2006 Bombardier Outlander 400/800 ATV Service Manual (P/N 219 100 228)

The 2006 Bombardier Outlander Vehicle Shop Manual (P/N 219 100 228) covers the Outlander 400 and 800 series, including XT, MAX, and MAX XT versions. It documents vehicle service and repair for the carbureted Rotax 400 and fuel-injected Rotax V-810 platforms.

• Maintenance and engine installation: Service intervals, storage procedures, lubrication and cooling system checks, exhaust service, and engine removal and installation for both engine platforms.

• Fuel and engine management: Mikuni BSR33 carburetor service, EFI pressure tests, injector checks, fuel pump module replacement, and throttle body, TPS, and idle actuator procedures.

• Electrical diagnosis: Charging and starting tests, ignition coil checks, Digitally Encoded Security System (DESS) key programming, multi-function speedometers, and XT winch motor and control switch diagnostics.

• CVT and gearboxes: Drive belt replacement, drive and driven pulley service, one-way clutch inspection, and Outlander 800 gearbox disassembly, shimming, and reassembly.

• Drivetrain: The 400 Series 4x4 coupling unit, front and rear differentials, driveshafts, CV boots, and gear mesh checks with backlash and preload adjustments.

• Steering and suspension: Steering column service, alignment, 400 MacPherson struts, 800 A-arms, rear trailing arms, shock absorbers, and trailing-arm bearing replacement.

• Brakes and bodywork: Hydraulic disc brakes, master cylinders, caliper inspection, bleeding procedures, brake hoses, body panel removal, MAX seats, and XT bumper arrangements.

Written for mechanical technicians already familiar with BRP service procedures, this manual assumes workshop experience and access to the specified diagnostic equipment and service tools.

Engine Service and Maintenance Breakdown

The maintenance charts organize inspections and replacement intervals by operating time and distance. Separate storage instructions distinguish the carbureted 400 from the EFI 800. Cooling system coverage includes radiator, thermostat, fan, and sensor diagnosis, alongside lubrication and magneto troubleshooting.

Engine removal and installation are documented for both platforms. Internal engine overhaul requires the appropriate Engine Shop Manual, which is a separate publication and is not included in this download.

EFI Fault Tracing and B.U.D.S. Procedures

The V-810 engine management section combines an EMS flowchart, diagnostic trouble-code tables, ECM connector pinout views, and individual sensor and actuator tests. B.U.D.S. procedures cover fault retrieval, DESS key programming, and Closed Throttle and Idle Actuator resets using the specified VCK or MPI-2 interface.

The fuel delivery diagnostic flowchart and pressure-loss tests help distinguish pump, regulator, injector, and fuel-rail leakage. This gives a technician a structured way to narrow a fault before replacing fuel-system components.

Component handling cautions address damage that can complicate diagnosis: direct probing can deform ECM connector terminals, and manually moving the idle bypass valve piston can damage its drive screw.

CVT, Drivetrain, and Chassis Repair

The transmission chapters distinguish the pulley designs and service procedures for each engine platform. Exploded gearbox views accompany the Outlander 800 disassembly and reassembly procedures. Gearbox and differential sections include shimming references, backlash checks, and special-tool identification. Torque tables, fluid-capacity data, wear limits, and electrical test specifications support inspection and assembly work.

Suspension illustrations distinguish the 400's MacPherson front suspension from the 800's double A-arms. Rear trailing-arm bearing and hydraulic-brake procedures cover inspection and replacement work. Follow the manual's safety precautions for pressurized fuel, spring-loaded clutch components, and brake repairs.

Selected Cooling and EFI Test Specifications

These values are a small selection of the manual's diagnostic specifications. For both Outlander engine platforms, the thermostat test specifies opening at 65°C (149°F).

For the Outlander 800 EFI system, the specified fuel-pump outlet pressure is 350 kPa (51 PSI), with the same pressure expected while the engine runs. Front and rear injector-circuit resistance is specified at 13.8–15.2 ohms at 20°C (68°F).

Chapter Bookmarks, Wiring Detail, and Download Contents

Text search and diagram navigation: Existing OCR makes much of the text searchable, but recognition errors and incomplete schematic labels limit search reliability. Chapter bookmarks link to the main systems. Small wiring labels require magnification; the large schematics are divided across multiple pages.

The download contains one printable, English-language 526-page PDF. Its total includes 503 pages of manual content and front matter, 22 blank pages, and one additional cover page.