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® AND THE BRP LOGO ARE TRADEMARKS OF BOMBARDIER RECREATIONAL PRODUCTS INC. OR ITS AFFILIATES.
©2009 BOMBARDIER RECREATIONAL PRODUCTS INC. ALL RIGHTS RESERVED. PRINTED IN CANADA.
219 100 388 CA
DPS/ACS TECHNICAL MANUAL / ENGLISH
MANUEL TECHNIQUE DPS/ACS / ANGLAIS
FAIT AU / MADE IN CANADA U/M:P.C.
Technical Manual
219 100 388
DPS
TM
/ACS
DPS
TM
/ACS
2010
2010
DPS/ACS
Technical Manual
Legal deposit:
National Library of Quebec
National Library of Canada 2009
All rights reserved. No parts of this manual may be reproduced in any form without the prior written
permission of Bombardier Recreational Products Inc. (BRP)
©Bombardier Recreational Products Inc. (BRP) 2009
Printed in Canada
Technical Publications
Bombardier Recreational Products Inc. (BRP)
Valcourt (Quebec) Canada
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
Can-Am™ Renegade™
DPS™ XPS™
Outlander™
This document contains the trademarks of the following companies:
AMP®is a trademark of Tyco Electronics Corporation
Loctite®is a trademark of Loctite Corporation
Snap-on®is a trademark of Snap-on Tools Corporation
TABLE OF CONTENTS
SAFETY NOTICE ......................................................................................................... II
INTRODUCTION......................................................................................................... III
COLOR CODE LEGEND .............................................................................................. III
01 TECHNICAL MANUAL
01 – DYNAMIC POWER STEERING (DPS) ......................................................................... 3
GENERAL ...................................................................................................... 5
SYSTEM DESCRIPTION (FEATURES)....................................................................... 5
SYSTEM DESCRIPTION (COMPONENTS).................................................................. 6
ADJUSTMENT................................................................................................ 7
TORQUE OFFSET RESET................................................................................... 7
DPS ASSIST MODE......................................................................................... 7
TROUBLESHOOTING........................................................................................ 8
PROCEDURES................................................................................................. 9
DPS UNIT ................................................................................................... 9
PITMAN ARM............................................................................................. 22
02 – AIR CONTROLLED SUSPENSION (ACS) ................................................................... 23
GENERAL .................................................................................................... 25
SYSTEM DESCRIPTION (FEATURES)..................................................................... 25
SYSTEM DESCRIPTION (COMPONENTS)................................................................ 27
TROUBLESHOOTING...................................................................................... 30
DIAGNOSTIC TIPS ........................................................................................ 30
TROUBLESHOOTING GUIDELINES ...................................................................... 30
TROUBLESHOOTING WITH B.U.D.S. .................................................................... 31
PROCEDURES............................................................................................... 31
ACS SOLENOID VALVE ................................................................................... 31
ACS MANIFOLD .......................................................................................... 33
ACS MODULE ............................................................................................ 35
ACS COMPRESSOR RELAY (R5) ......................................................................... 37
ACS COMPRESSOR ...................................................................................... 37
ACS AIR FILTER........................................................................................... 42
PRESSURE TRANSDUCER (ACS AUXILIARY LINE) ...................................................... 43
ACS HOSES............................................................................................... 44
SHOCK ABSORBERS ..................................................................................... 45
I
SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to cor-
rectly service and repair the DPS™ and ACS sys-
tems on 2010 Can-Am™ ATVs.
This edition was primarily published to be used by
mechanical technicians who are already familiar
with all service procedures relating to BRP prod-
ucts. Mechanical technicians should attend train-
ing courses given by B.R.P.T.I.
Please note that the instructions will apply only
if proper hand tools and special service tools are
used.
It is understood that this manual may be trans-
lated into another language. In the event of any
discrepancy, the English version shall prevail.
The content depicts parts and/or procedures appli-
cable to the particular product at time of writing.
Service and Warranty Bulletins may be published
to update the content of this manual. Make sure
to read and understand these. It does not include
dealer modifications, whether authorized or not by
BRP, after manufacturing the product.
In addition, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or ex-
act replicas of the parts.
The use of BRP parts is most strongly recom-
mended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt.
The engines and the corresponding components
identified in this document should not be utilized
on product(s) other than those for which it was
designed.
WARNING
Unless otherwise specified, engine should be
turned OFF and cold for all maintenance and
repair procedures.
This manual emphasizes particular information de-
noted by the wording and symbols:
WARNING
Indicates a potential hazard, if not avoided,
could result in serious injury or death.
CAUTION Indicates a hazard situation
which, if not avoided, could result in minor or
moderate injury.
NOTICE Indicates an instruction which, if not
followed, could severely damage vehicle com-
ponents or other property.
NOTE: Indicates supplementary information
needed to fully complete an instruction.
Although the mere reading of such information
does not eliminate the hazard, your understand-
ing of the information will promote its correct
use. Always use common shop safety practice.
BRP disclaims liability for all damages and/or in-
juries resulting from the improper use of the con-
tents. We strongly recommend that any services
be carried out and/or verified by a highly skilled
professional mechanic. It is understood that cer-
tain modifications may render use of the vehicle
illegal under existing federal, provincial and state
regulations.
II vmr2010-002
INTRODUCTION
INTRODUCTION
This Technical Manual covers the following BRP made 2010 Can-Am ATVs with a DPS or ACS system.
OUTLANDER™
ENGINE MODEL COLOR MODEL NUMBER
XT Yellow, Red, Camo 2UAA, 2UAB, 2UAC, 2UAD, 2UAE
XT-P Black 5JAB
MAX XT Yellow, Red, Camo 2XAA, 2XAB, 2XAC, 2XAD, 2XAE
MAX XT-P Black 5KAC
500
MAX LTD Steel grey 5NAA
XT Yellow, Red, Camo 2PAA, 2PAB, 2PAC, 2PAD, 2PAE, 2PAF
XT-P Black 5GAB
MAX XT Yellow, Red, Camo 2SAA, 2SAB, 2SAC, 2SAD, 2SAE, 2SAF
650
MAX XT-P Black 5HAC
XT Yellow, Red, Camo 2JAA, 2JAB, 2JAC, 2JAE, 2JAF
XT-P Black 5EAB, 5EAE
MAX XT Yellow, Red, Camo 2LAA, 2LAB, 2LAC, 2LAD, 2LAF
MAX XT-P Black 5FAC, 5FAF, 5FAJ
800R
MAX LTD Red, Steel grey 2MAA, 2MAB, 2MAC, 2MAD
RENEGADE™
ENGINE MODEL COLOR MODEL NUMBER
800R X xc Black 4DAA, 4DAB, 4DAC
The information and component/system descriptions contained in this manual are correct at time of writ-
ing. BRP however, maintains a policy of continuous improvement of its products without imposing upon
itself any obligation to install them on products previously manufactured.
Due to late changes, there may be some differences between the manufactured product and the de-
scription and/or specifications in this document.
BRP reserves the right at any time to discontinue or change specifications, designs, features, models or
equipment without incurring obligation.
COLOR CODE LEGEND
COLOR CODE
BE =BEIGE OR =ORANGE
BK =BLACK PK =PK
BU =BLUE RD =RED
BR =BROWN VI =VIOLET
GN =GREEN WH =WHITE
GR =GRAY YL =YELLOW
vmr2010-002 III
IV vmr2010-002
SERVICE TOOLS INDEX
FLUKE 115 MULTIMETER
(P/N 529 035 868)
Page: 9, 11, 32, 35, 37–38, 43–44
OETIKER PLIERS
(P/N 295 000 070)
Page: 44
SPRING REMOVER
(P/N 529 036 007)
Page: 46
1
2
Section01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
DYNAMIC POWER STEERING (DPS)
SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 .......................................9, 11
SERVICE TOOLS – OTHER SUPPLIER
Description Part Number Page
SNAP-ON®TELESCOPING GAUGE SET....................................... LST 52616 ...........................................20
SERVICE PRODUCTS
Description Part Number Page
XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 19
vmr2010-003 3
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
38 Nm
(28 lbfft)
If torqued
by screw head
XPS synthetic
grease (400 g)
NEW
NEW
XPS synthetic
grease (400 g)
NEW 24.5 Nm
(18 lbfft)
NEW
NEW
72 Nm
(53 lbfft)
NEW
NEW
24.5 Nm
(18 lbfft)
If torqued
by elastic nuts
24.5 Nm
(18 lbfft)
vmr2010-003-001_a
4vmr2010-003
Section01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan-
dards.
SYSTEM DESCRIPTION
(FEATURES)
The Dynamic Power Steering (DPS) provides
a computer controlled, variable power assist,
achieved by an electric motor to optimize the
amount of steering input required by the rider.
vmr2010-003-014_a
1. Dynamic power steering unit (DPS)
The DPS system uses the following parameters to
determine how much steering assist it provides:
–EngineRPM
– Battery/electrical system voltage
– Vehicle speed
– DPS shaft torque sensor input.
The amount of steering assist provided is depen-
dent on the handlebar effort (steering torque),
electrical power available, and vehicle speed.
The greater the handlebar effort (torque), the
greater the assist will be.
The slower the vehicle speed, the greater the as-
sist will be.
If the electrical system is activated but the engine
is not running, there is no power assist provided.
When the handlebar is in the straight ahead posi-
tion, there is no steering assist.
Steering torque may also come from the wheels
due to rough terrain. Steering kickback is reduced
while providing feedback to the driver.
The greater the power steering assist, the greater
the load on the electrical system.
When the electrical system is under high load
(battery not at full charge, operating the vehicle
for prolonged periods of time at slow speed and
low RPM which, requires higher power steering
assist), the battery power reserve will gradually
decrease. This further increases the load on the
charging system and the electrical system volt-
age will drop. As system voltage drops, so does
power steering assist.
NOTE: It is important to maintain the battery at
a full state of charge to ensure proper DPS op-
eration. The magneto output is increased to 650
watts minimize battery drain and system voltage
drop.
DPS Assist Mode
The DPS system normally provides two rider se-
lectable modes of operation.
DPS MAX provides maximum steering assist for
technical low speed riding in rough or muddy ter-
rain, or for touring.
DPS MIN provides less steering assist for in-
creased feedback and aggressive trail riding.
A third mode of operation is available as an acces-
sory to adjust the steering assist level for opera-
tion with an approved BRP track kit.
How to View DPS Assist Mode Selection
1. To view the active DPS ASSIST mode, press
and release the OVERRIDE/DPS button on the
LH multifunction switch assembly.
vmo2010-004-006_a
1. OVERRIDE/DPS button
vmr2010-003 5
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
The active DPS mode will be displayed in the
lower portion of multifunction gauge.
vmo2010-004-004_a
1. DPS mode indication
How to Change DPS Assist Mode
To change DPS ASSIST mode, press and hold
the OVERRIDE/DPS button for approximately
4 seconds, the DPS system will toggle to the
other available mode. The newly activated DPS
mode will be briefly displayed in the multifunction
gauge.
NOTE: The DPS mode cannot be changed if
the vehicle is in reverse, of if the ACS mode is
displayed in the multifunction gauge on vehicles
equipped with an Air Controlled Suspension.
SYSTEM DESCRIPTION
(COMPONENTS)
DPS Unit
The DPS unit is a self contained unit that includes
the steering gear, the DPS module, the DPS mo-
tor, and the torque sensor.
vmr2010-003-003
DPS UNIT
The DPS module provides DC power to the mo-
tor. The amount and duration of that DC power is
determined by the inputs to the DPS module. The
direction in which the motor turns is changed by
reversing the polarity of the circuit current.
The DPS motor does not "spin", but rather turns in
very small increments based on the amount, du-
ration, and direction of DC power delivered by the
DPS module.
DPS Unit Protection
To protect the DPS electronic components, the
steering assist behavior will change as follows.
CONDITION DPS BEHAVIOR
When motor internal
temperature reaches a certain
temperature (DPS continuously
estimates it)
DPS internal board temperature
is above 85°C (185°F)
Steering assist
will gradually
decrease.
DPS internal board temperature
is above 100°C (212°F) Steering assist is
stopped.
When the DPS unit temperature is back within
normal operating range:
– Turn the ignition key OFF.
– Wait 30 seconds.
– Turn the ignition key ON.
Steering assist should resume normal operation.
6vmr2010-003
Section01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
Steering Torque Sensor
rmr2008-019-017
The steering column is connected to the shaft on
the DPS unit. A small area of the DPS shaft is
magnetized. Inside the DPS unit, a torque sensor
surrounds the magnetized area of the DPS shaft.
When the handlebar is turned, torque is applied to
the shaft which tends to twist the shaft slightly,
deforming the magnetic field in the shaft. The
sensor detects the torque by measuring the devi-
ation of the magnetic field.
The torque sensor is very sensitive and can de-
tect very small changes in the magnetic field.
The harder the handlebar is turned, the greater
the magnetic deviation, the greater the power
steering assist.
ADJUSTMENT
TORQUE OFFSET RESET
When replacing the following parts or adjusting
steering alignment, the sensor torque offset must
be reset to zero) for proper system operation.
PART ADJUSTED OR
REPLACED WHAT TO DO
–DPSunit
– Steering column
bearing
–Tierod
–Tierodend
– Knuckle
– Wheel bearing
– Ball joint
– Front suspension arm
(lower/upper)
– Steering alignment
Reset Torque Offset
in Setting, DPS
1. Ensure proper
STEERING ALIGNMENT
, refer
to appropriate Shop Manual subsection.
2. Connect vehicle to the latest B.U.D.S. soft-
ware.
3. In B.U.D.S., select Read Data.
4. Choose the Setting tab.
5. At the bottom LH corner of the Setting page,
choose the DPS tab.
NOTICE Ensure handlebar is free and cen-
tered within ±10 degrees of center position.
There MUST NOT be any effort applied to the
steering column.
6. Press Reset Torque Offset button.
vmr2010-003-002_a
DPS TORQUE OFFSET RESET
1. Setting page tab
2. DPS tab
3. Reset Torque Offset button
DPS ASSIST MODE
1. To view the active DPS ASSIST mode, press
and release the OVERRIDE/DPS button on the
LH multifunction switch assembly.
vmr2010-003 7
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmo2010-004-006_a
1. OVERRIDE/DPS button
The active DPS mode will be displayed in the
lower portion of multifunction gauge.
vmo2010-004-004_a
1. DPS mode indication
2. To change DPS ASSIST mode, press and hold
the OVERRIDE/DPS button for approximately
4 seconds, the DPS system will toggle to the
other available mode. The newly activated DPS
mode will be briefly displayed in the multifunc-
tion gauge.
NOTE: The DPS mode of operation cannot be
changed if the vehicle is in reverse, of if the ACS
mode is displayed in the multifunction gauge.
TROUBLESHOOTING
NO POWER STEERING ASSIST
1. DPS malfunction.
- If the CHECK ENGINE light is on and a DPS FAULT
message is visible in the gauge, check for fault
codes using B.U.D.S. and carry out service action.
2. No power to DPS unit.
- Carry out a DPS UNIT FUSE TEST as detailed in
this subsection. Replace as required.
- Carry out a DPS UNIT INPUT VOLTAGE TEST
(POWER SIDE) as detailed in this subsection.
Repair or replace wiring/connectors as required.
- Carry out a DPS UNIT INPUT VOLTAGE TEST
(CONTROL SIDE) as detailed in this subsection.
Repair or replace wiring/connectors as required.
3. No ground to DPS unit.
- Carry out a DPS UNIT GROUND CIRCUIT TEST
as detailed in this subsection. Repair or replace
wiring/connectors as required.
4. No engine RPM signal from ECM.
- If engine RPM can be displayed in the multifunc-
tion gauge when the engine is running, carry out a
DPS UNIT COMMUNICATION LINK (CAN) CON-
TINUITY TEST as detailed in this subsection. Re-
pair or replace wiring/connector as required.
- If engine RPM cannot be displayed in the multi-
function gauge, use B.U.D.S. to check for appli-
cable fault codes. Carry out service actions.
LOW POWER STEERING ASSIST
1. Low battery voltage.
- Check battery terminals. Clean, repair, replace or
tighten as required.
- Test battery voltage. Recharge or replace battery
as required.
- Carry out a DPS UNIT INPUT VOLTAGE TEST
(POWER SIDE) as detailed in this subsection. En-
sure power connector pins (DPS2-A and DPS2-B)
are clean, corrosion free, tight, and make good
contact. Repair or replace wiring/connectors as
required.
- Carry out a DPS UNIT GROUND CIRCUIT TEST as
detailed in this subsection. Ensure ground post
connections and DPS connector pins are clean,
corrosion free, tight, and make good contact. Re-
pair or replace wiring/connectors as required.
- Carry out a DPS SYSTEM LOAD TEST as detailed
in this subsection.
2. Low input voltage to DPS unit.
- Carry out a DPS UNIT INPUT VOLTAGE TEST
(POWER SIDE) as detailed in this subsection. En-
sure power connector pins (DPS2-A and DPS2-B)
are clean, corrosion free, tight, and make good
contact. Repair or replace wiring/connectors as
required.
8vmr2010-003
Section01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
3. Faulty DPS ground circuit.
- Carry out a DPS UNIT GROUND CIRCUIT TEST.
Ensure DPS ground connector pins (DPS3-A and
DPS3-B) and frame ground post are clean, corro-
sion free, tight, and make good contact. Repair
or replace wiring/connector as required.
ASYMMETRICAL POWER STEERING
ASSIST (SIDE TO SIDE)
1. Torque sensor not reset to zero.
- Ensure steering alignment is within specification
and carry out the TORQUE OFFSET RESET pro-
cedure detailed in this subsection.
DPS WILL NOT CHANGE MODES OF
OPERATION
1. Faulty OVERRIDE/DPS switch.
- Set transmission to reverse with engine running.
- Press the OVERRIDE/DPS button.
- Look for the OVERRIDE message to appear in the
multifunction gauge. If it comes on, button and
wiring to gauge are good.
- If OVERRIDE message does not appear in gauge,
test drive vehicle to determine if OVERRIDE func-
tion can be activated. If the function can not be
activated, test the OVERRIDE/DPS switch and
wiring. If the function is activated, test wiring
from switch to multifunction gauge.
PROCEDURES
DPS UNIT
DPS Unit Power Fuse Test
A 40 A DPS fuse located in the rear fuse box (PF2-
F3) next to the voltage regulator/rectifier unit pro-
vides power for the DPS motor.
vmo2010-004-202_a
TYPICAL - OUTLANDER 800R LTD ILLUSTRATED
1. Rear fuse box (PF2)
1. To remove fuse box cover, simultaneously
squeeze tabs inwards on each end of fuse box
cover as you pull on the cover.
vmr2010-003-004_a
1. Squeeze and pull these tabs to remove cover
2. Using a FLUKE 115 MULTIMETER (P/N 529 035
868) set to selection, remove and test the
DPS fuse.
529035868
vmr2010-003 9
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-005_a
1. 40 amp DPS fuse (PF2-F3)
3. Replace fuse as required.
DPS Unit Input Voltage Test (Power
Side)
1. Disconnect the DPS PWR (power) connector.
vmr2010-003-013_d
1. DPS PWR connector (motor power)
2. Test for 12 Vdc DPS motor power at DPS2-A
and DPS2-B as per following table.
MULTIMETER PROBE POSITIONS VOLTAGE
DPS power
connector pin A
DPS power
connector pin B
Battery ground
Battery
voltage
rmr2008-028-091_a
If NO voltage is measured, test the 40 A DPS fuse
in the rear fuse box (PF2-F3). If good, check wires
and connector pins. Replace or repair defective
parts and reset fault codes.
If battery voltage is measured, carry out the fol-
lowing
DPS UNIT INPUT VOLTAGE TEST (CON-
TROL SIDE)
.
NOTE: This test may also be carried out by con-
necting a 12 Vdc test light between each DPS
PWR connector pins (A and B), and the battery (-)
negative terminal. The test light must come on
bright.
DPS Unit Input Voltage Test (Control
Side)
1. Disconnect DPS CTRL (control) connector and
turn ignition switch ON.
2. Set the ignition switch to ON.
3. Set the engine RUN/STOP switch to RUN.
4. Test for 12 Vdc power to the DPS module at
DPS1-A as per following table.
MULTIMETER PROBE
POSITIONS VOLTAGE
DPS control connector (pin A)
and battery ground
Battery voltage
rmr2008-028-093_a
If NO voltage is measured, check wires and con-
nector pins from DPS unit to the Relays/Speedo
fuse in front fuse box (PF1-F4). Replace or repair
defective parts and reset fault codes.
If battery voltage is measured, carry out the fol-
lowing
DPS UNIT GROUND CIRCUIT TEST
.
NOTE: This test may also be carried out by con-
necting a 12 Vdc test light between the DPS con-
trol connector (pin A), and the battery (-) negative
terminal. The test light must come on bright.
DPS Unit Ground Circuit Test
1. Disconnect the DPS ground connector (GDN).
10 vmr2010-003
Section01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-013_c
1. DPS ground connector (GDN)
2. Test for continuity between DPS3-A and
DPS3-B to battery ground.
MULTIMETER PROBE
POSITIONS READING
DPS GDN
connector pin A
DPS GDN
connector pin B
Battery ground Continuity
(close to 0 )
If there is NO continuity or a high resistance is
measured, check wires and connector pins from
DPS unit to chassis ground post. Replace or re-
pair defective parts and reset fault codes.
If there is good continuity, carry out the following
DPS UNIT COMMUNICATION LINK (CAN) CON-
TINUITY TEST
.
NOTE: This test may also be carried out by con-
necting a 12 Vdc test light between each GDN
connector pin and the battery (+) positive termi-
nal. The test light must come on bright.
DPS Unit Communication Link (CAN)
Continuity Test
NOTE: DPS unit must receive an RPM signal to
provide power steering assist.
Disconnect the DPS control connector and the di-
agnostic connector.
Test continuity of CAN Bus Wires at DPS1-C and
DPS1-D.
MULTIMETER PROBE
POSITIONS RESISTANCE @
20°C (68°F)
DPS control connector (pin C)
and diagnostic connector (pin 1)
rmr2008-028-094_a
DPS control connector (pin D)
and diagnostic connector (pin 2)
rmr2008-028-094_b
Below 1
If resistance measured is out of specification,
check wires and connector pins. Carry out re-
pairs as required and reset fault codes using
B.U.D.S software.
If resistance measured is good, replace the DPS
unit and reset fault codes using B.U.D.S software.
DPS System Load Test
If the charging system cannot sustain normal volt-
age when the DPS is operating, DPS ASSIST may
be greatly reduced or nonexistent. Carry out the
following steps.
1. Connect the red lead of a FLUKE 115 MULTIME-
TER (P/N 529 035 868) set to Vdc to the rear fuse
box battery terminal.
2. Connect the black multimeter lead to the bat-
tery ground.
vmr2010-003 11
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-006_a
1. Negative (-) battery terminal
2. Rear fuse box battery terminal
3. Measure the battery voltage.
NOTE: If battery voltage is low, recharge battery.
4. Ensure the vehicle transmission is set to PARK.
5. Start the engine.
6. Note the voltage on the multimeter with the en-
gine running (charging system voltage).
7. Press the RANGE button repeatedly to select
Manual Range 6 0.
mmr2009-023-027_a
VDC SELECTED TO MANUAL RANGE 6 0
8. Press the MIN MAX button on the multimeter
to engage the MIN function.
mmr2009-023-027_e
1. MIN function selected
9. Turn the handlebar momentarily against the
steering frame stops to each side.
NOTE: Do not hold steering against frame stops
for and extended period of time.
10. Read the MIN charging system voltage
recorded while the handlebar was turned
against each stop.
DPS SYSTEM LOAD TEST
PROBE POSITIONS STEERING
POSITION VOLTAGE
READING
LH stopBattery
(-)
terminal
Rear fuse
box battery
terminal RH stop
At least
12 Vdc
NOTE: Turning the handlebar momentarily
against the frame stops generates maximum
DPS load (maximum current draw on electrical
system). Electrical system must sustain at least
12 Vdc for proper DPS operation.
12 vmr2010-003
Section01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-007
If the electrical system cannot sustain at least
12 Vdc, check the following:
–Battery
– Battery connections
– DPS unit power and ground connections
– Charging system
– Frame and engine ground studs.
If the previously listed items, carry out the follow-
ing
DPS UNIT CURRENT TEST
.
DPS Unit Current Test
1. Connect vehicle to the latest B.U.D.S. soft-
ware.
2. Click on the Read Data button.
3. Choose the Monitoring page tab.
4. At the bottom of the Monitoring page, choose
the DPS tab.
vmr2010-003-008_a
Step 1: Press Data button
Step 2: Select Monitoring page tab
Step 3: Select DPS tab
5. With the vehicle engine running in PARK, turn
the handlebar side to side, momentarily against
each stop and observe the indications on the
B.U.D.S. DPS Monitoring page.
The DPS Torque Sensor Nm increase with torque
applied to handlebar.
The DPS Current ammeter should increase pro-
portionately to the torque applied, and decrease
with the torque as steering assist is provided.
vmr2010-003-009_a
TYPICAL - LH TURN
1. Torque sensor indication (negative)
2. DPS current indication (positive)
vmr2010-003-010_a
TYPICAL - RH TURN
1. Torque sensor indication (positive)
2. DPS current indication (negative)
NOTE: Increase and decrease in torque and cur-
rent readings is very brief as steering assist is
quickly provided. Current draw should remain
within green scale but may momentarily peak to
60amps,thendropoffcloseto0ampsastorque
applied is nulled out by steering assist. A residual
torque of 2 N•m (18 lbf•in) with a corresponding
current draw is acceptable.
If current draw tends to remain high, carry out the
following:
– Steering alignment check.
vmr2010-003 13
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
– Steering column shim adjustment at half bush-
ings as described in the
DPS UNIT INSTALLA-
TION
procedure detailed in this section.
–
TORQUE OFFSET RESET
procedure detailed in
this section.
–ReplaceDPSunit.
DPS Unit Removal
1. Remove the following items:
–Seat
–Centerpanel
– LH and RH side panels
– LH and RH inner fender panels.
2. Lift up on the dash board (gauge support) and
disconnect the following:
–Gauge
– Ignition switch
– 12 Vdc power outlet.
3. Remove dash board from vehicle.
4. Remove the screw securing the shift lever
guide plate to the engine air filter housing.
vmr2006-014-055_d
TYPICAL
1. Shift lever guide plate
2. Guide plate screws (forward screw not visible)
NOTE: It is not necessary to disconnect the shift
lever.
5. Loosen the gear clamp securing the air filter
housing duct to the throttle body.
vmr2010-003-012_a
1. Gear clamp to loosen
6. Remove the screws securing the engine air fil-
ter housing.
7. Move the shift lever and guide plate slightly to
the right.
8. Lift up on the air filter housing to release it from
the throttle body and move the filter housing
towards the RH side of the vehicle.
NOTE: Moving the air filter housing to the right
provides access required for CVT air inlet duct re-
moval.
9. Remove the CVT air inlet duct assembly.
vmr2010-003-011_a
1. CVT air inlet duct
10. Remove the ECM from it's support bracket.
11. Disconnect the 3 electrical connectors from
the DPS unit.
14 vmr2010-003
Section01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-013_a
1. DPS connectors (3x)
12. Cut the locking tie securing the bellows at the
bottom of steering column near the DPS unit,
and pull the bellows upwards sufficiently to
access the steering column pinch bolt.
vmr2010-003-016_a
1. Cut this locking tie
2. Steering column bellows
13. Remove the steering column pinch bolt and
retaining nut. Discard the retaining nut.
vmr2010-003-017_a
1. Steering column pinch bolt
14. Remove and discard the elastic nuts from
the 2 hexagonal screws that secure steering
column half bushings to the support on the
frame.
vmr2010-003-018_a
1. Elastic nuts to remove and discard
2. Frame support
3. Steering column half bushings
15. Remove the 2 hexagonal screws from the
ECM support.
vmr2010-003-021_a
1. Hexagonal screws to remove
2. ECM support
16. Remove and save the shim(s) from between
the rear half bushing and the steering support
on the frame.
vmr2010-003 15
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-019_a
1. Shim
2. Steering column frame support
3. Half bushings
17. Pull up on the steering column to disengage it
from the DPS unit and move it to the side.
vmr2010-003-020_a
Step 1: Pull up on steering column
Step 2: Disengage column from DPS unit
18. Remove the hardware that secures both tie-
rod ends to the pitman arm (steering lever).
Discard cotter pins.
vmr2010-003-022_a
1. Pitman arm
2. Tie rod ends
NOTE: Leavethetierodendsonthepitmanarm
at this time. They will come off easily when the
DPS unit is lifted from its frame support.
vmr2010-003-023
TIE ROD ENDS (HARDWARE REMOVED)
19. Remove the 4 hexagonal flanged screws se-
curing DPS unit to frame.
NOTE: Discard the 4 conical spring washers on
the DPS retaining screws. Do not remove the 2
small hexagonal forming screws from the DPS
unit unless it is being replaced.
16 vmr2010-003
Section01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-024_a
TYPICAL - LEFT SIDE ILLUSTRATED
Step 1: Remove DPS retaining screws (2 each side)
Step 2: Discard conical washers under screw head
20. Pull up on DPS unit to align the 2 small hexag-
onal forming screws with the extraction holes
in the DPS mounting bracket, then remove the
DPS unit from the bracket.
vmr2010-003-025_a
TYPICAL - RIGHT SIDE ILLUSTRATED
1. Hexagonal forming screws (1 each side)
2. Extraction holes
3. DPS unit
NOTE: As you pull the DPS unit from the frame
support, the 2 tie rod ends should release from
thepitmanarm. Becarefulnottoloosethehard-
ened steel washers on the tie rod ends.
DPS Unit Installation
NOTICE The following procedure MUST be
followed as specified. Failure to do so may re-
sult in steering column/DPS misalignment and
poor DPS operation due to an induced erro-
neous torque on the DPS shaft.
1. If installing a new DPS unit, install the two M5
hexagonal forming screws on the mounting
flange of the DPS unit.
vmr2010-003-026_a
1. Hexagonal forming screws
2. Position the DPS unit on the frame DPS mount-
ing bracket by engaging the two hexagonal
forming screws in the slots provided in the
bracket.
vmr2010-003-027_a
1. DPS mounting bracket
2. Engage hexagonal forming screw on DPS unit here
3. Engage the 2 tie rod ends in the pitman arm
as you lower the DPS unit on it's mounting
bracket.
NOTE: Ensure both tie rod ends has a hardened
steel washer on it.
vmr2010-003 17
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-023_a
1. Pitman arm
2. Tie rod ends inserted in pitman arm
3. Hardened steel washer on tie rod end
4. Engage NEW M8 hexagonal flanged screws
through the DPS frame support and into the
DPS unit.
NOTE: Ensure each retaining screw has a NEW
conical spring washer between the screw head
and the DPS frame support. Do not tighten the
retaining screws more than half thread length at
this time.
vmr2010-003-028_a
TYPICAL - RH SIDE ILLUSTRATED
Step 1: Engage NEW DPS mounting screws (2 each side)
Step 2: Install NEW conical washers
5. Remove the two half bushings from the steer-
ing column and ensure the two O-ring seals are
installed on the shaft and in good condition. Re-
place as required.
vmr2010-003-029_a
1. O-ring seals on steering column
6. Index steering column splines with DPS unit
splines.
NOTE: The DPS shaft splines have a key which
must be aligned with the keyway in the steering
column end.
vmr2010-003-031
STEERING COLUMN INDEXED TO DPS SHAFT SPLINES
7. Fully insert steering column end onto DPS shaft
splines. If necessary, place a rag on steering
cover and gently tap on it with a plastic ham-
mer.
NOTICE The following steps MUST be fol-
lowed as specified. Failure to do so may result
in steering column/DPS misalignment and
poor DPS operation due to an induced erro-
neous torque on the DPS shaft.
8. Install steering column pinch bolt and a NEW
elastic nut. Torque nut to 24 N•m (18 lbf•ft).
18 vmr2010-003
Section01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-032
Pull bellows down over steering column bolt and
edge of DPS unit housing extension. Secure bel-
lows using the appropriate locking tie.
NOTE: Ensure the locking tie is on the tube part of
the steering column, not on the forged end. Bel-
lows should cover end of ring flange on DPS unit
but not cover the drainage hole at the bottom of
the ring flange. Do not install a locking tie on the
DPS end of the bellows. Lower portion of bellows
MUST remain floating over the DPS housing.
vmr2010-003-016_a
1. Locking tie location
2. Steering column bellows
vmr2010-003-033_a
1. Drainage hole in DPS ring flange
2. Steering column bellows
9. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
totheinsideofbothsteeringcolumnhalfbush-
ings.
vmr2010-003-034
10.Looselysecurethesteeringcolumntoits
frame support by installing the following parts
to provide side to side alignment of steering
column.
– Half bushings (x2)
– Metal sleeves between bushings (x2)
– O-ring seals (x2)
– M8 hexagonal screws (x2)
– M8 elastic nuts (x2).
NOTE: Do not install shims and do not torque the
fasteners at this time. Hand tighten only. Steering
column must not be drawn in towards the column
support.
vmr2010-003 19
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
vmr2010-003-035_a
1. These nuts installed hand tight at this time
11. Torque DPS unit mounting screws to
24.5 N•m (18 lbf•ft).
vmr2010-003-028_b
TYPICAL - RH SIDE ILLUSTRATED
1. Torque DPS mounting screws (x4)
12. Using an 8 mm (5/16 ft) telescoping gauge as
foundintheSNAP-ON®TELESCOPING GAUGE
SET (P/N LST 52616), measure the distance be-
tween the steering column shaft and the face
of the column frame support. Measurement
is taken above rear half bushing.
vmr2010-003-036
STEERING COLUMN SHIM MEASUREMENT
NOTE: Ensure the forward end of the tool is in the
center of the steering column, and the rearward
end does not protrude through the notch in the
support.
13. Measure the telescoping gauge using a
Vernier caliper (or a micrometer) and com-
pare the measured distance to the following
table to establish the required shim thickness
vmr2010-003-037
STEERING COLUMN SHIM REQUIREMENT
MEASURED DISTANCE TOTAL SHIM
THICKNESS REQUIRED
8.63 mm (.34 in) None
9.63 mm (.379 in) 1 mm (.039 in)
10.65 mm (.419 in) 2 mm (.079 in)
11.66 mm (.459 in) 3 mm (.118 in)
12.65 mm (.498 in) 4 mm (.157 in)
NOTE: Shimscomein1mm(.039in)and2mm
(.079 in) thicknesses. Total shim thickness must
not exceed 4 mm (.157 in).
20 vmr2010-003
Section01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
If total shim thickness exceeds 4 mm (.157 in),
carry out the following:
– Re-measure the distance between steering
column and support. Ensure the forward end
of the tool is in the center of the steering col-
umn, and the rearward end does not protrude
through the notch in the support.
– Check steering column support and frame to
ensure they are not bent, twisted or damaged
in any way.
– Check machined flat mounting surface on new
DPS.
– Compare old and new DPS units.
– Ensure the 4 DPS mounting screws and
the steering column pinch bolt are properly
torqued.
14. Insert appropriate shim(s) between the rear
half bushing and the steering column support.
vmr2010-003-038_a
1. Insert required shim(s) here
15. As you hold each elastic nut with a wrench,
torque the hexagonal SCREWS retaining the
steering column to 38 N•m (28 lbf•ft).
vmr2010-003-021_b
Step 1: Hold elastic nuts with wrench (not illustrated)
Step 2: Apply specified torque to hexagonal screws
NOTE: If torque is applied to elastic nuts in-
stead of hexagonal screw head, use 24.5 N•m
(18 lbf•ft).
16. Install hardware on LH and RH tie rods on pit-
man arm. Follow parts assembly sequence as
in following illustration.
17. Torque tie rod end retaining nuts to 72 N•m
(53 lbf•ft).
vmr2010-003-022_b
1. Hardened steel washers (one each side of pitman arm)
2. Tie rod end retaining nut (torque applied)
3. NEW cotter pin installed
18. Turn handlebar fully to each side and check for
proper contact between pitman arm and pit-
man arm frame stops (both sides).
vmr2010-003-039_a
TYPICAL - LH ILLUSTRATED
1. Pitman arm
2. Contact point with frame stop
NOTE: Contactbetweenpitmanarmandpitman
arm stops must be checked with vehicle weight
on wheels.
19. Perform a
STEERING ALIGNMENT
as de-
scribed in the applicable Shop Manual sub-
section.
vmr2010-003 21
Section 01 TECHNICAL MANUAL
Subsection 01 (DYNAMIC POWER STEERING (DPS))
20. Install and connect ECM. Torque ECM mount-
ing screws to 7 N•m (62 lbf•in).
21. Install dash board and reconnect the following:
– Multifunction gauge
– Ignition switch
– 12 Vdc accessories outlet.
22. If installing a replacement DPS unit, refer to
DPS REPLACEMENT
in this subsection.
23. Perform the torque offset reset. Refer to
TORQUE OFFSET RESET
in this subsection.
24. Install all other removed parts in the reverse
order of removal.
25. Carry out a test ride of the ATV to ensure
proper operation of the DPS unit.
DPS Unit Replacement
New DPS units do not come with the required
software programmed into the unit. A DPS unit
fault will be generated when the vehicle is pow-
ered up. The check engine light will come on and
a DPS FAULT message will appear in the multi-
function gauge.
When DPS unit installation is complete, carry out
the following steps.
1. Connect the ATV to the latest B.U.D.S. soft-
ware.
2. Select the Read Data button.
3. In the Module menu, choose the DPS sub-
menu and install the latest DPS software
Update file as applicable to the type ATV (Out-
lander or Renegade).
vmr2010-003-040
DPS SOFTWARE UPDATE
4. Once the correct DPS software file is installed,
go to the Faults page and clear the fault codes.
5. Carry out the
TORQUE OFFSET RESET
proce-
dure as described in this subsection.
6. Test drive the ATV to ensure proper DPS oper-
ation.
PITMAN ARM
If the pitman arm requires replacement, the DPS
unit MUST be replaced.
WARNING
DO NOT attempt to replace or repair the pit-
man arm. Do not use a torch or arc welder on
the pitman arm. Failure to comply will result
in DPS unit malfunction.
22 vmr2010-003
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
AIR CONTROLLED SUSPENSION (ACS)
SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............. 32, 35, 37–38, 43–44
OETIKER PLIERS........................................................................... 295 000 070 ...........................................44
SPRING REMOVER....................................................................... 529 036 007 ...........................................46
SERVICE PRODUCTS
Description Part Number Page
LOCTITE 592 (PIPE SEALANT) ..................................................... 293 800 018 ......................... 33–34, 41, 47
vmr2010-004 23
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
53 Nm
(39 lbfft)
NEW
53 Nm
(39 lbfft)
53 Nm
(39 lbfft)
Loctite
592
(pipe
sealant)
ACS
module
NEW
ACS
compressor
ACS solenoid
release valve
ACS hose
vmr2010-004-033_a
24 vmr2010-004
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
GENERAL
During assembly/installation, use torque values
and service products as in the exploded views.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, cotter
pins, etc.) must replaced with new ones.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan-
dards. Hoses must be properly inserted.
Be careful while manipulating nylon hoses, they
must not be kinked.
CAUTION Always wear safety goggles
when working with pressurized air system.
CAUTION The ACS suspension system
may be under high pressure (up to 6 bar
(85 PSI)). Release air pressure prior to work-
ingonthesystem. Referto
RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING
.
SYSTEM DESCRIPTION
(FEATURES)
The ACS suspension automatically keeps air pres-
sure constant with changing rider weights or loads
applied. The system can be adjusted on the fly to
suit rider's preferences.
The multifunction gauge indicates suspension set-
ting as follows.
vmo2010-004-005_d
1. Requested setting (set point)
2. Actual setting (pressure transducer reading)
Refer to the following table to know the ACS pres-
sure related to multifunction gauge setting.
ACS SUSPENSION SETTINGS
SETTING PRESSURE RIDING
COMFORT RECOMMENDED
LOAD
ACS 1 0.5 bar (8PSI) Softest
ACS 2 1bar(15PSI) Soft Operator only
ACS 3 2bar(30PSI) Semi-soft
ACS 4 4bar(55PSI) Semi-firm
Transporting a
passenger OR
a cargo
ACS 5 5bar(70PSI) Firm
ACS 6 6bar(85PSI) Firmest
Transporting a
passenger AND
a cargo
Changing ACS Setting
To change the ACS setting proceed as follows:
– Press selector button several times until
AIR_SUSP
is displayed.
– Press and release ACS button until the re-
quested setting is displayed.
vmo2010-004-005_a
1. Selector button
2. AIR_SUSP displayed
vmo2010-004-006_a
TYPICAL
1. ACS button
vmr2010-004 25
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
The requested setting is controlled by the ACS
electronic module. The module is equipped with
a pressure transducer to keep air pressure con-
stant in the system. Depending on the rider ad-
justment, the module will increase pressure using
the compressor or release pressure using the so-
lenoid release valve.
ACS Setting Acknowledgement
If ACS suspension was set to
ACS 5
or
ACS 6
be-
fore shutting down the vehicle, the multifunction
gauge will scroll an acknowledgement message
at startup.
To acknowledge the ACS suspension setting,
press and release ACS button while message
appears.
vmo2010-004-006_a
TYPICAL
1. ACS button
NOTE: If the message is not acknowledged, the
suspension will automatically return to setting
ACS 3
.
NOTE: If the selector button in the multifunction
gauge is pressed while the acknowledgement
message appears, the suspension will directly
return to setting
ACS 3
.
NOTE: If the vehicle transmission is set to RE-
VERSE position at startup, the override message
will be displayed instead of acknowledgement
message.
Using the Auxiliary Line to Inflate Tires
The ACS system is equipped with an auxiliary line
specially designed to inflate tires. The air pressure
in this auxiliary line is controlled by a second pres-
sure transducer connected to the ACS module.
vmo2010-004-201_a
1. Auxiliary line adaptor to inflate tire
To ensure that the use of the auxiliary line will
not change the pressure setting inside shock
absorber, the system has been divided in two
zones using check valves. With this layout, both
pressure zones are independent to eliminate any
air pressure variation.
NOTE: The auxiliary line output pressure will vary
according to the ACS suspension setting. The
ACS 1
adjustment will provide less pressure than
the
ACS 6
adjustment.
NOTICE Never inflate tires above the recom-
mended pressure.
ACS SYSTEM
ZONE LINK WITH PRESSURE
TRANSDUCER
LOCATION
High-pressure
zone Shock
absorbers Inside ACS
module
Low-pressure
zone Auxiliary line
In line between
solenoid release
valve and
compressor
Releasing Air Pressure in System for
Servicing
It is recommended to release air pressure in the
system before servicing any components.
1. Remove seats.
2. Remove RH side panel.
3. Unscrew pneumatic valve cap.
26 vmr2010-004
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-001_a
1. Pneumatic valve cap
4. Push and hold pneumatic valve pin using a small
screwdriver.
vmr2010-004-002
5. Wait until the system is completely empty of
air.
NOTE: Make sure to wait enough time in order to
let the system expel the air. (no more pressurized
air sound from the valve).
6. Reinstall pneumatic valve cap.
SYSTEM DESCRIPTION
(COMPONENTS)
Fuse and Relay
ACS Fuse (F14)
1. ACS fuse (F14) is located in the front fuse box.
FRONT FUSES BOX
NO DESCRIPTION RATING
F14 ACS 20 A
vmo2007-003-017_b
TYPICAL - FRONT SERVICE COMPARTMENT
1. Front fuse box
ACS Compressor Relay (R5)
Compressor relay is located in the front fuse box,
under front service compartment panel. Note that
therelayisnotatthesamepositionona500LTD
andona800RLTDmodels. Refertothefollowing
table.
FRONT FUSE BOX PIN
RELAY (R5)
TERMINAL 500 LTD 800R LTD
86 6D 11B
85 7C 12A
30 7D 12B
87 6C 11A
Outlander 500 LTD
vmr2010-004-107_a
OUTLANDER 500 LTD MODEL
1. ACS compressor relay (R5)
vmr2010-004 27
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
Outlander 800R LTD
vmr2010-004-105_a
OUTLANDER 800R LTD MODEL
1. ACS compressor relay (R5)
28 vmr2010-004
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
ACS Main Components
ACS COMPONENTS MAIN FUNCTION
Filter To filter air intake of the compressor
Compressor To pressurize the system
Solenoid release valve To release air in the system
Electronic module To control the compressor or the solenoid release valve
Manifold To split the air hoses and allows to manually release air in the
system
Pressure transducer (Low-pressure zone) To monitor the air pressure of the auxiliary line
Pressure transducer (High-pressure zone) To monitor the air pressure of the shock absorbers
Check valve (compressor) To protect the compressor
Check valve (between both zones) To eliminate air pressure variation between low and high
pressure zone
Auxiliary line To inflate tire
Cluster To monitor the air pressure setting
Filter Compressor
Check-valve
Cluster
Pressure
transducer
Auxiliary
output
Low pressure
zone High pressure
zone
Check-valve
Release
valve
Pressure
transducer
Manifold
Shock 1
Shock 2
Electronic
module
Pneumatic
Electric
vdd2010-001-601_en
vmr2010-004 29
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
TROUBLESHOOTING
DIAGNOSTIC TIPS
Error Code (AIR FAULT) Displayed in
Gauge
The error code AIR FAULT can appear on the mul-
tifunction gauge for different reasons that are not
necessarily related to a failure of the ACS system.
If the error code appears on the multifunction
gauge, it indicates a disparity between the re-
quested and the actual suspension settings. The
system should react to correct this situation and
the error code will disappear.
If the error code remains active for a long period,
it may indicates a major leak in the system. In this
case, the module will automatically shut down the
compressor to prevent it from overheating. The
shut down procedure of the compressor will stay
active until the next restart of the vehicle (key OFF,
key ON).
If there is a major leak in the system, check the
system for leakage, refer to
ACS SYSTEM LEAK
TEST (TROUBLESHOOTING WITH B.U.D.S.)
sub-
section.
Error Code Displayed and Suspension Setting
Can Not Be Adjusted
If there is no leak, it is probably an electrical prob-
lem. In this case, an electrical failure of the com-
pressor or the solenoid valve will result the impos-
sibility to change the actual suspension setting.
After multiple attempts to change suspension
setting, the module will activate error code AIR
FAULT. Refer to
TROUBLESHOOTING GUIDE-
LINES
for further troubleshooting procedure.
TROUBLESHOOTING
GUIDELINES
Requested Setting Display Does Not
Change in Gauge
1. Check the override/ACS button as detailed in
OVERRIDE SWITCH
in the
LIGHTS GAUGE
AND ACCESSORIES
subsection of the appro-
priate Shop Manual.
Suspension Setting Can Not Be
Changed
1. Check the override/ACS button as detailed in
OVERRIDE SWITCH
in the
LIGHTS GAUGE
AND ACCESSORIES
subsection of the appro-
priate Shop Manual.
2. Check fuse (F14).
3. Check ACS module signal continuity.
4. Check ACS module input voltage.
5. Check ACS module ground.
Refer to
ACS MODULE
to see the complete test-
ing procedures.
Suspension Setting Can Be Reached to
Decrease Pressure Only
1. Check relay (R5).
2. Check ACS compressor operation.
3. Check ACS compressor input voltage.
Refer to
ACS COMPRESSOR
to see the complete
testing procedures.
Suspension Setting Can Be Reached
To Increase Pressure Only
1. Check ACS solenoid valve operation.
2. Check ACS solenoid valve input voltage.
Refer to
ACS SOLENOID VALVE
to see the com-
plete testing procedures.
No Pressure Output from the Auxiliary
Line
1. Ensure that ACS suspension setting is adjusted
to
ACS 6
to provide the maximum air pressure
in the auxiliary line.
2. Check pressure transducer for air leakage.
3. Check signal continuity of the auxiliary line pres-
sure transducer.
4. Check input voltage of the auxiliary line pres-
sure transducer.
5. Check ground of the auxiliary line pressure
transducer.
6. Check compressor operation.
Multifunction Gauge Display Flickers
OFF and Back ON
1. Check diode (D7) of the solenoid valve.
NOTE: The diode (D7) is located on the main har-
ness near the ACS sub-harness junction. Refer to
the appropriate
WIRING DIAGRAM
for location.
30 vmr2010-004
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
TROUBLESHOOTING WITH
B.U.D.S.
ACS System Leak Test
1. Connect vehicle to B.U.D.S. Refer to
COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
2. Select Activation page.
3. Select ACS folder.
4. Press Test START button to proceed.
vmr2010-004-201_a
Step 1: Activation page
Step 2: ACS folder
Step 3: Leak Test START button
After pressing Test START button, the com-
pressor will pressurize the air system at 6.5 bar
(90PSI) for approximately 2 minutes and B.U.D.S.
will monitor the system for any leakage. The
result will be indicated in the TEST STATUS box.
If a leak is detected, pressurize the system again
and inspect hoses and fittings with soapy water
to locate the faulty component.
If no leak is detected from hoses or fittings, in-
spect the compressor check valve and the auxil-
iary line check valve with soapy water.
vmr2010-004-202_b
1. Compressor check valve
vmr2010-004-401_a
1. Auxiliary line check valve
ACS Air Pressure Monitoring
To monitor air pressure in the system during trou-
bleshooting operation, proceed as follows:
1. Connect vehicle to B.U.D.S. Refer to
COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
2. Select Monitoring page.
3. Select ACS folder.
vmr2010-004-301_a
Step 1: Monitoring page
Step 2: ACS folder
PROCEDURES
ACS SOLENOID VALVE
ACS Solenoid Valve Operation Test
1. Connect vehicle to B.U.D.S. Refer to
COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
2. Select Activation page.
3. Select ACS folder.
4. Press Relief Valve button to proceed.
vmr2010-004 31
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-201_b
Step 1: Activation page
Step 2: ACS folder
Step 3: Solenoid valve operation test button
5. Verify that air exits from side port to confirm
proper solenoid operation.
vmr2010-004-202_a
1. Side port
ACS Solenoid Valve Input Voltage Test
1. Remove seats and RH side panel.
2. Place ignition switch to ON position.
3. Press selector button several times until
AIR_SUSP
is displayed.
vmo2010-004-005_a
1. Selector button
2. AIR_SUSP displayed
4. Set suspension mode to ACS 2 using the ACS
button.
5. Wait until the actual setting shows 2 (LH dis-
play).
vmr2010-004-101_a
1. Actual setting (pressure transducer reading)
NOTE: Make sure to wait enough time in order to
let the system adjust the air pressure.
6. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
7. Back probe solenoid connector (without discon-
necting).
vmr2010-004-102
8. Set suspension mode to ACS 1 using the ACS
button.
9. Measure voltage between solenoid connector
terminals as per the following table.
TEST PROBES VOLTAGE
Pin 2 (YL/GN)
Pin1(BK)
Battery voltage
(± 12 Vdc)
ACS Solenoid Valve Removal
1. Release air pressure, refer to
RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING
in this
subsection.
32 vmr2010-004
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
2. Disconnect solenoid valve connector.
vmr2010-004-003_a
1. Solenoid valve connector
3. Unscrew solenoid valve from manifold while
holding support.
vmr2010-004-004_a
1. Solenoid valve
ACS Solenoid Valve Installation
The installation procedure is the reverse of re-
moval procedure, however pay attention to the
following.
Apply LOCTITE 592 (PIPE SEALANT) (P/N 293 800
018) on solenoid valve male threads.
ACS MANIFOLD
ACS Manifold Removal
1. Release air pressure, refer to
RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING
in this
subsection.
2. Remove solenoid valve. Refer to
ACS SOLE-
NOID VALVE REMOVAL
.
3. Disconnect the following hoses from manifold
air fittings.
– Manifold air inlet hose (from compressor)
– Module hose
– Shocks hose.
vmr2010-004-005_a
1. Manifold air inlet hose (from compressor)
2. Module hose
3. Shocks hose
4. To disconnect hoses, proceed as follows:
4.1 Push fitting ring toward manifold.
4.2 Hold ring in place.
4.3 Pull air hose.
vmr2010-004-008_a
1. Fitting
2. Fitting ring
5. From underneath support, remove manifold re-
taining screws.
vmr2010-004 33
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-006_a
1. Retaining screws
6. Unscrew air fittings, pneumatic valve and check
valve.
vmr2010-004-007_a
1. Manifold air inlet fitting (from compressor)
2. Auxiliary line check valve
3. Pneumatic valve
4. Shocks fitting
5. Module fitting
ACS Manifold Installation
The installation procedure is the reverse of re-
moval procedure, however pay attention to the
following.
If fitting is the one previously removed (old one),
apply LOCTITE 592 (PIPE SEALANT) (P/N 293 800 018)
on all male threads.
If fitting is a new one, do not apply sealant, it
should be already applied on male threads.
On pneumatic valve, check valve, and solenoid
valve, apply LOCTITE 592 (PIPE SEALANT) (P/N 293
800 018) on all male threads.
Install check valve with arrows pointing toward
manifold.
vmr2010-004-007_b
Install air fittings, pneumatic valve and check valve
as follows.
vmr2010-004-007_a
RETAINING SCREWS ARE OFFSET TOWARD MODULE FITTING
1. Manifold air inlet fitting (from compressor)
2. Auxiliary line check valve
3. Pneumatic valve
4. Shocks fitting
5. Module fitting
Ensure that air hoses are properly inserted into fit-
tings, refer to the following illustrations.
vmo2010-011-102_a
PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED
1. Fitting
2. Mark
A. Must be inserted into fitting
vmo2010-011-103
HOSE PROPERLY INSERTED INTO FITTING
34 vmr2010-004
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
ACS MODULE
ACS Module Signal Circuit Continuity
Test
1. Remove seats and RH side panel.
2. Disconnect multifunction gauge from vehicle.
Refer to
LIGHTS, GAUGE AND ACCESSORIES
subsection of the appropriate Shop Manual.
3. Disconnect ACS module connector.
vmr2010-004-011_a
1. Module connector
4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
5. Measure resistance as per the following tables.
TEST PROBES RESISTANCE
Gauge pin 18 (BK/BE)
Modulepin5(BE/GN) Closeto0
TEST PROBES RESISTANCE
Gauge pin 19 (BE/GN)
Module pin 6 (WH/BE) Closeto0
ACS Module Input Voltage Test
1. Remove seats and RH side panel.
2. Disconnect module connector.
vmr2010-004-011_a
1. Module connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
4. Place ignition switch to ON position.
5. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin12(OR/GN)
Battery negative (-) post
Battery voltage
(± 12 Vdc)
ACS Module Ground Test
1. Remove seats and RH side panel.
2. Disconnect module connector.
vmr2010-004-011_a
1. Module connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
4. Place ignition switch to ON position.
5. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin 7 (BK)
Battery positive (+) post
Battery voltage
(± 12 Vdc)
vmr2010-004 35
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
ACS Module Removal
1. Release air pressure, refer to
RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING
in this
subsection.
2. Disconnect module hose from manifold air fit-
ting as follows:
2.1 Push fitting ring toward manifold.
2.2 Hold ring in place.
2.3 Pull air hose.
vmr2010-004-010_a
1. Module hose
NOTICE Do not attempt to disconnect hose
from module.
3. Disconnect module connector.
vmr2010-004-011_a
1. Module connector
4. Remove module retaining bolts and nuts.
vmr2010-004-012_a
1. Module retaining bolt
5. Remove module from vehicle.
ACS Module Installation
The installation procedure is the reverse of re-
moval procedure, however pay attention to the
following.
If a new ACS module is installed, check diode (D7)
of the solenoid valve to ensure that it is not de-
fective as it can damage the ACS module. The
diode (D7) is located on the main harness near the
ACS sub-harness junction. Refer to the appropri-
ate
WIRING DIAGRAM
for diode location.
Ensure that air hoses are properly inserted into fit-
tings, refer to the following illustrations.
vmo2010-011-102_a
PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED
1. Fitting
2. Mark
A. Must be inserted into fitting
vmo2010-011-103
HOSE PROPERLY INSERTED INTO FITTING
36 vmr2010-004
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
ACS COMPRESSOR RELAY (R5)
ACS Relay Continuity Test
1. Remove relay (R5), refer to
FUSE AND RELAY
at the beginning of this section.
2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
3. Measure resistance as per the following table.
TEST PROBES RESISTANCE
Terminal 30
Terminal 87 Open (OL)
4. Apply 12 volts on terminals 86 and 85.
5. Measure resistance again as per the following
table.
TEST PROBES RESISTANCE
Terminal 30
Terminal 87 Closeto0
If results are not as per the above tables, replace
relay.
ACS Relay Input Voltage Test
1. Remove relay (R5), refer to
FUSE AND RELAY
at the beginning of this section.
2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
3. Place ignition switch to ON position.
4. Measure voltage as per the following tables.
Outlander 500 LTD
TEST PROBES VOLTAGE
Fuse box pin 6D (OR/GN)
Battery negative (-) post
Battery voltage
(± 12 Vdc)
Outlander 800R LTD
TEST PROBES VOLTAGE
Fuse box pin 12A
(OR/GN)
Battery negative (-) post
Battery voltage
(± 12 Vdc)
Outlander 500 LTD
TEST PROBES VOLTAGE
Fuse box pin 7D (BE/PK)
Battery negative (-) post
Battery voltage
(± 12 Vdc)
Outlander 800R LTD
TEST PROBES VOLTAGE
Fuse box pin 12B (BE/PK)
Battery negative (-) post
Battery voltage
(± 12 Vdc)
If voltage is not as specified, check wiring, con-
nector and terminal condition.
ACS Relay Ground Wire Continuity
Test
1. Remove relay (R5), refer to
FUSE AND RELAY
at the beginning of this section.
2. Disconnect module connector.
vmr2010-004-011_a
1. Module connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
4. Measure resistance as per the following table.
Outlander 500 LTD
TEST PROBES RESISTANCE
Module pin 8 (OR/PK)
Fuse box pin 7C (OR/PK) Close to 0
Outlander 800R LTD
TEST PROBES RESISTANCE
Module pin 8 (OR/PK)
Fuse box pin 11B
(OR/PK)
Close to 0
ACS COMPRESSOR
ACS Compressor Operation Test
1. Connect vehicle to B.U.D.S. Refer to
COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection of the appropriate Shop Manual.
vmr2010-004 37
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
2. Select Activation page.
3. Select ACS folder.
4. Press Compressor button to proceed.
vmr2010-004-201_c
Step 1: Activation page
Step 2: ACS folder
Step 3: Compressor operation test button
5. Verify if compressor works properly.
ACS Compressor Power Wire
Continuity Test (from Relay)
1. Remove relay, refer to
FUSE AND RELAY
at the
beginning of this section.
2. Disconnect compressor connector.
vmr2010-004-103_a
1. Compressor connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
4. Measure resistance as per the following table.
Outlander 500 LTD
TEST PROBES RESISTANCE
Compressor pin C (BE/VI)
Fuse box pin 6C (BE/VI) Closeto0
Outlander 800R LTD
TEST PROBES RESISTANCE
Compressor pin C (BE/VI)
Fuse box pin 11A (BE/VI) Close to 0
ACS Compressor Input Voltage Test
1. Release air pressure, refer to
RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING
in this
subsection.
2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
3. Disconnect compressor connector.
vmr2010-004-103_a
1. Compressor connector
4. Place ignition switch to ON position.
5. Probe compressor connector.
6. Press selector button several times until
AIR_SUSP
is displayed.
vmo2010-004-005_a
1. Selector button
2. AIR_SUSP displayed
7. Set suspension mode to ACS 2 using the ACS
button.
38 vmr2010-004
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-101_a
1. Actual setting (pressure transducer reading)
8. Measure voltage between compressor connec-
tor terminals as per the following table.
TEST PROBES VOLTAGE
Pin C (BE/VI)
Pin A (BK)
Battery voltage
(± 12 Vdc)
ACS Compressor Removal
1. Release air pressure, refer to
RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING
in this
subsection.
2. Remove LH side panel.
3. Remove storage tray.
vmr2010-004-013_a
1. Storage tray
4. Remove solenoid valve. Refer to
ACS SOLE-
NOID VALVE REMOVAL
.
5. Remove manifold. Refer to
ACS MANIFOLD
REMOVAL
.
6. Remove module. Refer to
ACSMODULERE-
MOVAL
.
7. Remove connector of auxiliary line pressure
transducer from support.
vmr2010-004-014_a
1. Connector of auxiliary line pressure transducer
8. Disconnect compressor connector.
vmr2010-004-015_a
1. Compressor connector
9. Disconnect the following hoses from compres-
sor air fittings.
– Compressor air inlet hose
– Compressor air outlet hose
– Auxiliary line hose.
vmr2010-004-016_a
1. Compressor air inlet hose
2. Compressor air outlet hose
3. Auxiliary line hose
vmr2010-004 39
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
10. To disconnect hoses, proceed as follows:
10.1 Push fitting ring toward manifold.
10.2 Hold ring in place.
10.3 Pull air hose.
11. Remove compressor side retaining bolts and
nuts.
vmr2010-004-017_a
1. RH side retaining bolt
vmr2010-004-018_a
1. LH side retaining bolt
12. Remove compressor front retaining screws.
vmr2010-004-019_a
1. Front retaining screws
13. Remove compressor from vehicle by pulling it
upwards.
vmr2010-004-020
14. Detach compressor connector from front sup-
port.
15. Remove mounting nuts from compressor
front support.
16. Remove front support from compressor.
40 vmr2010-004
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-022_a
1. Front support mounting nuts
2. Compressor connector
3. Front support
NOTICE Do not remove rear support from
compressor.
17. Remove the following fittings from compres-
sor.
– Compressor air inlet fitting
– Compressor T-fitting
– Compressor check valve.
vmr2010-004-023_a
1. Compressor air inlet fitting
2. Compressor T-fitting
3. Compressor check valve
ACS Compressor Installation
The installation procedure is the reverse of re-
moval procedure, however pay attention to the
following.
If fitting or valve is the one previously removed
(old one), apply LOCTITE 592 (PIPE SEALANT)
(P/N 293 800 018) on all male threads.
If fitting or valve is a new one, do not apply
sealant, it should be already applied on male
threads.
Install T-fitting with an angle of 45° as shown on
following illustration.
vmr2010-004-025_a
A. 45°
Ensure that check valve is installed with arrows
pointing toward T-fitting.
vmr2010-004-024_a
Ensure that air hoses are properly inserted into fit-
tings, refer to the following illustrations.
vmo2010-011-102_a
PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED
1. Fitting
2. Mark
A. Must be inserted into fitting
vmo2010-011-103
HOSE PROPERLY INSERTED INTO FITTING
vmr2010-004 41
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
ACS AIR FILTER
ACS Air Filter Removal
1. Remove seat.
2. Remove central panel.
vmo2006-007-026_a
1. Central panel
2. Tabs to pull
3. Lift dashboard upwards.
vmr2008-068-002_a
TYPICAL
1. Central panel
2. Dashboard
4. Release clamps and remove air filter box cover.
vmo2006-007-027_a
1. Release clamps
5. Locate ACS compressor air filter.
6. Unscrew ACS compressor air filter from air box.
vmo2010-004-009_a
1. ACS compressor air filter
7. Push tabs then open cover.
vmo2010-004-010_a
1. tabs
8. Remove prefilter (foam) and filter (disc).
vmo2010-004-011_a
1. Prefilter (foam)
2. Filter (disc)
The installation is the reverse of removal proce-
dure.
ACS Air Filter Cleaning
Remove ACS compressor air filter, refer to
AIR
FILTER REMOVAL
.
Prefilter (Foam) Cleaning
1. Pour cleaning solution (P/N 219 700 341) or an
equivalent into a bucket.
2. Put the prefilter in to soak for a few minutes.
42 vmr2010-004
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
3. Rinse the prefilter with warm water until all
cleaning solution disappears.
4. Let the prefilter dry completely.
Filter (Disc) Cleaning
1. Blow low pressure compressed air on filter to
clean it.
NOTICE Do not wash the filter (disc) with any
cleaning solution.
Housing Cleaning
1. Blow low pressure compressed air in housing
to clean it.
PRESSURE TRANSDUCER (ACS
AUXILIARY LINE)
Pressure Transducer Signal Circuit
Continuity Test
1. Remove seats and RH side panel.
2. Disconnect module connector.
vmr2010-004-011_a
1. Module connector
3. Disconnect pressure transducer connector.
vmr2010-004-104_a
1. Pressure transducer connector
4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
5. Measure resistance as per the following table.
TEST PROBES RESISTANCE
Pressure transducer
pin 2 (PK/BR)
Module pin 3 (PK/BR)
Close to 0
Refer to the following illustration for the pressure
transducer connector pinout.
vmr2010-004-108
Pressure Transducer Input Voltage Test
1. Remove seats and RH side panel.
2. Disconnect pressure transducer connector.
vmr2010-004-104_a
1. Pressure transducer connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
4. Place ignition switch to ON position.
5. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin 3 (PK/OR)
Battery negative (-) post
Battery voltage
(± 12 Vdc)
Refer to the following illustration for the pressure
transducer connector pinout.
vmr2010-004 43
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-108
Pressure Transducer Ground Test
1. Remove seats and RH side panel.
2. Disconnect pressure transducer connector.
vmr2010-004-104_a
1. Pressure transducer connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
4. Place ignition switch to ON position.
5. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin 1 (BK/GY)
Battery positive (+) post
Battery voltage
(± 12 Vdc)
Refer to the following illustration for the pressure
transducer connector pinout.
vmr2010-004-108
Pressure Transducer Replacement
1. Release air pressure, refer to
RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING
in this
subsection.
2. Disconnect pressure transducer connector.
3. Remove Oetiker clamp.
4. Remove pressure transducer from hose.
vmr2010-004-030_a
1. Auxiliary line pressure transducer
2. Connector
3. Oetiker clamp
5. Install a new pressure transducer on hose.
6. Install a new Oetiker clamp using OETIKER PLI-
ERS (P/N 295 000 070).
7. Connect pressure transducer connector.
8. Ensure that there is no air leaks from pressure
transducer hose. Refer to
ACS SYSTEM LEAK
TEST (WITH B.U.D.S.)
.
ACS HOSES
ACS Hose and Fitting Replacement
1. Release air pressure, refer to
RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING
in this
subsection.
2. Locate hose or fitting to be replaced.
3. Remove it from vehicle.
4. Install the new hose or fitting.
5. Perform a
ACS SYSTEM LEAK TEST (WITH
B.U.D.S.)
.
Auxiliary Line Adapter Replacement
1. Release air pressure, refer to
RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING
in this
subsection.
2. Disconnect auxiliary line hose from adapter as
follows:
2.1 Push fitting ring toward adapter.
2.2 Hold ring in place.
2.3 Pull air hose.
44 vmr2010-004
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-031_a
1. Auxiliary line adapter
2. Fitting ring
3. Drill retaining rivets.
vmr2010-004-032_a
1. Retaining rivets
4. Install new adapter.
5. Secure adapter support using rivets.
6. Connect auxiliary line hose into adapter.
Ensure that air hoses are properly inserted into fit-
tings, refer to the following illustrations.
vmo2010-011-102_a
PUSH HOSE UNTIL THE MARK IS COMPLETELY INSERTED
1. Fitting
2. Mark
A. Must be inserted into fitting
vmo2010-011-103
HOSE PROPERLY INSERTED INTO FITTING
SHOCK ABSORBERS
Shock Absorber Removal
1. Lift rear of vehicle until rear shock absorbers are
fully extended.
2. Install jack stands or blocks under the frame to
support the vehicle.
3. Unscrew air hose from shock absorber as fol-
lows:
3.1 Install an appropriate wrench on shock fit-
ting to hold it in place.
3.2 Unscrew air hose fitting using another
wrench.
vmr2010-004-027_a
1. Shock absorber fitting
2. Air hose fitting
NOTICE To avoid damaging the shock fitting
threads, install a wrench on the shock fitting to
hold it in place while unscrewing the air hose
fitting.
4. Remove the shock absorber lower bolt and nut.
vmr2010-004 45
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-028_a
1. Shock absorber lower bolt
5. Remove the shock absorber upper bolt and nut.
vmr2010-004-029_a
1. Shock absorber upper bolt
6. Remove shock absorber from vehicle.
Shock Absorber Disassembly
NOTICE Be careful while manipulating or
installing the shock absorber in the spring
remover tool. The shock absorber body must
not be scratched or damaged to avoid air leak-
age.
1. Use the SPRING REMOVER (P/N 529 036 007).
529036007
2. Place the tool in a vise.
3. Position the shock absorber in the tool and in-
stall the spring compressor pins.
4. Tighten the spring remover screw until the
spring is sufficiently compressed to remove
spring locking devices.
5. Remove spring stopper and its cap then loosen
the spring remover screw.
6. Remove spring from shock.
Shock Absorber Inspection
Inspect the spring for damage. Replace if neces-
sary.
Secure the end of shock body in a vise with its rod
upward.
A14F0BA
1
TYPICAL
1. Clamp here
NOTICE Do not clamp directly on shock
body.
Inspect shock absorber as following:
1. Examine the shock absorber for leaks.
2. Extend and compress the shock absorber shaft
several times over its entire stroke.
3. Check that the shock absorber shaft moves
smoothly and with uniform resistance with its
rod upward.
Any of the following conditions will denote a de-
fective shock absorber:
– A skip or a hang back when reversing stroke at
mid travel.
– Seizing or binding condition except at extreme
end of either stroke.
– A gurgling noise, after completing one full com-
pression and extension stroke.
Replace shock absorber if any faults are present.
Shock Absorber Assembly and
Installation
Assembly and installation are the reverse of dis-
assembly and removal procedures, however pay
attention to the following.
Assemble shock absorber as per the following il-
lustrations.
46 vmr2010-004
Section01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-701_a
1. Sleeve
2. O-ring
vmr2010-004-702_a
1. Sleeve
2. O-ring
vmr2010-004-703_a
TYPICAL
1. Circlip
2. Small sleeve
3. Lower cap
4. Upper cap
5. Large sleeve
Install shock absorber cap opening at 180° from
spring stopper opening.
Torque upper and lower shock absorber bolts to
53 N•m (39 lbf•ft).
If the same shock absorber is reused, apply LOC-
TITE 592 (PIPE SEALANT) (P/N 293 800 018) on air
hose sleeve male threads.
While holding shock fitting with a wrench, tighten
air hose fitting to 19 N•m (168 lbf•in).
vmr2010-004 47
Section 01 TECHNICAL MANUAL
Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))
vmr2010-004-027_a
1. Shock absorber fitting
2. Air hose fitting
Ensure that there is no air leaks from shock ab-
sorber fitting and air hose. Refer to
ACS SYSTEM
LEAK TEST (WITH B.U.D.S.)
.
NOTICE Never screw shock absorber air
hose by using the air hose fitting only. To
avoid damaging the shock fitting threads, in-
stall a wrench on the shock fitting to hold it in
place while screwing the air hose fitting.
48 vmr2010-004
NOTES
NOTES
® AND THE BRP LOGO ARE TRADEMARKS OF BOMBARDIER RECREATIONAL PRODUCTS INC. OR ITS AFFILIATES.
©2009 BOMBARDIER RECREATIONAL PRODUCTS INC. ALL RIGHTS RESERVED. PRINTED IN CANADA.
219 100 388 CA
DPS/ACS TECHNICAL MANUAL / ENGLISH
MANUEL TECHNIQUE DPS/ACS / ANGLAIS
FAIT AU / MADE IN CANADA U/M:P.C.
Technical Manual
219 100 388
DPS
TM
/ACS
DPS
TM
/ACS
2010

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