2006 Bombardier Outlander 400/800 Service Manual (P/N vmr2006-002)
Bombardier Models Covered & Key Technical Specifications
Models: 2006 Bombardier Outlander 400, 2006 Bombardier Outlander 800, 2006 Bombardier Outlander MAX 400, 2006 Bombardier Outlander MAX XT 400, 2006 Bombardier Outlander XT 800, 2006 Bombardier Outlander MAX 800, 2006 Bombardier Outlander MAX XT 800
Sub-models / Variants: Outlander 400 Series, Outlander 800 Series, Outlander MAX Series, XT trim
Model Years: 2006
Technical Data:
- Engine Displacement: 400 cc (Rotax 400) and 800 cc (Rotax V-810)
- Engine Oil Capacity (400 Series): 3 L (3.17 qt)
- Engine Oil Capacity (800 Series): 1.7–2 L (1.8–2.11 qt)
- Coolant System Capacity: 50/50 antifreeze/distilled water mix
- Radiator Cap Pressure Rating: 110 kPa (16 PSI)
- Radiator Fan Operation: On at 98°C (208°F), off at 95°C (203°F) (800 Series)
- Fastener Torque (M8/8.8 Grade): 24.5 Nm (18 lbf-ft)
- Fastener Torque (M10/8.8 Grade): 48 Nm (35 lbf-ft)
- Fastener Torque (M12/8.8 Grade): 85 Nm (63 lbf-ft)
Bombardier Manual Features & Content Preview
- Official 526-page OEM publication (ref vmr2006-002) covering the 2006 Bombardier Outlander 400 and 800 series ATVs
- Details MAX and XT trim configurations across both the 400 cc and 800 cc Rotax engine platforms
- Features over 150 detailed exploded-view diagrams, 8 comprehensive troubleshooting charts, and indexed torque specification tables for chassis and engine fasteners
- Documents all diagnostic parameters, maintenance intervals, and system specifications distinct to the 400 and V-810 powerplants
Engine and Maintenance Breakdown
This service manual provides a systematic look at maintenance and repair parameters, organized logically by functional vehicle system. It extensively covers engine management, specifically highlighting the Rotax V-810 electronic fuel injection system. You will find specialized diagnostic flow charts for the cooling, magneto, and transmission systems designed to streamline shop floor troubleshooting. The coverage details precise maintenance schedules tailored to both hour-based and distance-based service intervals, alongside correct storage procedures for both EFI variants.
Mechanics get exhaustive documentation on the Continuously Variable Transmission (CVT), drivetrain coupling units, steering geometry, and suspension components. Every major section is supported by technical illustrations and defined assembly sequences to reduce guesswork during complex teardowns. Because hands-on mechanical work carries inherent risks of severe injury or vehicle damage, all maintenance should always be performed by qualified individuals adhering strictly to the safety protocols outlined inside the documentation.
Specification Highlights
Reliable data is the backbone of any accurate service job. This document supplies essential reference values for system maintenance and performance verification, including exact tightening torque metrics for all hardware grades. It breaks down critical fluid capacities, mapping out the 3 L oil requirement for the 400 series against the 1.7 to 2 L range for the 800 series.
Technicians can quickly pull up specialized data such as the 110 kPa radiator cap pressure threshold, 65°C thermostat opening temperatures, and baseline electrical specifications for starters, stators, and charging circuits. Having these exact factory tolerances readily accessible directly on the bench ensures every component is verified against standard manufacturer baselines.
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