Can-Am DS 450 EFI 2007 2008 2009 Repair Service Manual
Can-Am DS 450 EFI 2007 2008 2009 Repair Service Manual
LANGUAGE:ENGLISH
PAGES:384
DOWNLOADABLE:YES
FILE TYPE:PDF
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Can-Am DS 450 EFI 2007 2008 2009 Repair Service Manual
1. Low coolant level.
– Check condition of hoses and hose clamps fixation. Tighten or replace.
– Check if hoses are pinched or if the routing is good. Change the routing, repair or replace.
– Check coolant drain screw on water pump housing. Tighten and/or replace sealing washer.
– Check gaskets on water pump, cylinder head and cylinder. Tighten or replace.
– Check leak indicator hole (located in clutch cover) if coolant leaks. Replace seal, refer to COOLING SYSTEM.
– Check if the self-bleeding system nipples on radiator or cylinder head are blocked. Clean or replace.
– Check engine oil for contamination (white appearance). Overhaul engine and repair.
2. Clogged radiator.
– Check radiator fins for dirt or damages. Clean or replace.
3. Defective cooling fan.
– Check if the cooling fan fuse is burnt. Replace.
– Check if cooling fan motor turns. Replace.
– Check condition of wires and connector. Repair or replace.
4. Defective thermostat (does not open when engine gets hot).
– Replace thermostat. Refer to COOLING SYSTEM section.
5. Defective water pump
– Check water pump impeller for broken wings. Replace
– Check if the spring pin retaining impeller is damaged. Replace.
6. Faulty temperature sensor.
– Check if temperature sensor works properly. Replace.
7. Defective intermediate gear (less coolant supply).
– Check if intermediate gear (located behind clutch cover) is worn out or broken. Replace.
– Check if intermediate gear is clipped correctly onto needle pin.
TABLE OF CONTENTS:
Can-Am DS 450 EFI 2007 2008 2009 Repair Service Manual
SAFETY NOTICE VIII
INTRODUCTION IX
GENERAL INFORMATION IX
VEHICLE INFORMATION IX
ENGINE EMISSIONS INFORMATION X
SELF-LOCKING FASTENERS PROCEDURE X
LOCTITE® APPLICATION PROCEDURE X
TIGHTENING TORQUES XIV
MANUAL INFORMATION XV
01 MAINTENANCE
01 – MAINTENANCE CHART 1
02 – PRESEASON PREPARATION 5
03 – STORAGE PROCEDURE 7
FUEL SYSTEM 7
ENGINE 7
ELECTRICAL SYSTEM 7
COOLING SYSTEM 7
VEHICLE 7
04 – SPECIAL PROCEDURES 9
TURN OVER 9
ATV IMMERSION 9
02 TROUBLESHOOTING
01 – TECHNICAL GUIDELINES (ENGINE) 11
COOLING SYSTEM 11
LUBRICATION SYSTEM 11
CLUTCH 12
CYLINDER HEAD AND CYLINDER 13
CRANKSHAFT AND BALANCER SHAFT 13
GEARBOX 14
02 – DIAGNOSTIC FLOW CHART 15
FUEL SYSTEM 15
03 ENGINE
01- ENGINE REMOVAL AND INSTALLATION 17
GENERAL 18
PROCEDURES 18
ENGINE 18
02 – AIR INTAKE SYSTEM 25
GENERAL 26
PROCEDURES 26
AIR FILTER 26
AIR FILTER HOUSING 26
03 – EXHAUST SYSTEM 29
GENERAL 30
PROCEDURES 30
MUFFLER 30
EXHAUST PIPE 31
SPARK ARRESTER 32
HEAT SHIELD 32
04 – LUBRICATION SYSTEM 33
GENERAL 36
MAINTENANCE 36
ENGINE OIL 36
OIL FILTER 37
OIL TANK STRAINER 38
INSPECTION 39
ENGINE OIL PRESSURE 39
PROCEDURES 40
OIL TANK 40
OIL HOSE CONNECTOR 41
ENGINE OIL PRESSURE REGULATOR 42
OIL PRESSURE PUMP 43
ENGINE OIL STRAINER 46
OIL SUCTION PUMP 47
OIL NOZZLE 48
OIL TUBE 48
05 – COOLING SYSTEM 51
GENERAL 54
INSPECTION 54
COOLING SYSTEM LEAK TEST 54
MAINTENANCE 55
COOLANT REPLACEMENT 55
PROCEDURES 57
COOLANT TANK CAP 57
COOLANT TANK 57
RADIATOR 58
COOLING FAN 59
THERMOSTAT 60
COOLANT TEMPERATURE SENSOR (CTS) 60
WATER PUMP HOUSING 61
WATER PUMP IMPELLER 62
WATER PUMP SHAFT, BEARING AND SEALS 62
06 – MAGNETO/STARTER 67
GENERAL 69
PROCEDURES 69
MAGNETO COVER 69
CRANKSHAFT POSITION SENSOR (CPS) 71
STATOR 71
ROTOR 76
SPRAG CLUTCH 78
SPRAG CLUTCH GEAR 79
STARTER DRIVE GEARS 79
STARTER 80
07 – CYLINDER HEAD/CYLINDER 85
GENERAL 89
MAINTENANCE 89
VALVE CLEARANCE 89
INSPECTION 90
CYLINDER LEAK TEST 90
PROCEDURES 91
VALVE COVER 91
TIMING CHAIN TENSIONER 94
CAMSHAFT TIMING GEAR 94
CAMSHAFT 97
VALVE LIFTER BUCKET 99
CYLINDER HEAD 100
VALVE SPRINGS 102
VALVE 103
VALVE GUIDE 106
TABLE OF CONTENTS
CYLINDER 107
PISTON 108
PISTON RINGS 111
PISTON PIN 112
08 – CRANKCASE/CRANKSHAFT 115
GENERAL 117
PROCEDURES 117
MAIN SHAFT OIL SEAL 117
PRIMARY DRIVE GEAR 118
TIMING CHAIN AND CHAIN TENSIONER GUIDE 118
TIMING CHAIN DRIVE GEARS 119
CRANKCASE 121
BALANCER SHAFT 126
CRANKSHAFT 127
09 – CLUTCH 131
GENERAL 134
MAINTENANCE 134
CLUTCH ADJUSTMENT 134
PROCEDURES 136
CLUTCH RELEASE COVER 136
CLUTCH CABLE 139
CLUTCH LEVER 139
RETAINING PLATE AND CLUTCH SPRING 140
CLUTCH 141
CLUTCH COVER 144
CLUTCH DRUM 146
10 – GEARBOX 149
GENERAL 152
PROCEDURES 152
NEUTRAL INDICATOR SWITCH 152
SHIFTING MECHANISM 152
GEARBOX 155
04 ENGINE MANAGEMENT SYSTEM
01 – OVERVIEW 161
SYSTEM DESCRIPTION 164
CONTROLLER AREA NETWORK (CAN) 164
ENGINE CONTROL MODULE (ECM) 164
POWER DISTRIBUTION 165
02- COMMUNICATION TOOLS/B U D S SOFTWARE 167
MULTI-PURPOSE INTERFACE-2 (MPl-2) · 167
B U D S SOFTWARE 168
03 – MONITORING SYSTEM/FAULT CODES 171
MONITORING SYSTEM 171
FAULT CODES 171
FAULT CODE TABLE 173
05 FUEL SYSTEM
01 – ELECTRONIC FUEL INJECTION (Efl) 179
GENERAL 179
SYSTEM DESCRIPTION 179
GENERAL RECOMMENDATIONS 180
BASIC ADJUSTMENTS 182
IDLE SPEED 182
CLOSED THROTILE AND IDLE ACTUATOR RESET 182
PROCEDURES 183
ENGINE CONTROL MODULE (ECM) 183
FUEL INJECTOR 191
FUEL RAIL 193
THROTILE BODY 195
THROTILE POSITION SENSOR (TPS) 198
IDLE AIR CONTROL VALVE 200
CRANKSHAFT POSITION SENSOR (CPS) 201
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS) 203
AMBIENT AIR PRESSURE AND TEMPERATURE SENSOR (AAPTS) 205
COOLANT TEMPERATURE SENSOR (CTS) 209
02 – FUEL TANK/FUEL PUMP 211
GENERAL 213
INSPECTION 213
FUEL TANK LEAK TEST 213
FUEL PUMP PRESSURE TEST 214
PROCEDURES 216
FUEL HOSE AND OETIKER CLAMPS 216
FUEL PUMP 216
FUEL TANK 222
06 ELECTRICAL SYSTEM
01 – IGNITION SYSTEM 225
GENERAL 225
IGNITION SYSTEM DESCRIPTION 225
IGNITION SYSTEM OPERATION 225
TROUBLESHOOTING 225
IGNITION SYSTEM TESTING 225
PROCEDURES 227
IGNITION SWITCH 227
ENGINE STOP SWITCH 229
IGNITION COIL 232
SPARK PLUG 236
02 – CHARGING SYSTEM 239
GENERAL 239
SYSTEM DESCRIPTION 239
PROCEDURES 240
VOLTAGE REGULATOR/RECTIFIER 240
BATIERY 243
ELECTRICAL SYSTEM MAIN GROUNDS 246
03 – STARTING SYSTEM 247
GENERAL 247
TROUBLESHOOTING 247
PROCEDURES 248
STARTER SOLENOID 248
START BUTION 253
CLUTCH SWITCH 255
04- LIGHTS 257
GENERAL 257
LIGHTS SYSTEM DESCRIPTION 257
LIGHTS SYSTEM OPERATION 257
TROUBLESHOOTING 257
LIGHTS SYSTEM TESTING 257
PROCEDURES 257
HEADLIGHT POWER REGULATOR 257
HEADLIGHTS 259
HEADLIGHT SWITCH 261
TABLE OF CONTENTS
TAILLIGHT/BRAKE LIGHT 262
NEUTRAL INDICATOR LIGHT (GREEN) 263
CHECK ENGINE INDICATOR LIGHT (YELLOW) 265
LOW FUEL LEVEL INDICATOR LIGHT (YELLOW) 266
07 DRIVE SYSTEM
01 – DRIVE CHAIN/REAR AXLE 271
GENERAL 273
PROCEDURES 273
DRIVE CHAIN 273
FRONT SPROCKET 276
REAR SPROCKET 277
REAR AXLE 278
REAR SPROCKET HUB 280
CHAIN TENSIONER 281
08 CHASSIS
01 – WHEELS/TIRES 283
GENERAL 284
MAINTENANCE 284
TIRE PRESSURE 284
PROCEDURES 284
TIRE 284
WHEEL 285
FRONT WHEEL HUB 285
REAR WHEEL HUB 287
WHEEL BEARING 289
02 – STEERING 291
GENERAL 293
ADJUSTMENT 293
STEERING ALIGNMENT 293
PROCEDURES 294
HANDLEBAR GRIP 294
MULTIFUNCTION SWITCH 294
THROTILE LEVER 295
THROTILE CABLE 295
HANDLEBAR 298
STEERING COLUMN 299
TIE-ROD 301
KNUCKLE 302
03 – FRONT SUSPENSION 305
GENERAL 307
ADJUSTMENTS 307
FACTORY SETIINGS 307
ADJUSTING SUSPENSION 308
MAINTENANCE 309
LUBRICATION 309
PROCEDURES 310
SHOCK ABSORBER 310
UPPER SUSPENSION ARM 311
UPPER BALL JOINT 312
LOWER SUSPENSION ARM 313
LOWER BALL JOINT 314
04 – REAR SUSPENSION 317
GENERAL 319
ADJUSTMENTS 319
v
TABLE OF CONTENTS
VI
FACTORY SETIINGS 319
ADJUSTING SUSPENSION 319
MAINTENANCE 320
LUBRICATION 320
PROCEDURES 321
SHOCK ABSORBER 321
SPRING 322
SWING ARM 323
BELL CRANK LEVER 325
PIVOT ARM 326
05 – BRAKES 329
GENERAL 332
SYSTEM DESCRIPTION 332
MAINTENANCE 332
BRAKE FLUID 332
PROCEDURES 334
CALIPER 334
BRAKE PADS 336
BRAKE DISC 338
BRAKE LEVER 339
FRONT MASTER CYLINDER 340
REAR MASTER CYLINDER 340
BRAKE PEDAL 342
BRAKE DISC HUB 344
REAR CALIPER BRACKET 344
FRONT BRAKE LIGHT SWITCH 345
REAR BRAKE LIGHT SWITCH 346
FLEXIBLE BRAKE HOSE 347
06- BODY 351
GENERAL 354
PROCEDURES 354
DECALS 354
SEAT 354
ACCESS COVER 356
CONSOLE 356
FRONT BUMPER 356
FRONT BODY ASSEMBLY 356
FRONT FENDER 358
FRONT GRILLE 358
SIDE PANELS 358
FRONT FASCIA 359
FOOTREST 359
FOOTREST SUPPORT 359
REAR FENDER 359
REAR BUMPER 360
ENGINE SKID PLATE 360
NERF BAR 361
07 – FRAME 363
GENERAL 364
PROCEDURES 364
FRAME 364
REAR FRAME EXTENSION 364
REAR ENGINE SUPPORTS 365
FOOTPEG 365
SIDE MEMBER 366
LOWER SUSPENSION ARM ATIACHMENTS 367
TABLE OF CONTENTS
09 TECHNICAL SPECIFICATIONS
01 – DS 450/DS 450 X 369
10 WIRING DIAGRAM
01 – OS 450/DS 450 X 377
WIRING DIAGRAM 377
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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