2004 Bombardier Outlander 330/400/MAX ATV Service Manual | RepairLoader.com

Comprehensive repair and service manual for all 2004 Bombardier Outlander 330, 400, and MAX ATV models. Covers engine, drivetrain, and electrical systems.

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Document Details

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Document Number / Seller:
29698 / Amy Peterson
File Size:
26.56 MB
File Type:
PDF
Language:
English
Pages:
393
Printable:
Yes
Category:
ATV
Last updated / verified
Jan 10, 2026

Models Covered & Key Technical Specifications

Bombardier Outlander 330/400 ATV Shop Manual: Bombardier Outlander 330/400 ATV Shop Manual (2004) 392 Page Volume Workshop Ready Product-Line: ATV / Engine-Type: Rotax 4-stroke / Machine-Range: 330-400 Series Specification Baseline Logic
Bombardier Propulsion Logic: Rotax four-stroke single-cylinder engine features a single overhead camshaft (SOHC) and liquid cooling within a 325cc or 400cc displacement framework. Engine Architecture
Cylinder Block Architectures: Motor framework utilizes an 82mm to 91mm bore and 61.5mm stroke with 33 Nm cylinder head bolt torque specifications. Engine Displacement
Fuel Injection Framework: Mikuni BSR33 carburetor incorporates a vacuum-operated fuel pulsation pump and 1300 RPM idle speed logic. Fuel System Type
Valve Train Specifications: Four-valve assembly maintains 0.06mm to 0.14mm intake and 0.11mm to 0.19mm exhaust clearance logic. Valve Clearance Settings
Cooling Logic Architectures: Centrifugal pump drives liquid circulation through a thermostat-regulated framework with a 65°C to 75°C opening range. Cooling System Type
Drivetrain Gearbox Specifications: Continuously Variable Transmission (CVT) operates via a dual-range sub-gearbox logic including Park, Neutral, and Reverse functionality. Transmission Type

Outlining the operational framework across various systems including engine, fuel, electrical, drive train, steering, suspension, brakes, body/frame, and technical data. Key procedures cover maintenance, troubleshooting, and removal/installation of components. Diagnostic information is provided for common issues.

Professional Workshop Service Manual & Technical Specifications

Bombardier Outlander 330/400 ATV Shop Manual: Bombardier Outlander 330/400 ATV Shop Manual (2004) 392 Page Volume | Workshop Ready

Product-Line: ATV / Engine-Type: Rotax 4-stroke / Machine-Range: 330-400 Series Specification Baseline Logic
Bombardier Propulsion Logic: Rotax four-stroke single-cylinder engine features a single overhead camshaft (SOHC) and liquid cooling within a 325cc or 400cc displacement framework. Engine Architecture
Cylinder Block Architectures: Motor framework utilizes an 82mm to 91mm bore and 61.5mm stroke with 33 Nm cylinder head bolt torque specifications. Engine Displacement
Fuel Injection Framework: Mikuni BSR33 carburetor incorporates a vacuum-operated fuel pulsation pump and 1300 RPM idle speed logic. Fuel System Type
Valve Train Specifications: Four-valve assembly maintains 0.06mm to 0.14mm intake and 0.11mm to 0.19mm exhaust clearance logic. Valve Clearance Settings
Cooling Logic Architectures: Centrifugal pump drives liquid circulation through a thermostat-regulated framework with a 65°C to 75°C opening range. Cooling System Type
Drivetrain Gearbox Specifications: Continuously Variable Transmission (CVT) operates via a dual-range sub-gearbox logic including Park, Neutral, and Reverse functionality. Transmission Type

Outlining the operational framework across various systems including engine, fuel, electrical, drive train, steering, suspension, brakes, body/frame, and technical data. Key procedures cover maintenance, troubleshooting, and removal/installation of components. Diagnostic information is provided for common issues.

This manual documents engine and vehicle serial numbers, arrangement of sections, and lists abbreviations used. It details procedures for turn over, ATV immersion, air filter cleaning/draining, bolts/fasteners/nuts checks, engine oil and filter replacement, oil strainer, spark arrester, tires and wheels, and engine area.

FAQ

What is the **required** fluid capacity for the engine oil? keyboard_arrow_down

1.7 L is the recommended engine oil capacity for the Bombardier Outlander 330/400/MAX series (2004 models).

Calculate the **specified** component torque for the CVT cover. keyboard_arrow_down

10 N·m (89 lbf·in) is the specified torque for the CVT cover screws, applied in a criss-cross sequence.

What **essential** values are documented for valve adjustments? keyboard_arrow_down

0.06 to 0.14 mm for intake valves and 0.11 to 0.19 mm for exhaust valves are the essential values for valve adjustments on the 330/400 series Outlander.

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This workshop manual is a must-have for anyone working on a 2004 Bombardier Outlander. The instructions are clear and the diagrams are very helpful. The download process was smooth, and I received the email with the link almost instantly! Highly recommend!