hose first. See procedure below. Otherwise,
port plate. omit the next steps concerning the brake hose.
NOTICE Do not let caliper hang by the hose
and do not stretch or twist the hose.
Install a drain pan under caliper to catch brake
fluid.
Loosen the Banjo fitting. Disconnect brake hose
and discard sealing washers.

rmr2013-036 13
Subsection XX (BRAKES)

Tighten caliper screws to specification.

CALIPER SCREWS TORQUE
68 N•m (50 lbf•ft)

Rear Caliper
Tighten caliper screws to specification.
CALIPER SCREWS TORQUE
105 N•m (77 lbf•ft)

Check wheel speed sensor adjustment. Refer to

VEHICLE STABILITY SYSTEM subsection.
rmr2013-036-010_b
Adjust parking brake cable, refer to PARKING
1. Banjo fitting BRAKE CABLE ADJUSTMENT in this subsection.
2. Sealing washers

Remove caliper. BRAKE PAD

Caliper Inspection Brake Pad Inspection
Check piston(s) for scratches, rust or other dam- Measure brake pad lining thickness.
ages. If so, replace caliper.
BRAKE PAD THICKNESS
Caliper Installation SERVICE LIMIT 1 mm (.04 in)
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. NOTICE Brake pads must always be replaced
in pairs.
Install NEW caliper screws.
If hoses were disconnected: Front Brake Pad Replacement
– Install NEW sealing washers. Place the vehicle on a level surface.
– Tighten Banjo fitting to specification. Apply parking brake.
BANJO FITTING TORQUE Lift seat.
25 N•m (18 lbf•ft) Clean and remove the rear reservoir cap.

Front Caliper
NOTICE To ensure good clamping of calipers
screws, it is imperative to clean knuckle
threads using a metric tap M10 x 1.5.

rmr2013-036-002_b

TYPICAL
1. Remove this cap

Loosen wheel lug nuts.

rbg2008-002-107_a

TYPICAL
Lift the front of vehicle.
1. Knuckle threads Safely support the vehicle on jack stands.

14 rmr2013-036
 Subsection XX (BRAKES)

Remove brake pads.

Check the condition of pistons pins. Replace
caliper as required.
Install NEW brake pads.
Install caliper. Refer to CALIPER in this subsec-
tion.
Install wheel.
Ride the vehicle a few minutes to make sure the
repair is successful.

rmr2008-032-016 WARNING
TYPICAL
When installing new brake pads, always ob-
Remove wheel. serve a break-in period of 300 km (200 mi).
During this time, the brakes and the VSS
Remove and discard caliper screws. will not operate at their maximum efficiency.
Remove and discard brake pads retaining screw You could lose control and crash – use extra
and retaining clip. caution.

Rear Brake Pad Replacement

Place vehicle on a level surface.
Lift seat.
Clean and remove the front reservoir cap.

rmr2013-036-009_a

TYPICAL
1. Caliper screws
2. Retaining clip
3. Brake pad retaining screw

Using a flat screwdriver, depress pistons into their rmr2013-036-002_c

bores. TYPICAL
1. Remove this cap

Remove muffler from swing arm.

Remove cables protector and cables fastener
from swing arm.

rmr2008-032-018_a

TYPICAL

rmr2013-036 15
Subsection XX (BRAKES)

rmr2013-036-012_a rmr2013-036-063_a

1. Cables protector 1. Retaining clip

2. Cables fastener 2. Retaining screw

Remove parking brake cable, refer to PARKING
BRAKE CABLE subsection.
Remove and discard both caliper screws.
rmr2013-036-001_c
Check brake pad pins for wear, replace as re-
quired.
Rotate the parking brake lever on the caliper to pull
back piston.
Remove and discard brake pads.
Install NEW brake pads.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of brake pad pin.
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 retaining clip.
Install caliper with NEW screws.
Tighten caliper screws to specification.
CALIPER SCREWS TORQUE

1. Caliper screws
Front caliper screws 68 N•m (50 lbf•ft)
Rear caliper screws 105 N•m (77 lbf•ft)
Remove and discard retaining clip securing brake
pad retaining screw. Tighten brake pad pins to specification.
Unscrew and remove brake pad retaining screw.
BRAKE PAD PINS TORQUE
46 N•m (34 lbf•ft)

Apply brake a few times.

Proceed with PARKING BRAKE CABLE TEN-
SIONER INSTALLATION. See procedure in this
subsection.
Check wheel speed sensor adjustment. Refer to
VEHICLE STABILITY SYSTEM subsection.
Ride the vehicle a few minutes to make sure the
repair is successful.

16 rmr2013-036
 Subsection XX (BRAKES)

WARNING MAXIMUM BRAKE DISC WARPAGE

When installing new brake pads, always ob- FRONT AND REAR 0.100 mm (.0039 in)
serve a break-in period of 300 km (200 mi).
During this time, the brakes and the VSS Brake Disc Removal
will not operate at their maximum efficiency.
You could lose control and crash – use extra Front Brake Disc
caution. Place vehicle on a level surface.
Loosen wheel lug nuts.
BRAKE DISC
Lift the front of vehicle.
Brake Disc Inspection Safely support the vehicle on jack stands.
Remove front wheels.
Measure front brake disc thickness.

rmr2008-032-016

TYPICAL

Remove wheel.
Remove caliper screws.
rmr2013-036-056

TYPICAL - FRONT BRAKE DISC

Measure rear brake disc thickness.

rmr2013-036-009_a

TYPICAL
1. Caliper screws

NOTICE Do not let caliper hang by the hose

rmr2013-036-057

REAR BRAKE DISC

and do not stretch or twist the hose.

MINIMUM BRAKE DISC THICKNESS Remove brake disc.

FRONT AND REAR 6.4 mm (.25 in)

Using a dial gauge, verify the brake disc warpage.

rmr2013-036 17
Subsection XX (BRAKES)

Rear Brake Disc

Remove rear wheel. Refer to DRIVE BELT AND
REAR WHEEL subsection.
Remove encoder wheel by unscrewing encoder
wheel screws. Discard screws.

rmr2008-032-034

Front Brake Disc

Install all other removed parts.
Rear Brake Disc
Install NEW brake disc screws.
Tighten brake disc screws to specification as per
tightening sequence.
rmr2013-036-013_a
BRAKE DISC SCREWS TORQUE
1. Encoder wheel screws 25 N•m (18 lbf•ft)
Remove and discard brake disc screws.

rmr2013-036-013_c

rmr2013-036-013_b TIGHTENING SEQUENCE

1. Brake disc screws
Install ENCODER WHEEL, see procedure further
Remove brake disc. in this subsection.
Install all other removed parts.
Brake Disc Installation
The installation is the reverse of the removal pro- ENCODER WHEEL
cedure. However, pay attention to the following.
Position the brake disk so that directional arrow Encoder Wheel Removal
points forward. Front Encoder Wheel
Remove front wheel.
Remove BRAKE DISC, see procedure in this sub-
section.
Remove encoder wheel retaining screws.

18 rmr2013-036
 Subsection XX (BRAKES)

rmr2013-036-059_a rmr2013-036-058_a

1. Encoder wheel retaining screws 1. Encoder wheel

Pull encoder wheel to remove it.
Rear Encoder Wheel
Remove rear wheel. Refer to DRIVE BELT AND
REAR WHEEL subsection.
Remove and discard encoder wheel screws.
Install all other removed parts.
Rear Encoder Wheel
Position the encoder wheel with the inscription
SENSOR SIDE facing outward.

rmr2013-036-013_a rmr2013-036-060_a

1. Encoder wheel screws 1. Sensor side location

Encoder Wheel Inspection Install NEW encoder wheel screws.

Check if encoder wheel teeth are bent or other- Tighten encoder wheel screws to specification as
wise damaged. Replace encoder wheel if neces- per tightening sequence.
sary. ENCODER WHEEL SCREWS TORQUE
Encoder Wheel Installation 5 N•m (44 lbf•in)

Front Encoder Wheels

Position the encoder wheel onto wheel hub.
Install retaining screws and torque to specifica-
tion.
ENCODER WHEEL RETAINING SCREW
7.5 N•m (66 lbf•in)

rmr2013-036 19
Subsection XX (BRAKES)

rmr2013-036-016_a

1. Brake pedal bolt

rmr2013-036-013_d 2. Tab
TIGHTENING SEQUENCE
Remove brake pedal and both washers.
Install rear wheel.

BRAKE PEDAL
Brake Pedal Removal
Remove body parts as required to access to the
following components. Refer to BODY subsec-
tion.
– Brake pedal
– Master cylinder.
Unhook connecting rod from brake pedal.
rmr2010-037-103_a

TYPICAL
1. Brake pedal
2. Both washers

Brake Pedal Disassembly

Remove and discard brake pedal bearings using
the BLIND HOLE BEARING PULLER SET (P/N 529 036
117).
Remove brake pedal sleeve.

rmr2013-036-015_a

1. Connecting rod
2. Brake pedal

From the LH side, underneath vehicle:

529036117
– Unfold tab
– Remove and discard brake pedal bolt.

20 rmr2013-036
 Subsection XX (BRAKES)

rmr2010-037-104_a

TYPICAL rmr2013-036-016_a
1. Brake pedal bearings
2. Brake pedal sleeve 1. Brake pedal bolt
2. Folded tab

Brake Pedal Assembly
Assembly is the reverse of the disassembly pro-
cedure.
NOTE: When assembly brake pedal, always use
NEW bearings.
Brake Pedal Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install brake pedal using a NEW brake pedal bolt.
Make sure to install washers as per the following
illustration.
Each time brake pedal is re-installed, the adjust-
ment of the master cylinder rod is necessary. Re-
fer to MASTER CYLINDER ROD.
All SE5 Models Equipped with Front Footrest
Following brake pedal installation, make sure the
footrest release mechanism is working properly.
Refer to FOOTREST RELEASE MECHANISM sub-
section.
FOOTREST RELEASE
MECHANISM
Footrest Release Mechanism Removal
ST-S and ST-LTD SE5 Only

rmr2013-036-027_a

TYPICAL
1. Brake pedal
2. Washers

Tighten brake pedal bolt to specification.

BRAKE PEDAL BOLT TORQUE rmr2013-036-028_a

PARTS REMOVED FOR CLARITY

48 N•m (35 lbf•ft) 1. Footrest mechanism stud
2. Footrest release mechanism retaining screw
3. Footrest release mechanism spring
Fold either tabs against a flat side of brake pedal 4. Spring retaining screw
bolt head. 5. Brake pedal
6. Footrest release mechanism latch

rmr2013-036 21
Subsection XX (BRAKES)

Remove retaining screw securing footrest release

mechanism spring and remove spring.
Remove retaining screw and both washer secur-
ing footrest release mechanism latch to footrest
support.

Footrest Release Mechanism

Disassembly
Remove footrest release mechanism from vehi-
cle. Refer to FOOTREST RELEASE MECHANISM
REMOVAL.
rmr2013-036-030_a
Remove retaining ring and bearing from latch.
1. Latch pin location
Remove latch pin and washer from footrest.
Remove brake pedal. Refer to BRAKE PEDAL RE-
MOVAL in this subsection.
Remove footrest support. Refer to FOOTREST
SUPPORT REMOVAL in BODY.
Remove retaining screw securing footrest release
mechanism spring and remove spring.
Remove retaining screw and both washers, secur-
ing footrest release mechanism latch to footrest
support.
RT-S and RT-LTD SE5 Only

rmr2013-036-033_a

1. Latch pin
2. Washer

Footrest Release Mechanism

Installation
Installation is the reverse of the removal for both
models however pay attention to the following.
TIGHTENING TORQUE
Latch pin 34 N•m (25 lbf•ft)
Footrest release
mechanism retaining 35 N•m (26 lbf•ft)
screw
rmr2013-036-031_a

RT MODEL SHOWN - PARTS REMOVED FOR CLARITY
1. Footrest mechanism stud
2. Footrest release mechanism retaining screw
3. Footrest release mechanism spring
4. Spring retaining screw
5. Footrest release mechanism latch
6. Brake pedal
7. Latch pin
Remove brake pedal. Refer to BRAKE PEDAL RE-
MOVAL in this subsection.
Remove footrest support. Refer to FOOTREST
SUPPORT REMOVAL in BODY.
Spring retaining screw 8 N•m (71 lbf•in)
Before installing footrest support assembly onto
vehicle verify proper functioning.
– Press on brake pedal far enough to activate
footrest release mechanism.
– Apply pressure on footrest to make sure it ro-
tates all the way down. Then let go of footrest
to make sure it rotates back to its starting posi-
tion.
Install footrest support assembly onto vehicle.

22 rmr2013-036
 Subsection XX (BRAKES)

BRAKE FLUID RESERVOIR Place a container under master cylinder to catch

Brake Fluid Reservoir Removal
Remove body parts as required to access to the
brake fluid reservoir. Refer to BODY subsection.
Unplug brake fluid level sensor connectors.
Remove reservoir screws.
brake fluid.
Loosen Banjo fittings retaining metal brake lines
to master cylinder.
Apply on brake pedal to empty the brake fluid
reservoir and the dual master cylinder.
Remove Banjo fittings and discard sealing wash-
ers.

rmr2008-032-040_a

TYPICAL
1. Sensors connector
2. Reservoir screws rmr2013-036-017_a

1. Banjo fittings
Remove reservoir caps.
Empty reservoir as much as possible. Remove and discard master cylinder screws.
Cut Oetiker clamps and disconnect hoses.

Brake Fluid Reservoir Installation

Connect hoses with NEW Oetiker clamps.
Install reservoir on frame.
Plug brake fluid level sensors.
Fill up reservoir with recommended brake fluid
and bleed brake system. Refer to BRAKE FLUID
in this subsection.
NOTE: Make sure reservoir is filled completly to
avoid low brake fluid error message.
NOTICE Do not overfill to avoid spill.
Install all other removed parts.
rmr2013-036-018_a

SOME PARTS REMOVED FOR CLARITY

DUAL MASTER CYLINDER 1. Master cylinder screws

Dual Master Cylinder Removal Unscrew brake fluid reservoir screws.

Remove body parts as required to access to the Unplug brake fluid level sensor connectors.
following components. Refer to BODY subsec- Remove master cylinder by moving it toward the
tion. front.
– Master cylinder
Cut Oetiker clamps and remove reservoir hoses
– Brake fluid reservoir. from master cylinder.
Cut locking ties securing brake fluid reservoir
hoses to frame.

rmr2013-036 23
Subsection XX (BRAKES)

Dual Master Cylinder Inspection MASTER CYLINDER ROD

Check bellows for cracks or other damages. Re-
place bellows as necessary.
Check if the master cylinder plunger is not stuck
by pushing it on. Replace master cylinder if nec-
essary.
Dual Master Cylinder Installation
NOTICE During installation, ensure all parts
are cleaned to avoid brake system contamina-
tion.
Install reservoir hoses with NEW Oetiker clamps.
Master Cylinder Rod Adjustment
WARNING
This adjustment is necessary to calibrate the
dual master cylinder and avoid braking sys-
tem malfunction.
The adjustment of master cylinder rod must be
performed when one of the following items is re-
placed or removed:
– Brake pedal
– Brake pedal stop
– RH footrest support
– Master cylinder rod
– Connecting rod.
Remove dual master cylinder. Refer to DUAL
MASTER CYLINDER in this subsection.
Unscrew the nut locking the master cylinder rod.
Tighten master cylinder rod into hook.

rmr2008-032-053_a

TYPICAL
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.
MASTER CYLINDER SCREWS TORQUE
25 N•m (18 lbf•ft)

Install metal brake lines on master cylinder with rmr2013-036-019_a

1. Locking nut
NEW sealing washers. 2. Hook
Tighten Banjo fitting to specification.
Install the MASTER CYLINDER ROD ADJUSTER
BANJO FITTING TORQUE (P/N 529 036 119) instead of dual master cylinder.
28 N•m (21 lbf•ft) Position the end of rod inside tool.

Install brake fluid reservoir.

Plug brake fluid level sensors.
Bleed complete brake system. Refer to BRAKE
FLUID BLEEDING PROCEDURE (COMPLETE
SYSTEM) at the beginning of this subsection.
Install all other removed parts.
529036119

24 rmr2013-036
 Subsection XX (BRAKES)

rmr2008-032-054_a

TYPICAL rmr2013-036-019_a
1. Master cylinder rod adjuster
1. Lock nut
2. Hook lock
Ensure brake pedal leans against its rubber stop.
Hold brake pedal in this position. Remove master cylinder rod from vehicle by mov-
Adjust the rod position until it just touches the in- ing it toward the rear.
side of the adjuster hole without compressing rub- Unscrew clevis from master cylinder rod.
ber stop.
Hold the master cylinder rod and tighten lock nut.
Ensure rod does not turn.

rmr2008-032-063_a

1. Master cylinder rod

2. Lock nut
3. Clevis

Master Cylinder Rod Installation

Completely screw the clevis on master cylinder
rmr2008-032-057
rod.
TYPICAL Secure clevis to brake pedal using the clevis lock.
Remove tool and install the dual master cylinder. Adjust master cylinder rod, refer to MASTER
Refer to DUAL MASTER CYLINDER in this sub- CYLINDER ROD ADJUSTMENT.
section.
Attach reservoir hoses with NEW locking ties. PARKING BRAKE FRONT PULLEY
Parking Brake Front Pulley Removal
Master Cylinder Rod Removal
Remove body parts as required to access to the
Remove body parts as required to access to the parking brake front pulley. Refer to BODY subsec-
master cylinder. Refer to BODY subsection. tion.
Loosen lock nut. Detach parking brake cable from pulleys as fol-
Remove hook lock. lows:
– Ensure parking brake is released.
– Unscrew nut securing parking brake cable on
parking brake support.
– Remove cable from parking brake support.
– Unhook cable from parking brake cable ten-
sioner.
– Unhook cable from front pulley.

rmr2013-036 25
Subsection XX (BRAKES)

Carefully pull front pulley toward the outside then

remove spacer.

rmr2013-036-001_d

1. Parking brake support

2. Nut securing cable to parking brake support
3. Parking brake cable tensioner rmr2010-037-111_a

TYPICAL
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.

rmr2010-037-108_a

TYPICAL - FRONT PULLEY

1. Parking brake cable

Remove front pulley retaining nut.

rmr2010-037-118_a

TYPICAL
1. Front pulley
2. Lower pulley stopper
3. Driver footpeg

Install and tighten retaining nut to secure front pul-

rmr2010-037-110_a ley.
TYPICAL
1. Front pulley Connect vehicle to B.U.D.S. Refer to COMMUNI-
CATION TOOLS AND B.U.D.S. SOFTWARE sub-
section.

26 rmr2013-036
 Subsection XX (BRAKES)

Select Activation page.

Select WPM folder.
Press Park Brake Sequence button to set pulley
at its reference position.

rmr2013-036-001_d

1. Parking brake support

2. Nut securing cable to parking brake support
3. Parking brake cable tensioner

rmr2011-086-001_a

PARK BRAKE SEQUENCE BUTTON

Attach parking brake cable on front pulley.

Attach parking brake cable on parking brake cable
tensioner.
Adjust parking brake cable, refer to PARKING
BRAKE CABLE ADJUSTMENT in this subsection. rmr2010-037-108_a

Apply and release the parking brake a few times TYPICAL - FRONT PULLEY
1. Parking brake cable
to ensure normal operation of the mechanism.
Remove retaining nut from parking brake cable
PARKING BRAKE CABLE tensioner.
TENSIONER Remove parking brake cable tensioner and its
spring.
Parking Brake Cable Tensioner
Removal
Detach parking brake cable from pulleys as fol-
lows:
– Ensure parking brake is released.
– Unscrew nut securing parking brake cable on
parking brake support.
– Remove cable from parking brake support.
– Unhook cable from parking brake cable ten-
sioner.
– Unhook cable from front pulley.

rmr2013-036 27
Subsection XX (BRAKES)

rmr2013-036-061_c
rmr2013-036-001_b
1. Parking brake cable tensioner
1. Parking brake cable 2. Parking brake cable support
2. Parking brake support
3. Parking brake cable tensionerr
4. Parking brake tensioner bolt 5. Rotate parking brake cable adjustment nut
clockwise to rotate the lever clockwise up until
the distance (A) between parking brake cable
PARKING BRAKE CABLE tip and parking brake cable support is short-
Parking Brake Cable Adjustment ened by 6 mm (.24 in).
1. Loosen parking brake cable retaining nut.
2. Remove cable tip from the tensioner and cable
from the cable support.

rmr2013-036-061_b

A. Shorter by 6 mm (.24 in)

6. Rotate parking brake cable adjustment nut

rmr2013-036-061_d counterclockwise for 4 1/2 turns or 5.6 mm
1. Parking brake tensioner (.22 in).
2. Parking brake cable tip
3. Parking brake cable retaining nut 7. Finger tighten parking brake cable retaining nut.
4. Parking brake cable adjustment nut
5. Rubber part 8. Once adjusted properly, the minimum distance
6. Cable support between the parking brake cable retaining nut
and the rubber part should be 1 mm (.04 in).
3. Using parking brake cable tip, pull on cable to
remove slack.
4. Insert parking brake cable tip into parking brake
tensioner and parking brake cable into parking
brake cable support.

28 rmr2013-036
 Subsection XX (BRAKES)

rmr2013-036-064_a rmr2013-036-001_d

A. Minimum distance of 1 mm (.04 in) 1. Parking brake support

2. Nut securing cable to parking brake support
3. Parking brake tensioner
9. Tighten retaining nuts on the parking brake ca-
ble support to 12 N•m (106 lbf•in).
10. Apply and release the parking brake a few
times to ensure normal operation of the
mechanism.
If parking brake cable cannot be properly adjusted
using this procedure, replace cable. Refer to
PARKING BRAKE CABLE REMOVAL in this sub-
section.

Parking Brake Cable Removal

Remove body parts as required to access to the
parking brake cable. Refer to BODY subsection.
rmr2010-037-108_a
Detach parking brake cable from pulley and ten-
TYPICAL - FRONT PULLEY
sioner as follows: 1. Parking brake cable
– Ensure parking brake is released.
– Unscrew nut securing parking brake cable on From underneath swing arm, remove parking
parking brake support. brake cable fasteners.
– Remove cable from parking brake support.
– Unhook cable from parking brake cable ten-
sioner.
– Unhook cable from front pulley.

rmr2013-036-020_a

SOME PARTS REMOVED FOR CLARITY

1. Parking brake cable fastener behind passenger footrest
2. Parking brake cable fastener behind master cylinder

rmr2013-036 29
Subsection XX (BRAKES)

From RH side of vehicle, remove cable fastener PARKING BRAKE MOTOR

and locking tie securing parking brake cable.
Parking Brake Operation
To apply parking brake, press parking brake switch
(PBS) down.
To release parking brake, press PBS switch down
until brake indicator lamp turns OFF.
The parking brake cannot be activated while the
vehicle is moving faster than 10 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:
rmr2010-037-113_a
1. Connect vehicle to B.U.D.S. Refer to COMMU-
TYPICAL - SOME PARTS REMOVED FOR CLARITY NICATION TOOLS AND B.U.D.S. SOFTWARE
1. Parking brake cable fastener subsection.
2. Locking tie
2. Select Monitoring page.
Unscrew nut securing parking brake cable on the
3. Select WPM folder.
upper support.
Remove cable from the upper support by passing
it through the hole.

rmr2010-038-059_a

TYPICAL
Step 1: Select monitoring
Step 2: Select WPM
rmr2010-037-114_a
4. Press parking brake switch (PBS) on vehicle.
1. Nut securing cable to support
2. Hole to remove cable

Remove cable from vehicle.

Parking Brake Cable Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Align white lines on the cable with cable fasteners
on swing arm.
Adjust parking brake cable, refer to PARKING
BRAKE CABLE ADJUSTMENT in this subsection.
rmo2010-001-038_o

TYPICAL - PARKING BRAKE SWITCH (PBS)

5. Check proper operation in B.U.D.S.

30 rmr2013-036

Parking Brake Motor Operation Test
1. Connect vehicle to B.U.D.S. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection.
2. Select Activation page.
3. Select WPM folder.
4. Press Park Brake Sequence button.
rmr2011-086-001_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 WIRING DIAGRAM.
– Check ground circuit continuity at motor (PIN-
2), refer to the WIRING DIAGRAM.
– Check connector and terminal condition.
If the fault is not found after having carried out the
previous tests:
– Test motor operation by connecting it directly to
the battery posts.
• If motor works properly, test module, refer to
WINDSHIELD AND PARKING BRAKE MOD-
ULE (WPM) in this subsection.
• If motor does not work properly, replace mo-
tor.
NOTICE Do not power motor directly with the
battery for a long period. Apply voltage quickly
to ensure that the motor will not overheat at
the end of its stroke.
rmr2013-036
Subsection XX (BRAKES)
Parking Brake Motor Removal
Remove body parts as required to access to the
parking brake motor. Refer to BODY subsection.
Remove parking brake front pulley, refer to PARK-
ING BRAKE FRONT PULLEY REMOVAL in this
subsection.
Disconnect parking brake motor connectors.
rmr2013-036-021_a
1. Parking brake motor connectors
Remove retaining bolts and nuts of parking brake
motor.
rmr2010-037-112_a
TYPICAL
1. Motor retaining bolts
Remove motor from vehicle by pulling it upwards.
Parking Brake Motor Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install parking brake front pulley, refer to PARK-
ING BRAKE FRONT PULLEY INSTALLATION in
this subsection.
Adjust parking brake cable, refer to PARKING
BRAKE CABLE ADJUSTMENT in this subsection.
31
Subsection XX (BRAKES)

PARKING BRAKE MODULE (PBM) TEST PROBES RESISTANCE

(ST MODELS) PBS switch connector
pin 2 (YL/LT GN)
PBM Module Signal Circuit Continuity Close to 0
Test WPM module connector
pin 10 (YL/LT GN)
1. Remove body parts as required to access to the
PBM module. TEST PROBES RESISTANCE
2. Remove retaining screws securing eyelet to ve-
PBS switch connector
hicle.
pin 3 (LT BU/GN)
Close to 0
WPM module connector
pin 1 (LT BU/GN)

TEST PROBES RESISTANCE

PBS switch connector
pin 1 (GY/OG)
Close to 0
WPM module connector
pin 12 (GY/OG)

If results are not as per the previous tables:

– Check connector and terminal condition.
– Repair open circuit in wiring.
If the fault is not found after having carried out the
previous operations:
rmr2013-036-025_a
– Test PBS switch, refer to PARKING BRAKE
1. Eyelets
SWITCH (PBS) in this subsection.
3. Remove the 4 retaining bolts securing PBM to – Check input voltage at WPM module (PIN-5),
PBM support. refer to the WIRING DIAGRAM.
– Check ground circuit continuity at WPM module
(PIN-7), refer to the WIRING DIAGRAM.
– Test HBS switch, refer to PARKING BRAKE
LIGHT SWITCH (HBS) in this subsection.
– Check wiring continuity between HBS switch
(PIN-1) and WPM module (PIN-3), refer to the
WIRING DIAGRAM.
If the fault is still not found:
– Replace PBM module.

rmr2013-036-026_a

1. Rear retaining bolts securing PBM to PBM support

4. Disconnect PBM module connector.
5. Disconnect parking brake switch (PBS) connec-
tor. Refer to PARKING BRAKE SWITCH (PBS)
in this subsection.
6. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
7. Measure resistance as per the following tables.
WINDSHIELD AND PARKING
BRAKE MODULE (WPM) (RT
MODELS)
NOTE: WPM module has 2 functions, it controls
windshield and parking brake. The WPM module
is integrated into the windshield base.
For troubleshooting and removal procedures relat-
ing to the WPM module, refer to WINDSHIELD
MODULE (WPM) in BODY (RT SERIES) subsec-
tion.

32 rmr2013-036
 Subsection XX (BRAKES)

TEST PROBES RESISTANCE

PBS switch connector
pin 1 (GY/OG)
Close to 0
WPM module connector
pin 12 (GY/OG)

If results are not as per the previous tables:

rmr2010-038-058
WPM MODULE AND WINDSHIELD BASE
WPM Module Signal Circuit Continuity
Test
1. Remove body parts as required to access to the
WPM module. Refer to WPM MODULE RE-
MOVAL in BODY subsection.
2. Disconnect WPM module connector.
– Check connector and terminal condition.
– Repair open circuit in wiring.
If the fault is not found after having carried out the
previous operations:
– Test PBS switch, refer to PARKING BRAKE
SWITCH (PBS) in this subsection.
– Check input voltage at WPM module (PIN-5),
refer to the WIRING DIAGRAM.
– Check ground circuit continuity at WPM module
(PIN-7), refer to the WIRING DIAGRAM.
– Test HBS switch, refer to PARKING BRAKE
LIGHT SWITCH (HBS) in this subsection.
– Check wiring continuity between HBS switch
(PIN-1) and WPM module (PIN-3), refer to the
WIRING DIAGRAM.
If the fault is still not found:
– Replace WPM module.

PARKING BRAKE SWITCH (PBS)

Parking Brake Switch Test
Remove central panel. Refer to BODY subsec-
tion.
rmr2010-038-053_a

1. WPM module connector

3. Disconnect parking brake switch (PBS) connec-

tor. Refer to PARKING BRAKE SWITCH (PBS)
in this subsection.
4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
5. Measure resistance as per the following tables.
TEST PROBES RESISTANCE
PBS switch connector
pin 2 (YL/LT GN)
Close to 0
WPM module connector
pin 10 (YL/LT GN) rmr2010-037-006_a

1. Parking brake switch

TEST PROBES RESISTANCE 2. Parking brake switch connector

PBS switch connector Check switch operation as follows.

pin 3 (LT BU/GN)
Close to 0
WPM module connector
pin 1 (LT BU/GN)

rmr2013-036 33
Subsection XX (BRAKES)

PARKING BRAKE
PIN RESISTANCE
SWITCH POSITION
Firmly pushed Close to 0
2 3
Released (FREE) Infinite (OL)

PARKING BRAKE
PIN RESISTANCE
SWITCH POSITION
Firmly pushed Infinite (OL)
1 2
Released (FREE) Close to 0

If switch is defective, replace it with a new one.

Parking Brake Switch Replacement

Remove central panel. Refer to BODY subsec- rmr2013-036-021_b

tion. 1. Parking brake light switch

2. Parking brake light switch connector
Remove parking brake switch from central panel
by pushing tabs. Check switch operation as follows.
PARKING BRAKE RESISTANCE @
PIN
SWITCH POSITION 20°C (68°F)
Firmly pushed 0.2 max
1 3
Released Infinite (OL)

If switch is defective, replace it with a new one.

If the switch tests good, verify wire continuity
between harness connector and multifunction
gauge.
MULTIFUNCTION
GAUGE HARNESS RESISTANCE
CONNECTOR WIRES @ 20°C (68°F)
PIN
rmr2010-037-006_b
17 GREEN/WHITE Close to 0
1. Parking brake switch
2. Central panel

Install a NEW switch on console.

Parking Brake Light Switch Removal
Remove body parts as required to access to the
Re-install central panel as the reverse of removal
parking brake light switch. Refer to BODY subsec-
procedure.
tion.
PARKING BRAKE LIGHT SWITCH Unplug parking brake light switch connector.
(HBS)
Parking Brake Light Switch Test
Remove body parts as required to access to the
parking brake light switch. Refer to BODY subsec-
tion.
Unplug parking brake light switch connector.

34 rmr2013-036
 Subsection XX (BRAKES)

rmr2010-037-009_a

TYPICAL - RH SIDE OF VEHICLE

rmr2013-036-021_b
1. Brake light switch
1. Parking brake light switch 2. Brake light switch connector
2. Parking brake light switch connector
Check switch operation as follows.
Cut locking ties retaining the switch harness.
BRAKE LIGHT RESISTANCE @
Drill switch rivets. PIN
SWITCH POSITION 20°C (68°F)
Firmly pushed 0.2 max.
1 2
Released Infinite (OL)

If switch is defective, replace it with a new one.

If the switch tests good, verify wire continuity be-
tween harness connector and ECM-B connector.
ECM-B
HARNESS RESISTANCE
CONNECTOR
WIRES @ 20°C (68°F)
PIN
C3 WHITE Close to 0

Brake Light Switch Removal

Remove body parts as required to access to the
rmr2013-036-021_c brake light switch. Refer to BODY subsection.
1. HBS switch rivets
Cut locking ties retaining the switch harness.
Remove parking brake light switch. Drill brake light switch rivets.
Parking Brake Light Switch Installation
The installation is the reverse of the removal pro-
cedure.

BRAKE LIGHT SWITCH (BLS)

Brake Light Switch Test
Remove body parts as required to access to the
brake light switch. Refer to BODY subsection.
Unplug brake light switch connector.

rmr2013-036 35
Subsection XX (BRAKES)

LOW PRESSURE RESISTANCE @

PIN
SWITCH POSITION 20°C (68°F)
Firmly pushed Infinite (OL)
2 3
Released 0.2 max.

If switch is defective, replace it with a new one.

If the switch tests good, verify wire continuity be-
tween harness connector and VCM.
VCM
HARNESS RESISTANCE
CONNECTOR
WIRES @ 20°C (68°F)
PIN

rmr2010-037-009_b
8 WHITE/VIOLET Close to 0
TYPICAL - RH SIDE OF VEHICLE
1. BLS switch rivets
LPS Removal
Remove switch. Remove body parts as required to access to the
brake light switch. Refer to BODY subsection.
Brake Light Switch Installation
Drill LPS rivets.
The installation is the reverse of the removal pro-
cedure. Cut locking ties retaining the switch harness.

LOW PRESSURE SWITCH (LPS)

NOTE: After a low pressure switch (LPS) prob-
lem has been solved, it is necessary to clear the
occurred fault in the VCM. Refer to LPS FAULT
(BRAKING SYSTEM) below.
Low Pressure Switch Test
Remove body parts as required to access to the
brake light switch. Refer to BODY subsection.
Unplug LPS connector.

rmr2010-037-009_d

TYPICAL - RH SIDE OF VEHICLE

1. LPS switch rivets

Remove switch.

LPS Installation
The installation is the reverse of the removal pro-
cedure.

LPS Fault (Braking System)

After a low pressure switch (LPS) problem has
been solved, it is necessary to clear the occurred
rmr2010-037-009_c fault in the VCM as follows:
TYPICAL - RH SIDE OF VEHICLE 1. Turn ignition switch OFF.
1. LPS switch
2. LPS switch connector 2. Wait 30 seconds.
Check switch operation as follows. 3. Turn ignition switch ON.

36 rmr2013-036
 Subsection XX (BRAKES)

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 1st 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.

rmr2008-039-011_a

TYPICAL

NOTE: Use B.U.D.S. to monitor brake pressure if

desired.

rmr2008-039-012

MONITORING TAB, VCM MODULE

5. Turn ignition switch OFF.

6. Wait 30 seconds.
7. Turn ignition switch ON.
8. Validate fault was cleared.

rmr2013-036 37
 Subsection XX (BODY (RS AND ST SERIES))

BODY (RS AND ST SERIES)

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................... 44–45, 47
XPS MULTI-PURPOSE CLEANER ................................................. 219 701 709 ........................................... 21

rmr2013-037 1
Subsection XX (BODY (RS AND ST SERIES))

BODY PARTS NOMENCLATURE (VEHICLE FRONT VIEW - RS MODEL)

17 18
1
16

19 20
2
3 4

15

5
14 6
13
12 11

10
7

9 8

rmr2011-037-001_a

1. Mirror
2. Windshield
3. Upper console
4. Front fender
5. Storage compartment cover
6. Front fascia
7. Bumper cover
8. Air duct
9. Mudguard
10. Front panel
11. Lower console
12. Driver footrest
13. Rear panel
14. Passenger footrest
15. Rear fender support
16. Rear fender
17. Upper tail cover
18. Passenger handle
19. Seat
20. Central panel

2 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

BODY PARTS NOMENCLATURE (VEHICLE REAR VIEW - RS MODEL)

1
17

16
2
15
14
3

12 11 9
13 10
8 7
6

rmr2013-037-100_a

1. Handlebar cover
2. Central panel
3. Upper tail cover
4. Lower tail cover
5. Rear fender
6. Rear fender support
7. Drive belt guard
8. Rear panel
9. Lower side panel
10. Middle side panel
11. Upper side panel
12. Front panel
13. Mudguard
14. Front fender
15. Storage compartment cover
16. Lower console
17. Upper console

rmr2013-037 3
Subsection XX (BODY (RS AND ST SERIES))

BODY PARTS NOMENCLATURE (VEHICLE FRONT VIEW - ST MODEL)

16
17
2
15 18 1

14 5
12
6
13 10

11
7

8
9
rmr2013-037-104_a

1. Mirror
2. Windshield
3. Windshield trim
4. Front fender
5. Storage compartment cover
6. Front fascia
7. Bumper cover
8. Air duct
9. Front fender
10. Lateral console panel
11. Driver footrest
12. Rear panel
13. Passenger footrest
14. Saddlebag
15. Rear fender
16. Upper tail cover
17. Passenger handle
18. Seat

4 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

BODY PARTS NOMENCLATURE (VEHICLE REAR VIEW - ST MODEL)

17 1

16
2
18
15 3
14

9
12 11 10
8
7
6

13
rmr2013-037-103_a

1. Handlebar
2. Central panel
3. Upper tail cover
4. Lower tail cover
5. Rear fender
6. Rear fender support
7. Drive belt guard
8. Rear panel
9. Lower side panel
10. Middle side panel
11. Upper side panel
12. Front panel
13. Saddlebag
14. Front fender
15. Storage compartment cover
16. Dashboard
17. Speaker grill
18. Lateral console panel

rmr2013-037 5
Subsection XX (BODY (RS AND ST SERIES))

8 9 10
11
6 7

4 1
5 3 2
rmr2013-037-114_a

1. Central panel
2. Lateral console panel
3. Lower console grill
4. Dashboard
5. Air deflector
6. Speaker grill
7. Front console
8. Upper console
9. Safety card holder
10. Upper console trim
11. Dashboard trim

6 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

FRONT BODY PARTS

8 N•m
(71 lbf•ft)

2.5 N•m
(22 lbf•in)

2.5 N•m
(22 lbf•in)

2.5 N•m
(22 lbf•in)

10 N•m
(89 lbf•in)

4.5 N•m
(40 lbf•in)

4.5 N•m
(40 lbf•in)
2.5 N•m
(22 lbf•in) 2.5 N•m
(22 lbf•in)

11 N•m
(97 lbf•in)

2.5 N•m European model

(22 lbf•in)
rmr2013-037-110_a

rmr2013-037 7
Subsection XX (BODY (RS AND ST SERIES))

FRONT FENDER (BASE MODELS)

3.0 N•m
(27 lbf•in)

25.0 N•m
(18 lbf•ft)

7.0 N•m
(62 lbf•in)

25.0 N•m
(18 lbf•ft)
7.0 N•m
(62 lbf•in)

LH side shown, RH side identical

rmr2013-037-107_a

8 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

FRONT FENDERS (RS-S, ST-S AND ST LTD MODELS)

B
B

D
NEW

NEW
A

A
B

B
A 2.5 N•m (22 lbf•in)
B 1.0 N•m (9 lbf•in) C
C 4.5 N•m (40 lbf•in) C
D 25.0 N•m (18 lbf•ft)
D
NEW
rmr2013-037-106_a

rmr2013-037 9
Subsection XX (BODY (RS AND ST SERIES))

CONSOLE (RS MODELS)

0.7 N•m
(6 lbf•in)
2.5 N•m Hand tight
(22 lbf•in)

0.7 N•m
(6 lbf•in)
Hand tight
4.5 N•m
(40 lbf•in)

5 N•m
(44 lbf•in)

7 N•m
(62 lbf•in)

3.5 N•m
(31 lbf•in)

3.5 N•m
(31 lbf•in)
rmr2008-034-002_b

10 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

CONSOLE (ST MODELS)

2.5 N•m
(22 lbf•in)

2.5 N•m 2.5 N•m

(22 lbf•in) (22 lbf•in)

2.5 N•m
(22 lbf•in) 2.5 N•m
(22 lbf•in)

1.8 N•m
1.8 N•m (16 lbf•in)
2.5 N•m (16 lbf•in)
(22 lbf•in)

4.5 N•m
(40 lbf•in)
2.5 N•m
(22 lbf•in)

rmr2013-037-112_a

rmr2013-037 11
Subsection XX (BODY (RS AND ST SERIES))

MIRRORS (ST MODELS)

1.8 N•m
(16 lbf•in)

1.8 N•m
(16 lbf•in)

1.8 N•m
(16 lbf•in)

rmr2013-037-113_a

12 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

LATERAL BODY PARTS - RS MODEL

Hand 3 N•m
tight (27 lbf•in)
4.5 N•m
(40 lbf•in)

3 N•m
(27 lbf•in)
3 N•m
(27 lbf•in)

3 N•m 4.5 N•m

(27 lbf•in) (40 lbf•in)

3 N•m
(27 lbf•in)
3 N•m
(27 lbf•in)
3.5 N•m
(31 lbf•in)

4.5 N•m
(40 lbf•in)

3 N•m
4.5 N•m (27 lbf•in)
(40 lbf•in)
3 N•m
(27 lbf•in)

4.5 N•m
(40 lbf•in)

3.5 N•m 0.7 N•m

(31 lbf•in) (6 lbf•in)
Hand tight

rmr2013-037-102_a

rmr2013-037 13
Subsection XX (BODY (RS AND ST SERIES))

LATERAL BODY PARTS (RH SIDE) - ST MODEL

3 N•m
(27 lbf•in)
4.5 N•m
(40 lbf•in)

3 N•m
(27 lbf•in)

3 N•m
(27 lbf•in)
3 N•m
(27 lbf•in)

3 N•m
(27 lbf•in)
3.5 N•m
(31 lbf•in)

4.5 N•m
(40 lbf•in)
rmr2013-037-115_a

14 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

LATERAL BODY PARTS (LH SIDE) - ST MODEL

3 N•m
(27 lbf•in)

3.5 N•m 3 N•m

(31 lbf•in) (27 lbf•in)

3 N•m
(27 lbf•in)

4.5 N•m
(40 lbf•in)

rmr2013-037-116_a

rmr2013-037 15
Subsection XX (BODY (RS AND ST SERIES))

REAR BODY PARTS (RS MODEL)

9 N•m European 2.5 N•m

(80 lbf•in) model (22 lbf•in)

3.5 N•m
15 N•m 15 N•m (31 lbf•in)
(133 lbf•in) (133 lbf•in) 3.5 N•m
(31 lbf•in)
10 N•m
(89 lbf•in)
15 N•m
(133 lbf•in)

10 N•m
15 N•m (89 lbf•in)
(133 lbf•in)

7 N•m
(62 lbf•in)

7 N•m
(62 lbf•in)

rmr2013-037-101_a

16 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

REAR BODY PARTS (ST MODEL)

9 N•m European 2.5 N•m

(80 lbf•in) model (22 lbf•in)

3.5 N•m
(31 lbf•in)
3.5 N•m
(31 lbf•in)
10 N•m
(89 lbf•in)

10 N•m
(89 lbf•in)

7 N•m
(62 lbf•in)

7 N•m
(62 lbf•in)

rmr2013-037-109_a

rmr2013-037 17
Subsection XX (BODY (RS AND ST SERIES))

FOOTPEGS/FOOTREST ST MODELS

48 N•m 15.5 N•m

(35 lbf•ft) (22 lbf•in)
2.5 N•m
(22 lbf•in)

2.5 N•m
(22 lbf•in)
15.5 N•m
(22 lbf•in)

48 N•m
(35 lbf•ft)

15.5 N•m
5 N•m 15.5 N•m (22 lbf•in)
(44 lbf•in) (22 lbf•in)
15.5 N•m
(22 lbf•in) 48 N•m
(35 lbf•ft)
48 N•m
(35 lbf•ft)
48 N•m
(35 lbf•ft) 5 N•m
(44 lbf•in)

48 N•m
(35 lbf•ft)

2.5 N•m
(22 lbf•in)

2.5 N•m
(22 lbf•in)

rmr2013-037-117_a

18 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

SADDLEBAGS (ST LTD MODELS)

7 N•m
(62 lbf•in)
7 N•m NEW
(62 lbf•in) 10 N•m
NEW (89 lbf•in)
10 N•m NEW
(89 lbf•in)
NEW

NEW
7 N•m
(62 lbf•in)

NEW = Component must be replaced when removed.

rmr2013-037-105_a

rmr2013-037 19
Subsection XX (BODY (RS AND ST SERIES))

SEAT

10 N•m
(89 lbf•in)

8 N•m
(71 lbf•in)
7 N•m 9 N•m
(62 lbf•in) (80 lbf•in)

Loctite
243

5.5 N•m
(49 lbf•in)

5.5 N•m
(49 lbf•in)

rmr2008-034-005_b

20 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))
GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.
NOTICE Hoses, cables or locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
VEHICLE CARE
Vehicle Cleaning
To clean the vehicle, do not use high-pressure
washers (like the ones found in car washes) as
they 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:
– Rinse the vehicle thoroughly with water to re-
move loose dirt.
– Using a soft, clean cloth, wash the vehicle with
water mixed with a mild detergent, such as
soap specially formulated for motorcycles or
automobiles.
– While washing the vehicle, check for grease or
oil. You can use XPS MULTI-PURPOSE CLEANER
(P/N 219 701 709) or a mild automotive de-
greaser. Thoroughly follow the manufacturer's
instructions.
– Dry the vehicle with a chamois or a soft towel.
Vehicle Waxing
Apply only nonabrasive wax safe for clearcoat
paints on glossy finishes.
Avoid applying wax on matte surfaces.
Windshield can be polished with a plastic
cleaner/polisher.
rmr2013-037
WARNING
Do not apply a vinyl or plastic protector on
the seat as the surface will become slippery
and the operator or the passenger may slip
off the vehicle.
PROCEDURES
DECALS
Decal Removal
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.
If decal tears while pulling off, it has to be heated
for a few seconds longer. If decal tends to stretch
while pulling off, stop heating and wait a few sec-
onds to let it cool, then peel it off.
Decal Installation
Using isopropyl alcohol, clean the surface and dry
thoroughly.
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.
NOTICE Do not apply isopropyl alcohol or
solvent directly on decals.
MIDDLE SIDE PANEL
Middle Side Panel Removal
LH Side
Unscrew 3 clips.
21
Subsection XX (BODY (RS AND ST SERIES))

rmo2008-001-034_a
rmo2008-001-032_a
1. Lower side panel's slot
LH SIDE SHOWN 2. Middle side panel tab
1. Middle side panel clips
Press down top edge of panel with both hands
Press down panel's top edge with both hands and
and push in.
pull out.
NOTE: While pressing, ensure that the lower tabs
Lift panel.
remain in the slots.
RH Side
Remove 3 screws.

rmo2008-001-033_b

Step 1: Press down top edge

rmr2008-034-010_a Step 2: Push top edge under top side panel edge
1. Middle side panel screws
RH Side
Press down top edge of panel with both hands Install 3 screws to secure the panel.
and pull out.
LH Side
Lift panel.
Secure panel by pushing and turning each clip
Middle Side Panel Installation clockwise (1/4 turn) to its maximum rotation.
Insert the middle side panel tabs into the lower NOTE: Clip is properly fixed when a small amount
side panel slots. of force is required while turning clip.

rmo2008-001-035_a

22 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

UPPER SIDE PANEL Remove service cover.

Upper Side Panel Removal Remove screws securing front ends of central
panel.
Remove both upper side panels by removing illus-
trated screws.

rmr2008-034-012_a

rsi2008-013-003_a 1. Central panel

2. LH front screw
LH SIDE SHOWN

Pull central panel rearward to remove it.

Upper Side Panel Installation
The installation is the reverse of the removal pro- ST Models
cedure. Unlatch and lift seat.
NOTICE Do not over torque. Any deforma- Remove reusable plastic rivets securing central
tion on the panel around the screw is an indi- panel and lateral console panels to frame.
cation that it is too tight. You may damage the
panel.

CENTRAL PANEL
Central Panel Removal
RS Models
Unlatch and lift seat.
Remove reusable plastic rivets securing central
panel to frame.

rmr2013-037-056_a

TYPICAL - PARTS REMOVED FOR CLARITY

1. Reusable plastic rivets
2. Lateral console panels
3. Central panel

Gently pull central panel from under console rear-

ward to remove it.

Lateral Console Panels

rmr2008-034-011_a

1. Reusable plastic rivets

Remove mirrors.
2. Central panel
3. Frame
Remove upper side panels.
Open storage compartment cover.
Remove upper side panels.
Remove service cover.
Open storage compartment cover.
Remove central panel.
rmr2013-037 23
Subsection XX (BODY (RS AND ST SERIES))

Remove retaining screws securing lateral console

panels to frame

rmr2013-037-095

PUSH FORWARD TO INSTALL

For ST Models, make sure tabs are inserted prop-

erly to ensure adequate fit.
Install retaining screws from front to rear.
NOTE: During lateral panel installation, ensure
turn signal harness is kept outside of lateral con-
sole panel to allow for routing.
rmr2013-037-057_a

TYPICAL - PARTS REMOVED FOR CLARITY

1. Retaining screws to remove
FRONT PANEL
2. Lateral console panels
Front Panel Removal
Remove screws securing front ends of lateral con- Remove upper side panel.
sole panels.
Remove front panel screw.

rmr2008-034-013_a

1. Central panel
2. Front panel
3. Front panel screw
rm2013-037-060_a

LH SIDE SHOWN Open the storage compartment cover.

1. Lateral console panel
2. Lateral retaining screw Remove reusable plastic rivets (two on top, one
3. Front retaining screw on the bottom).
Gently pull lateral console panels to unlock tabs
securing them to console module and remove
them.

Central and Lateral Panel Installation

The installation is the reverse of the removal pro-
cedure. However pay attention to the following:
Push central panel forward to install it.

24 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

rmr2008-034-014_a

TYPICAL
rmr2008-074-004_a

Remove front panel. 1. Locking ties

Front Panel Installation Detach the position light from the front fender by
pushing it rearward.
The installation is the reverse of the removal pro-
cedure.
European Models
For best fit, move front panel backward.
Secure rear screw.

rmr2008-074-001_a

Step 1: Push rearward

Step 2: Lift the front of position light

Remove the bulb socket from the position light.

rbl2008-003-100_c

Step 1: Move front panel backward

Step 2: Check gap between air duct and headlight
Step 3: Tighten screw

NOTICE Do not over torque. Any deforma-

tion on the panel around the screw is an indi-
cation that it is too tight. You may damage the
panel.

FRONT FENDER
Front Fender Removal rmr2008-074-002_a

1. Bulb socket
RS Models 2. Position light

Cut locking ties securing the position light harness Remove screws securing the front fender support
to front fender support. to the knuckle.

rmr2013-037 25
Subsection XX (BODY (RS AND ST SERIES))

rmr2008-074-003_a

1. Fender support screws

Remove fender from vehicle.

Turn fender upside down.
Remove screws retaining fender support mount- rmr2013-037-042_a
ing plates. FENDER ASSEMBLY
1. Fender
2. Reflector
3. Fender moulding
4. Position light

rmr2008-074-005_a

1. Mounting plates
2. Fender supports

Remove the mudguard from fender.

rmr2008-074-003_a

TYPICAL
1. Fender support screws

Remove the 3 retaining screws securing inner

fender to fender support mounting plates.

rmr2008-074-006_a

1. Mudguard
2. Fender

RS-S and ST LTD Models

Remove the retaining screws securing front
fender assembly to knuckle.

26 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

rmr2013-037-044_a rmr2013-037-038_a

1. Fender support mounting plates retaining screws 1. Screws securing fender support mounting plates

Remove retaining screws securing inner fender to Remove retaining screws securing front fender
fender. moulding.

rmr2013-037-023_a rmr2013-037-025_a
1. Retaining screws to remove 1. Retaining screws to remove

Remove screws retaining fender support mount-

ing plates.

rmr2013-037-036_a

1. Retaining screws to remove

rmr2013-037 27
Subsection XX (BODY (RS AND ST SERIES))

Remove both fender moulding tab from inner

fender
Remove Retaining screw securing position light to
fender.
Unhook position light harness from harness re-
taining.

rmr2013-037-043_a

UPPER REFLECTOR
1. Push nuts to remove

Front Fender Installation

The installation is the reverse of the removal pro-
cedure.

rmr2013-037-041_a REAR FENDER

1. Position light retaining screw
2.
3.
Position light
Position light harness
Rear Fender Removal
4. Harness retainer Lift the seat.
Fender Reflectors Removal On RH side, remove the reusable plastic rivets se-
Remove push nuts securing reflector into place. curing rear panel.

rmr2008-030-007_a

1. Reusable plastic rivets

Remove screws securing the RH side of the lower

rmr2013-037-037_a

FORWARD REFLECTOR
tail cover to rear panel.
1. Push nuts to remove

28 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

rmr2013-037-050_a

1. Remove these screws rmr2008-073-009_a

TYPICAL - REAR WHEEL REMOVED FOR CLARITY

Unplug brake light connector and cut locking tie. 1. Locking ties
2. RH fender support
3. LH fender support

Unscrew bolts securing rear fender to rear fender

supports.

rmr2008-073-008_a

TYPICAL
1. Brake light connector
2. Locking tie
3. RH fender support

Remove cable protector from swing arm.

rmr2013-037-070_a

1. Rear fender
2. LH fender support
3. RH fender support

Remove rear fender from vehicle.

Turn rear fender upside down and remove nuts se-
curing the brake light housing.

rmr2013-037-063_a

1. Cable protector screws

Cut locking ties retaining the brake light harness

to RH rear fender support.
rmr2008-073-011_a

1. License plate light housing nuts

2. License plate light
3. Rear fender

rmr2013-037 29
Subsection XX (BODY (RS AND ST SERIES))

Unscrew bolts retaining rear fender to central sup-

port.

rmr2008-073-012_a

1. Central support bolts

2. Central support rm2013-037-006_a
3. Rear fender
TYPICAL
1. Retaining screws to remove
Remove the central rear fender support and the
brake light housing. Remove bolt retaining fender support to swing
arm.
Rear Fender Installation
The installation is the reverse of the removal pro-
cedure.

REAR FENDER SUPPORT

Rear Fender Support Removal
LH Rear Fender Support
Unscrew bolts securing rear fender to its support.

rmr2013-037-072_a

TYPICAL
1. Fender support
2. Bolt to remove

Remove the upper drive belt guard.

rmr2013-037-071_a

1. LH fender support
2. Remove these bolts
3. Rear fender

Remove nuts securing lower rear fender to rear

fender.
rmr2013-037-073_a
Remove retaining screws securing lower rear
TYPICAL
fender to fender support and remove lower rear 1. Upper drive belt guard
fender. 2. Fender support

30 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

Remove bolts retaining the lower drive belt guard

and the bottom of fender support.

rm2013-037-006_a

TYPICAL
1. Retaining screws to remove
rmr2013-037-074_a
Behind muffler, remove screws securing the bot-
TYPICAL
1. Lower drive belt guard tom of fender support.
2. Fender support

RH Rear Fender Support

Unscrew bolts securing rear fender to its support.

rmr2013-037-076_a

1. Fender support lower bolts

Cut locking ties retaining the brake light harness.

rmr2013-037-075_a
Rear Fender Support Installation
1. RH fender support The installation is the reverse of the removal pro-
2. Remove these bolts
3. Rear fender cedure.

Remove nuts securing lower rear fender to rear REAR BODY ASSEMBLY
fender.
Remove retaining screws securing lower rear To work on frame, fuel tank or rear suspension,
fender to fender support and remove lower rear the removal of rear body assembly is necessary.
fender. The rear body assembly includes:
1. Both rear panels
2. Lower tail cover.

Rear Body Assembly Removal

Unlatch and lift seat.
Remove upper side panels.
Remove saddlebags and saddlebag supports.

rmr2013-037 31
Subsection XX (BODY (RS AND ST SERIES))

Remove screws securing front part of both rear

panels.

rmr2008-030-008_a

1. Left turn signal connectors

rmr2008-030-006_a 2. Right turn signal connectors
RIGHT SIDE SHOWN
1. Rear panel screw Pull rear body to remove it.
Remove the 4 reusable plastic rivets securing rear Rear Body Assembly Installation
panels.
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Connect turn signal connectors by matching the
correct wire color.
Install reusable plastic rivets.
Tighten screws.
NOTICE Do not over torque. Any deforma-
tion on the panel around the screw is an indi-
cation that it is too tight. You may damage the
panel.

REAR PANEL
rmr2008-030-007_a

RIGHT SIDE SHOWN Rear Panel Removal

1. Reusable plastic rivets
Unlatch and lift seat.
Remove screw securing lower tail cover to upper Remove upper side panels.
tail cover. Remove saddlebags and saddlebags supports.
Remove screws securing front part of rear panel.

rmr2008-030-006_a
rmr2008-030-005_a RIGHT SIDE SHOWN
1. Rear panel screw
Pull rear panels rearward and unplug turn signal
connectors. Remove the reusable plastic rivets securing rear
panel.

32 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

rmr2008-030-007_a rmr2008-030-005_a

RIGHT SIDE SHOWN

1. Reusable plastic rivets Using a small screwdriver, release the upper tail
cover tabs.
Remove screws securing lower tail cover to rear
panel.

rmr2008-034-016_a

rmr2013-037-050_b 1. Upper tail cover tabs

1. Remove these screws
Remove upper tail cover.
Unplug turn signal connectors.
Upper Tail Cover Installation
Rear Panel Installation Reverse the removal procedure.
Connect turn signal connectors by matching the
correct wire color. LOWER TAIL COVER
Install reusable plastic rivets and screws. Lower Tail Cover Removal
NOTICE Do not over torque. Any deforma- Remove screws securing the lower tail cover to
tion on the panel around the screw is an indi- rear panels.
cation that it is too tight. You may damage the Remove screw securing lower tail cover to upper
panel. tail cover.

UPPER TAIL COVER

Upper Tail Cover Removal
Remove screw securing lower tail cover to upper
tail cover.

rmr2013-037 33
Subsection XX (BODY (RS AND ST SERIES))

rmr2008-030-006_a

rmr2013-037-050_a RIGHT SIDE SHOWN

1. Rear panel screw
1. Remove these screws
Remove the reusable plastic rivets securing rear
Lower Tail Cover Installation panel.
Reverse the removal procedure.

LOWER SIDE PANEL

Lower Side Panel Removal
LH Side on ST Models
Remove LH middle side panel.
Remove front retaining screws.
Remove upper retaining screws.

rmr2008-030-007_a

RIGHT SIDE SHOWN

1. Reusable plastic rivets

Remove lower side panel screws.

rmr2013-037-097_a

PARTS REMOVED FOR CLARITY

1. Upper retaining screw

Slide panel downwards and pull out. rmo2008-001-036_a

LH SIDE SHOWN
RS Models and RH Side on ST Models 1. Screws under rear panel
2. Screw located at the front of lower side panel
Remove middle side panel.
Unlatch and lift seat. Lower Side Panel Installation
Remove upper side panel. The installation is the reverse of the removal pro-
Remove screws securing front part of rear panel. cedure. However pay attention to the following.
For RH side, pull on front section of lower side
panel to position and install upper retaining screw.

34 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

rmr2013-037-096_a rm2013-037-013_a

PULLING ON FRONT SECTION TO INSTALL UPPER RETAINING TYPICAL - PARTS REMOVED FOR CLARITY
SCREW 1. Flasher connectors
1. Upper section retaining screw
Remove retaining screw securing flasher support
NOTICE Do not over torque. Any deforma- to vehicle.
tion on the panel around the screw is an indi-
cation that it is too tight. You may damage the
panel.

REAR SADDLEBAGS SUPPORT

Rear Saddlebags Support Removal
Remove saddlebags from vehicle.
Remove retaining screws securing saddlebag rack
to vehicle using tool included in vehicle tool kit.

rmr2013-037-092_a

1. Retaining screw to remove

2. Flasher support

Remove saddlebag rack support from vehicle.

Rear Saddlebags Installation

Installation is the reverse of the removal proce-
dure.

WINDSHIELD
Windshield Removal
rmr2013-037-091_a

TYPICAL RS Models
1. Retaining screws securing saddlebag rack to vehicle
Remove screws (4) securing windshield to con-
Disconnect both flasher connectors. sole.

rmr2013-037 35
Subsection XX (BODY (RS AND ST SERIES))

rmr2008-034-019_a rmr2008-034-020_a

1. Protective cap
ST Models 2. Mirror support

Remove the 4 retaining screws, washers and nuts Remove mirror screws.
securing windshield trim panels and windshield to
windshield support.
NOTICE Be careful not to drop washers into
windshield mechanism.

rmr2008-034-021_a

1. Mirror screws

Remove mirror.
ST Models
Remove both retaining screws securing lower de-
flector.

rmr2013-037-046_a

1. Windshield retaining screws

Windshield Installation
The installation is the reverse of the removal pro-
cedure.

MIRROR
Mirror Removal
RS Models
Remove the multifunction gauge. Refer to
LIGHTS, GAUGE AND ACCESSORIES subsec- rmr2013-037-067_a

tion. 1. Retaining screws to remove

Unplug turn signal connector. Remove lower mirror cover.

Cut locking tie retaining turn signal harness.
Remove the protective cap near mirror support.

36 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

rmr2013-037-082_a rmr2013-037-068_A

1. Lower mirror cover PARTS REMOVED FOR CLARITY

1. Turn signal connector
Remove retaining screw securing top mirror cover
to mirror assembly. Push mirror towards rear of vehicle until first re-
taining tab is free.

rmr2013-037-069_a
rmr2013-037-083_a TYPICAL
1. Retaining screw to remove
Slide mirror up and out of retaining tab.
Remove top cover.
NOTICE Make sure retaining tab is completly
Disconnect turn signal connector.
disengaged before pulling on mirror.

rmr2013-037 37
Subsection XX (BODY (RS AND ST SERIES))

rmr2013-037-069_b
rmr2013-037-251_a
TYPICAL

Remove retaining screws securing mirror support CONSOLE ASSEMBLY

plate.
Console Assembly Removal
NOTE: In this procedure, console assembly is
removed (including headlights, mirrors and wind-
shield). All components can be also removed
separately. See other procedures in this subsec-
tion or the LIGHTS, GAUGE AND ACCESSORIES
subsection for the headlights procedures.
RS Model
Remove central panel.
Remove the four screws securing the top of stor-
age compartment.

rmr2013-037-250_a

RETAINING SCREWS TO REMOVE

Mirror Installation
The installation is the reverse of the removal pro-
cedure. However pay attention to the following.
Make sure to route wire as per guiding arrow on
vehicle.

rmr2013-037-094_a

UPPER SCREWS RETAINING FRONT STORAGE COMPARTMENT

Remove screws securing console support to

frame.

38 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

Slide the console assembly gently forward and

slightly upward to remove.
NOTE: Rear fasteners are two caged nuts in-
serted in console rear extensions. These fasten-
ers could fall out when the console is inverted
and should be removed to avoid loosing them.
ST Model
Remove the UPPER CONSOLE, see procedure in
this subsection.
Remove central panel, see procedure above in
this subsection.
Remove lateral console panels, see procedure
above in this subsection.
rmr2013-037-093_a
Disconnect the 3 dashboard connectors.
TYPICAL
1. Console support screws

Remove the multifunction gauge. Refer to

LIGHTS, GAUGE AND ACCESSORIES subsec-
tion.
Unplug headlights and turn signal lights.
Remove front panel screw.

rmr2013-037-088_a

CONNECTORS TO DISCONNECT

Remove retaining screws securing front of lower

console to frame.
rmr2008-034-018_a

1. Front panel screw

Lift the storage compartment a little to release its

upper section.
Remove two mounting bolts at rear of console,
one each side.

rmr2013-037-090_a

FRONT LOWER CONSOLE RETAINING SCREW

rsi2008-013-019_a

rmr2013-037 39
Subsection XX (BODY (RS AND ST SERIES))

Remove retaining screws securing rear of lower RS Models

console to frame. Insert a small screwdriver through console access
holes and release upper console tabs. There are
5 access holes.

rmr2013-037-089_a

REAR LOWER CONSOLE RETAINING SCREW

rmr2008-034-022_a

Remove lower console. 1. Access hole

2. Upper console
3. Lower console
Console Assembly Installation
ST Models
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. Remove retaining screws securing windshield
support to windshield support assembly.
RS Model
Note protruding tab on caged nut, it must be in-
serted in the slot on installation.

rmr2013-037-065_a

rsi2008-012-012_a 1. Retaining screws to remove

1. Protruding tab
2. Slot Remove upper console trim retaining screws (4).

UPPER CONSOLE
Upper Console Removal
Remove WINDSHIELD, see procedure above in
this subsection.
Remove both MIRROR, see procedure above in
this subsection.

40 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

Upper Console Installation

RS Models
Align upper console tabs into lower console tab
housings.

rmr2013-037-085_b

REMOVE UPPER RETAINING SCREWS (RH SIDE SHOWN)

Remove dashboard trim retaining screws.

rmr2008-034-023_a

1. Upper console tab

2. Lower console tab housing

All Models
Install all other removed parts.

LOWER CONSOLE
Lower Console Removal
rmr2013-037-086_a RS Models Only
REMOVE DASHBOARD TRIM RETAINING SCREWS
Remove the UPPER CONSOLE, see procedure
Remove upper console trim. above in this subsection.
Remove dashboard retaining screws. Remove central panel.
Remove the four screws securing the top of stor-
age compartment.

rmr2013-037-087_a
rmr2013-037-094_a
REMOVE DASHBOARD RETAINING SCREWS (1 SHOWN)
UPPER SCREWS RETAINING FRONT STORAGE COMPARTMENT
Carefully slide upper console assembly upwards
Remove screws securing console support to
to remove it.
frame.

rmr2013-037 41
Subsection XX (BODY (RS AND ST SERIES))

NOTE: Rear fasteners are two caged nuts in-

serted in lower console rear extensions. These
fasteners could fall out when the lower console is
inverted and should be removed to avoid loosing
them.

Lower Console Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Note protruding tab on caged nut, it must be in-
serted in the slot on installation.

rmr2013-037-093_a

1. Console support screws

Remove front panel screw.

rsi2008-012-012_a

1. Protruding tab
2. Slot

rmr2008-034-018_a SERVICE COVER

1. Front panel screw
Service Cover Removal
Slightly lift the storage compartment to release its RS Models
upper section.
Lift the front storage compartment cover.
Remove two mounting bolts at rear of console,
one each side. Pull out the service cover extremities with both
hands.

rsi2008-013-019_a rmo2008-001-022_a

1. Service cover
Slide the lower console forward and slightly up- 2. Service cover extremities
ward to remove.
ST Models
Lift the front storage compartment cover.

42 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

Remove service covers. FRONT FASCIA

Front Fascia Removal
Open the storage compartment cover.
Release the three tabs retaining front fascia to
storage compartment cover.

rmr2013-037-066_a

1. RH service cover
2. LH service cover

Service Cover Installation

RS Models
Insert cover tabs into rubber grommets.
rmr2008-034-025_a

1. Tabs

Front Fascia Installation

The installation is the reverse of the removal pro-
cedure.

STORAGE COMPARTMENT
COVER
Storage Compartment Cover Removal
rmr2008-034-024_a
Remove the FRONT FASCIA, see procedure
1. Cover tab
above in this subsection.
2. Rubber grommet Remove caps on hinge bolts.
ST Models Remove upper and lower hinge bolts.
Position service cover into place and press on ser-
vice cover while supporting the lights bezel from
below.

rmr2008-034-026_a

1. Upper hinge bolt cap

2. Lower hinge bolt cap

Remove the storage compartment cover.

rmr2013-037-253_a
Storage Compartment Cover
SNAPPING SERVICE COVER INTO PLACE
Installation
The installation is the reverse of the removal pro-
cedure.

rmr2013-037 43
Subsection XX (BODY (RS AND ST SERIES))

Storage Compartment Cover

Adjustment
Check the gap between cover and front panel.
This gap must be equal.
A

1
rmr2008-034-054_a
rmr2008-034-035_a
1. Lock pin
A. Same gap 2. Adjustment nut. Torque to 8 N•m (71 lbf•in)
A. 36.7 mm ± 1 mm (1.445 in ± .039 in)
If an adjustment is necessary, screw or unscrew
the cover latch pin.
NOTE: Apply LOCTITE 243 (BLUE) (P/N 293 800 060)
STORAGE COMPARTMENT
on threads of lock pin if adjusted. If a new lock pin Storage Compartment Removal
is used, the threads are coated with a self-locking Open storage compartment cover.
product.
Remove service cover.
Remove diagnostic connector from storage
holder.

rmr2008-034-036_a

1. Cover latch pin

rmr2013-037-022_a

1. Diagnostic connector

Remove both front panels. Refer to UPPER SIDE

PANEL.
Unplug and detach the Ambient Air Pressure/Tem-
perature Sensor (AAPTS) from the RH side of stor-
age compartment.

44 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

rsi2008-013-009_a

rmr2008-034-027_a
TYPICAL
1. AAPTS connector
Lift storage compartment to remove it.
On the LH side, unplug horn.
Storage Compartment Installation
Install front storage compartment.
Torque front storage compartment upper screws
to 4.5 N•m (40 lbf•ft).
NOTICE Be careful not to apply excessive
torque to screws. Too much torque will dam-
age threads in chassis.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of lower screws.
Torque them to 10 N•m (89 lbf•in).
rmr2008-034-028_a
Plug horn connector.
1. Horn connectors Plug AAPTS connector.
Remove the four upper screws retaining the front Install all other removed parts.
storage compartment. When reassembly is completed, test horn and
check if temperature is indicated in cluster.

STORAGE COMPARTMENT
COVER CABLE
Cover Cable Removal
On the front storage compartment latch, remove
the cable from it's retainer.
Remove the cable end from the latch fork.

rmr2013-037-052_a

1. Upper screws retaining front storage compartment

Underneath vehicle, remove the two lower

screws retaining the front storage compartment
to frame.

rmr2013-037 45
Subsection XX (BODY (RS AND ST SERIES))

rmr2013-037-064_a rmr2008-034-030_a

TYPICAL LH SIDE SHOWN

1. Cable retainer 1. Screws
2. Latch fork 2. Reusable plastic rivet

Detach storage compartment cover cable from ig- Remove bumper cover.
nition switch.
Bumper Cover Installation
The installation is the reverse of the removal pro-
cedure.

SKID PLATE
The skid plate is located under storage compart-
ment.

Skid Plate Removal

Place vehicle on a level surface.
rmr2008-034-029_a Apply parking brake.
1. Storage compartment cover cable
2. Seat cable Lift the front of vehicle.
Support the vehicle with jack stands.
Cut locking ties retaining cable.
Remove screws securing skid plate to frame.
Remove the cable.

Cover Cable Installation

The installation is the reverse of the removal pro-
cedure.

BUMPER COVER
Bumper Cover Removal
Remove front panels. Refer to FRONT PANEL in
this subsection.
Remove screws and reusable plastic rivets secur-
ing the front bumper.

rmr2013-037-077_a

STORAGE COMPARTMENT REMOVED FOR CLARITY

1. Skid plate screws

46 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

Skid Plate Installation

The installation is the reverse of the removal pro-
cedure.

SEAT
Seat Removal
Remove the UPPER TAIL COVER, see procedure
in this subsection.
Unlatch and lift seat. rmr2008-034-033_a

Insert a flat head screwdriver between retaining 1. Hexagonal bolts

2. Torx screw
spring and shock absorber.
Pull the top of shock absorber to remove it. Unscrew bolt retaining seat to its support.
Remove seat.

Seat Installation
The installation is the reverse of the removal pro-
cedure.

Seat Adjustment
NOTE: Apply LOCTITE 243 (BLUE) (P/N 293 800 060)
on threads of lock pin if adjusted. If a new lock pin
is used, the threads are coated with a self-locking
rmr2008-034-031_a
product.
1. Shock absorber retaining spring

Unplug pillion rider's switch.

2
A
rmr2008-034-032_a

1. Pillion rider's switch connector 1

Remove both hexagonal bolts and the Torx screw. rmr2008-034-053_a

1. Lock pin
2. Adjustment nut. Torque to 8 N•m (71 lbf•in)
A. 30 mm ± 1 mm (1.181 in ± .039 in)

SEAT CABLE
Seat Cable Removal
Remove the RH UPPER SIDE PANEL, see proce-
dure in this subsection.
Unlatch and lift seat.
Unscrew seat latch from frame.
Remove the cable end from the latch fork.

rmr2013-037 47
Subsection XX (BODY (RS AND ST SERIES))

rmr2008-034-034_a

1. Seat latch
2. Cable retainer
3. Latch fork

Detach seat cable end from ignition switch. rmr2013-037-019_a

OIL COOLER SIDE SHOWN

1. Screw securing bottom plate and the air duct to frame
2. Bottom plate reusable plastic rivets

NOTE: On RH side, remove fuel vapor canister

hose.

Bottom Plate Installation

Installation is the reverse of removal. However
pay attention to the following.
Snap rear section of bottom plates into place.

rmr2008-034-029_a

1. Storage compartment cover cable

2. Seat cable

Cut locking ties retaining cable.

Remove the cable.

Seat Cable Installation

The installation is the reverse of the removal pro-
cedure.

BOTTOM PLATE
Bottom Plate Removal rmr2013-037-098_b

The bottom plates are located behind oil cooler SNAP REAR SECTION OF BOTTOM PLATE PROPERLY
and coolant radiator. On RH side, make sure to reinstall fuel vapor can-
To remove either plate, remove the LOWER SIDE ister hose.
PANEL, see procedure in this subsection.
Remove the screw securing bottom plate and the
air duct to frame.
Underneath bottom plate, remove reusable plastic
rivets securing it to frame.

48 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

rmr2008-034-045_a
rmr2013-037-098_a
1. Remove this screw
FUEL VAPOR CANISTER HOSE REINSTALLED PROPERLY
Near the end of front panel, remove the air duct
OIL COOLER AIR DUCT upper screw.
Air Duct Removal
Remove the LOWER SIDE PANEL, see procedure
in this subsection.
Remove the screw securing bottom plate and the
air duct to frame.

rmr2008-034-046_a

1. Air duct upper screw

2. Front panel

rmr2008-034-042_a
Air Duct Installation
OIL COOLER SIDE SHOWN The installation is the reverse of the removal pro-
1. Bottom plate
2. Oil cooler air duct cedure.
NOTE: On radiator side, make sure rubber pro-
Underneath vehicle, remove plastic rivet securing tectors are still installed on fins to avoid friction
the air duct to frame. between air duct and radiator.

RADIATOR AIR DUCT

Follow the same procedure as for the OIL
COOLER AIR DUCT.

DRIVER FOOTPEG SUPPORT

AND FOOTPEG (RS MODELS)
Driver Footpeg Support Removal
rmr2008-034-044_a LH Footpeg Support
TYPICAL
1. Plastic rivet Remove the LOWER SIDE PANEL, see procedure
above in this subsection.
Behind front shock absorber, remove screw se- Remove screws holding parking brake pedal sup-
curing the top of air duct to frame. port and LH lateral support.

rmr2013-037 49
Subsection XX (BODY (RS AND ST SERIES))
rmr2013-037-080_a
1. Parking brake support screw
2. LH lateral support screws
Pull the footpeg support to remove it.
Remove parking brake pedal from footpeg sup-
port. Refer to BRAKES subsection.
RH Footpeg Support
Remove the LOWER SIDE PANEL, see procedure
above in this subsection.
Remove master cylinder screws.
rmr2013-037-079_a
1. Master cylinder
2. Master cylinder screws (one not illustrated)
Remove screws retaining lateral support to foot-
peg support.
50
rmr2008-034-048_a
TYPICAL
1. Lateral support
2. Lateral support screws
3. Driver's footpeg support
Pull the footpeg support to remove it.
Remove brake pedal from footpeg support. Refer
to BRAKES subsection.
Driver Footpeg Support Installation
The installation is the reverse of the removal pro-
cedure.
Each time RH footpeg support is re-installed, the
adjustment of the master cylinder rod is nec-
essary. Refer to MASTER CYLINDER ROD in
BRAKE.
Driver Footpeg
Driver Footpeg Removal
Remove circlip, retaining pin and spring securing
footpeg to footpeg support.
Driver Footpeg Installation
Installation is the reverse of the removal proce-
dure. However pay attention to the following.
Install a NEW circlip.
PASSENGER FOOTPEG SUPPORT
Passenger Footpeg Support
Passenger Footpeg Support Removal
Remove the REAR PANEL, see procedure above
in this subsection.
Unscrew the footrest from the frame.
rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

FOOTREST SUPPORT AND

FOOTPEG (ST MODELS)
Footrest Support
Footrest Support Removal
LH Footrest Support
Remove the LOWER SIDE PANEL, see procedure
above in this subsection.
Remove brake pedal. Refer to BRAKE PEDAL RE-
MOVAL in the BRAKES subsection.
Remove bolt retaining shifting link to shifting
block.

rmr2013-037-081_a

1. Footrest screws

On RH side, unscrew muffler mounting bolt.

rmr2010-006-017_a

TYPICAL – SM5 ENGINE SHOWN

1. Shifting block
2. Shifting link

Remove retaining screws securing LH footrest to

vehicle.

rmr2013-037-078_a

1. RH pillion rider's footrest

2. Muffler mounting bolt

Passenger Footpeg Support Installation

The installation is the reverse of the removal pro-
cedure.

Passenger Footpeg
Passenger Footpeg Removal
Remove circlip, retaining pin, spring, indexation
plate and ball securing footpeg to footpeg support.
Passenger Footpeg Installation
Installation is the reverse of the removal proce-
rmr2013-037-030_a
dure. However pay attention to the following.
1. Retaining screws securing LH lateral support to footrest support
Install a NEW circlip. 2. Retaining screw securing footrest support to vehicle

Pull on footrest support to remove it.

RH Footrest Support
Remove the LOWER SIDE PANEL, see procedure
above in this subsection.
rmr2013-037 51
Subsection XX (BODY (RS AND ST SERIES))

Remove master cylinder screws.

rm2013-037-015_a

1. Rear footrest support retaining screw

2. Muffler retaining bolt
rm2013-037-011_a

1. Master cylinder screws (second screw not illustrated)
Remove screws retaining lateral support to
footrest support.
rmr2013-037-061_a
Remove rear footrest support retaining screw and
muffler retaining bolt.
Pull on footrest support to remove it.
Footrest Support Installation
The installation is the reverse of the removal pro-
cedure. However pay attention to the following.
Each time RH footrest support is re-installed, the
adjustment of the master cylinder rod is nec-
essary. Refer to MASTER CYLINDER ROD in
BRAKE.
Driver Footpeg and Driver Footrest
Driver Footpeg and Footrest Removal
On Models equipped with Footrest, remove
footrest release mechanism. Refer to FOOTREST
RELEASE MECHANISM in the BRAKES section.
LH Side
Remove the 3 retaining screws securing driver
footrest (2 for footpeg) to footrest support.

rmr2013-044-306_a

RETAINING SCREWS TO REMOVE

52 rmr2013-037
 Subsection XX (BODY (RS AND ST SERIES))

Remove footpeg/footrest and support assembly Passenger Footrest Installation

from vehicle. The installation is the reverse of the removal pro-
RH Side cedure. However pay attention to the following.
Remove retaining screw and retaining bolt secur- Reinstall spacer going between footrest and
ing footpeg/footrest to footrest support. footrest support.

rmr2013-044-307_a

TYPICAL - BOLT AND SCREW TO REMOVE

Driver Footpeg and Footrest Installation

The installation is the reverse of the removal pro-
cedure.

Passenger Footrest
Passenger Footrest Removal
Remove retaining screw securing passenger
footrest to footrest support. Keep spacer going
between footrest and footrest support.

rm2013-037-007_a

1. Passenger footrest
2. Retaining screw securing passenger footrest to footrest support
3. Passenger footrest height adjustment mechanism

Remove passenger footrest from vehicle.

rmr2013-037 53
 Subsection XX (BODY (RT SERIES))

BODY (RT SERIES)

SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................................... 37–38

SERVICE PRODUCTS
Description Part Number Page
BRP HEAVY DUTY CLEANER ....................................................... 293 110 001 ........................................... 13

BODY PARTS NOMENCLATURE (VEHICLE FRONT VIEW)

13 9

12
10 8

1
11 7
2

3 4 5 6

rmr2010-038-001_a

1. 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
11. Lower wind deflector
12. Upper wind deflector
13. Windshield

rmr2013-044 1
Subsection XX (BODY (RT SERIES))

BODY PARTS NOMENCLATURE (VEHICLE REAR VIEW)

16
15 12
1

2
14
13
3 11

17

10

4 5 6 7 8 9

rmr2013-044-102_a

1. 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
10. Rear fender
11. Rear panel
12. Top storage compartment cover
13. Glove box
14. Central panel
15. Ignition switch cover
16. Gauge trim
17. Grille

2 rmr2013-044
 Subsection XX (BODY (RT SERIES))

FRONT CARGO MODULE

Actuator

5.5 N•m H
(49 lbf•in)
4.5 N•m
(40 lbf•in)

4.5 N•m
(40 lbf•in) H
4.5 N•m
(40 lbf•in)

4.5 N•m
(40 lbf•in)

H H
3.5 N•m
2.5 N•m (31 lbf•in)
(22 lbf•in)

B H
2.5 N•m 4.5 N•m
(22 lbf•in) (40 lbf•in)
A K50 X 16
B K50 X 20
C M5 X 14
D M5 X 25
E M6 X 10
F M6 X 12
G M6 X 16
H M6 X 20
LH side shown, RH side identical I M6 X 25
rmr2011-087-100_a

rmr2013-044 3
Subsection XX (BODY (RT SERIES))

CONSOLE MODULE
H C A K50 X 16
4.5 N•m 2.5 N•m B K50 X 20
(40 lbf•in) (22 lbf•in) C M5 X 14
D M5 X 25
STD E M6 X 10
F M6 X 12
G M6 X 16
H M6 X 20
I M6 X 25

D
2.5 N•m
(22 lbf•in)

NEW
H
4.5 N•m C
(40 lbf•in)
2.5 N•m
H
(22 lbf•in) 3.5 N•m
(31 lbf•in)

H
H H 3.5 N•m
3.0 N•m 4.5 N•m (31 lbf•in)
(27 lbf•in) (40 lbf•in)
H
4.5 N•m
(40 lbf•in)
A
H 2.0 N•m
3.5 N•m (18 lbf•in)
(31 lbf•in)

Windshield
motor

H
H 3.5 N•m
3.5 N•m (31 lbf•in)
(31 lbf•in)
NEW XPS
synthetic
grease

H
3.5 N•m 4.5 N•m
(31 lbf•in) (40 lbf•in)
See tightening
sequence
NEW
WPM
module

XPS
NEW = Component must be replaced when removed. synthetic grease
rmr2011-087-102_a

4 rmr2013-044
 Subsection XX (BODY (RT SERIES))

CONSOLE MODULE
A K50 X 16
B K50 X 20
C M5 X 14
D M5 X 25
E M6 X 10
F M6 X 12
G M6 X 16
H M6 X 20
I M6 X 25

4.5 N•m
(40 lbf•in)

7.5 N•m
(66 lbf•in)
4.5 N•m
(40 lbf•in)

4.5 N•m 7.5 N•m 4.5 N•m

(40 lbf•in) (66 lbf•in) (40 lbf•in)

NEW = Component must be replaced when removed.

rmr2011-087-101_a

rmr2013-044 5
Subsection XX (BODY (RT SERIES))

LATERAL BODY PARTS

A K50 X 16
B K50 X 20
C M5 X 14
D M5 X 25
E M6 X 10
F M6 X 12
G M6 X 16
H M6 X 20
I M6 X 25

3.5 N•m H
(31 lbf•in) 3.5 N•m
(31 lbf•in)

F
3.5 N•m
(31 lbf•in)

4.5 N•m
4.5 N•m (40 lbf•in)
(40 lbf•in)

H
3.5 N•m
(31 lbf•in)

I
F
3.5 N•m
(31 lbf•in)
LH side shown, RH side identical
rmr2013-044-101_a

6 rmr2013-044
 Subsection XX (BODY (RT SERIES))

LATERAL BODY PARTS

A K50 X 16
B K50 X 20
C M5 X 14
D M5 X 25
E M6 X 10
F M6 X 12
G M6 X 16
H M6 X 20
I M6 X 25

3.5 N•m
(31 lbf•in)

15.5 N•m 5.5 N•m

(22 lbf•in) (49 lbf•in)

2.5 N•m
(22 lbf•in)

48 N•m
(35 lbf•ft)

H
5 N•m
(44 lbf•in) 2.5 N•m
LH side shown, RH side identical (22 lbf•in)
rmr2013-044-100_a

rmr2013-044 7
Subsection XX (BODY (RT SERIES))

REAR CARGO MODULE (REAR VIEW)

2.5 N•m A K50 X 16
(22 lbf•in) B K50 X 20
C M5 X 14
D M5 X 25
E M6 X 10
F M6 X 12
A G M6 X 16
2.5 N•m H M6 X 20
(22 lbf•in) I M6 X 25

2.5 N•m
(22 lbf•in)

4.5 N•m A
(40 lbf•in) 2.5 N•m
(22 lbf•in)
I F
2.5 N•m 3.5 N•m
(22 lbf•in) (31 lbf•in)
F
3.5 N•m
(31 lbf•in)

9 N•m
G (80 lbf•in)
3.5 N•m
(31 lbf•in)

E
3.5 N•m
(31 lbf•in)
4.5 N•m
(40 lbf•in)

G
3.5 N•m
(31 lbf•in)

G H
3.5 N•m 3.5 N•m
(31 lbf•in) (31 lbf•in)
rmr2011-087-105_a

8 rmr2013-044
 Subsection XX (BODY (RT SERIES))

REAR CARGO MODULE (RH SIDE VIEW)

A K50 X 16
B K50 X 20
C M5 X 14 1.0 N•m
See tightening (9 lbf•in)
D M5 X 25
E M6 X 10 sequence
F M6 X 12 4.5 N•m
G M6 X 16 (40 lbf•in)
H M6 X 20
I M6 X 25

G
3.5 N•m
(31 lbf•in)
4.5 N•m
(40 lbf•in)
H
G 4.5 N•m
3.5 N•m (40 lbf•in)
(31 lbf•in) 1.0 N•m
(9 lbf•in)

G
3.5 N•m
(31 lbf•in)

4.5 N•m
(40 lbf•in)

E
3.5 N•m
(31 lbf•in)
See tightening
sequence G
4.5 N•m
(40 lbf•in)

rmr2011-087-106_a

rmr2013-044 9
Subsection XX (BODY (RT SERIES))

FRONT FENDER (BASE MODEL)

3.0 N•m
(27 lbf•in)

25.0 N•m
(18 lbf•ft)

7.0 N•m
(62 lbf•in)

25.0 N•m
(18 lbf•ft)
7.0 N•m
(62 lbf•in)

LH side shown, RH side identical

rmr2013-037-107_a

10 rmr2013-044
 Subsection XX (BODY (RT SERIES))

FRONT FENDER (RT-S AND RT LTD MODELS)

B
B

D
NEW

NEW
A

A
B

B
A 5.0 N•m (44 lbf•in)
B 2.0 N•m (18 lbf•in) C
C 10.0 N•m (89 lbf•in) C
D 25.0 N•m (18 lbf•ft)
D
NEW
rmr2013-037-106_a

rmr2013-044 11
Subsection XX (BODY (RT SERIES))

SEAT
2.5 N•m
A (22 lbf•in)

H
4.5 N•m
(40 lbf•in)

H
4.5 N•m
(40 lbf•in)

5.5 N•m 4.5 N•m

(49 lbf•in) (40 lbf•in)

8 N•m
(71 lbf•in)

7 N•m
(62 lbf•in)
A K50 X 16
B K50 X 20
C M5 X 14
D M5 X 25
E M6 X 10
F M6 X 12
G M6 X 16
H M6 X 20
I M6 X 25
rmr2011-087-108_a

12 rmr2013-044

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
NOTICE Be careful when tightening plastic
panels. Any deformation on the panel around
the screw is an indication that it is too tight.
Do not over torque panels in order to avoid to
damage them.
NOTE: Install a battery charger on battery termi-
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.
VEHICLE CARE
Vehicle Cleaning
To clean the vehicle, do not use high-pressure
washers (like the ones found in car washes) as
they 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:
– Rinse the vehicle thoroughly with water to re-
move loose dirt.
– Using a soft, clean cloth, wash the vehicle with
water mixed with a mild detergent, such as
soap specially formulated for motorcycles or
automobiles.
rmr2013-044
Subsection XX (BODY (RT SERIES))
– While washing the vehicle, check for grease
or oil. You can use BRP HEAVY DUTY CLEANER
(P/N 293 110 001) or a mild automotive de-
greaser. Thoroughly follow the manufacturer's
instructions.
– Dry the vehicle with a chamois or a soft towel.
Vehicle Waxing
Apply only nonabrasive wax safe for clearcoat
paints on glossy finishes.
Avoid applying wax on matte surfaces.
NOTICE Do not polish windshield with any
plastic cleaner/polisher.
WARNING
Do not apply a vinyl or plastic protector on
the seat as the surface will become slippery
and the operator or the passenger may slip
off the vehicle.
TROUBLESHOOTING
TROUBLESHOOTING
GUIDELINES (WINDSHIELD)
Before any troubleshooting operations on wind-
shield, it is important to check the fault codes
using B.U.D.S. to properly diagnose the problem.
Refer to DIAGNOSTIC AND FAULT CODES sub-
section.
WINDSHIELD DOES NOT WORK
1. Faulty WPM module or wiring.
- Check if parking brake works properly.
- Carry out a WPM MODULE SIGNAL CIRCUIT
CONTINUITY TEST.
- Carry out a WPM MODULE CAN TEST.
2. Faulty windshield motor or wiring.
- Carry out a WINDSHIELD MOTOR OPERATION
TEST.
PROCEDURES
DECALS
Decal Removal
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.
13
Subsection XX (BODY (RT SERIES))

If decal tears while pulling off, it has to be heated SERVICE COVERS

for a few seconds longer. If 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.
NOTICE Do not apply isopropyl alcohol or
solvent directly on decals.

MIRRORS
NOTE: The procedures are the same for LH and
RH mirrors. rmr2010-038-021_a

1. RH service cover
Mirror Removal 2. Plastic rivet

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.

rmr2010-038-061_a

4. Lift service cover to remove it.

rmr2011-087-009_a

Step 1: Hit with a sharp blow NOTICE For the RH service cover, pay at-
Step 2: Slide mirror upwards
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.
The installation is the reverse of the removal pro-
Mirror Installation cedure.
The installation is the reverse of the removal pro-
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 MIRRORS in this
engage lower attachment. subsection.
14 rmr2013-044
 Subsection XX (BODY (RT SERIES))

2. Remove service covers. Refer to SERVICE

COVERS in this subsection.
3. Remove middle side panels. Refer to MIDDLE
SIDE PANELS in this subsection.
4. Remove top side panels. Refer to TOP SIDE
PANELS in this subsection.
5. Remove upper retaining screws and washers
from front fascia.

rmr2010-038-024_a

1. Lower retaining screw

8. Remove front fascia from vehicle.

Front Fascia Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Torque front fascia retaining screws to 3.5 N•m
(31 lbf•in).
rmr2010-038-022_a

1. Upper retaining screw

MIDDLE SIDE PANELS
NOTE: The procedures are the same for LH and
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.
2. Remove grille.
rmr2010-038-023_a

1. Middle retaining screw

7. Remove lower retaining screws and washers

from front fascia.

rmo2010-008-003_d

REMOVAL SEQUENCE

Middle Side Panel Installation

1. Install grille onto panel.

rmr2013-044 15
Subsection XX (BODY (RT SERIES))

2. Install middle side panel as follows:

2.1 Push the front of panel in its grommet.
2.2 Rotate the panel and clip it on the support.
2.3 Push the bottom of the panel in its grom-
met.
2.4 Push the rear of the panel in its grommet.
2.5 Push the top of the panel to fix the plastic
hook.

rmr2010-038-005_a

1. Upper retaining screws

7. Remove rear retaining screw from top side

panel.

rmo2010-008-003_e

INSTALLATION SEQUENCE

TOP SIDE PANELS

NOTE: The procedures are the same for LH and
RH top side panels.

Top Side Panel Removal

1. Lift seat.
2. Open front storage compartment. rmr2010-038-006_a

1. Rear retaining screw

3. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection. 8. Remove LH service cover. Refer to SERVICE
4. Remove retaining screws from lower wind de- COVERS in this subsection.
flector.

rmr2010-038-007_a
rmr2010-038-004_a
1. LH service cover
1. Retaining screws of wind deflector

5. Remove mirror. Refer to MIRRORS in this sub- 9. Remove front retaining screw from top side
section. panel.
6. Remove upper retaining screws from top side
panel.

16 rmr2013-044
 Subsection XX (BODY (RT SERIES))

REAR SIDE PANELS

NOTE: The procedures are the same for LH and
RH rear side panels.

Rear Side Panel Removal

1. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection.
2. Remove top side panel. Refer to TOP SIDE
PANELS in this subsection.
3. Remove front retaining screw of rear side
rmr2010-038-008_a panel.
1. Front retaining screw
4. Remove upper retaining screw and washer
10. Pull out lower part of top side panel to remove from rear side panel.
it from grommets.
NOTE: Do not remove lower screws from top
side panel.

rmr2010-038-010_a

1. Front retaining screw

2. Upper retaining screw

5. Remove front plastic rivet from rear side panel.

rbl2010-002-305

11. Remove top side panel by lifting it upwards.

rmr2010-038-011_a

1. Front plastic rivet

rmr2010-038-009_a
6. Open side storage compartment cover.
1. Top side panel 7. Remove rear retaining screws from rear side
panel.
Top Side Panel Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Torque top side panel retaining screws to 3.5 N•m
(31 lbf•in).

rmr2013-044 17
Subsection XX (BODY (RT SERIES))

GLOVE BOX
Glove Box Removal
1. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection.
2. Remove top side panel. Refer to TOP SIDE
PANELS in this subsection.
3. Remove lateral acoustic panels. Refer to
ACOUSTIC PANELS in this subsection.
rmr2010-038-012_a 4. Disconnect glove box cable from glove box.
1. Rear retaining screws
5. Remove locking ties securing glove box cable.
8. Remove top retaining screw of rear side panel.

rmr2010-038-013_a rmr2011-087-005_a
1. Top retaining screw
6. Remove locking ties securing central panel
9. Remove rear side panel from vehicle. switches harness.
NOTICE Be careful not to break lower tabs. 7. Disconnect central panel switches harness con-
nector.

rbl2010-002-356_a

LH REAR SIDE PANEL

1. Lower tabs

Rear Side Panel Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. rmr2011-087-006_a

Torque rear side panel retaining screws to

8. Remove 3 plastic rivets from glove box on both
3.5 N•m (31 lbf•in).
side.
9. Remove 2 retaining screws from glove box on
both side.

18 rmr2013-044
 Subsection XX (BODY (RT SERIES))

rmr2010-038-030_a

1. Plastic rivets
2. Retaining screws rmr2010-038-500_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.

rmr2011-087-007_a
rmr2010-038-502_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

The installation is the reverse of the removal pro-
cedure.

CENTRAL PANEL
Central Panel Removal
1. Remove glove box as a unit with central panel
from vehicle, refer to GLOVE BOX REMOVAL
in this subsection.
2. Remove plastic rivet securing central panel to
glove box.

rmr2013-044 19
Subsection XX (BODY (RT SERIES))

rmr2010-038-016_a
rmr2010-038-501_a
1. Lower plastic rivets
1. Plastic rivet
2. Central panel
3. Glove box
5. Remove bottom front side panel from vehicle.

3. Remove central panel from glove box.
Central Panel Installation
The installation is the reverse of the removal pro-
cedure.
BOTTOM FRONT SIDE PANELS
NOTE: The procedures are the same for LH and
RH bottom front side panels.
Bottom Front Side Panel Removal
1. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection.
2. Remove upper retaining screw from panel.
3. Remove upper plastic rivet from panel.
Bottom Front Side Panel Installation
The installation is the reverse of the removal pro-
cedure.
BOTTOM REAR SIDE PANELS
NOTE: The procedures are the same for LH and
RH bottom rear side panels.
Bottom Rear RH Side Panel Removal
1. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection.
2. Remove top side panel. Refer to TOP SIDE
PANELS in this subsection.
3. Remove rear side panel. Refer to REAR SIDE
PANELS in this subsection.
4. Remove bottom front side panel. Refer to BOT-
TOM FRONT SIDE PANELS in this subsection.
5. Remove front plastic rivet from bottom RH rear
side panel.

rmr2010-038-015_a

1. Upper retaining screw

2. Upper plastic rivet

4. From underneath panel, remove lower plastic

rivets. rmr2010-038-017_a

1. Front plastic rivet

6. Remove retaining screws from bottom rear RH

side panel.

20 rmr2013-044
 Subsection XX (BODY (RT SERIES))

ACOUSTIC PANELS
Acoustic Panel Replacement
Lateral
1. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection.
2. Remove top side panel. Refer to TOP SIDE
PANELS in this subsection.
3. Remove retaining screws from acoustic panel.

rmr2010-038-018_a

1. Retaining screws

7. Remove bottom rear RH side panel from vehi-

cle.

Removal of Bottom Rear LH Side

Panel
1. Remove middle side panel.
2. Remove top side panel.
3. Remove rear LH side panel.
rmr2010-038-019_a
4. Remove bottom front side panel. 1. Retaining screws
2. LH lateral acoustic panel
5. Remove bottom retaining screw from bottom
rear LH side panel. 4. Replace acoustic panel on vehicle.
5. Torque acoustic panel retaining screws to
6 N•m (53 lbf•in).
6. Reinstall all removed panels.
Top
1. Remove glove box as a unit with central panel
from vehicle. Refer to GLOVE BOX REMOVAL
rmo2013-005-010_a
in this subsection.
1. Bottom retaining screw 2. Remove plastic rivets securing acoustic panel
2. Upper retaining screw to glove box.
6. Loosen upper retaining screw.
NOTE: Upper retaining screw remains attached
to bottom panel.
7. Remove bottom rear side panel from vehicle by
pulling forward to release panel from bracket.
NOTE: The back of the panel is inserted between
the bracket and aluminium support.

Bottom Rear Side Panel Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Torque bottom side panel retaining screws to
2.5 N•m (22 lbf•in).
Torque bottom side panel retaining nut (located at
the rear) to 5.5 N•m (49 lbf•in).

rmr2013-044 21
Subsection XX (BODY (RT SERIES))

rmr2011-087-001_a

rmr2010-038-500_a 1. Front panel retaining screw

TYPICAL
1. Plastic rivets 7. On applicable models, remove nut securing
2. Top acoustic panel
3. Glove box headlight adjustment cable (LB) on both side.

3. Replace acoustic panel on glove box.

4. Reinstall all removed panels and components.

FRONT CARGO MODULE

rmr2010-038-027_b

ON APPLICABLE MODELS
1. Headlight adjustment cable (LB)

8. Disconnect the following components from ve-

hicle (if equipped).
– B.U.D.S. connector
rmr2010-038-020

FRONT CARGO MODULE – Storage cover switch (FCS) connector

– Storage cover actuator connector
Front Cargo Module Removal – Storage cover cable.
1. Remove mirrors. Refer to MIRRORS in this 9. Remove upper retaining screws from cargo
subsection. module.
2. Remove service covers. Refer to SERVICE
COVERS in this subsection.
3. Remove middle side panels. Refer to MIDDLE
SIDE PANELS in this subsection.
4. Remove top side panels. Refer to TOP SIDE
PANELS in this subsection.
5. Remove front fascia. Refer to FRONT FASCIA
in this subsection.
6. Remove front panel retaining screw on both
side.

22 rmr2013-044
 Subsection XX (BODY (RT SERIES))

2. Remove bumper cover air ducts.

2.1 Remove 2 screws at the rear on both side.
2.2 Remove 4 plastic rivets from inside air
ducts on both side.
2.3 Remove 2 plastic rivets from underneath
bumper cover on both side.
3. Remove front panels.
3.1 Remove 1 retaining washer from inside
front panel on both side.
rmr2010-038-025_a
3.2 Remove 3 screws from inside front panel
SOME PARTS REMOVED FOR CLARITY PURPOSE on both side.
1. Upper retaining screws
3.3 Remove 3 plastic rivets on the top of front
10. From underneath bumper cover, remove panel on both side.
lower retaining screws from cargo module. 4. Remove front bumper.

Front Cargo Module Assembly and

Installation
Assemble front cargo module as the reverse of
disassembly.
Install front cargo module as the reverse of re-
moval procedure, however, pay attention to the
following.
Adjust front storage compartment latch, refer to
FRONT STORAGE COMPARTMENT in this sub-
section.
Torque storage compartment screws to 4.5 N•m
rmr2010-038-026_a (40 lbf•in).
1. Lower retaining screws

11. Slightly pull cargo module toward front of ve- FRONT STORAGE
hicle. COMPARTMENT LATCH
12. Disconnect the following components from Front Storage Compartment Latch
vehicle (if equipped). Adjustment
– AAPTS sensor connector
1. Open front storage compartment cover.
– Horn connector
2. Loosen 4 retaining screws at the front of cover.
– Low beam light connectors (CE)
– Fog light connectors
– Storage compartment light.
13. Completely remove cargo module from vehi-
cle.

Front Cargo Module Disassembly

Sequence
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. rbg2010-008-006_a

1. Retaining screws

rmr2013-044 23
Subsection XX (BODY (RT SERIES))

3. Move cover upper section backward while

pulling lower section forward.
4. Tighten 4 retaining screws at the front of cover.

rbg2010-008-008_a

1. Retaining screws of cover hinge

2. Hinge housing wall
rmr2010-038-503_b
A. Hinge bracket parallel with housing wall
1. Upper section backward
2. Lower section forward
8. Tighten 2 retaining screws of cover hinge.
5. Loosen 2 retaining screws of cover hinge. 9. Carry out the FRONT STORAGE COMPART-
6. Completely move cover hinge toward the front. MENT SEAL VERIFICATION. See procedure in
this subsection.
Front Storage Compartment Seal Verification
NOTICE This test must be performed each
time the latch is adjusted in order to avoid
water intrusion into storage compartment.
1. Open front storage compartment cover.
2. Place a sheet of paper on storage compartment
seal.
3. Close front storage compartment cover.

rbg2010-008-008_b

1. Retaining screws of cover hinge

2. Moving cover hinge

7. Align hinge bracket with housing wall. They

must be parallel.

rbg2010-008-010_a

4. Check that cover is properly sealed by pulling

on the sheet of paper.
5. Repeat the previous steps for the other side.
FRONT STORAGE COMPARTMENT SEAL
VERIFICATION
PASS Sheet not easily removable
FAIL Sheet easily removable

24 rmr2013-044
 Subsection XX (BODY (RT SERIES))

6. If test fail, adjust front storage compartment
latch as follows:
6.1 Loosen latch nuts.
6.2 Adjust latch mechanism accordingly.
6. Remove top side panels. Refer to TOP SIDE
PANELS in this subsection.
7. Remove lateral acoustic panels. Refer to
ACOUSTIC PANELS in this subsection.
8. Remove front fascia. Refer to FRONT FASCIA
in this subsection.
9. Disconnect module harness connectors located
on the LH side of vehicle.

rbg2010-008-007_a

1. Latch nuts
2. Latch mechanism
rmr2010-038-029_a
7. Ensure cover height fits with front panels SOME PARTS REMOVED FOR CLARITY PURPOSE
height when cover is closed. 1. Module harness connectors

10. Remove nut securing headlight adjustment ca-

CONSOLE MODULE ble (HB) on both side.
11. Remove front retaining screws from console
module.

rmr2010-038-032
rmr2010-038-028_a
CONSOLE MODULE
SOME PARTS REMOVED FOR CLARITY PURPOSE
1. Front retaining screws
Console Module Removal
1. Lift seat. 12. Remove 3 plastic rivets from glove box on
both side.
2. Open front storage compartment.
13. Remove 2 retaining screws from glove box on
3. Remove mirrors. Refer to MIRRORS in this both side.
subsection.
4. Remove both service covers. Refer to SER-
VICE COVERS in this subsection.
5. Remove middle side panels. Refer to MIDDLE
SIDE PANELS in this subsection.

rmr2013-044 25
Subsection XX (BODY (RT SERIES))
rmr2010-038-030_a
1. Plastic rivets
2. Retaining screws
14. Slightly lift glove box upwards.
15. Remove side retaining screws from console
module.
rmr2010-038-031_a
1. Side retaining screw
16. Carefully pull console module toward front of
vehicle.
Console Module Disassembly
Sequence
To disassemble the console module, carry out the
following steps. Refer to the exploded view at the
beginning of this subsection for details.
1. Remove multifunction gauge.
1.1 Remove 4 screws securing gauge trim.
1.2 Pull down both upper tabs.
1.3 Move top of gauge toward rear.
1.4 Disconnect gauge connector.
2. Remove headlights.
2.1 Remove 4 retaining screws from head-
light.
2.2 Disconnect headlight connector.
26
3. Remove windshield. Refer to WINDSHIELD in
this subsection.
Console Module Installation
Assemble console module as the reverse of disas-
sembly, however, pay attention to the following.
Torque gauge trim screws to 2.5 N•m (22 lbf•in).
Install console module as the reverse of removal
procedure, however, pay attention to the follow-
ing.
Torque console module front retaining screws to
4.5 N•m (40 lbf•in).
Torque console module side retaining screws to
4.5 N•m (40 lbf•in).
REAR CARGO MODULE
rmr2010-038-033
REAR CARGO MODULE
Rear Cargo Module Removal
1. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection.
2. Remove top side panel. Refer to TOP SIDE
PANELS in this subsection.
3. Remove rear side panel. Refer to REAR SIDE
PANELS in this subsection.
4. Remove seat from vehicle as follows:
4.1 Disconnect shock absorber from seat
base.
4.2 Unplug pillion rider (passenger) switch.
4.3 Remove seat base retaining bolts.
rmr2013-044
 Subsection XX (BODY (RT SERIES))

10. Remove audio player access panel from vehi-

cle.

rmr2010-038-034_a

1. Seat base retaining bolt

4.4 Remove spacer and caged nuts.

rmr2010-038-037_a

1. Audio player access panel

2. Rear retaining screw

11. Disconnect LH ground strap by unscrewing

each retaining screw.

rmr2010-038-035_a

1. Spacer
2. Caged nut

5. Remove rear retaining screw from battery ac-

cess panel (LH side).
6. Disconnect passenger heated grip switch.
rmr2010-038-038_a

7. Remove battery access panel from vehicle. 1. LH ground strap retaining screw

12. On the LH side of the vehicle near passenger

grab handle.
– Disconnect both cargo harness connectors.
– Disconnect accessories connector (if appli-
cable).

rmr2010-038-036_a

1. 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).
rmr2013-044 27
Subsection XX (BODY (RT SERIES))

15. With the assistance of a coworker, carefully

pull rear cargo module toward rear.
16. Install rear cargo module on an appropriate
support.

rmr2010-038-040_a

1. Cargo harness connectors

13. Remove lateral retaining screws and washers

(on both side) of rear cargo module.

rmr2011-087-008

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
the exploded view at the beginning of this subsec-
tion for details.
rmr2010-038-041_a
1. Remove rear panel.
1. Lateral retaining screw
1.1 Open top and side storage compartment
14. Remove top retaining screws of rear cargo covers.
module. 1.2 Remove 2 screws on the top of each side
storage compartment.
1.3 Remove 4 screws on the rear of top stor-
age compartment.
2. Remove rear fender.
2.1 Remove 3 screws on the upper portion of
rear fender.
2.2 Remove 2 screws on the rear of each side
storage compartment.
2.3 Remove 1 screw on the back of each side
storage compartment.
rmr2010-038-042_a
2.4 Disconnect licence plate connector.
1. Top retaining screws 3. Remove passenger backrest.
NOTICE To avoid damaging the rear cargo 3.1 Remove 3 screws inside top storage com-
module: partment.
– Never lift rear cargo module by the passen- 3.2 Remove 2 screws on the top of passenger
ger grab handle. backrest.
– Always install rear cargo module on an ap- 4. Remove taillight.
propriate support. 4.1 Remove 3 screws on the taillight housing.
28 rmr2013-044
 Subsection XX (BODY (RT SERIES))

4.2 Disconnect taillight connector. Remove brake pedal. Refer to BRAKE PEDAL RE-
MOVAL in the BRAKES subsection.
Rear Cargo Module Installation Remove bolt retaining shifting link to shifting
Assemble cargo module as the reverse of disas- block.
sembly, however, pay attention to the following.
Torque taillight screws to 2.5 N•m (22 lbf•in).
Torque passenger backrest screws to 4.5 N•m
(40 lbf•in) 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.

rmr2010-006-017_a

TYPICAL – SM5 ENGINE SHOWN

1. Shifting block
2. Shifting link

Remove retaining screws securing LH footrest

support to vehicle.

rmr2011-087-004_a

TIGHTENING SEQUENCE

Torque rear panel screws to 3.5 N•m (31 lbf•in).

Install cargo module as the reverse of removal
procedure, however, pay attention to the follow-
ing.
Torque rear cargo top retaining screws to 9 N•m rmr2013-044-301_a

(80 lbf•in). RETAINING SCREWS TO REMOVE

Torque rear cargo lateral retaining screws to

4.5 N•m (40 lbf•in).
Torque battery and audio player access panels re-
taining screws to 3.5 N•m (31 lbf•in).
Torque seat base retaining bolts to 4.5 N•m
(40 lbf•in).

FOOTREST SUPPORT AND

FOOTREST REMOVAL (ALL RT
MODELS)
Footrest Support
Footrest Support Removal
LH Footrest Support rmr2013-044-302_a

Remove the LOWER SIDE PANEL, see procedure RETAINING SCREWS SECURING FOOTREST SUPPORT TO
FRAME
above in this subsection.
Pull on footrest support to remove it.

rmr2013-044 29
Subsection XX (BODY (RT SERIES))

RH Footrest Support
Remove the LOWER SIDE PANEL, see procedure
above in this subsection.
Remove master cylinder screws.

rmr2013-044-304_a

RETAINING SCREWS SECURING FOOTREST SUPPORT TO

FRAME

Pull on footrest support to remove it.

Footrest Support Installation
rmr2013-044-303_a
The installation is the reverse of the removal pro-
MASTER CYLINDER SCREW TO REMOVE (SECOND SCREW cedure. However pay attention to the following.
NOT ILLUSTRATED)
Each time RH footrest support is re-installed, the
Remove screws retaining lateral support to adjustment of the master cylinder rod is nec-
footrest support. essary. Refer to MASTER CYLINDER ROD in
BRAKE.
Driver Footpeg and Driver Footrest
Driver Footpeg and Footrest Removal
On Models equipped with Footrest, remove
footrest release mechanism. Refer to FOOTREST
RELEASE MECHANISM in the BRAKES subsec-
tion.
LH Side
Remove the 3 retaining screws securing driver
rmr2013-044-305_a
footrest (2 for footpeg) to footrest support.
RETAINING SCREWS TO REMOVE

30 rmr2013-044
 Subsection XX (BODY (RT SERIES))

rmr2013-044-306_a rmr2013-044-312_a

RETAINING SCREWS TO REMOVE 1. Retaining bolt

2. Bushing
3. Sleeve
RH Side 4. Sleeve
Remove retaining screw and retaining bolt secur- 5. Rubber suppport
6. Footpeg
ing footpeg/footrest to footrest support. 7. Washer
8. Retaining nut

Remove footpeg/footrest from vehicle.

Driver Footpeg Installation
The installation is the reverse of the removal pro-
cedure.

Passenger Footrest
Passenger Footrest Removal
Remove retaining screw securing passenger
footrest to footrest support

rmr2013-044-307_a

rmr2013-044-310_a

RETAINING SCREW SECURING PASSENGER FOOTREST TO

FOOTREST SUPPORT

Remove passenger footrest from vehicle.

rmr2013-044 31
Subsection XX (BODY (RT SERIES))

Passenger Footrest Installation

The installation is the reverse of the removal pro-
cedure.

WINDSHIELD
Windshield Removal
1. From inside windshield, remove retaining
screws from windshield trim panels.

rmr2010-038-044_a

1. Windshield trim panels

4. Remove windshield retaining screws and

sleeves from support.

rmr2010-038-043_a

1. Windshield trim panels retaining screws

2. Place a sheet of paper on windshield to protect

it, refer to illustration.
NOTICE If this precaution is not taken,
scratch on the windshield may occur.

rmr2010-038-045_a

1. Windshield retaining screws

5. Carefully remove windshield from vehicle.

Windshield Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
NOTICE Prior to installing windshield trim
panel, place a sheet of paper on windshield to
rbl2010-002-028 protect it.

3. Remove windshield trim panels from vehicle.

32 rmr2013-044
 Subsection XX (BODY (RT SERIES))

rmr2010-038-047_a
rbl2010-002-028
1. Center arm
SHEET OF PAPER POSITIONING 2. C-clip

Torque windshield retaining screws to 4.5 N•m 6. Remove center arm pin.
(40 lbf•in).
7. Remove windshield support from vehicle.
Torque windshield trim panels retaining screws to
2.5 N•m (22 lbf•in). Windshield Support Installation
The installation is the reverse of the removal pro-
WINDSHIELD SUPPORT cedure. However, pay attention to the following.
Windshield Support Removal Make sure that arm bushings are installed as per
the following illustration.
NOTE: To access directly to windshield motor, it
is not necessary to remove windshield from wind-
shield support (step 1).
1. Remove windshield. Refer to WINDSHIELD in
this subsection.
2. Remove C-clips from side arm pins.

rmr2010-038-048_a

1. Bushings

Install NEW C-clip on arm pins.

WINDSHIELD MOTOR
NOTICE Do not remove windshield motor
from windshield base. Both are calibrated at
the factory. If windshield motor needs to be
changed, replace windshield base with WPM
rmr2010-038-046_a

1. Side arm
module and windshield motor as an assembly.
2. C-clip

3. Remove side arm pins.

4. Rotate windshield support toward front.
5. Remove C-clip from center arm pin.

rmr2013-044 33
Subsection XX (BODY (RT SERIES))

Windshield Wiring Diagram

MULTIFUNCTION MAIN RELAY 2

SWITCH (LEFT) (R3)
CAN-LO (PIN-8)

OR/RD-16
WH/BE-20 D CAN-HI (PIN-6)
D
2-
IC
WH/BK-20

OR/RD-16

-2
-1
-8

-5
-6

0
-1

PM
PM
PM

PM
PM

rmo2010-001-020_h
PM

W
W
W

W
W

1. Windshield adjustment switch

WPM WINDSHIELD & PARKING BRAKE MODULE
DWN UP

-7
5. Check proper operation in B.U.D.S.
1
-2

-9

-3
-4

-1

PM
PM

PM

PM
PM

PM

W
W

W
W

W
GY/LTGN-18

GY/RD-18

BK-16
-2

-1
GN/OR-20

BU/OR-20
M

M
W

WM
WINDSHIELD MOTOR
rmr2011-087-200_a

Windshield Motor Monitoring

(with B.U.D.S.) rmr2010-038-059_b

TYPICAL
To monitor windshield motor during troubleshoot- 1. Windshield operation monitoring lights
ing operation, proceed as follows:
1. Connect vehicle to B.U.D.S. Refer to COMMU- Windshield Motor Operation Test
NICATION TOOLS AND B.U.D.S. SOFTWARE 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. Select WPM tab. 2. Select Activation page.
3. Select WPM tab.

rmr2010-038-059_a

TYPICAL
Step 1: Select monitoring
Step 2: Select WPM

4. Press windshield adjustment switch on vehicle.

34 rmr2013-044

rmr2010-038-060_a
TYPICAL
Step 1: Activation page
Step 2: WPM folder
4. Press Windshield Up button.
rmr2010-038-060_b
TYPICAL
1. Windshield Up and Down button
5. Verify if windshield motor works to raise wind-
shield.
If windshield motor does not work:
– Check input voltage at motor (PIN-1), refer to
the WIRING DIAGRAM.
– Check ground circuit continuity at motor (PIN-
2), refer to the WIRING DIAGRAM.
– Check connector and terminal condition.
6. Press Windshield Down button.
rmr2013-044
Subsection XX (BODY (RT SERIES))
rmr2010-038-060_b
TYPICAL
1. Windshield Up and Down button
7. Verify if windshield motor works to lower wind-
shield.
If windshield motor does not work:
– Check input voltage at motor (PIN-2), refer to
the WIRING DIAGRAM.
– Check ground circuit continuity at motor (PIN-
1), refer to the WIRING DIAGRAM.
– Check connector and terminal condition.
If the fault is not found after having carried out the
previous tests:
– Test motor operation by connecting it directly to
the battery posts.
• If motor works properly, test module, refer to
WINDSHIELD MODULE (WPM) in this sub-
section.
• If motor does not work properly, replace
windshield base with WPM module and
windshield motor as an assembly.
NOTICE Do not power motor directly with the
battery for a long period. Apply voltage quickly
to ensure that the motor will not overheat at
the end of its stroke.
Windshield Motor Removal
1. Remove windshield and windshield support
together. Refer to WINDSHIELD SUPPORT in
this subsection.
2. Remove front fascia. Refer to FRONT FASCIA
in this subsection.
3. Remove retaining screws of upper wind deflec-
tors.
4. Remove upper wind deflectors from vehicle.
35
Subsection XX (BODY (RT SERIES))

7. Remove console panel by lifting it toward front.

8. Remove retaining screws from WPM module.

rmr2010-038-049_a

1. Upper wind deflector

2. Retaining screws

5. Remove lower retaining screws from console

panel. rmr2010-038-052_a

1. WPM module
2. Retaining screws

9. Slightly lift WPM module upwards.

10. Disconnect WPM module connector.

rmr2010-038-050_a

1. Console panel
2. Lower retaining screws

6. Remove upper retaining screws from console

panel. rmr2010-038-053_a

1. WPM module connector

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.

rmr2010-038-051_a

1. Upper retaining screws

36 rmr2013-044
 Subsection XX (BODY (RT SERIES))

NOTICE Do 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

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Torque WPM module retaining screws to 4.5 N•m
(40 lbf•in) as per the following sequence.

rmr2010-038-058

WPM MODULE AND WINDSHIELD BASE

WPM Module CAN Wire Test

1. Check WPM module power and ground cir-
cuits. refer to WINDSHIELD WIRING DIA-
GRAM in this subsection.
2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
rmr2011-087-003_a

TIGHTENING SEQUENCE
3. Measure resistance as per the following table.
WPM MODULE CAN WIRE TEST
Torque console panel retaining screws to specifi-
cation as per the following sequence. TEST PROBES OHMS ( )
CONSOLE PANEL RETAINING SCREWS TORQUE DLC (Diagnostic
WPM module Close to
Link Connector)
Upper retaining screws 2.5 N•m (22 lbf•in) pin 6 (CAN HI) 0.2
connector pin 1
Lower retaining screws 3.0 N•m (27 lbf•in) DLC (Diagnostic
WPM module Close to
Link Connector)
pin 8 (CAN LO) 0.2
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
1. Remove body parts as required to access to the
rmr2011-087-002_a WPM module. Refer to WPM MODULE RE-
TIGHTENING SEQUENCE MOVAL in this subsection.
Torque upper wind deflector retaining screws to 2. Disconnect WPM module connector.
4.5 N•m (40 lbf•in).

rmr2013-044 37
Subsection XX (BODY (RT SERIES))

NOTICE 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.

rmr2010-038-053_a

1. WPM module connector

3. Disconnect LH multi-switch (MSL) connector.

Refer to LIGHTS, GAUGE AND ACCESSORIES
subsection.
4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
5. Measure resistance as per the following table.
TEST PROBES RESISTANCE
MSL switch connector
pin 2 (WH/BK)
Close to 0
WPM module connector
pin 8 (WH/BK)

TEST PROBES RESISTANCE

MSL switch connector
pin 3 (WH/BG)
Close to 0
WPM module connector
pin 6 (WH/BG)

If results are not as per the previous tables:

– Test MSL switch, refer to LIGHTS, GAUGE
AND ACCESSORIES.
– Check connector and terminal condition.
– Repair open circuit in wiring.
If the fault is not found after having carried out the
previous operations:
– Check input voltage at WPM module (PIN-5),
refer to the WIRING DIAGRAM.
– Check ground circuit continuity at WPM module
(PIN-7), refer to the WIRING DIAGRAM.
If the fault is still not found:
– Replace WPM module.

WPM Module Replacement

To replace WPM module, refer to WINDSHIELD
MOTOR in this subsection.

38 rmr2013-044
 Subsection XX (FRAME)

FRAME
RS AND ST MODELS

ST LTD Model ST Models

NEW NEW
24 N•m 24 N•m 24 N•m
(17 lbf•ft) (17 lbf•ft) (17 lbf•ft)

ST LTD Model
NEW 7 N•m NEW
15 N•m (62 lbf•in)
24 N•m
(133 lbf•in) (17 lbf•ft)

15 N•m
(133 lbf•in)
ST Models
15 N•m NEW
(133 lbf•in)
24 N•m
NEW (17 lbf•ft)
NEW
15 N•m
(133 lbf•in)

15 N•m
(133 lbf•in)

15 N•m
(133 lbf•in) 15 N•m
(133 lbf•in)
NEW = Component must be replaced when removed.
rmr2013-038-101_a

rmr2011-038 1
Subsection XX (FRAME)

RT MODELS

NEW
24 N•m
(17 lbf•ft)

24 N•m 7 N•m
(17 lbf•ft) (62 lbf•in)
NEW
15 N•m
(133 lbf•in)

15 N•m
(133 lbf•in)
NEW
24 N•m
15 N•m (17 lbf•ft)
(133 lbf•in)
NEW

7 N•m
(62 lbf•in)

15 N•m
(133 lbf•in)
NEW
15 N•m
(133 lbf•in)

NEW
15 N•m
(133 lbf•in) NEW = Component must be replaced when removed.
rmr2013-038-100_a

2 rmr2011-038
 Subsection XX (FRAME)

GENERAL – Front panel

– Rear panel assembly
During assembly/installation, use the torque val-
ues and service products as in the exploded – Middle side panel.
views. Remove the two rear screws on the lower side
Clean threads before applying a threadlocker. Re- panel.
fer to SELF-LOCKING FASTENERS and LOCTITE Remove the forward mounting bolt on the fuel
APPLICATION at the beginning of this manual for tank.
complete procedure.

WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.

NOTICE Hoses, cables or locking ties re-

moved during a procedure must be reinstalled
as per factory standards.
rmr2008-035-002_a

PROCEDURES 1. Rear mounting screws on lower side panel

2. Forward mounting bolt on fuel tank

FRONT FRAME (RS AND ST Cut the three locking ties securing the ignition coil
MODELS) and spark plug wires to the lateral frame support.
The front frame serves as the lower support for
the front storage compartment assembly, the
bumper cover, and the front skid plate.

Front Frame Removal

To remove the front frame, remove the following
from the vehicle, refer to BODY subsection:
– Both front panels
– The front storage compartment assembly. rmr2013-038-001_a

LOCKING TIES ON RH LATERAL SUPPORT

Remove the following parts from the front frame,
refer to BODY subsection: Remove the top screw on the oil cooler air duct.
– Bumper cover Remove top mounting screw on the ignition coil
– Front storage compartment bracket.
– Front skid plate.

Front Frame Installation

Installation is the reverse of the removal proce-
dures.

LATERAL SUPPORTS (RS AND

ST MODELS)
LH Lateral Support Removal
Remove the following LH body panels, refer to
BODY subsection:
– Upper side panel

rmr2011-038 3
Subsection XX (FRAME)

RH Lateral Support Removal

Remove the following RH body panels, refer to
BODY subsection:
– Upper side panel
– Front panel
– Rear panel assembly.
Remove the two rear screws on the lower side
panel.
Remove the forward mounting bolt on the fuel
tank.

rmr2013-038-002_a

1. Remove top screw on oil cooler air duct

2. Remove top screw on ignition coil bracket

Remove the two mounting screws on the voltage

regulator.
Remove the two rear mounting screws on the LH
lateral support.

rmr2008-035-008_a

1. Rear mounting screws, lower side panel

2. Forward mounting bolt on fuel tank

Cut the three locking ties securing the engine

coolant tank and the seat latch cable, to the RH
lateral frame support.

rmr2013-038-004_a

REAR MOUNTING SCREWS, LH LATERAL SUPPORT

Remove the two front mounting screws on the LH

lateral support.

rmr2013-038-005_a

LOCKING TIES ON RH LATERAL SUPPORT

Remove the two rear mounting screws on the RH

lateral support.

rmr2013-038-003_a

FRONT MOUNTING SCREWS, LH LATERAL SUPPORT

4 rmr2011-038
 Subsection XX (FRAME)

rmr2013-038-025_a

REAR MOUNTING SCREWS, RH LATERAL SUPPORT

rmr2010-039-002_a

Remove the two front mounting screws on the 1. Top side panel
2. Front panel
RH lateral support. 3. Rear side panel
4. Middle side panel
5. Bottom rear side panel

Cut locking ties securing wires to the lateral frame

support.

rmr2013-038-007_a

FRONT MOUNTING SCREWS, RH LATERAL SUPPORT

Lateral Support Installation

Install lateral support, components, fasteners and rmr2010-039-003_a

panels in the reverse order of removal. 1. Cut locking ties

2. LH lateral frame support

LATERAL SUPPORTS (RT Remove the top screw on the oil cooler air duct.
MODELS) Remove the two mounting screws on the voltage
regulator.
LH Lateral Support Removal
Remove the two front mounting screws on the LH
Remove the following LH body panels: lateral support.

rmr2013-038-021_a

1. Oil cooler air duct upper screw

2. Front mounting screws

Remove screws securing the top of the lateral

panel support.
rmr2011-038 5
Subsection XX (FRAME)

rmr2013-038-017_a rmr2013-038-011_a

1. Lateral panel support 1. Rear mounting screws

2. Upper retaining screws
Remove top mounting nut on the ignition coil
bracket.
Remove the LH lateral support.
RH Lateral Support Removal
Remove the following RH body panels:

rmr2013-038-018_a

1. Top nut on ignition coil bracket

2. Ignition coil

Remove bolt and nut securing lateral support to rmr2010-039-009_a

fuel tank. 1. Top side panel

2. Front panel
3. Rear side panel
4. Middle side panel
5. Bottom rear side panel

Cut locking ties securing the engine coolant tank

and the seat latch cable, to the RH lateral frame
support.

rmr2013-038-008_a

1. Retaining bolt

Remove the two rear mounting screws.

6 rmr2011-038
 Subsection XX (FRAME)

rmr2010-039-010_a

1. Cut these locking ties rmr2013-038-022_a

1. Coolant radiator
Remove the two front mounting screws. 2. Upper retaining bolt

Disconnect parking brake motor connectors.

rmr2013-038-020_a
rmr2011-088-002_a
1. Front mounting bolts
1. Parking brake motor connectors
Remove screws securing the top of the lateral Cut locking tie securing the reverse cable to lateral
panel support. support.
Unscrew locking nut retaining parking brake cable.
Remove the cable end from parking brake pulley.

rmr2013-038-017_a
rmr2013-038-006_a
1. Lateral panel support
2. Retaining screws 1. Cut this locking tie
2. Locking nut
3. Cable end in parking brake pulley
Remove bolt retaining the top of coolant radiator.
Remove bolt and nut securing lateral support to
fuel tank.

rmr2011-038 7
Subsection XX (FRAME)

Arc Welding on Frame

WARNING
Welding should be performed by a profes-
sional welder and limited to areas that are
not safety related.

Before any arc welding is carried out anywhere on

the vehicle, disconnect the following:
– Battery (refer to CHARGING SYSTEM subsec-
tion)
rmr2013-038-023_a
– Dynamic Power Steering (DPS) unit (refer to
1. Retaining bolt STEERING (DPS) AND FRONT WHEELS sub-
section)
Remove the two rear mounting screws on the RH – Front chassis ground (see procedure below)
lateral support. – Fuel tank grounding cable (see procedure be-
low).
NOTICE 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.

WARNING
If welding is to be carried out near the fuel
tank, the fuel tank should be removed.
rmr2013-038-024_a

1. Rear mounting bolts Front Chassis Ground Removal

Remove LH upper side panel, refer to BODY sub-
Lateral Support Installation section.
Install lateral support, components, fasteners and Unscrew nut enough to remove torque, then un-
panels in the reverse order of removal. screw ground post bolt.
NOTE: Note position of wires and star washer for
FRAME reinstallation.
Frame Inspection
Inspect the frame and subassemblies for:
– Cracks
– Bends
– Twisting
– Buckling
– Paint condition
– Any other damages.
Repair or replace as required.

8 rmr2011-038
 Subsection XX (FRAME)

NOTE: Note position of star washer for reinstalla-

tion.
NOTICE Make sure fuel tank grounding cable
is completely isolated from the frame. Apply a
piece of electrical tape over lug if necessary.
Arc Welding Specifications
When arc welding, use the following specifica-
tions:
– Amperage: 70 - 110 A
– Voltage: 20 - 24 V
– Rod: E-7014 (3/32 in).
NOTE: Install the welder ground as close as pos-
rmr2013-024-005_a
sible to the area to be repaired.
FRONT GROUNDS — LH FRONT SIDE OF FRAME, NEAR OIL
TANK
1. Oil tank Frame Care
2. Frame grounds
3. From DPS (dynamic power steering) Clean the frame with appropriate cleaners and
4. From wiring harness rinse thoroughly.
5. From engine
6. DPS (dynamic power steering) ground Touch up all areas where paint has been scratched
7. Ignition coil ground
8. Ignition coil ground or chipped off.
9. To jump start negative post
Spray all bare metal parts of vehicle with metal
NOTICE Make sure wires are completely iso- protector.
lated from the frame. Apply a piece of electri- For frame welding, see ARC WELDING ON
cal tape over each lug if necessary. FRAME in this subsection.
Fuel Tank Static Ground Removal
Remove the following RH body panels, refer to
BODY subsection:
– Upper side panel
– Rear panel.
Locate fuel tank static ground on the RH rear cor-
ner of the fuel tank.

rmr2013-027-006_a

FUEL TANK GROUND — REAR RH SIDE

1. Fuel tank
2. Fuel tank ground

While holding bolt, remove elastic nut.

rmr2011-038 9
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RS (SM5/SE5))

SPYDER RS (SM5/SE5)
SPYDER RS
MODEL
SM5 SE5
ENGINE
ROTAX® 991, 4-stroke, 60° V-twin,
Engine type
Dual Over Head Camshaft (DOHC), 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 12.2:1
Type Dry sump with separate oil reservoir and oil cooler
Oil filter (engine and
BRP Rotax microglass fiber type, replaceable
transmission)
Engine oil
Minimum 350 kPa (51 PSI) @ 5000 RPM / 80°C (176°F) oil temperature
pressure
Capacity
(oil change
3.9 L (4.1 qt (U.S. liq.)) 4.2 L (4.4 qt (U.S. liq.))
with engine
Lubrication filter)
Capacity
(oil change
Engine oil –
with engine 4.3 L (4.5 qt (U.S. liq.))
and HCM
filters)
XPS synthetic blend oil (summer grade) (P/N 293 600 121) 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 (.04 in)
Intake valve closing 40° ABDC @ 1 mm (.04 in)
Exhaust valve opening 45° BBDC @ 1 mm (.04 in)
Exhaust valve closing 5° ATDC @ 1 mm (.04 in)
Intake 0.11 mm to 0.18 mm (.0043 in to .0071 in)
Valve clearance
Exhaust 0.22 mm to 0.29 mm (.0087 in to .0114 in)
New 5.961 mm to 5.975 mm (.2347 in to .2352 in)
Intake
Service 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 0.006 mm (.0002 in)
Valve runout
exhaust Service limit 0.06 mm (.0024 in)
New 6.006 mm to 6.018 mm (.2365 in to .2369 in)
Valve guide diameter
Service limit 6.050 mm (.2382 in)

rmr2010-040 1
Section 02 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RS (SM5/SE5))

SPYDER RS
MODEL
SM5 SE5
ENGINE (cont'd)
New 1.00 mm to 1.40 mm (.0394 in to .0551 in)
Intake
Service limit 1.60 mm (.063 in)
Valve seat contact width
New 1.25 mm to 1.55 mm (.0492 in to .061 in)
Exhaust
Service limit 1.80 mm (.0709 in)
New 33.459 mm to 33.475 mm (1.3173 in to 1.3179 in)
Valve lifter bucket diameter
Service limit 33.440 mm (1.3165 in)
Valve lifter bucket radial clearance Service limit 0.08 mm (.0031 in)
New 39.24 mm (1.5449 in)
Inner spring
Service limit 38.00 mm (1.4961 in)
Valve springs free length
New 41.97 mm (1.6524 in)
Outer spring
Service limit 40.50 mm (1.5945 in)
New 96.940 mm to 96.950 mm (3.8165 in to 3.8169 in)
Size 1 / A
Service limit 96.920 mm (3.8157 in)
Piston measurement
New 96.950 mm to 96.960 mm (3.8169 in to 3.8173 in)
Size 2 / B
Service limit 96.930 mm (3.8161 in)
New 0.050 mm to 0.075 mm (.002 in to .003 in)
Piston/cylinder clearance
Service limit 0.090 mm (.0035 in)
1st Upper compression ring, L-section
Piston ring type 2nd Lower compression ring, taper-face
3rd Oil scraper ring
All New 0.15 mm to 0.35 mm (.0059 in to .0138 in)
Ring end gap
All Service limit 1 mm (.0394 in)
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 (3.8189 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)
New 23.967 mm to 23.980 mm (.9436 in to .9441 in)
Camshaft bearing journal
Service limit 23.950 mm (.9429 in)
New 24.007 mm to 24.020 mm (.9452 in to .9457 in)
Camshaft bearing journal bore
Service limit 24.040 mm (.9465 in)
Camshaft radial clearance Service limit 0.060 mm (.0024 in)
MAG side Service limit 0.070 mm (.0028 in)
Crankshaft deflection
Clutch side Service limit 0.040 mm (.0016 in)
New 41.979 mm to 42.010 mm (1.6527 in to 1.6539 in)
Crankshaft pin diameter
Service limit 41.960 mm (1.652 in)
Connecting rod big end diameter
Service limit 42.080 mm (1.6567 in)
(with plain bearings)

2 rmr2010-040
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RS (SM5/SE5))

SPYDER RS
MODEL
SM5 SE5
ENGINE (cont'd)
New 0.020 mm to 0.045 mm (.0008 in to .0018 in)
Connecting rod big end radial play
Service limit 0.070 mm (.0028 in)
New 22.010 mm to 22.020 mm (.8665 in to .8669 in)
Connecting rod small end diameter
Service limit 22.030 mm (.8673 in)
New 21.997 mm to 22.000 mm (.866 in to .8661 in)
Piston pin diameter
Service limit 21.990 mm (.8657 in)
CLUTCH
Centrifugal clutch +
Wet clutch, multi-plate,
wet multi-plate clutch,
Type hydraulic operation
automatically controlled by
(pneumatic assist)
the TCM
Recommended Brake fluid DOT 4
Clutch fluid Use engine oil for lubrication
Capacity 60 ml (2 U.S. oz)
Clutch spring free length Service limit 58.00 mm (2.283 in)
Clutch plate assembly
(friction and steel driven plates) Service limit 43.5 mm (1.713 in) 41.00 mm (1.614 in)
thickness
Steel driven plate warpage Service limit 0.15 mm (.0059 in)
Engagement – 2000 ± 200 RPM
Centrifugal clutch speed
Stall – 3200 ± 200 RPM
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
4th 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 (.1772 in)
1st, 2nd and
Service limit 29.035 mm (1.143 in)
3rd
Free pinion bore diameter 4th Service limit 29.125 mm (1.1467 in)
5th Service limit 26.025 mm (1.0246 in)
Reverse Service limit 40.040 mm (1.5764 in)
MAG side 34.975 mm (1.377 in)
Free pinion
Main shaft journal diameter Service limit 24.970 mm (.9831 in)
bearing
Clutch side 19.970 mm (.7862 in)

rmr2010-040 3
Section 02 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RS (SM5/SE5))

SPYDER RS
MODEL
SM5 SE5
GEARBOX (cont'd)
MAG side Service limit 19.970 mm (.7862 in)
Free pinion
Service limit 29.030 mm (1.1429 in)
bearing 4th
Clutch shaft journal diameter
Free pinion
Service limit 21.970 mm (.865 in)
bearing 5th
Clutch side Service limit 29.965 mm (1.1797 in)
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 L (3.2 qt (U.S. liq.))
Thermostat Opening temperature 75°C (167°F)
Turn on @ 101°C (214°F)
Radiator fan
Turn off @ 97°C (207°F)
Radiator cap opening pressure 90 kPa (13 PSI)
ELECTRICAL SYSTEM
Magneto generator output 500 W @ 6000 RPM
Ignition system type Electronic ignition with dual output coil
Ignition timing Electronically controlled, not adjustable
Quantity 2
NGK KR8Bi (irridium)
Spark plug Type (apply heat-sink paste P12 (P/N 420 897 186)
on spark plug thread)
Gap 0.7 mm - 0.8 mm (.028 in - .031 in)
Engine RPM limiter setting Forward 9500 RPM
Type Maintenance free
Model Yuasa YTX24HL-BS
Battery
Voltage 12 V
Nominal rating 21A•h
Halogen, 2 x 55 W
Headlight
CE models: 4 x 60 W
Taillight/brake light 2 x 5/21 W
Front 2 x 21 W
Turn signal lights 2 x 10 W
Rear
CE models: 2 x 21 W
RS 2 x 5 W
Position lights
RS-S LED 2 x 1 W
License plate light 10 W
Backup light 2 x 21 W

4 rmr2010-040
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RS (SM5/SE5))

SPYDER RS
MODEL
SM5 SE5
ELECTRICAL SYSTEM (cont'd)
LEFT fuse box F1: Cluster, DLC, DESS 15 A
F2: Wakeup ECM, VCM, MSR
10 A
and DESS, SAS, YAS, PRS
F3: Not used Not used
F4: WPM, PBM Not used
F5: ECM 5 A
F6: Injectors, coils 15 A
F7: Wakeup TCM, DPS, Cluster 10 A
F8: HO2S, CAPS, Fuel pump,
15 A
EVAP, CSV
J1: VCM pump 40 A
J2: VCM valves 25 A
Fuses J3: DPS 40 A
J4: Main control 40 A
J5: Cooling fan 30 A
R1: Reverse actuator —
R2: Pre-starting —
R3: Cooling fan —
Relays (in left fuse box)
R4: Main 2, Accessories —
R5: Main 1, Motor —
R6: Not used —
RIGHT fuse box F1: Daylights, Parking lamps,
15 A
Plate lights
F2: Brake lights, Hazard 10 A
F3: Radio Not used
F4: Trailer Not used
F5: Load shedding 20 A
F6: DC plugs, Vkey 10 A
F7: DC Plugs, Vbat 10 A
F8: Not used Not used
J1: Not used Not used
J2: Accessories 40 A
Fuses J3:TCM solenoids 20 A
J4: LO headlamps 30 A
J5: HI headlamps 20 A
R1: HI headlamps —
R2: LO headlamps —
R3: Load shedding —
Relays (in right fuse box)
R4: Suspension Not used
R5: Main headlamps —
R6: DC plugs Not used
FUEL SYSTEM

rmr2010-040 5
Section 02 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RS (SM5/SE5))

SPYDER RS
MODEL
SM5 SE5
Multi-point Electronic Fuel Injection (EFI)
Type with ETC (Electronic Throttle Control),
Fuel delivery system 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 ± 100 (not adjustable)

6 rmr2010-040
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RS (SM5/SE5))

SPYDER RS
MODEL
SM5 SE5
FUEL SYSTEM (cont'd)
MINIMUM OCTANE RATING
Type REGULAR unleaded gasoline
Inside North
87 (R+M)/2
America
Octane rating
Outside North
92 RON
America
Fuel
OCTANE RATING (OPTIMUM PERFORMANCE)
Type PREMIUM unleaded gasoline
Inside North
91 (R+M)/2
America
Octane rating
Outside North
95 RON
America
Fuel tank capacity 24.5 L (6.47 U.S. gal.)
DRIVE SYSTEM
Type Drive belt
Final drive
Ratio 28/79
Material Carbon reinforced
Drive belt 1 050 N ± 150 N (236 lbf ± 33.7 lbf)
Tension (with rear wheel lifted)
(fully extended suspension)
Final drive ratio 2.8:1
STEERING
Turning radius 3 m (9.8 ft)
0° ± 0.2°
Total toe-in (vehicle on ground)
(see STEERING (DPS) AND WHEELS subsection
Camber angle 0° ± 0.5°
Tie-rod maximum length unengaged threads 12 mm (.4724 in) maximum
Tie-rod maximum length (c/c ball joints) 577 mm (22.72 in)
SUSPENSION
FRONT
Suspension type Double suspension arm with anti-roll bar
RS 151 mm (5.9 in)
Suspension travel
RS-S 142 mm (5.6 in)
Qty 2
Shock absorber RS Oil damper
Type
RS-S Gas damper
Spring free length 208 mm ± 3 mm (8.2 in ± .1 in)
RS Not adjustable
Spring preload adjustment
RS-S Threaded ring adjusters
REAR
Suspension type Swing arm with single shock
Preload adjustment Not adjustable
Suspension travel 152 mm (6 in)
Qty 1
Shock absorber
Type Oil damper

rmr2010-040 7
Section 02 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RS (SM5/SE5))

SPYDER RS
MODEL
SM5 SE5
Spring free length 268 mm ± 3 mm (10.6 in ± .1 in)
Spring color code Part number indicated on spring, no color code available
BRAKES
Foot-actuated. Fully integrated hydraulic 3-wheel braking
Type
system with ABS and EBD
Front brake Dual discs of 270 mm (10.6 in) with 4 piston calipers
Rear brake Single disc of 270 mm (10.6 in) with 1 piston caliper
Capacity 530 ml (17.9 U.S. oz)
Brake fluid
Type DOT 4
Parking brake Mechanical, foot-operated to the rear caliper. Self adjustment
Front 4 pistons caliper
Caliper
Rear Single piston. Sliding pins caliper
Front Sintered
Brake pad material
Rear Sintered
Minimum brake pad thickness 1 mm (.04 in)
Minimum brake disc thickness Front/rear 7 mm (.28 in)
Maximum brake disc warpage 0.1 mm (.004 in)
TIRES AND WHEELS
TIRES
Type (use BRP recommended Front KR31 165/55/R15 (special motorcycle type)
tires) Rear KR21 225/50/R15 (special motorcycle type)
Minimum: 89 kPa (13 PSI) (0.9 bar).
Front
Recommended: 103 kPa (15 PSI) (1.03 bar)
Pressure
Minimum: 179 kPa (26 PSI) (1.79 bar).
Rear
Recommended: 193 kPa (28 PSI) (1.93 bar)
Front 2.5 mm (3/32 in)
Minimum tire thread depth
Rear 4.0 mm (5/32 in)
WHEELS
Front 15 in x 5 in
Size
Rear 15 in x 7 in
Front wheel nuts torque 109 N•m (80 lbf•ft)
225 N•m (166 lbf•ft)
Rear drive axle nut torque
DIMENSION
Overall length 2 667 mm (105 in)
Overall width 1 506 mm (59 in)
Overall height 1 146 mm (45 in)
Seat height 737 mm (29 in)
Wheel base 1 711 mm (67 in)
Front wheel track 1 308 mm (51.5 in)
Ground clearance (front and under engine) 110 mm (4.3 in)

8 rmr2010-040
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RS (SM5/SE5))

SPYDER RS
MODEL
SM5 SE5
WEIGHT AND LOADING CAPACITY
Dry weight 362 kg (798 lb)
Capacity 58 L (15.3 U.S. gal.)
Front storage compartment
Maximum load 16 kg (35 lb)

Total vehicle load allowed (including operator, passenger, cargo

208 kg (459 lb)
and added accessories)
Gross vehicle weight rating (GVWR) 593 kg (1,307 lb)
Maximum weight on trailer tongue 18 kg (40 lb)
Maximum towed weight (trailer and cargo) 182 kg (401 lb)

rmr2010-040 9
10
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 02 (SPYDER ST (SM5/SE5))

SPYDER ST (SM5/SE5)
SPYDER ST
MODEL
SM5 SE5
ENGINE
ROTAX® 991, 4-stroke, 60° V-twin,
Engine type
Dual Over Head Camshaft (DOHC), 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 12.2:1
Type Dry sump with separate oil reservoir and oil cooler
Oil filter (engine and
BRP Rotax microglass fiber type, replaceable
transmission)
Engine oil
Minimum 350 kPa (51 PSI) @ 5000 RPM / 80°C (176°F) oil temperature
pressure
Capacity
(oil change
3.9 L (4.1 qt (U.S. liq.)) 4.2 L (4.4 qt (U.S. liq.))
with engine
Lubrication filter)
Capacity
(oil change
Engine oil –
with engine 4.3 L (4.5 qt (U.S. liq.))
and HCM
filters)
XPS synthetic blend oil (summer grade) (P/N 293 600 121) 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 (.04 in)
Intake valve closing 40° ABDC @ 1 mm (.04 in)
Exhaust valve opening 45° BBDC @ 1 mm (.04 in)
Exhaust valve closing 5° ATDC @ 1 mm (.04 in)
Intake 0.11 mm to 0.18 mm (.0043 in to .0071 in)
Valve clearance
Exhaust 0.22 mm to 0.29 mm (.0087 in to .0114 in)
New 5.961 mm to 5.975 mm (.2347 in to .2352 in)
Intake
Service 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 0.006 mm (.0002 in)
Valve runout
exhaust Service limit 0.06 mm (.0024 in)
New 6.006 mm to 6.018 mm (.2365 in to .2369 in)
Valve guide diameter
Service limit 6.050 mm (.2382 in)

rmr2010-040 11
Section 02 TECHNICAL SPECIFICATIONS
Subsection 02 (SPYDER ST (SM5/SE5))

SPYDER ST
MODEL
SM5 SE5
ENGINE (cont'd)
New 1.00 mm to 1.40 mm (.0394 in to .0551 in)
Intake
Service limit 1.60 mm (.063 in)
Valve seat contact width
New 1.25 mm to 1.55 mm (.0492 in to .061 in)
Exhaust
Service limit 1.80 mm (.0709 in)
New 33.459 mm to 33.475 mm (1.3173 in to 1.3179 in)
Valve lifter bucket diameter
Service limit 33.440 mm (1.3165 in)
Valve lifter bucket radial clearance Service limit 0.08 mm (.0031 in)
New 39.24 mm (1.5449 in)
Inner spring
Service limit 38.00 mm (1.4961 in)
Valve springs free length
New 41.97 mm (1.6524 in)
Outer spring
Service limit 40.50 mm (1.5945 in)
New 96.940 mm to 96.950 mm (3.8165 in to 3.8169 in)
Size 1 / A
Service limit 96.920 mm (3.8157 in)
Piston measurement
New 96.950 mm to 96.960 mm (3.8169 in to 3.8173 in)
Size 2 / B
Service limit 96.930 mm (3.8161 in)
New 0.050 mm to 0.075 mm (.002 in to .003 in)
Piston/cylinder clearance
Service limit 0.090 mm (.0035 in)
1st Upper compression ring, L-section
Piston ring type 2nd Lower compression ring, taper-face
3rd Oil scraper ring
All New 0.15 mm to 0.35 mm (.0059 in to .0138 in)
Ring end gap
All Service limit 1 mm (.0394 in)
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 (3.8189 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)
New 23.967 mm to 23.980 mm (.9436 in to .9441 in)
Camshaft bearing journal
Service limit 23.950 mm (.9429 in)
New 24.007 mm to 24.020 mm (.9452 in to .9457 in)
Camshaft bearing journal bore
Service limit 24.040 mm (.9465 in)
Camshaft radial clearance Service limit 0.060 mm (.0024 in)
MAG side Service limit 0.070 mm (.0028 in)
Crankshaft deflection
Clutch side Service limit 0.040 mm (.0016 in)
New 41.979 mm to 42.010 mm (1.6527 in to 1.6539 in)
Crankshaft pin diameter
Service limit 41.960 mm (1.652 in)
Connecting rod big end diameter
Service limit 42.080 mm (1.6567 in)
(with plain bearings)

12 rmr2010-040
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 02 (SPYDER ST (SM5/SE5))

SPYDER ST
MODEL
SM5 SE5
ENGINE (cont'd)
New 0.020 mm to 0.045 mm (.0008 in to .0018 in)
Connecting rod big end radial play
Service limit 0.070 mm (.0028 in)
New 22.010 mm to 22.020 mm (.8665 in to .8669 in)
Connecting rod small end diameter
Service limit 22.030 mm (.8673 in)
New 21.997 mm to 22.000 mm (.866 in to .8661 in)
Piston pin diameter
Service limit 21.990 mm (.8657 in)
CLUTCH
Centrifugal clutch +
Wet clutch, multi-plate,
wet multi-plate clutch,
Type hydraulic operation
automatically controlled by
(pneumatic assist)
the TCM
Recommended Brake fluid DOT 4
Clutch fluid Use engine oil for lubrication
Capacity 60 ml (2 U.S. oz)
Clutch spring free length Service limit 58.00 mm (2.283 in)
Clutch plate assembly
(friction and steel driven plates) Service limit 43.5 mm (1.713 in) 41.00 mm (1.614 in)
thickness
Steel driven plate warpage Service limit 0.15 mm (.0059 in)
Engagement – 2000 ± 200 RPM
Centrifugal clutch speed
Stall – 3200 ± 200 RPM
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
4th 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 (.1772 in)
1st, 2nd and
Service limit 29.035 mm (1.143 in)
3rd
Free pinion bore diameter 4th Service limit 29.125 mm (1.1467 in)
5th Service limit 26.025 mm (1.0246 in)
Reverse Service limit 40.040 mm (1.5764 in)
MAG side 34.975 mm (1.377 in)
Free pinion
Main shaft journal diameter Service limit 24.970 mm (.9831 in)
bearing
Clutch side 19.970 mm (.7862 in)

rmr2010-040 13
Section 02 TECHNICAL SPECIFICATIONS
Subsection 02 (SPYDER ST (SM5/SE5))

SPYDER ST
MODEL
SM5 SE5
GEARBOX (cont'd)
MAG side Service limit 19.970 mm (.7862 in)
Free pinion
Service limit 29.030 mm (1.1429 in)
bearing 4th
Clutch shaft journal diameter
Free pinion
Service limit 21.970 mm (.865 in)
bearing 5th
Clutch side Service limit 29.965 mm (1.1797 in)
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 L (3.2 qt (U.S. liq.))
Thermostat Opening temperature 75°C (167°F)
Turn on @ 101°C (214°F)
Radiator fan
Turn off @ 97°C (207°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
NGK KR8Bi (irridium)
Spark plug Type (apply heat-sink paste P12 (P/N 420 897 186)
on spark plug thread)
Gap 0.7 mm - 0.8 mm (.028 in - .031 in)
Engine RPM limiter setting Forward 9500 RPM
Type Maintenance free
Model Yuasa YTX24HL-BS
Battery
Voltage 12 V
Nominal rating 21A•h
Halogen, 2 x 60 W
Headlight
CE models: 4 x 60 W

Taillight/brake light 2 x 5/21 W

Front LED, 2 x 3.5 W
Turn signal lights 2 x 10 W
Rear
CE models: 2 x 21 W
ST 2 x 5 W
Position lights ST-S and ST
LED 2 x 1 W
Limited
License plate light 5 W
2 x 21 W
Backup light
CE models: 2 x 20 W

14 rmr2010-040
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 02 (SPYDER ST (SM5/SE5))

SPYDER ST
MODEL
SM5 SE5
ELECTRICAL SYSTEM (cont'd)
LEFT fuse box F1: Cluster, DLC, DESS 15 A
F2: Wakeup ECM, VCM, MSR
10 A
and DESS, SAS, YAS, PRS
F3: Not used Not used
F4: WPM, PBM 20 A
F5: ECM 5 A
F6: Injectors, coils 15 A
F7: Wakeup TCM, DPS, Cluster 10 A
F8: HO2S, CAPS, Fuel pump,
15 A
EVAP, CSV
J1: VCM pump 40 A
J2: VCM valves 25 A
Fuses J3: DPS 40 A
J4: Main control 40 A
J5: Cooling fan 30 A
R1: Reverse actuator —
R2: Pre-starting —
R3: Cooling fan —
Relays (in left fuse box)
R4: Main 2, Accessories —
R5: Main 1, Motor —
R6: Not used —
RIGHT fuse box F1: Daylights, Parking lamps,
15 A
Plate lights
F2: Brake lights, Hazard 10 A
F3: Radio 15 A
F4: Trailer 10 A
F5: Load shedding 20 A
F6: DC plugs, Vkey 10 A
F7: DC Plugs, Vbat 10 A
F8: Not used Not used
J1: Not used Not used
J2: Accessories 40 A
Fuses J3:TCM solenoids 20 A
J4: LO headlamps 30 A
J5: HI headlamps 20 A
R1: HI headlamps —
R2: LO headlamps —
R3: Load shedding —
Relays (in right fuse box)
R4: Suspension —
R5: Main headlamps —
R6: DC plugs —
FUEL SYSTEM

rmr2010-040 15
Section 02 TECHNICAL SPECIFICATIONS
Subsection 02 (SPYDER ST (SM5/SE5))

SPYDER ST
MODEL
SM5 SE5
Multi-point Electronic Fuel Injection (EFI)
Type with ETC (Electronic Throttle Control),
Fuel delivery system 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 ± 100 (not adjustable)

16 rmr2010-040
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 02 (SPYDER ST (SM5/SE5))

SPYDER ST
MODEL
SM5 SE5
FUEL SYSTEM (cont'd)
MINIMUM OCTANE RATING
Type REGULAR unleaded gasoline
Inside North
87 (R+M)/2
America
Octane rating
Outside North
92 RON
America
Fuel
OCTANE RATING (OPTIMUM PERFORMANCE)
Type PREMIUM unleaded gasoline
Inside North
91 (R+M)/2
America
Octane rating
Outside North
95 RON
America
Fuel tank capacity 24.5 L (6.47 U.S. gal.)
DRIVE SYSTEM
Type Drive belt
Final drive
Ratio 28/79
Material Carbon reinforced
Drive belt 1 050 N ± 150 N (236 lbf ± 33.7 lbf)
Tension (with rear wheel lifted)
(fully extended suspension)
Final drive ratio 2.8:1
STEERING
Turning radius 3 m (9.8 ft)
0° ± 0.2°
Total toe-in (vehicle on ground)
(see STEERING (DPS) AND WHEELS subsection
Camber angle 0° ± 0.5°
Tie-rod maximum length unengaged threads 12 mm (.4724 in) maximum
Tie-rod maximum length (c/c ball joints) 577 mm (22.72 in)
SUSPENSION
FRONT
Suspension type Double suspension arm with anti-roll bar
Suspension travel 151 mm (5.9 in)
Qty 2
Shock absorber
Type Oil damper
Spring free length 239 mm ± 3 mm (9.4 in ± .1 in)
Spring preload adjustment Not adjustable
REAR
Suspension type Swing arm with single shock
Preload adjustment Not adjustable
Suspension travel 152 mm (6 in)
Qty 1
Shock absorber
Type Oil damper
Spring free length 268 mm ± 3 mm (10.6 in ± .1 in)
Spring color code Part number indicated on spring, no color code available
BRAKES

rmr2010-040 17
Section 02 TECHNICAL SPECIFICATIONS
Subsection 02 (SPYDER ST (SM5/SE5))

SPYDER ST
MODEL
SM5 SE5
Foot-actuated. Fully integrated hydraulic 3-wheel braking
Type
system with ABS and EBD
Front brake Dual discs of 270 mm (10.6 in) with 4 piston calipers
Rear brake Single disc of 270 mm (10.6 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 Sintered
Brake pad material
Rear Sintered
Minimum brake pad thickness 1 mm (.04 in)
Minimum brake disc thickness Front/rear 7 mm (.28 in)
Maximum brake disc warpage 0.1 mm (.004 in)
TIRES AND WHEELS
TIRES
Type (use BRP recommended Front KR31 165/55/R15 (special motorcycle type)
tires) Rear KR21 225/50/R15 (special motorcycle type)
Minimum: 89 kPa (13 PSI) (0.9 bar).
Front
Recommended: 103 kPa (15 PSI) (1.03 bar)
Pressure
Minimum: 179 kPa (26 PSI) (1.79 bar).
Rear
Recommended: 193 kPa (28 PSI) (1.93 bar)
Front 2.5 mm (3/32 in)
Minimum tire thread depth
Rear 4.0 mm (5/32 in)
WHEELS
Front 15 in x 5 in
Size
Rear 15 in x 7 in
Front wheel nuts torque 109 N•m (80 lbf•ft)
225 N•m (166 lbf•ft)
Rear drive axle nut torque
DIMENSION
Overall length 2 667 mm (105 in)
Overall width 1 506 mm (59 in)
Overall height 1 332 mm (52 in)
Seat height 737 mm (29 in)
Wheel base 1 711 mm (67 in)
Front wheel track 1 308 mm (51.5 in)
Ground clearance (front and under engine) 110 mm (4.3 in)

18 rmr2010-040
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 02 (SPYDER ST (SM5/SE5))

SPYDER ST
MODEL
SM5 SE5
WEIGHT AND LOADING CAPACITY
Dry weight 392 kg (864 lb)
Capacity 55 L (14.5 U.S. gal.)
Front storage compartment
Maximum load 16 kg (35 lb)

23.5 L (6.2 U.S. gal.)

Capacity
Side storage compartment (ST
Limited) 7 kg (15 lb)
Maximum load

Total vehicle load allowed (including operator, passenger, cargo

208 kg (459 lb)
and added accessories)
Gross vehicle weight rating (GVWR) 623 kg (1,373 lb)
Maximum weight on trailer tongue 18 kg (40 lb)
Maximum towed weight (trailer and cargo) 182 kg (401 lb)

rmr2010-040 19
20
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 03 (SPYDER RT (SM5/SE5))

SPYDER RT (SM5/SE5)
SPYDER RT
MODEL
SM5 SE5
ENGINE
ROTAX® 991, 4-stroke, 60° V-twin,
Engine type
Dual Over Head Camshaft (DOHC), 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 12.2:1
Type Dry sump with separate oil reservoir and oil cooler
Oil filter (engine and
BRP Rotax microglass fiber type, replaceable
transmission)
Engine oil
Minimum 350 kPa (51 PSI) @ 5000 RPM / 80°C (176°F) oil temperature
pressure
Capacity
(oil change
3.9 L (4.1 qt (U.S. liq.)) 4.2 L (4.4 qt (U.S. liq.))
with engine
Lubrication filter)
Capacity
(oil change
Engine oil –
with engine 4.3 L (4.5 qt (U.S. liq.))
and HCM
filters)
XPS synthetic blend oil (summer grade) (P/N 293 600 121) 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 (.04 in)
Intake valve closing 40° ABDC @ 1 mm (.04 in)
Exhaust valve opening 45° BBDC @ 1 mm (.04 in)
Exhaust valve closing 5° ATDC @ 1 mm (.04 in)
Intake 0.11 mm to 0.18 mm (.0043 in to .0071 in)
Valve clearance
Exhaust 0.22 mm to 0.29 mm (.0087 in to .0114 in)
New 5.961 mm to 5.975 mm (.2347 in to .2352 in)
Intake
Service 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 0.006 mm (.0002 in)
Valve runout
exhaust Service limit 0.06 mm (.0024 in)
New 6.006 mm to 6.018 mm (.2365 in to .2369 in)
Valve guide diameter
Service limit 6.050 mm (.2382 in)

rmr2010-040 21
Section 02 TECHNICAL SPECIFICATIONS
Subsection 03 (SPYDER RT (SM5/SE5))

SPYDER RT
MODEL
SM5 SE5
ENGINE (cont'd)
New 1.00 mm to 1.40 mm (.0394 in to .0551 in)
Intake
Service limit 1.60 mm (.063 in)
Valve seat contact width
New 1.25 mm to 1.55 mm (.0492 in to .061 in)
Exhaust
Service limit 1.80 mm (.0709 in)
New 33.459 mm to 33.475 mm (1.3173 in to 1.3179 in)
Valve lifter bucket diameter
Service limit 33.440 mm (1.3165 in)
Valve lifter bucket radial clearance Service limit 0.08 mm (.0031 in)
New 39.24 mm (1.5449 in)
Inner spring
Service limit 38.00 mm (1.4961 in)
Valve springs free length
New 41.97 mm (1.6524 in)
Outer spring
Service limit 40.50 mm (1.5945 in)
New 96.940 mm to 96.950 mm (3.8165 in to 3.8169 in)
Size 1 / A
Service limit 96.920 mm (3.8157 in)
Piston measurement
New 96.950 mm to 96.960 mm (3.8169 in to 3.8173 in)
Size 2 / B
Service limit 96.930 mm (3.8161 in)
New 0.050 mm to 0.075 mm (.002 in to .003 in)
Piston/cylinder clearance
Service limit 0.090 mm (.0035 in)
1st Upper compression ring, L-section
Piston ring type 2nd Lower compression ring, taper-face
3rd Oil scraper ring
All New 0.15 mm to 0.35 mm (.0059 in to .0138 in)
Ring end gap
All Service limit 1 mm (.0394 in)
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 (3.8189 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)
New 23.967 mm to 23.980 mm (.9436 in to .9441 in)
Camshaft bearing journal
Service limit 23.950 mm (.9429 in)
New 24.007 mm to 24.020 mm (.9452 in to .9457 in)
Camshaft bearing journal bore
Service limit 24.040 mm (.9465 in)
Camshaft radial clearance Service limit 0.060 mm (.0024 in)
MAG side Service limit 0.070 mm (.0028 in)
Crankshaft deflection
Clutch side Service limit 0.040 mm (.0016 in)
New 41.979 mm to 42.010 mm (1.6527 in to 1.6539 in)
Crankshaft pin diameter
Service limit 41.960 mm (1.652 in)
Connecting rod big end diameter
Service limit 42.080 mm (1.6567 in)
(with plain bearings)

22 rmr2010-040
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 03 (SPYDER RT (SM5/SE5))

SPYDER RT
MODEL
SM5 SE5
ENGINE (cont'd)
New 0.020 mm to 0.045 mm (.0008 in to .0018 in)
Connecting rod big end radial play
Service limit 0.070 mm (.0028 in)
New 22.010 mm to 22.020 mm (.8665 in to .8669 in)
Connecting rod small end diameter
Service limit 22.030 mm (.8673 in)
New 21.997 mm to 22.000 mm (.866 in to .8661 in)
Piston pin diameter
Service limit 21.990 mm (.8657 in)
CLUTCH
Centrifugal clutch +
Wet clutch, multi-plate,
wet multi-plate clutch,
Type hydraulic operation
automatically controlled by
(pneumatic assist)
the TCM
Recommended Brake fluid DOT 4
Clutch fluid Use engine oil for lubrication
Capacity 60 ml (2 U.S. oz)
Clutch spring free length Service limit 58.00 mm (2.283 in)
Clutch plate assembly
(friction and steel driven plates) Service limit 43.5 mm (1.713 in) 41.00 mm (1.614 in)
thickness
Steel driven plate warpage Service limit 0.15 mm (.0059 in)
Engagement – 2000 ± 200 RPM
Centrifugal clutch speed
Stall – 3200 ± 200 RPM
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
4th 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 (.1772 in)
1st, 2nd and
Service limit 29.035 mm (1.143 in)
3rd
Free pinion bore diameter 4th Service limit 29.125 mm (1.1467 in)
5th Service limit 26.025 mm (1.0246 in)
Reverse Service limit 40.040 mm (1.5764 in)
MAG side 34.975 mm (1.377 in)
Free pinion
Main shaft journal diameter Service limit 24.970 mm (.9831 in)
bearing
Clutch side 19.970 mm (.7862 in)

rmr2010-040 23
Section 02 TECHNICAL SPECIFICATIONS
Subsection 03 (SPYDER RT (SM5/SE5))

SPYDER RT
MODEL
SM5 SE5
GEARBOX (cont'd)
MAG side Service limit 19.970 mm (.7862 in)
Free pinion
Service limit 29.030 mm (1.1429 in)
bearing 4th
Clutch shaft journal diameter
Free pinion
Service limit 21.970 mm (.865 in)
bearing 5th
Clutch side Service limit 29.965 mm (1.1797 in)
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 L (3.2 qt (U.S. liq.))
Thermostat Opening temperature 75°C (167°F)
Turn on @ 101°C (214°F)
Radiator fan
Turn off @ 97°C (207°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
NGK KR8Bi (irridium)
Spark plug Type (apply heat-sink paste P12 (P/N 420 897 186)
on spark plug thread)
Gap 0.7 mm - 0.8 mm (.028 in - .031 in)
Engine RPM limiter setting Forward 9500 RPM
Type Maintenance free
Model Yuasa YTX24HL-BS
Battery
Voltage 12 V
Nominal rating 21A•h
Halogen, 2 x 60 W (type H4)
Headlight
CE models: Halogen, 2 x 55 W (type H9)
Taillight/brake light LED, 2 x 3.1 W
Front LED, 2 x 4.5 W
Turn signal lights LED, 2 x 10 W
Rear
CE models: 2 x20 W
RT 2 x 5 W
Position lights RT-S and RT
LED 2 x 1 W
Limited
License plate light 5 W
2 x 10 W
Backup light
CE models: 2 x 20 W
Day light (RT-S, RT Limited) 2 x 35 W
Front storage compartment light (RT-S, RT Limited) 0.2 W

24 rmr2010-040
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 03 (SPYDER RT (SM5/SE5))

SPYDER RT
MODEL
SM5 SE5
ELECTRICAL SYSTEM (cont'd)
LEFT fuse box F1: Cluster, DLC, DESS 15 A
F2: Wakeup ECM, VCM, MSR
10 A
and DESS, SAS, YAS, PRS
F3: Not used Not used
F4: WPM, PBM 20 A
F5: ECM 5 A
F6: Injectors, coils 15 A
F7: Wakeup TCM, DPS, Cluster 10 A
F8: HO2S, CAPS, Fuel pump,
15 A
EVAP, CSV
J1: VCM pump 40 A
J2: VCM valves 25 A
Fuses J3: DPS 40 A
J4: Main control 40 A
J5: Cooling fan 30 A
R1: Reverse actuator —
R2: Pre-starting —
R3: Cooling fan —
Relays (in left fuse box)
R4: Main 2, Accessories —
R5: Main 1, Motor —
R6: Not used —
RIGHT fuse box F1: Daylights, Parking lamps,
15 A
Plate lights
F2: Brake lights, Hazard 10 A
F3: Radio 15 A
F4: Trailer 10 A
F5: Load shedding 20 A
F6: DC plugs, Vkey 10 A
F7: DC Plugs, Vbat 10 A
F8: Not used Not used
J1: Not used Not used
J2: Accessories 40 A
Fuses J3:TCM solenoids 20 A
J4: LO headlamps 30 A
J5: HI headlamps 20 A
R1: HI headlamps —
R2: LO headlamps —
R3: Load shedding —
Relays (in right fuse box)
R4: Suspension —
R5: Main headlamps —
R6: DC plugs —
FUEL SYSTEM

rmr2010-040 25
Section 02 TECHNICAL SPECIFICATIONS
Subsection 03 (SPYDER RT (SM5/SE5))

SPYDER RT
MODEL
SM5 SE5
Multi-point Electronic Fuel Injection (EFI)
Type with ETC (Electronic Throttle Control),
Fuel delivery system 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 ± 100 (not adjustable)

26 rmr2010-040
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 03 (SPYDER RT (SM5/SE5))

SPYDER RT
MODEL
SM5 SE5
FUEL SYSTEM (cont'd)
MINIMUM OCTANE RATING
Type REGULAR unleaded gasoline
Inside North
87 (R+M)/2
America
Octane rating
Outside North
92 RON
America
Fuel
OCTANE RATING (OPTIMUM PERFORMANCE)
Type PREMIUM unleaded gasoline
Inside North
91 (R+M)/2
America
Octane rating
Outside North
95 RON
America
Fuel tank capacity 24.5 L (6.47 U.S. gal.)
DRIVE SYSTEM
Type Drive belt
Final drive
Ratio 28/79
Material Carbon reinforced
Drive belt 1 050 N ± 150 N (236 lbf ± 33.7 lbf)
Tension (with rear wheel lifted)
(fully extended suspension)
Final drive ratio 2.8:1
STEERING
Turning radius 3 m (9.8 ft)
0° ± 0.2°
Total toe-in (vehicle on ground)
(see STEERING (DPS) AND WHEELS subsection
Camber angle 0° ± 0.5°
Tie-rod maximum length unengaged threads 12 mm (.4724 in) maximum
Tie-rod maximum length (c/c ball joints) 577 mm (22.72 in)
SUSPENSION
FRONT
Suspension type Double suspension arm with anti-roll bar
Suspension travel 174 mm (6.9 in)
Qty 2
Shock absorber
Type Oil damper
Spring free length 233 mm ± 3 mm (9.2 in ± .1 in)
Spring preload adjustment Not adjustable
REAR
Swing arm with single shock
RT
Air pressure
Suspension type
RT-S, RT Swing arm with single shock
Limited ACS (air controlled suspension)
RT Through air pressure setting
Preload adjustment RT-S, RT
5 positions selectable through the cluster
Limited
Suspension travel 152 mm (6 in)

rmr2010-040 27
Section 02 TECHNICAL SPECIFICATIONS
Subsection 03 (SPYDER RT (SM5/SE5))

SPYDER RT
MODEL
SM5 SE5
Qty 1
Shock absorber
Type Oil damper
Spring free length 273 mm ± 3 mm (10.7 in ± .1 in)
Spring color code Part number indicated on spring, no color code available
BRAKES
Foot-actuated. Fully integrated hydraulic 3-wheel braking
Type
system with ABS and EBD
Front brake Dual discs of 270 mm (10.6 in) with 4 piston calipers
Rear brake Single disc of 270 mm (10.6 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 Sintered
Brake pad material
Rear Sintered
Minimum brake pad thickness 1 mm (.04 in)
Minimum brake disc thickness Front/rear 7 mm (.28 in)
Maximum brake disc warpage 0.1 mm (.004 in)
TIRES AND WHEELS
TIRES
Type (use BRP recommended Front KR31 165/55/R15 (special motorcycle type)
tires) Rear KR21 225/50/R15 (special motorcycle type)
Minimum: 89 kPa (13 PSI) (0.9 bar).
Front
Recommended: 103 kPa (15 PSI) (1.03 bar)
Pressure
Minimum: 179 kPa (26 PSI) (1.79 bar).
Rear
Recommended: 193 kPa (28 PSI) (1.93 bar)
Front 2.5 mm (3/32 in)
Minimum tire thread depth
Rear 4.0 mm (5/32 in)
WHEELS
Front 15 in x 5 in
Size
Rear 15 in x 7 in
Front wheel nuts torque 109 N•m (80 lbf•ft)
225 N•m (166 lbf•ft)
Rear drive axle nut torque
DIMENSION
Overall length 2 667 mm (105 in)
Overall width 1 572 mm (62 in)
Overall height 1 510 mm (59 in)
Seat height 772 mm (30.4 in)
Wheel base 1 711 mm (67 in)
Front wheel track 1 384 mm (54.5 in)
Ground clearance (front and under engine) 110 mm (4.3 in)

28 rmr2010-040
 Section 02 TECHNICAL SPECIFICATIONS
Subsection 03 (SPYDER RT (SM5/SE5))

SPYDER RT
MODEL
SM5 SE5
WEIGHT AND LOADING CAPACITY
Dry weight 433 kg (955 lb)
Capacity 55 L (14.5 U.S. gal.)
Front storage compartment
Maximum load 16 kg (35 lb)
Capacity 1.2 L (.32 U.S. gal.)
Glove box
Maximum load 2 kg (4.4 lb)
49.7 L (13.1 U.S. gal.)
Capacity
Side storage compartment
7 kg (15 lb)
Maximum load
Capacity 40.5 L (10.7 U.S. gal.)
Rear storage compartment
Maximum load 9 kg (20 lb)
Total vehicle load allowed (including operator, passenger, cargo
224 kg (494 lb)
and added accessories)
Gross vehicle weight rating (GVWR) 680 kg (1,499 lb)
Maximum weight on trailer tongue 18 kg (40 lb)
Maximum towed weight (trailer and cargo) 180 kg (397 lb)

rmr2010-040 29
 Subsection XX (WIRING DIAGRAM INFORMATION)

WIRING DIAGRAM INFORMATION

GENERAL Relay Identification
The relays are identified on the WIRING DIA-
WIRING DIAGRAM LOCATION GRAM as per following example:
The wiring diagram are located in the pocket in-
side the back cover page of the manual.

WIRING DIAGRAM CODES

Fuse Identification
The fuses are identified on the WIRING DIAGRAM
as per following example:

rmr2013-040-017_a

RELAY IDENTIFICATION
1. Relay location:
LFB = Left fuse box
RFB = Right fuse box
2. Relay name
3. Relay identification and its position in fuse box (position R5)
4. Terminal position in fuse box

Wire Identification
The wires used in the electrical system are
rmr2013-040-015_a
identified on the WIRING DIAGRAM using an
J-CASE FUSE IDENTIFICATION
1. Fuse location: alphanumeric code which, identifies the color and
LFB = Left fuse box the AWG (American Wire Gauge) gauge of a wire.
RFB = Right fuse box
2. Fuse name When a 2-color scheme is used, the first color
3. Fuse identification is the main color while the second color is the
4. Fuses (F) and relays (R) supplied by that fuse
5. Fuse amperage rating tracer color.
6. Position of fuse in fuse box (position J4)

OR/WH-20
1 2 3
rmr2008-038-001_a

1. Main wire color

2. Tracer color
3. Wire gauge

The splices used in wiring harnesses are identi-

fied on the WIRING DIAGRAM using an alphabetic
code that identifies the color of all the wires that
rmr2013-040-016_a
are joined together. Ex: JT GY/GN.
BLADE FUSE IDENTIFICATION
1. Fuse location
LFB: Left fuse box Connector Identification
RFB: Right fuse box
2. Fuse identification The connectors used in the electrical system are
3. Components supplied by that fuse identified on the WIRING DIAGRAM using an al-
4. Fuse amperage rating
5. Position of fuse blades in fuse box (position A8 and B8) phanumeric code which identifies the following:

rmr2013-040 1
Subsection XX (WIRING DIAGRAM INFORMATION)
-1
PS
5-T
1 2
rmr2008-038-002_a
1. Connector location in vehicle
2. Connector code
3. Terminal position in connector
Some electrical components have more than one
connector attached to them. In theses cases, the
connectors will be identified as follows.
MULTIPLE CONNECTOR IDENTIFICATION
EXAMPLE
VR2-1 Voltage regulator connector 2, pin 1
ECMB-L1 ECM connector B, pin L1
Connector Location in Vehicle
It is provided using a vehicle outline and tables
on the wiring diagram. The zones identified by a
number on the vehicle indicate the general area in
which the connector can be found. A body panel
or component must usually be removed to access
the connector.
NOTE: Use the connector location in conjunction
with the vehicle outline on the WIRING DIAGRAM
to find where in vehicle the connector is located.
Connector Code
It refers to the component or system wiring har-
ness the connector is attached to.
NOTE: Use the connector code table in POWER
DISTRIBUTION AND GROUNDS subsection for a
description of the connectors.
Terminal Position in Connector
The last digit(s) after the dash identifies the termi-
nal (pin) position.
2 rmr2013-040
TROUBLESHOOTING
DIAGNOSTIC TIPS
IMPORTANT: When trying to solve an electrical
problem, check the following:
– The ignition switch is turned ON.
– The engine RUN/STOP switch is in RUN posi-
tion.
– The battery condition as well as its cables and
connections.
– The system fuse condition of the related circuit
using an ohmmeter.
– Ensure a positive electrical connection of the
3 fuse to the fuse holder contacts.
– Examine related circuit harness and connec-
tions.
Install a battery charger before any tests that in-
volve prolonged "key ON". If system voltage is too
low, some accessories will be shut off and test
results can be altered. Also, it is advisable to re-
move the headlight relay while testing, however
fault codes will have to be erased afterwards.
Pay particular attention to electrical connectors
and ensure that pins are not out of their housings,
loose, or damaged. The troubleshooting proce-
dures may not cover problems resulting from one
of these causes.
NOTE: Ensure all terminals are properly crimped
on wires and connector housings are properly fas-
tened. 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 or terminals.
If a fault is intermittent and cannot be found
through static continuity checks, it may indicate:
– A loose connection
– A bad splice in a harness
– A pin that is unlocked in a connector and barely
making contact
– An intermittent electronic component within a
module.
Do the following:
– Try moving the harness and connectors to sim-
ulate vehicle vibration as you carry out your
checks with the multimeter.
– Try spraying water to the harness, connectors
or sensors to simulate riding under the rain or
high humidity as you carry out your checks with
the multimeter.
 Subsection XX (WIRING DIAGRAM INFORMATION)

IMPORTANT: In an electrical circuit, the bat-

tery usually provides power to a switch, which
then supplies the electric component when the
switch is closed (low power circuits). There-
fore the switch opens and closes the positive
side of the circuit. In circuits controlled by the
ECM and other modules, the battery supplies
the electric component, and the ECM/module
acts as the switch which completes the circuit to
ground. A relay acts as a remote switching device
for higher power components or for supplying
multiple circuits. Take this into account when
troubleshooting the electrical system.
Pay attention to ground wires. They could be-
come loose or corroded which causes them to
act as an additional load in a circuit, dropping
voltage and reducing current to components.
Some components may be grounded through
their outer casing and mounting hardware. This
should also be considered.

rmr2013-040 3
Subsection XX (WIRING DIAGRAM INFORMATION)

Simplifying Electrical System Tests

For complex systems where there are electronic modules, sensors, actuators, relays etc., it is often
beneficial for diagnosing problems to divide up the system into some basic smaller subsystems, to help
narrow down where the problem lies.
Use B.U.D.S. to check for fault codes, refer to COMMUNICATION TOOLS AND B.U.D.S. and also DIAG-
NOSTIC AND FAULT CODES subsections. Follow Service Actions listed in B.U.D.S..
COMMON SUBSYSTEM GUIDELINE
POWER AND GROUNDS – Battery – Check if a group of components or systems
– Fuses stopped working or if nothing works (lights, gauge,
– Relays etc.).
– Connections – Start from the power source (battery) and move
outwards towards the modules, checking for
voltage at each connection.
– Check grounds and battery (+) using a voltmeter.
– Disconnect and test wiring.
INPUTS AND OUTPUTS – Sensors – View monitoring functions in B.U.D.S.
– Gauges – Activate each item and monitor response.
– Actuators – Disconnect and test wiring.
– Motors
COMMUNICATION – Between Modules and – View monitoring functions in B.U.D.S.
with B.U.D.S. – Disconnect and test wiring.

For ALL wiring tests, you need to check for:

POSSIBLE PROBLEM COMMON CAUSE
– Open circuit – Loose terminals, broken wires.
– Shorts to ground (battery -) – Wires rubbed through, water in connectors.
– Shorts to battery (+) – Corroded wires and terminals.
– Shorts to other circuits
– Higher resistance than desired

4 rmr2013-040
rmr2013-040-230
2013 Spyder RS

J
L

E
S

P
R

B
K

A
G
H
N

D
Q

M
VR
1-
3
VR
BK- 10 2- VR RD- 10 RD- 8 RD- 8
FB

1
1

1 1-
1

V
60

FUSE

VR
YE- 14 2-
JT RD
2
RECTIFIER

MAG

BK- 6
VR
YE- 14 2-
3

MAGNETO
U
BS BA BS
T2 T2 YE- 14 T1
JT RD2

JT BK2A
JT RD1

JT BK1A

(2/2)
BA

BST
BK- 6 BK- 6 BK- 6 T1 RD- 6 RD- 6 RD- 6 RD- 6

VR
(1/2)
BST
POST

BK- 12

FP
BK- 12

BA

D2
JT RD3

BK- 6

BLS
VOLTAGE
RD- 6

CES
BOOSTER

FLH
RD- 6

GN

BAT
RECTIFIER

DC2
DC1
21 AH

CIC3
CIC2
CIC1

DIC3
DIC2
DIC1

FPL2
FPL1
BFS2
BFS1
BOOSTER POST

DPS2
DPS1
D1

DLC3
DLC2
DLC1
BK- 12

ECMB
12 VDC
REGULATOR

JT BK6
BK- 6
BATTERY
BK- 12

JT BK5
D3 PIC CH
D3 -C 1- BK- 6 LF RF
B

JT BK4
AS

9
9
6
6
5
9
9
1
1
1
5
5
5
1
1
1
7
7
7
6
8
8
8
6
-A G BK- 12 B

JT BK3A
BK- 18 DI
C2 BK- 20
-

JT BK3
CAN-HI

F
CAN-LO

(BRP USING ONLY)

BK- 16 DI BK- 16

BK- 6
WH/BK- 20

C2
WH/BG- 20
WH/BG- 20

JT BK2
-R

BK- 16

JT BK10
D3 DIODE
BK- 16

2
2

710003215
JT BK9
M

ACRONYMSZONESCABLES BRP #
FUEL
GN

TANK
OT

BK- 12
D7
CAN-HI
CAN-LO

CIC HB
1- S-
L 3

PL
JT WH/BK 3
WH/BK- 20 JT WH/BK 2
JT WH/BK 1

CL

KIC
JT WH/BG 3
JT WH/BG 2
JT WH/BG 1

HIC

LPS
LFB

PRS

RFB
RCF
FRH

HBS

HN2
HN1

PIC3
PIC1
HB DI -1

RLF2
RLF1
RD- 18 7

LBHL
GN/WH- 20

RBHL
BK- 16 BK- 18 C2

MSL3
MSL2
BK- 20

MSR2
S-

GND1
1 GN/WH- 20 -E

HO2S2
HO2S1
CL
DI
BU- 18 C1

SENSOR
FP 1/2
FUEL LEVEL
-P

7
7
1
1
4
4
8
5
5
6
6
6
6
1
3
2
5
5
3
3
5
5
9
6
CL

CLUSTER 1/5
-8

HBS
OG/RD- 20

PARKING
BRAKE
SWITCH
CL OG/RD- 20
JT WH/BN
JT WH/GN

-2
CL 4 DI
FP DI -1
2 C1

L
-D BK/VT- 20 C1
- BK/VT- 18 CL WH/BG- 20 -S WH/BG- 20
K -2
CL
-1 3
FP DI VIM DI 5 DI DI
-A BU- 20 C1
-D 1- C1 BU- 20 CL WH/BK- 20 C2
-B
C1
-R WH/BK- 20
1 -B

710003215
CL -9
VIM -6 LF LF

ACRONYMSZONESCABLES BRP #
BK- 20 VIM
2-
BU- 20 VT- 20 1- YE/BN- 20 YE/BN- 20 RD/YE- 18 RD/YE- 18 B-
B8
B-
J4
2 2
MS VIM PK- 20 VIM LF
R2
-
BG- 20 1- WH/RD- 20 2- RD/YE- 20 RD/YE- 16 B- RD/WH- 16 RD/WH- 12
BK/YE- 20 4

CL
3 3 A8

TIC

FLF
40

FRF
YRS

LHL
SAS

TAS
ECMB- E4

RHL
PBM

CIC2
VCM
STS2
STS1

DIC3
DIC2
DIC1
VSS3
VSS2
VSS1
RRF2
RRF1

VIM2
VIM1
AN
BK/YE- 20 BK/PK- 20
15

BK- 20 BK- 20 T-
2 BK- 20

ANT

D.E.S.S
D.E.S.S.

3
3

VIM

RUN
STOP
AN

MODULE
JT RD/YE
(J4)
LFB

ANTENNA
BK- 20 T-
JT RD/WH

7
6
2
2
2
2
5
5
5
2
2
8
9
9
1
1
9
6
6
1
1
9
8
8
BK- 20

JT BK9
JT BK6
JT BK5
JT BK4
JT BK3
JT BK2
1

D3- A
JT BK10
V
DLC

EC
(F1)
LFB
DESS

WH/YE- OG/PK- 20

MULTI.
MB 20 IM2-
MAIN FUSE

MSR 1/4

RIGHT
SWITCH
3

(STOP SWITCH)
-A
F1, R4, R5, F2

EC 2
M
CLUSTER

B- EC OG/PK- 20
BK- 16 L1 MB
-B
EC 4
MB EC
BK- 16 -M
2
MB WH/GN- 20

710002615
710002616
710003215
-A
EC 4

ACRONYMSZONESCABLES BRP #
MS KS MB EC
R2 1 BK- 16 -M MB WH/BN- 20

+
-5 -1
3 -C
EC 2

KS1
KS EC

PL
MA
BK- 20 BK- 20 1- BE/BU- 20 WH/BK- 20

HIC
TL2
TL1

KS2
KS1
CTS
MB

ETA
CPS
KNOCK
-G

CSV
S
2

EOP

INJ2
INJ1
2

COIL
RLF2
RLF1

RRF2
RRF1
-C

EVAP
GBPS
CAPS
PIEZO
1

MAPS
ECMA
EC

AAPTS
SENSOR #1
MA EC LF
YE/BU- 20

JT BK
-C MB WH/BG- 20 B-
3 -M B4
4

5
5
5
5
5
5
5
6
6
6
5
6
5
5
5
5
4
8
8
9
8
7
7
8
KS LF
2 -1 LT GN/OG- 20 B- VT/PK- 16

+
A4
EC IN

KS2
KS J1 HI
5

MA
BN/BG- 20 EC C-

#1
2- -1
1

KNOCK
-D

S
2 MA

INJ1

(FRONT)
2

INJECTOR

PIEZO
-J
EC 1
IN

SENSOR #2
MA
YE/BG- 20 -B BN/RD- 18 J1
VT/BU- 16
1 -2 VT/BU- 18 VT/BU- 16

4
4

IN
ECM

J2
(F5)
LFB

910266339
710002615
EC -1
MA

+
1/4
HIC

ACRONYMSZONESCABLES BRP #
EC -K
M 1

SPLICE 1
TA B- IN LF
VT- 22

#2
S- BN/BU- 18 J2 B-

S2
D OG/LT BU- 20 J3

ECM ENGINE CONTROL MODULE

-2 VT/BU- 18 B3
EC

INJ2
M

HL
HL
HS

TIC
(REAR)

PTS
TPS

RFB
TA B-

BHL
FBG
LF

GSC
BU- 22 EC CO HI

PIC2
CIC1
VT/PK- 16

HALL
S-

BST2
BST1
C-

LRHL
B-

GPS2
GPS2
GPS1
GPS1
F GN/LT GN- 20 A3 IL- VT/BU- 16

AUX1
AUX1
MA

RDO1
-

TCMB
3 2

AAPTS
-M A3
EC
M 1
TA CO
BN- 22 S- BN/BK- 16 VT/GY- 16
15

IL-
E OG/LT GN- 20 B- B3 VT/BU- 16

+
2

1
1
1
4
4
2
2
2
2
6
6
6
5
5
8
8
8
8
8
8
8
7
8
5
TAS
(REAR)
TA EC GN
JT VT/BU

RD- 22

SPK A
S- PK/LT GN- 20 MB- D-
A

S1
2/4

8
HIC

K1
EC GN

OIL
TA M
(F6)
LFB

GN- 22

TANK
D-

HALL
S-
C BK- 14 9

-
PK/LT BU- 20 B- E

COIL
1
COILS &

GN
COIL
IGNITION

EC
BK- 22 TA
S- M D- IGNITION HI
INJECTORS

C-
B GN/LT BU- 20 B- K 10 3

B
3

THROTTLE ACCELERATOR SENSOR

(R5)
MAIN
LFB

710002716
710003032
710002829
710002830
710002622
710002370
710003218
710003113
710003111
710002831
910266339
RELAY
MOTOR

CP EC CO
S-

ACRONYMSZONESCABLES BRP #
IL-

SPK B
MA VT/BU- 16
1

(FRONT)

S
1

INJECTOR SPARK PLUG SPARK PLUG

-M
EC 2

CPS
CP MA LF
S- BU/YE- 20 EC BN/OG- 16 B-

IK
-H

FL
3/4

MB
2

R1
HIC

1 D4

SM
KIC

STS
LFB
-H

RFB
VR1

FGS
BHL
HN3
HN2
HN1
2

PIC1

CIC1
EC

GND
COIL
STS3
-

BST1
HO

BAT1

TANK
CHAS
LF

GND7
YE/WH- 20 MA EC 2S BN- 20
-K MB BN- 20 1- B- RD/WH- 16
2 -L D C6
2

5
5

H0 LF
EC BN/GN- 20 2S WH- 20 WH- 20 HO
OG/GN- 20 B-

S
2S

7
5
5
5
1
8
8
9
5
8
1
1
1
1
1
1
3
3
3
2
2
6
MB 1-
A 1- D6

-
-J
EC 1 C
CT M HO LF

3&4
EC

CTS
GY- 20

t
S- BG/OG- 20 A- 2S VT/PK- 16 B- RD/WH- 16
1 A1
MB
-D BK/PK- 20 1- C4
B

S
2
JT VT/PK

EC

-
HEATER

CRANK SHAFT COOLANT

CT MA EC BK- 20 LF
S BK/OG- 20 -J MB WH/PK- 20 HO2S1 B-

02SENSOR
-2 2 -J D7
2
EC HO LF
MB BN/LT BU- 20 2S B- RD/WH- 16
2-

710003082
710003216
710002372
710003031
710002374
710002373
3 & 4 710002619
710003114
710003112
710003334
710002716
-L
D C8
EC 3

ACRONYMSZONESCABLES BRP #
GB MA EC H0 LF LF
PS OG/BU- 20 -C MB RD/LT BU- 20 2S WH- 20 WH- 20 HO2 OG/GN- 20 B- B-
4

S
-1 2- S2

GBPS
-H
- B2 D8
A

POSITION SENSORTEMP SENSOR SENSOR

EC 4 C
GB HO

R1
MA LF

HALL

D3
P S- WH/RD- 20 EC
BK/BN- 20 2S GY- 20 LF LT GN/YE- 16 B- RD/WH- 16

FGS
DPS
-F MB OG/RD- 16 B-

PIC1
2 4 2-

MOT
BST2
C7

BAT2
GPS2
B A2

CHAS
-G
S
HIC 4/4

VALVE

EC 3
PURGE

HEATER
EVAP

-
GB MA BK- 20 EV
HO2S2

PS BK/RD- 20 EC WH/YE- 20 AP
10

02SENSOR

-G MA
-3 1 -M -1

GEARBOX POSITION
3

5
5
5
5
9
9
9
1
1
8
EV
LFB

HI
(R4)

BK/YE- 20 BK/YE- 20 AP OG/GN- 20

MAIN

C-
RELAY

-2 4
JT OG/RD1
ACCES.

8
EC

7
MA EC CA
LT BU- 18
(F7)
LFB

P
D3

EO OG/GN- 18
+

P -E MA PS OG/GN- 20
CAPS
CAM

SENSOR

3
SHAFT
DIODE

POSITION

-E -2
FG,CTG,

2
HALL
CLUSTER,

EC

EOP
YE/GN- 20 CA CA
TCM & DPS

MA PS PS OG/GN- 20
-D

SWITCH
-1 -3
-

6
6

710003216
710002378
710003082
EC CS
MA BK/GN- 20 V-
CSV

ACRONYMSZONESCABLES BRP #
VALVE
CLUTCH

-L
SOLENOID

EC 3

T
AA PT MA CS
PT GN/BU- 20 S- BK/GN- 20 GN/GY- 20 GN/GY- 20 V- OG/GN- 20

S
S- 1 -F
1 2 2

6
EC

5
2

9
6

6
5
AA PT MA LF

SENSOR
EC FP B-
WH/GY- 20 S-

AAPTS
D4

PT
S- 2 WH/GY- 20 -H
4
MB -C B1

S
DIODE

2 -M

ZONE #
EC 1
OG/GN- 16

hPa
AA PT MA

ENGINE OIL AMBIENT AIR

PT OG/BU- 20 S- GY/BU- 20 EC CE FP LF VT/PK- 16
4
-G BN/PK- 16 -B OG/GN- 16 B-
S

S- 3
MB S-
4 A A1

PRESSURE PRESSURE/TEMP
FP

-D

2
EC 3
CES

AA PT MA
PUMP

PT GY/BU- 20 GN/YE- 20 BN- 20

15

S- S-
3
PK/BU- 20 PK/BU- 20 -B
4
SWITCH

4
3
2/2 FUEL

3
EC CE ST
JT OG/GN

+
MB S- S4
B

1
-B
1
-

SPLICE 3
MA PK/BU- 20
(F8)

RD- 6
LFB

SERVICE CENTER
BK- 20 SM ST
CAPS

RD- 6
CLUTCH ENGAGE

PS

DPS- VCM ZONE

BK/LT GN- 20

REAR LEFT PANEL

S3

FRONT LEFT PANEL

REAR RIGHT PANEL

-1

MAPS

FRONT RIGHT PANEL

MIDDLE LEFT PANELS

STEERING - CONSOLE
EC
M

MIDDLE RIGHT PANELS

hPa

ZONE DESCRIPTION
SM

MA A-
STS

PS WH/BU- 20

9
G4
MOTOR
STARTER

-3
PURGE VALVE,

STARTER

-
HO2S HEATERS

EC D2
CLUTCH VALVE,

ST
SOLENOID

MB -A S1

PRESSURE SENSOR
-L
EC 4
FUEL PUMP MOTOR

YE
VT

PK
BK
M

GY
BU
BG

BN

RD
GN
OG
MA ST

WH
BK/BU- 20 A- VT/BG- 20

MANIFOLD ABSOLUTE
PS YE/PK- 20 YE/PK- 20 S2
PRE- STARTING RELAY

H2

LT BU
-2

LT GN
(R2)
PRE-
LFB

RELAY

7
7

STARTING

D2 LF
EC
D2

-C B-
OG/GN- 16

+
MB B1
DIODE

-E 0
EC
MA 3
ET LF
A- BG/RD- 18 -L VT/BG- 20 VT/BG- 20 B-

RED
1

PINK
3

BLUE
A9

GRAY
BEIGE

WHITE
BLACK

GREEN

VIOLET
LF

BROWN
EC

YELLOW
COLOR CODE

ORANGE
B-

ACTUATOR
MB
-C B9 OG/GN- 16
4

ETA (GPA)

LIGHT BLUE
LIGHT GREEN
LF
BG/GY- 20 BG/GY- 20 B-
A1

ELECTRIC TROTTLE
0

-
EC
ET M
A- BG/BK- 18 A-
4 L2
EC LF
JT BG/GY

MB B- OG/RD- 16
B1

+
-G
1 1
EC
TP MA LF
S- BG/YE- 20 -K LT BU/VT- 20 B-

S1
3 4 A1

TPS
EC LF 2
TP M B-
(R3)

SENSOR
S-
LFB
FAN
RELAY

2 BG/WH- B1 OG/RD- 16

-
COOLING

20 A- F3 2
EC
TP MA EC LF
S- BG/GY- 20 -A MB B-
1 2 -F A1

M
EC 1 1 LF
MA LF

S2
TP B-

FREE
- EC B-

TROTTLE POSITION
S- BG/GN- 20 K3 MB BN/WH- 20 RD/VT- 14 J5
4 85
JT BN/WH

REVERSE

FREE
-J
ECMB- C3 4

8
8

UP SHIFT
LF
WH- 20 BN/GY- 20 B- RD/VI- 16

DOWN SHIFT
86
LFB

(R1)
30

RELAY

LF
B-
REVERSE

BK- 16 87 RD/VT- 14
ACTUATOR
FAN

RC
JT RD/VT
(J5)

BU- 16 LF
LFB

BK- 16 F- RC YE/OG- 16 B-
A F-
RELAY

B 30
COOLING

FAN
RCF

LEFT

RIGHT
/RESET
BACKUP

/RESET
FREE
COOLING
ACTUATOR
BA

BA
BK- 18 BA
-1
RD- 18 BU- 18 - 2 YE- 18
RIGHT

LEFT
MULTI.

FREE
(START)

START
SWITCH

DL

MSL
MSR 2/4

C1
-2 WH/BK- 20

FREE

MODE
DL
BK- 20 C1 WH/BG- 20

MULTI. SWITCH
-1
DLC1

MS DL DL
C1 OG/RD- 18

(OTHER FUNCTIONS)
R2
DIAGNOSTIC

BG/GY- 20 C1
YE/RD- 20 -4 -3 -4
LINK CONNECTOR

9
9

DL
BK- 16 C1 RD/YE- 16
-5

LEFT
FP

UP

FREE
L FPL1
PILOT
LIGHT
FRONT
1-

RIGHT
2

DOWN
SET
FP

FREE
BK- 20 BK- 20 OG- 20 L1 OG- 20
JT WH/BN

-
JT WH/GN

1
JT WH/BG3
JT WH/BG2
JT WH/BG1

JT WH/BK 3
JT WH/BK 2
JT WH/BK 1

PILOT
LIGHT

FP
FPL2
FRONT

L2
- 2
IK
(F2)
& MSR
DESS, PRS,
SAS, YRS,
LFB
VCM, ECM,

FP
BK- 20 BK- 20 L 2- OG- 20
OG- 20 1

ALL THESES SWITCHES USED CAN SYSTEM

10

LEFT

LAMP
HEAD
IGNITION KEY

OFF
ON

LOCK

LBHL

CE

LB LB K IC LF
H GY/GN- 18 B-
BOTTOM

L- HL -A
(LOW

B7
ONLY

HEAD

2 -3
LAMP)

LB IK - IK - LF
BK- 18 BK- 20 GY/BE- 20 HL
-1 GY/BG- 18 KIC M A RD/BN- 18 RD/BN- 18 B- RD/WH- 16
-E A7
RB KIC
H L- BK- 18 BK- 18 - IK -
2 OG/PK- 18D I
(F1)
RFB

RB OG/PK- 18

10
10

BK- 18 BK- 20 H GY/GN- 18 KIC

GY- 20 L- IK -
15

3 -C
LDL,RDL

G
FPL1,FPL2

RB K IC RF
GY/BG- 18 OG/PK- 18OG/PK- 18 B-
PL, RTL, LTL,

HL
(FOG

-B B8
LAMP
HEAD

ONLY

-1
RIGHT
RBHL

LIGHTS)
CAN/US
JT OG/PK

RF
BOTTOM

IK - YE/RD- 16
KIC IK - B RD/YE- 18 B- OG/BK- 16
-F F A8
DI LH LH DI
CE
LEFT

OG- 18 C1 L- L- C2
LHL

OG- 18 5 2
JT OG1

-A -N
MODEL

DI
LH C2
L- -P YE/WH- 20 YE/WH- 18OR/BK- 18 OR/BK- 16 OG/BK- 20
HEADLAMP
HI

JT GY/BG2

1 RF
(R1)

DI RF
RFB

LH LH B-
LAMP
HEAD

HL C2
JT GY

GY/BG- 18 B-
RELAY

L-
4
-3 L-
3
GY/BG- 16 GY/BG- 16 -S B1
2 J5
1

LEGEND
HL RF
BK- 18 BK- 18 -5 GY- 18 GY- 18 GY- 16 GY- 16 B- YE/BK- 16
6A A1
1
20

RF
PL

& OPTIONS
PLATE
LIGHT

B- RF
PL PL B1 B-

JT BK9
-1 1 D6

D3- A
JT BK8
JT BK6
JT BK5
JT BK4
JT BK3

-2
JT BK2
HI

JT BK10
ONLY
(J5)

BK- 20 WH- 20 RF
RFB

BK- 20 OR- 20
JT

BN/WH- 20 B- BN/VT- 20
HEAD

JUMPER
CAN/US
LAMPS

A1
2
RF RF
B- B- RF
B9 D5 B- OG/BK- 16
YL/WH

__________ ( FULL LINE ) = STANDARD MODEL SM

C4
RF RF

11
11

BN/WH- 20 B- YE/WH- 20 YE/WH- 20 B-

PL A1 D4
-3 RF 0
B- RF RF
PK/BG- 20 B- OG/BK- 16 B-
LIGHT

B1
0 GN/RD- 20 C6 J4
JT GY/BG1

MODEL
BACKUP

CAN/US

RF
RHL

GY/BG- 16
AUSTRALIA

RIGHT

B- OG/BK- 16
A9 OG/BK- 12
(R5)
RFB
30

MAIN

LAMP
HEAD

RELAY

HL RH
HEADLAMP

-5 GY/BG- 18 L- GY/BG- 18
LO

6 B 1
LO

(R2)

- - - - - - - - - - - - - - - ( DASHED LINE ) = ALL OTHERS MODELS

RFB

LAMP
HEAD
(J4)

RELAY

RH
JT OG/BK
RFB

HL
L
HEAD

-4 -3
LAMPS

1
LIGHTS,

HL RH DL
BK- 18 BK- 18 -5 GY- 18 L- GY- 18 C 2- WH/GN- 20
6 A 3 2
DL
C DL
C WH/BN- 20
DLC2

2- 2-
3 1
BK- 20
LINK CONNECTOR
DIAGNOSTIC(ROTAX)

FOG

ON
OFF
FGS
LIGHTS

FG FG PIC
SWITCH

S- S- 1-
1 4 E
HI

R1 FG GN/RD- 22

12
12

BK- 18 BU- 18 MS
-8
5
S-
3
RD- 18 OG/RD- 18 OG/RD- 18 L2
-2
R1 FG
HI

BK- 18 -8 YL/RD- 18 BK- 20 S-

2
6
LOW

PASS

FR FR PIC R1 PIC
F- F-
1
1- -8
7
BK- 20 LT GN/GY- 16 1-
2 F A
LEFT

BK- 20 BN/YE- 20 R1
BK- 20 WH- 20 GY/GN- 16 GY/GN- 16 -3 LT GN/GY- 16 LT GN/GY- 16 LT GN/GY- 16
0
MULTI.
SWITCH

(HEADLAMP)
MSL1/3

BLS
BRAKE
LIGHTS
SWITCH

JT GY/GN

FRF
RIGHT
FLASHER
FRONT
R1
FOG

TL TL
RELAY

1- OG- 20
LIGHTS

3 GY/BN- 20 1- 1
JT LT GN/GY2

BL BL RF
S- B-
BK- 20 BK- 20 S-
2 1 B7
JT WH1

RD- 18 RF
WH- 20 TL
1- WH- 20 WH- 20 BK- 18 RD/OG- 20 RD/OG- 18 B- OG/BK- 16
2 A7
MODEL

MS
CAN/US
TL1

R2
10

-6
BRAKE &

13
13

JT RD/OG

OG/PK- 20 OG/PK- 20
TAIL LIGHT

DI
(F2)

RR C1
RFB

RTL

F2 GY- 18
JT BN/YE

-L CL
BRAKE

BRAKE, TAIL LIGHT

FREE
LIGHTS

-1
CL 6
HAZARD

RR DI MS
BK- 20 GN- 20 BN/YE- 20 -5 C2 R2
HAZARD &

BK- 20 F1 BN/YE- 20 BN/YE- 20 CL -A -2

-1
DI
CL 0 MS
RL
F2
C1
-M
BK- 20 -1
1 YE/GY- 20 YE/GY- 20 R2
-1
DI
CL
BK- 20 GY- 20 RL C1 GY/PK- 20
BK- 20 F1 GY/PK- 20 GY/PK- 20
-4 OG/BK- 20 RD/OG- 20
CL

-C
2/5
YE/GY- 20

CLUSTER

CL
PK/BG- 20
LTL

PK/BG- 20 -7
RIGHT
MULTI.

HARNESS WIRES EXIT

SWITCH

SWITCH)
(HAZARD

JT GY/PK

TIC
MSR 3/4

- J
TC
TL2
BRAKE &
TAIL LIGHT

GS M-
WH- 18 C- BU/OG- 20 34 TIC
WH/GN- 20
CE

6 - H
VALVE

TC
BRAKE, TAIL LIGHT
+

CLUTCH

M-
TL TL RD- 18 GS 9
MODEL
N/A

2- WH- 20 2- C BU/YE- 20
SOLENOID

WH- 20 WH/BN- 20
GSC 2/4

3 2 -3
TC GS
SHIFT UP

BK- 20 BK- 20 M- C-
-
-

8 WH- 18
SOLENOID

32
GSC 3/4

TC
TL GS M- GS
14
14

OG- 20 WH- 18 C BU/VT- 20 TC BU/WH- 20

CONTROL MODULE

2- -5 30 C-
GY/BN- 20 1 M- 1 RD- 18
CLUTCH

TC 7
+
+

SOLENOID
GSC 1/4

GS M- TC
OR- 18 C PK/VT- 20 5 PK/WH- 20
TIC
-
TCM TRANSMISSION

-4 M- C
LEFT
FLF

4
FRONT

TC TIC
-
FLASHER

OG/RD- 18 OG/RD- 18
-

M- G
TC 1
GS TC
FL
F-
FL
F- WH- 20 C- BU/BK- 20
M-
M- TIC
2 1 7 33
19
WH/BK- 20 - F
WH/BK- 20
MODULATION SOLENOID
GSC 4/4

TC
+

GS M- TC
SHIFT DOWN

BK- 20 BK- 20 WH- 20 GY/PK- 20 RD- 18 C- VT/WH- 20 8

TIC
HI HEADLAMPS (R1)

2
M-
17
WH/BG- 20 - B
WH/BG- 20
TC
LOAD SHEDDING (R3) NOT USED (R4)

M- RF
LO HEADLAMPS (R2)

TIC TC B-
BK- 18 - D BK- 18 10 RD/GY- 18 TIC
- RD/GY- 18
HI HEADLAMPS (J5)

M- J3
35 A
TCM- 28
TIC
DAYS LIGHTS / PARKING LAMPS / PLATE LIGHTS (F1)

- BK- 18
LO HEADLAMPS (R4)

BK- 18 E RD/GY- 18 RD/GY- 18 RD/GY- 16

JT
20

(J3)
TCM

FUSE
RFB

DP
S
RD/GY
SOLENOID

VS VS DP
S1 S3 BK- 6 S1
-
OG/RD- 20
-2 -2 A
POWER

VC VCM- 17
DPS

RADIO (F3)
STEERING
DYNAMIC

M- DP
LEFT)

VS VS WH/BK- 20
(REAR

S PK/RD- 20
SPEED

BU/RD- 20 S1
SPEED
VSS3

19
RIGHT)

HALL
HALL

S3
VSS1

VC -
WHEEL

1-
WHEEL

(FRONT

1 D
SENSOR

-1
SENSOR

M-
VC 29
M- DP LF
WH/BG- 20
15
15

BU/GN- 20 8 PK/GN- 20 S1 B-
- C J3
RFB VUE DE DESSUS RFB

VC
M VC
VS
S2 DP
BK- 12 -1
3 M -2 S2
-
RD/GN- 10
A
DPS

-1
(J3)

6
LFB
40

FUSE

MAIN HEADLAMPS (J3)

VS
VT/RD- 20
MOTOR

VC S2
SPEED

HALL
VSS2

BRAKE LIGHTS / HAZARD (F2)

RIGHT)

M
WHEEL

(FRONT

-1
TCM SOLENOIDS
JT BK5
JT BK4
JT BK2
SENSOR

-4
VC
NOT USED (F4)

BF
S M VT/GN- 20 LF
BK- 20 1- BG/BU- 20 -9 VC B-
A M- J2
VC 25
JT WH/BE 3
JT WH/BE 2
JT WH/BE 1

JT WH/BK 3
JT WH/BK 2
JT WH/BK 1

M
L

BF
BK- 20 S1 -3 VC RD/PK- 14
NOT USED (F6)

BG/BK- 20 4
BRAKE FLUID

-B M-
LOAD SHEDDING (F5)

/ TOP VIEW
25

LEVEL SENSOR

VC 28
(J2)
VCM

M
LFB

FUSE

BF
BFS1 & BFS2

BK- 20 S2 BG/GN- 20
-2
2 VC OG/PK- 20
VALVES

-A
VCMVEHICLE CONTROL MODULE

M-
VC 14
BF
ACCESSORIES (J3)

M-
BK- 20 S2
-B BG/WH- 20 2 VC
M- WH/BK- 20
VC 26
M- LF
LP
S- BK- 14 38 VC WH/BG- 20 B-
3 M- J1
NOT USED (F7)

VC 1 PR PR
BK- 20 BK- 18 BU- 18 LPS WH/VT- 20 M- VC RD/BK- 12 S- S-
-2 12 M- B A
+

S
40

(J1)
VCM
LFB

37
FUSE
PUMP

PR BU- 18 RD- 18 OG/PK- 20

RD- 18 VC
NOT USED (J1)

VT/BN- 20
LPS

M S-
C
NOT USED (F8)
-

-3
2
SWITCH

YR
YAW

16
16

RATE
YRS

BK/BU- 20 OG/PK- 20
PRS

GN- 18 S-
PRESSURE
RIDER

4
NOT USED (R6)
LOW BRAKE
SENSOR

PILLION

SWITCH

YR YR
S- S- WH/BK- 20
1 2
POWER CABLE EXIT

YR SA
BK- 20 S- WH/BG- 20 S-
2
3
SA
BK- 20 S- OG/PK- 20
1
GP SA
S2 S- WH/BK- 20
-A 4
SAS

COOLING FAN (R3)

ANGLE

RF RF
USB

SA
SENSOR

GND B- B-
BK- 18 S- WH/BG- 20
REVERSE ACTUATOR (R1)

J2
STEERING

FL DI AU 3 CIC B6
FL H C2 X1 1-
SYSTEM

-1 PIC -H CIC -T K
GLOBAL

H-
GPS

3 LT GN/WH- 18 1- 1- RF
POSITION

BK- 20 LT GN/WH- 20 B DI PK/BK- 18 G AU TIP- 22 LT GN/RD- 16 B- LT BU/GY- 14 LT BU /GY- 14

FL C2 X1 PIC A6
40

H- PIC - 1-
2 1- G CIC
1-
-S N DI
C1
LT GN/BU- 18 C PK- 18
MIC IN

F PK/GY- 20
PRE- STARTING (R2)

LT GN/BU- 20 SHIELD- 22
15

N/A

AU -E
(J2)
FUSE
RFB

X1
N/A
N/A

-R
(F3)
RFB
SORIES

GP GP
VBAT:
ACCES-

CIC
CLUSTER / DLC / DESS (F1)
RADIO

S1 S2 1-
RING- 20 - -
N/A

FR DI B B N CIC
2A

FR H- C2 1-
N/A

CIC
JT LT BU /GY

H- 1 -K 1 R
GPS

BK- 20 3 LT GN/WH- 20 BN/LT GN- 18

-J
RD- 18 WH/BK- 20
FR DI RD- 18 RD- 18 CIC
COOLING FAN (J5)

H- C2 1-
JT LT GN/WH

2 CIC S
JT LT GN/BU

-J
17
17

1-
LT GN/BU- 20 LT GN- 18 D RF WH/BG- 20
MAIN ACCESSORIES (R4)

B-
A5
MAIN CONTROL (J4)

LT BU/GY- 14
LT GN/PK- 20
(F5)
RFB

CL
(R3)
RELAY
HORN,

RFB
LOAD

RELAY
SHEDDING

LOAD
SHEDDING

DI DI RF RF
C1 B- B-
4/4

C1
DPS (J3)
CLUSTER 3/5

-N CL -J 85 LT BU/BG- 14 B4
MSR

RIGHT
JT LT GN/PK

MULTI.

CL -1
SWITCH

(CRUISE)

-2 RF RF
LT GN/PK- 20 LT GN/PK- 20 2 YE/LT BU- 20 YE/LT BU- 20 B- LT BU/BG- 14 B- LT BU/GY- 14
86 A4
RF
LFB VUE DE DESSUS LFB
ON
SET

B-
20

OFF

87 LT BU/BG- 14
RESUME

NOT USED (F3)

MS MS RF
R1 L2 B-
- 2
-1 LT GN/GY- 16 30
NOT USED (F4)
JT LT BU/BG

M
ECM (F5)

MS MS
GN- 22 R1
-
L1
- GN- 22 OG/RD- 20 SL3 LT GN/PK- 20
3 2 -2
JT LT GN/GY1

MS MS M
L1 WH/BK- 20
MAIN MOTOR (R5)

BN- 22 R1 - BN- 22 WH/BK- 20 SL3-

-4 3 3
MS MS
WH/BG- 20 WH/BG- 20
/ TOP VIEW

WH- 22 R1 L1 WH- 22
LEFT

- 1 -4
JT BK5
JT BK4
MULTI.
SWITCH

WAKE UP ECM, VCM, MSR & DESS / SAS / YAS / PRS (F2)

VCM VALVES (J2)

MS
18
18

MS
BN/BK- 22 L2
-
L1
-1 BN/BK- 22
4
(HEADLAMP)
MSL2/3

MS
BK- 18 L2 BK- 22
-4
MS
VCM PUMP (J1)

L2 HN
-6 1
MS HN
L2 BN/GY- 18 2 LT BU/BG- 18
-5 GN/GY- 18
INJECTORS / COILS (F6)

BK- 18 BK- 18
(HORN)
HN
HORN

FREE

NOT USED (R6)

SWITCH LEFT

HORN
MSL3/3
MULTIFONCTION

WAKE UP TCM, DPS / CLUSTER (F7)

PLUG
DC12
FRONT

DC
ACCESSORY

2
DC
BK- 16 1
19

LT GN/GY- 16
19

HARNESS WIRES EXIT

710003009
H02S / CAPS / FUEL PUMP / EVAP / CSV (F8)

a
J
L

E
S

P
R

B
K

A
G
H
N

D
Q

M
rmr2013-040-232
J
L

E
S

P
R

B
K

A
G
H
N

D
Q

M
VR
1-
3
VR
BK- 10 2- VR
1- RD- 10 RD- 8 RD- 8
1 1

V
60

1
1

VR
YE- 14

JT RD
2-
2

MAG
FB

BK- 6
VR
2013 Spyder RT

FUSE

YE- 14 2-
3

MAGNETO
U
RECTIFIER

BS BA BS
T2 T2 YE- 14
JT RD1

T1
JT RD2

JT BK2A

JT BK1A

(2/2)
BA

BST
BK- 6 BK- 6 BK- 6 T1 RD- 6 RD- 6 RD- 6 RD- 6

-
VR
(1/2)
BST

WP
POST

BK- 12 M-
GN/OG- 20WM2 GY/LT GN- 18 2
BK- 12

JT RD3

BK- 6
VOLTAGE
RD- 6
BOOSTER

RD- 6

GN

BAT
RECTIFIER

PARKING
21 AH

BOOSTER POST
D1
BK- 12

12 VDC

WM
REGULATOR

WPM

JT BK6
BK- 6
BATTERY
BK- 12

JT BK5
+
WINDSHIELD &
D3 PIC CH WP

BRAKE MODULE
BK- 6 WM RF
D3 1- BU/OG- 20 1 GY/RD- 18 WP LF B

JT BK4
- C AS M-
- A G BK- 12 9 M- B

JT BK3A
8
BK- 20 DIC BK- 20 WP WH/BK- 20

-
2-

JT BK3
F M-
6

FP
BA

D2
WP

BLS
CES

FLH
BK- 16

FRH
ASC
LF

DC2
DC1
BK- 16 DIC

BK- 6
DIC DIC

CIC3
CIC2
CIC1
VT/LT GN- 18 M-

DIC3
DIC2
DIC1

FPL2
FPL1
BFS2
BFS1
GN/OG- 20PM2 VT/LT GN- 18 WP WH/BG- 20 B-

DPS2
DPS1
DLC3
DLC2
DLC1
2- 3- 4 2-

ECMB
JT BK2
R C M- D B5
5

PM
BK- 16 PIC PB LF

JT BK10
D3 DIODE
BG/OG- 16 DIC
BK- 16CIC1- WP BG/OG- 16 1- S B-
LT GN/YE- 16

MOTOR
M- 3- - 2
C A K A5

6
9
9
6
6
5
9
9
1
1
1
5
5
5
1
1
1
7
7
7
6
8
8
10

2
2

JT BK9
WP

21
18
23
M P M- PB

FUEL
PBS
BK- 16 CIC BK- 16 GN DIC DIC PIC

TANK
VT/LT BU- 18 YE/LT GN- 20 YE/LT GN- 20 S

WINDSHIELD MOTOR PARKING BRAKE

(1/2)
20
2 OT BU/OG- 20M1 VT/LT BU- 18 11 WP 2- 1- YE/LT GN- 20

BK- 12
BRAKE
D7 3- - 3
- A B M- C L

SWITCH
1

PARKING
WP
(BRP USING ONLY)

BK- 16 BK- 16 GN/WH- 20

M-
3 WP LT BU/GN- 20
DIC
3- LT BU/GN- 20
PIC
1- LT BU/GN- 20
PB
S
J - 1
M- D

JT BK8
WPM- 7 12
PB

(F4)
LFB
GY/OG- 20

WPM
BK- 16 GY/OG- 20 GY/OG- 20 S - 7 PBS- 8 OG/RD- 18

710003214
CIC
1-
HB
S-