2006 Bombardier Outlander Max 400, Max 650, and Max 800 Shop Manual (P/N vmr2006-002)

• Official 528-page manufacturer shop publication (version vmr2006-002) for the 2006 Bombardier Outlander and Outlander MAX ATV family
• Covers both 400 and 800 engine configurations, including the optional XT trim packages
• Features 124 exploded-view diagrams to assist with complex teardowns and reassembly
• Includes extensive maintenance schedules, fluid capacities, and detailed torque specification tables
• Serves as the primary reference documentation for the 219 100 228 build-spec line

Manual Contents Breakdown

When dealing with early-generation Bombardier ATVs, guesswork wastes valuable shop time. This service publication organizes essential mechanical and electrical data into twelve distinct sections to streamline your diagnostic workflow. It opens with comprehensive maintenance charts and critical safety notices. From there, the manual dives straight into deep-level diagnostic troubleshooting specific to the Outlander 400 and 800 series powerplants.

You will find extensive documentation covering the air intake silencer, lubrication network, cooling systems, and exhaust assemblies. Further chapters break down the complex engine management systems. They also detail the fuel tank configurations, charging systems, ignition, transmission, drivetrain, steering, suspension, and brake service alongside structural frame data.

Specification and Data Overview

Accurate technical data is the backbone of any reliable engine rebuild or routine service. This reference outlines exact factory parameters to keep these ATVs running at peak performance. For example, the cooling system section defines precise leak testing procedures and sets the radiator cap pressure threshold at 110 kPa (16 PSI). Engine lubrication charts specify a 3 L (3.17 qt) oil capacity for the 400 series block.

You will also find comprehensive hardware torque values throughout the document. Grade 12.9 fasteners require specific tightening loads, ranging from 4 N•m (35 lbf•in) for M4 bolts up to 200 N•m (148 lbf•ft) for massive M14 hardware. Working on high-performance ATVs involves significant mechanical risks, so the values listed here serve strictly as a reference overview. Mechanics must always rely on the full factory documentation and use proper safety gear before starting any actual hands-on work.