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Can AM Maverick 1000R Series 2013 Shop Manual

Can AM Maverick 1000R Series 2013 Shop Manual

SAFETY NOTICE
INTRODUCTION
VEHICLE INFORMATION
ENGINE EMISSIONS INFORMATION
MANUAL INFORMATION
FASTENER INFORMATION
01 MAINTENANCE
01 ? BREAK-IN INSPECTION
02 ? PERIODIC MAINTENANCE SCHEDULE
03 ? PERIODIC MAINTENANCE PROCEDURES
GENERAL
PROCEDURES
ENGINE (AIR INTAKE SYSTEM)
ENGINE (EXHAUST SYSTEM)
ENGINE (LUBRICATION SYSTEM)
ENGINE (COOLING SYSTEM)
ENGINE (TOP END)
CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
GEARBOX
FUEL SYSTEM
ELECTRICAL SYSTEM
DRIVE SYSTEM
CHASSIS (WHEELS AND TIRES)
CHASSIS (STEERING SYSTEM)
CHASSIS (SUSPENSION)
CHASSIS (BRAKES)
CHASSIS (PASSENGER HANDHOLDS)
CHASSIS (TOW HITCH)
04 ? STORAGE PROCEDURE
GENERAL
PROCEDURES
FUEL SYSTEM
ENGINE
ELECTRICAL SYSTEM
DRIVE SYSTEM
CHASSIS
05 ? PRESEASON PREPARATION
06 ? SPECIAL PROCEDURES
GENERAL
ROLLED OVER VEHICLE
SUBMERGED VEHICLE
02 ENGINE, CVT AND GEARBOX
01 ? ENGINE REMOVAL AND INSTALLATION
PROCEDURES
ENGINE REMOVAL
ENGINE INSTALLATION
ENGINE MOUNTS
02 ? AIR INTAKE SYSTEM
GENERAL
PROCEDURES
AIR FILTER
AIR FILTER HOUSING
I
TABLE OF CONTENTS
02 ENGINE, CVT AND GEARBOX (cont’d)
03 ? EXHAUST SYSTEM
GENERAL
PROCEDURES
SPARK ARRESTER
MUFFLER
“Y” EXHAUST PIPE
RESONATOR
HEAD PIPE (FRONT CYLINDER)
HEAD PIPE (REAR CYLINDER)
04 ? LUBRICATION SYSTEM
INSPECTION
ENGINE OIL PRESSURE
TROUBLESHOOTING
PROCEDURES
OIL COOLER
OIL PRESSURE SWITCH (OPS)
ENGINE OIL PRESSURE REGULATOR
OIL PUMP
ENGINE OIL STRAINER
REED VALVE
OIL NOZZLES
05 ? COOLING SYSTEM
GENERAL
PROCEDURES
THERMOSTAT
RADIATOR
COOLANT TEMPERATURE SENSOR (CTS)
RADIATOR COOLING FAN RELAY (R1)
RADIATOR COOLING FAN
WATER PUMP HOUSING
WATER PUMP IMPELLER
WATER PUMP SHAFT AND SEALS
WATER PUMP GEARS
06 ? MAGNETO SYSTEM
PROCEDURES
MAGNETO COVER
STATOR
ROTOR
SPRAG CLUTCH
SPRAG CLUTCH GEAR
STARTER DRIVE GEARS
07 ? INTAKE MANIFOLD
PROCEDURES
PLENUM BRACKET
INTAKE MANIFOLD
08 ? TOP END
GENERAL
INSPECTION
LEAK TEST
PROCEDURES
VALVE COVER
ROCKER ARM
CAMSHAFT
CYLINDER HEAD
II
TABLE OF CONTENTS
02 ENGINE, CVT AND GEARBOX (cont’d)
08 ? TOP END (cont’d)
PROCEDURES (cont’d)
VALVE SPRINGS
VALVES
VALVE GUIDES
CYLINDER
PISTON
PISTON RINGS
09 ? TIMING CHAIN
GENERAL
TROUBLESHOOTING
PROCEDURES
TIMING CHAIN TENSIONERS
CAMSHAFT TIMING GEARS
TIMING CHAIN
TIMING CHAIN GUIDE (TENSIONER SIDE)
10 ? BOTTOM END
GENERAL
PROCEDURES
ENGINE DRIVE SHAFT
FRONT OIL SEAL (ENGINE DRIVE SHAFT)
REAR OIL SEAL (ENGINE DRIVE SHAFT)
PTO COVER OIL SEAL
PTO COVER
DRIVE GEARS
CRANKCASE
CRANKSHAFT
11 ? CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
GENERAL
PROCEDURES
CVT COVER
DRIVE BELT
DRIVE PULLEY
DRIVEN PULLEY
CVT AIR GUIDE
12 ? GEARBOX AND 4X4 COUPLING UNIT
GENERAL
GEARBOX OVERVIEW
TROUBLESHOOTING
PROCEDURES
VSS (VEHICLE SPEED SENSOR)
GBPS (GEARBOX POSITION SENSOR)
4WD INDICATOR SWITCH
ACTUATOR
GEARBOX OIL SEALS
GEARBOX
13 ? SHIFTER
PROCEDURES
SHIFT LEVER
SHIFTER CABLE
SHIFT PLATE
III
TABLE OF CONTENTS
03 ELECTRONIC MANAGEMENT SYSTEM
01 ? ENGINE MANAGEMENT SYSTEM (EMS)
GENERAL
SYSTEM DESCRIPTION
02 ? CONTROLLER AREA NETWORK (CAN)
GENERAL
SYSTEM DESCRIPTION
03 ? COMMUNICATION TOOLS AND B
GENERAL
REQUIRED TOOLS
TROUBLESHOOTING
DIAGNOSTIC TIPS
PROCEDURES
MULTI-PURPOSE INTERFACE-2 (MPI-2)
B
04 ? DIAGNOSTIC SYSTEM AND FAULT CODES
GENERAL
MONITORING SYSTEM
FAULT CODES
FAULT CODE DIAGNOSTIC
SPECIFIC FAULTS
04 FUEL SYSTEM
01 ? INTELLIGENT THROTTLE CONTROL (iTC)
GENERAL
SYSTEM DESCRIPTION
SYSTEM MAIN FEATURES
SYSTEM OTHER FEATURES
PROCEDURES
SPORT/NORMAL SWITCH
SEAT BELT SWITCH
OVERRIDE SWITCH
THROTTLE ACCELERATOR SENSOR (TAS)
02 ? ELECTRONIC FUEL INJECTION (EFI)
GENERAL
SYSTEM DESCRIPTION
ADJUSTMENT
IDLE SPEED
TROUBLESHOOTING
DIAGNOSTIC TIPS
PROCEDURES
ENGINE CONTROL MODULE (ECM)
FUEL INJECTOR
FUEL RAIL
THROTTLE BODY
THROTTLE POSITION SENSOR (TPS)
CRANKSHAFT POSITION SENSOR (CPS)
MANIFOLD AIR PRESSURE AND TEMPERATURE SENSOR (MAPTS)
CTS (COOLANT TEMPERATURE SENSOR)
KNOCK SENSOR (KS)
03 ? FUEL TANK AND FUEL PUMP
GENERAL
SYSTEM DESCRIPTION
INSPECTION
FUEL TANK LEAK TEST
IV
TABLE OF CONTENTS
04 FUEL SYSTEM (cont’d)
03 ? FUEL TANK AND FUEL PUMP (cont’d)
INSPECTION (cont’d)
FUEL PUMP PRESSURE TEST
TROUBLESHOOTING
FUEL SYSTEM DIAGNOSTIC FLOW CHART
PROCEDURES
FUEL HOSE AND OETIKER CLAMPS
FUEL TANK
FUEL PUMP
FUEL LEVEL SENDER
FUEL TANK VENT VALVE
05 ELECTRICAL SYSTEM
01 ? POWER DISTRIBUTION AND GROUNDS
GENERAL
POWER DISTRIBUTION DIAGRAM
FUSE BOX 1
FUSE BOX 2
GROUND
02 ? WIRING HARNESSES AND CONNECTORS
GENERAL
WIRING HARNESS AND SPLICE LOCATION
PROCEDURES
DEUTSCH CONNECTORS
PACKARD CONNECTORS
PACKARD CONNECTOR (MULTIFUNCTION GAUGE)
MOLEX CONNECTOR
FURUKAWA CONNECTOR
BATTERY AND STARTER CABLE TERMINALS
03 ? IGNITION SYSTEM
GENERAL
SYSTEM DESCRIPTION
TROUBLESHOOTING
DIAGNOSTIC GUIDELINES
PROCEDURES
IGNITION SWITCH
IGNITION COIL
SPARK PLUG
04 ? CHARGING SYSTEM
GENERAL
SYSTEM DESCRIPTION
INSPECTION
CHARGING SYSTEM OUTPUT
TROUBLESHOOTING
PROCEDURES
VOLTAGE REGULATOR/RECTIFIER
BATTERY
05 ? STARTING SYSTEM
GENERAL
SYSTEM DESCRIPTION
TROUBLESHOOTING
DIAGNOSTIC GUIDELINES
PROCEDURES
D2 DIODE (STARTER SOLENOID)
V
TABLE OF CONTENTS
05 ELECTRICAL SYSTEM (cont’d)
05 ? STARTING SYSTEM (cont’d)
PROCEDURES (cont’d)
START BUTTON
STARTER SOLENOID
ELECTRIC STARTER
06 ? DIGITALLY ENCODED SECURITY SYSTEM (D
GENERAL
SYSTEM DESCRIPTION
TROUBLESHOOTING
DIAGNOSTIC TIPS
PROCEDURES
KEY PROGRAMMING
07 ? LIGHTS, GAUGE AND ACCESSORIES
GENERAL
TROUBLESHOOTING
DIAGNOSTIC TIPS
PROCEDURES
CONSOLE SWITCHES
MULTIFUNCTION GAUGE (LCD AND ANALOG/DIGITAL)
12 VOLT POWER OUTLET
HEADLIGHTS
TAILLIGHTS/BRAKE LIGHTS
WINCH
TURN SIGNALS/HAZARD(EC MODELS ONLY)
HORN (EC MODELS ONLY)
06 DRIVE SYSTEM
01 ? FRONT DRIVE
GENERAL
SYSTEM DESCRIPTION
PROCEDURES
WHEEL HUB
FRONT DRIVE SHAFT
DRIVE SHAFT BOOT
FRONT DIFFERENTIAL
FRONT PROPELLER SHAFT
PROPELLER SHAFT U-JOINTS
02 ? REAR DRIVE
PROCEDURES
WHEEL HUB
DRIVE SHAFT
DRIVE SHAFT BOOT
PROPELLER SHAFT
PROPELLER SHAFT U-JOINTS
REAR FINAL DRIVE
07 CHASSIS
01 ? WHEELS AND TIRES
PROCEDURES
TIRES
WHEELS
02 ? STEERING SYSTEM
GENERAL
VI
TABLE OF CONTENTS
07 CHASSIS (cont’d)
02 ? STEERING SYSTEM (cont’d)
ADJUSTMENT
STEERING ALIGNMENT
TROUBLESHOOTING
DIAGNOSTIC TIPS
PROCEDURES
STEERING WHEEL
STEERING COLUMN
RACK AND PINION
TIE-ROD ENDS
KNUCKLES
WHEEL BEARINGS
03 ? FRONT SUSPENSION
GENERAL
PROCEDURES
SHOCK ABSORBER
SPRINGS
LOWER SUSPENSION ARM
UPPER SUSPENSION ARM
SUSPENSION ARM BUSHINGS
BALL JOINTS
04 ? REAR SUSPENSION
GENERAL
PROCEDURES
SHOCK ABSORBERS
SPRINGS
ANTI-SWAY BAR
UPPER SUSPENSION ARM
LOWER SUSPENSION ARM
SUSPENSION ARM BUSHINGS
REAR TOE LINK
05 ? BRAKES
GENERAL
INSPECTION
BRAKE SYSTEM PRESSURE VALIDATION
PROCEDURES
BRAKE LIGHT SWITCH
MASTER CYLINDER
CALIPER
BRAKE PADS
BRAKE DISC
WHEEL SCRAPER (REAR WHEELS ONLY)
06 ? BODY
PROCEDURES
PLASTIC RIVET
DECALS
UPPER CONSOLE
LOWER CONSOLE
LATERAL CONSOLE PANELS
GLOVE BOX
FUEL TANK COWL
SEAT COVER
VII
TABLE OF CONTENTS
07 CHASSIS (cont’d)
07 ? FRAME
PROCEDURES
CAGE
FRAME
08 TECHNICAL SPECIFICATIONS
01 ? MAVERICK 1000R
09 WIRING DIAGRAM
01 ? WIRING DIAGRAM INFORMATION
GENERAL
WIRING DIAGRAM LOCATION
WIRING DIAGRAM CODES
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