Bombardier Outlander/MAX 400 & 800 ATV Shop & Engine Manual Set, 2006 (P/N 219 100 228)

BRP/Bombardier directs users to pair the vehicle manual with the appropriate engine volume. The vehicle book handles vehicle systems and engine removal/installation; the engine books supply the internal teardown, inspection and assembly procedures.

PDF Search, Diagram Detail and File Contents

Text search and wiring detail: Manual content is not searchable in these three PDFs, and none has embedded PDF bookmarks. Several vehicle wiring diagrams span multiple sheets; small pin numbers and wire-color codes require zooming.

The ZIP download contains three printable English PDFs totaling 722 pages, including six cover/title pages and 34 otherwise blank pages: 24 in the vehicle manual and five in each engine manual.

Engine, CVT and Vehicle-System Repair

These selected topics preview the vehicle manual’s 14 sections and the engine volumes. Further subjects include preseason preparation, storage and ATV-immersion procedures.

• Engine repair: Step-by-step engine removal and installation, cylinder-head service, piston and ring inspection, camshaft timing, and crankshaft/crankcase repair.

• Fuel and engine management: Carburetor service for the 400; EFI component testing, ECM fault-code diagnosis and sensor checks for the 800.

• Electrical troubleshooting: Charging, ignition and starter-circuit tests, D.E.S.S. key programming, instrument diagnosis, connector views and wiring diagrams.

• CVT and drivetrain: Drive-belt and pulley service, transmission-linkage adjustment, gearbox and 4x4 coupling repair, differential and propeller-shaft work.

• Cooling system: Pressure testing, thermostat and fan checks, radiator service, coolant replacement and engine-volume procedures for water-pump repair.

• Steering, suspension and brakes: Wheel alignment, steering-column and wheel-bearing service, suspension repair, master-cylinder/caliper service and hydraulic brake bleeding.

These manuals were written primarily for mechanical technicians already familiar with BRP service procedures, using the specified hand tools and special service tools.

Carburetion, EFI and Electrical Diagnosis

The 400 uses a Mikuni BSR33 constant-depression carburetor with manual choke and ECS. The 800 uses a DellOrto 46 mm throttle body, one injector per cylinder, a Bosch electric in-tank pump and ECM-based engine management.

The 800 diagnostic material distinguishes TPS electrical faults from adaptation faults and explains closed-throttle and idle-actuator resets after relevant component work. This connects component replacement with the ECM settings that affect starting, idle quality and deceleration behavior.

The diagnostic chapter covers on-board fault-code display and computer communication. It specifies B.U.D.S. version 2.3.2 or later and documents the MPI-2 interface card P/N 529 036 018, diagnostic cable P/N 710 000 851 and VCK communication kit.

The Engine Management System Flow Chart relates sensor inputs to ECM outputs. The Fuel Delivery System Diagnostic Flow Chart supports fuel-pump and delivery-system fault isolation.

Vehicle schematics include Outlander 400 2006 General System, Outlander 800 2006 General System, Outlander 800 2006 Charging System and Outlander 800 2006 Injection/Ignition System.

Internal Engine and Gearbox Work

ROTAX 400: The engine volume adds leak testing, rewind-starter repair, water-pump and magneto service, oil-pressure testing and decompressor work. Timing-chain, camshaft, valve, piston/ring and crankshaft procedures extend through the integrated gearbox and output shaft.

ROTAX V-810: Separate front and rear cylinder-head procedures accompany camshaft timing and piston inspection. Cooling, lubrication and magneto chapters cover the water pump, oil pump and sprag-clutch components; bottom-end work includes the PTO cover, drive gears, reed valve, crankcase and crankshaft.

The V-810 connecting-rod screws are single-use fasteners with a specified torque-plus-angle procedure; reuse or incorrect tightening can allow a screw to loosen and damage the engine.

CVT and Drive Components

The vehicle book separates 400 and 800 pulley procedures and covers the 800 gearbox and 4x4 coupling mechanism. CVT service identifies driven-pulley expander P/N 529 035 747, with inspection limits for belts, rollers and pulley bushings.

The pulley assemblies use metric threads and are precisely balanced; an incorrect puller can damage threads, while mixing used clutch parts can upset balance. The manual also prohibits impact-wrench use during drive-pulley removal and installation.

General tightening tables cover metric M4 through M14 hardware across grades 5.8, 8.8, 10.9 and 12.9. Component-specific tightening information appears throughout the repair text and exploded views.

Cooling-System Diagnosis

Leak-indicator checks distinguish coolant leakage from oil-seal leakage, with the engine volumes providing the related repair procedures. The V-810 coolant-refilling procedure addresses bleeding both cylinders.

Cooling-system testing identifies test cap P/N 529 035 991, pressure/vacuum pump P/N 529 021 800 and hose pincher P/N 295 000 076. The cooling chapter warns that running without coolant can damage engine parts and the ceramic seal on the water-pump shaft.

Suspension, Brakes and Body Service

The chassis material distinguishes the 400’s MacPherson front suspension from the 800’s double A-arm layout and covers TTI independent rear suspension. Body/frame procedures address panels, seats, racks, exhaust-related access, plastic repair and frame inspection.

Brake coverage includes the separate hydraulic circuits, parking-brake mechanism, pads, discs and hoses, with DOT 4 fluid specified for the system.

Unless a procedure states otherwise, the factory safety notice calls for the engine to be off and cold during maintenance and repair. Follow the publication’s system-specific precautions for electrical, fuel, brake, and rotating-component work.

A Preview of Lubrication and Cooling Specifications

The 800’s separate gearbox has an oil capacity of 400 mL (14 U.S. oz). Cooling-system capacity is 2.5 L (2.65 qt) for the covered 400 and 800 models.

For the V-810 oil-pressure test, the manual specifies a warm engine at 90°C (194°F), using the recommended oil. Minimum pressure at 6000 RPM is 350 kPa (51 PSI).