Can-Am DS 450 2008 Shop Manual
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Can-Am DS 450 2008 Shop Manual

Can-Am DS 450 2008 Shop Manual

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2008
Shop Manual
DS 450™
DS 450™ X

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Summary of Contents for Can-Am DS 450 2008

  • Page 1 2008 Shop Manual DS 450™ DS 450™ X...
  • Page 2 Bombardier Recreational Products Inc. (BRP) Valcourt (Quebec) Canada ™ Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates. ® * Trademarks of Bombardier Inc., used under license. Can-Am™ Rotax ® DS 450™ XP-S™ This document contains the trademarks of the following companies: Loctite ®...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTICE ................. . VIII INTRODUCTION ..
  • Page 4 TABLE OF CONTENTS OIL FILTER ......................37 OIL TANK STRAINER .
  • Page 5 TABLE OF CONTENTS CYLINDER ......................107 PISTON.
  • Page 6 TABLE OF CONTENTS ENGINE CONTROL MODULE (ECM)................183 FUEL INJECTOR .
  • Page 7 TABLE OF CONTENTS TAILLIGHT/BRAKE LIGHT ..................262 NEUTRAL INDICATOR LIGHT (GREEN) .
  • Page 8 TABLE OF CONTENTS FACTORY SETTINGS....................319 ADJUSTING SUSPENSION.
  • Page 9 TABLE OF CONTENTS TECHNICAL SPECIFICATIONS 01 – DS 450/DS 450 X ................... . 369 WIRING DIAGRAM 01 –...

  • Page 10: Safety Notice

    SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair 2008 Can-Am ATVs as describe INTRODUCTION in the model list in the This edition was primarily published to be used by mechanical technicians who are already familiar with all service procedures relating to BRP products.

  • Page 11: Introduction

    INTRODUCTION INTRODUCTION GENERAL INFORMATION This shop manual covers the following BRP made 2008 Can-Am ATVs. MODEL COLOR ENGINE MODEL NUMBER DS 450 EFI Yellow/Black 3F8A, 3F8B, 3F8C DS 450 EFI X Black 3G8A, 3G8B, 3G8C Vehicle Identification Number (V.I.N.) The information and component/system descrip- tions contained in this manual are correct at time of writing.

  • Page 12: Engine Emissions Information

    INTRODUCTION ENGINE EMISSIONS The responsibilities listed above are general and in no way a complete listing of the rules and regu- INFORMATION lations pertaining to the EPA requirements on ex- haust emissions for ATVs products. For more de- Manufacturer's Responsibility tailed information on this subject, you may contact Manufacturers of ATVs engines must determine the following locations:...
  • Page 13 INTRODUCTION Threadlocker Apply several drops on screw threads. Tighten as required. Uncovered Holes (bolts and nuts) Stud in Blind Holes lmr2007-040-005_a 1. On stud threads 1. Apply here 2. On hole threads 2. Do not apply 3. Onto nut threads Clean threads (bolt and nut) with solvent.
  • Page 14 INTRODUCTION Assemble components. Standard Thread Repair Tighten nuts. Follow instructions on Loctite FORM-A-THREAD 81668 package. Apply drops of proper strength Loctite on bolt/nut contact surfaces. If a plate is used to align bolt: – Apply release agent on mating surfaces. Avoid touching metal with tip of flask.
  • Page 15 INTRODUCTION Case-In Components Spray Loctite Primer N on both mating surfaces and on both sides of gasket. Allow to dry 1 or 2 Metallic Gaskets minutes. Apply Loctite 518 (P/N 293 800 038) on both sides of gasket, using a clean applicator. Place gasket on mating surfaces and assemble im- mediately.

  • Page 16: Tightening Torques

    INTRODUCTION TIGHTENING TORQUES In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the Tighten fasteners to torque mentioned in explod- following procedure: ed views and/or text. When they are not speci- Manually screw all screws, bolts and/or nuts. fied, refer to following table.

  • Page 17: Manual Information

    INTRODUCTION MANUAL INFORMATION The manual is divided into many major sections as you can see in the main table of contents at the beginning of the manual. Each section is divided in various subsections, and again, each subsection has one or more division. The illustrations show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts...
  • Page 18 INTRODUCTION Typical_iso_2008_en vmr2008-002...
  • Page 19 INTRODUCTION typical_txt_2008_en XVII vmr2008-002...

  • Page 21: Maintenance

    Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) MAINTENANCE CHART The schedule should be adjusted according to operating conditions and use. NOTE: The chart gives an equivalence between number of hours and months/year. Perform the mainte- nance operation to whatever time comes first. IMPORTANT: Intensive use of the ATV, will require greater frequency of inspection and maintenance.
  • Page 22 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) 10 HOURS OR 30 DAYS OR 400 KM (250 mi) (The initial maintenance is very important and must not be neglected.) ADJUST EVERY 25 HOURS OR 1250 KM (800 mi) CLEAN EVERY 50 HOURS OR 2500 KM (1600 mi) INSPECT EVERY 100 HOURS OR 5000 KM (3100 mi) OR LUBRICATE...
  • Page 23 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) 10 HOURS OR 30 DAYS OR 400 KM (250 mi) (The initial maintenance is very important and must not be neglected.) ADJUST EVERY 25 HOURS OR 1250 KM (800 mi) CLEAN EVERY 50 HOURS OR 2500 KM (1600 mi) INSPECT EVERY 100 HOURS OR 5000 KM (3100 mi) OR LUBRICATE...

  • Page 25: Preseason Preparation

    Section 01 MAINTENANCE Subsection 02 (PRESEASON PREPARATION) PRESEASON PREPARATION Prior to use vehicle, proper vehicle preparation is required after a storage period. Any worn, broken or damaged parts found during the storage procedure should have been replaced. If not, proceed with the replacement. Using the maintenance chart, performed items in the column indicated: EVERY 100 HOURS OR 5000 KM (3100 mi) OR 1 YEAR.

  • Page 27: Storage Procedure

    Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURE) STORAGE PROCEDURE SERVICE PRODUCTS Description Part Number Page BRP fuel stabilizer..............413 408 600 ..........7 storage oil ................413 711 600 ..........7 storage oil (US) ..............413 711 900 ..........7 If the ATV is not used or is to be stored for an Remove spark plugs and spray storage oil (P/N 413 extended period of time, more than 4 months, be...
  • Page 28 Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURE) Protect the vehicle with a cover to prevent dust accumulation during storage. CAUTION: The vehicle has to be stored in a cool and dry place. If vehicle is stored outside, it must be covered with an opaque tarpaulin. This will prevent sun rays and grime from af- fecting plastic components and vehicle finish.

  • Page 29: Special Procedures

    Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) SPECIAL PROCEDURES SERVICE PRODUCTS Description Part Number Page XP-S Lube ................293 600 016 ..........9 TURN OVER ATV Submerged for a Short Time (Less than Oone Hour) When vehicle is turned over or stays tilted on the side, put the vehicle back on its wheels, then wait Fuel System 3 to 5 minutes before starting the engine.

  • Page 31: Troubleshooting

    Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES (ENGINE)) TECHNICAL GUIDELINES (ENGINE) The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. COOLING SYSTEM Symptom: HIGH ENGINE OPERATING TEMPERATURE 1. Low coolant level. Check condition of hoses and hose clamps fixation.

  • Page 32: Clutch

    Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES (ENGINE)) Symptom: (cont’d) LOW OR NO OIL PRESSURE 2. Clogged oil filter. Check the condition of the oil filter. Change engine oil and filter. 3. Clogged oil tank strainer. Check if oil tank connector and oil tank strainer are clogged. Clean and replace engine oil and filter.

  • Page 33: Cylinder Head And Cylinder

    Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES (ENGINE)) Symptom: (cont’d) THE CLUTCH DOES NOT “DISENGAGE” 3. Clutch discs stuck together. Clean or replace. 4. Clutch discs or support plate distorted. Replace. 5. Clutch parts are worn out or damaged. Check clutch condition. Replace worn out or damaged parts. CYLINDER HEAD AND CYLINDER Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATION AT IDLE SPEED...

  • Page 34: Gearbox

    Section 02 TROUBLESHOOTING Subsection 01 (TECHNICAL GUIDELINES (ENGINE)) Symptom: (cont’d) UNUSUAL ENGINE NOISE AND/OR VIBRATIONS 3. Balance shaft bearing failure. Check balance shaft bearings for damages. Replace bearings. 4. Damaged connecting rod. Check if the connecting rod big end clearance is within specifications. Repair and/or replace. Check the connecting rod small end bearing condition.

  • Page 35: Diagnostic Flow Chart

    Section 02 TROUBLESHOOTING Subsection 02 (DIAGNOSTIC FLOW CHART) DIAGNOSTIC FLOW CHART FUEL SYSTEM vmr2008-023-100_aen vmr2008-008...

  • Page 37: Engine

    Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) ENGINE REMOVAL AND INSTALLATION vmr2008-009-001_a vmr2008-009...

  • Page 38: General

    Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded view. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to APPLICATION at the beginning of this manual for complete procedure.
  • Page 39 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) vmr2008-009-003_a vmr2008-009-006_a 1. Indicator switches 1. Exhaust pipe Remove the front sprocket and discard the circlip. Disconnect the crankcase vent tube. vmr2008-009-004_a 1. Circlip securing front sprocket vmr2008-009-007_a 1. Crankcase vent tube Remove the lower protector.
  • Page 40 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) vmr2008-009-013_a vmr2008-009-009_a 1. Coolant reservoir bolt 1. Breather hose Remove bolts securing upper engine supports to Unplug spark plug cables. frame. Remove the RH upper engine support. vmr2008-009-010_a 1. Spark plug cables Cut all locking ties securing wiring harness on RH side member.
  • Page 41 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) vmr2008-009-016_a SCREW BEHIND SHOCK ABSORBER 1. Side member front screw vmr2008-009-100_a 1. Intake adapter screws 2. Throttle body Remove the LH lower protector. vmr2008-009-017_a 1. Side member rear screws 2. Side member vmr2008-009-101_a Cut all locking ties holding wiring harness to upper 1.
  • Page 42 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) Disconnect the oil tank inlet hose. vmr2008-009-019_a 1. Ground wire Disconnect the thermostat hose from cylinder. vmr2008-009-023_a 1. Oil tank inlet hose 2. Oil tank Unscrew the oil tank outlet fitting from oil tank. Discard O-ring.

  • Page 43: Engine Installation

    Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) vmr2008-009-026_a vmr2008-009-102_a 1. Bell crank lever 1. Shifter 2. Bolt to be removed From the RH side, push cylinder head to unplug Unscrew and remove the swing arm bolt. the coolant temperature sensor (CTS). vmr2008-009-027_a 1.
  • Page 44 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) vmr2008-009-031 Install spacers with the cut bolts. vmr2008-009-032_a 1. Short spacer in front 2. Long spacer at the bottom Route oil hoses underneath the front of engine. Insert the bottom of engine into the lower brace of frame.

  • Page 45: Air Intake System

    Section 03 ENGINE Subsection 02 (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM SERVICE PRODUCTS Description Part Number Page air filter oil ................219 700 340 ........... 26 air filter cleaner ..............219 700 341 ........... 26 vmr2008-010-001_a vmr2008-010...

  • Page 46: General

    Section 03 ENGINE Subsection 02 (AIR INTAKE SYSTEM) GENERAL Loosen clamp and remove filter. During assembly/installation, use the torque val- ues and service products as in the exploded view. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to APPLICATION at the beginning of this manual for complete procedure.
  • Page 47 Section 03 ENGINE Subsection 02 (AIR INTAKE SYSTEM) vmr2008-010-002_a 1. Air intake hose 2. Deflector 3. Plastic rivet vmo2008-011-020_a 1. Air filter housing Cut locking ties holding air intake hose and 2. Drain tube crankcase vent tube. 3. Clamp NOTE: If vehicle is used in dusty area, inspect MAINTENANCE more frequently than specified in CHART...
  • Page 48 Section 03 ENGINE Subsection 02 (AIR INTAKE SYSTEM) vmr2008-010-004_a 1. Rear fender 2. Rear frame extension 3. Remove this screw (one each side) From the top, remove air filter housing screws. vmr2008-010-005_a 1. Air filter housing screws Remove air filter housing cover. Lower the housing and pull it rearward.

  • Page 49: Exhaust System

    Section 03 ENGINE Subsection 03 (EXHAUST SYSTEM) EXHAUST SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 271 (red) ..............293 800 005 ........... 32 vmr2008-011-001_a vmr2008-011...

  • Page 50: General

    Section 03 ENGINE Subsection 03 (EXHAUST SYSTEM) GENERAL WARNING To avoid potential burns, never touch ex- haust system immediately after the engine is stopped, as it can be very hot. Let engine and exhaust system cool down before per- forming any servicing. During assembly/installation, use the torque val- vmr2008-011-008_a ues and service products as in the exploded...

  • Page 51: Exhaust Pipe

    Section 03 ENGINE Subsection 03 (EXHAUST SYSTEM) Install a NEW muffler gasket. Loosen muffler clamp. First, tighten muffler screw. vmr2008-011-002_a 1. Exhaust pipe vmr2008-011-010_a 2. Muffler clamp 1. Muffler screw Pull exhaust pipe forward to remove it. Then the muffler pipe screw. Discard the muffler gasket and the exhaust gas- ket.

  • Page 52: Spark Arrester

    Section 03 ENGINE Subsection 03 (EXHAUST SYSTEM) Exhaust Pipe Installation Spark Arrester Cleaning For the installation, reverse the removal proce- Remove carbon deposits from the spark arrester dure. However, pay attention to the following. using a brush. Install NEW gaskets. NOTE: Use a soft brush and be careful to avoid damaging spark arrester.

  • Page 53: Lubrication System

    Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) LUBRICATION SYSTEM SERVICE TOOLS Description Part Number Page adapter hose................. 529 035 652 ........... 40 pressure gauge..............529 035 709 ........... 40 timing chain tensioner adapter ..........529 036 079 ........... 40 SERVICE PRODUCTS Description Part Number Page...
  • Page 54 Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) vmr2008-012-100_a vmr2008-012...
  • Page 55 Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) vmr2008-012-001_a vmr2008-012...

  • Page 56: General

    Do not use other synthetic oil, synthetic blend oil or oil additives 1. Full 2. Add in Can-Am ATV wet clutch equipped vehicles. 3. Operating range There is no known equivalent on the market for the moment. If a high quality equivalent were To add oil, remove the dipstick.

  • Page 57: Oil Filter

    Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) Remove oil tank cap. In accordance with the maintenance chart, clean OIL TANK STRAINER . See further in this sec- tion for the procedure. Wipe out any oil spillage. Refill oil tank at the proper level with the recom- mended oil.

  • Page 58: Oil Tank Strainer

    Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) vmr2008-012-036_a 1. Oil filter cover screws 2. Oil filter cover 3. O-ring 4. Oil filter vmo2008-011-042_a Dispose filter as per your local environmental reg- 1. Oil filter cover 2. Screw 25 mm ulations. 3.

  • Page 59: Inspection

    Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) INSPECTION ENGINE OIL PRESSURE From LH side of vehicle, remove the plug screw of timing chain tensioner and discard the sealing washer. vmo2008-011-099 STRAINER Oil Tank Strainer Cleaning Clean oil tank strainer with a parts cleaner then use an air gun to dry it.

  • Page 60: Procedures

    Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) vmr2008-012-102_a 1. Timing chain tensioner in position Install the timing chain tensioner adapter (P/N 529 036 079) on the adapter hose (P/N 529 035 652). vmr2008-012-103_a Start engine. The engine oil pressure should be within the fol- 529036079 lowing specification with the recommended oil at TIMING CHAIN TENSIONER ADAPTER...

  • Page 61: Oil Hose Connector

    Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) Disconnect the oil tank inlet hose. vmr2008-012-043_a 1. Oil tank bolts Withdraw oil tank from frame. vmr2008-012-040_a Oil Tank Installation 1. Oil tank inlet hose 2. Oil tank The installation is the reverse of the removal pro- Remove the crankcase vent tube from the oil tank.

  • Page 62: Engine Oil Pressure Regulator

    Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) Install hoses to connector. vmr2008-012-005_b vmr2008-012-105_a 1. Connect oil tank LOWER hose to this fitting Remove oil hoses from connector. 2. Connect oil tank UPPER hose to this fitting Remove screws securing the oil hose connector Reinstall plastic protector on LH side of engine.

  • Page 63: Oil Pressure Pump

    Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) OIL PRESSURE PUMP Remove plug screw and gasket ring. Discard gas- ket ring. The oil pressure pump is located in the crankcase Pull out oil pressure regulator. on the clutch side. vmr2008-012-008_a vmr2008-012-009_A 1.
  • Page 64 Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) vmr2008-012-015_b 1. Outer rotor 2. Inner rotor vmr2008-012-013_a 3. Needle pin 1. Snap ring 4. Oil pump bore 2. Oil pump gear 3. Needle pin Check inner rotor for corrosion pin holes or other 4.
  • Page 65 Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) Check oil pump cover for damages and for surface straightness with a straight edge. Difference between measurements should not exceed 0.2 mm (.008 in). If damaged or out of tolerance, replace the com- plete oil pump assembly.

  • Page 66: Engine Oil Strainer

    Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) Unscrew the bolts retaining the oil strainer cover. vmr2008-012-014_b vmr2008-012-021_a 1. Markings on inner and outer rotor 1. Screws 2. Oil strainer cover Coat inner and outer rotors with oil. Remove snap ring retaining the oil strainer. After installation of the remaining parts, check for smooth operation of the oil pump assembly.

  • Page 67: Oil Suction Pump

    Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) Remove ENGINE OIL STRAINER COVER , see pro- cedure above in this section. Remove outer and inner rotors. Remove the needle pin. Pull out the oil pump shaft. vmr2008-012-023_a 1. Oil collector 2. O-ring Check engine oil strainer for damage and change if necessary.

  • Page 68: Oil Nozzle

    Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) Oil Nozzle Removal Check oil pump shaft and surface of oil strainer cover for scratches or other damages. CRANKCASE/CRANK- Split crankcase. Refer to SHAFT section. Remove screw retaining the oil nozzle to crankcase. Oil Nozzle Cleaning Clean oil nozzle with a parts cleaner, then use an air gun and dry the parts.
  • Page 69 Section 03 ENGINE Subsection 04 (LUBRICATION SYSTEM) vmr2008-012-030_a 1. Oil tube NOTE: If the engine has to be dismantled within the scope of repair work, take this opportunity to clean the oil tube. Oil Tube Removal Split crankcase. Refer to CRANKCASE/CRANK- SHAFT section.

  • Page 71: Cooling System

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number Page Oetiker pliers ................ 295 000 070 ........... 54 small hose pincher..............295 000 076 ........... 57 handle ................... 420 877 650 ........... 64 vacuum/pressure pump kit ........... 529 021 800 ........... 54 large hose pincher ..............
  • Page 72 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) vmr2008-013-001_a vmr2008-013...
  • Page 73 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) vmr2008-013-100_a vmr2008-013...

  • Page 74: General

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded views. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to APPLICATION at the beginning of this manual for complete procedure.

  • Page 75: Maintenance

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) vmr2008-013-002_a 1. Leak indicator hole 2. Water pump housing 3. Clutch cover MAINTENANCE COOLANT REPLACEMENT WARNING To avoid potential burns, do not remove the coolant tank cap or loosen the cooling drain plug if the engine is hot. Recommended Coolant Use BRP premixed coolant (P/N 219 700 362) or a blend of 50% antifreeze with 50% water.
  • Page 76 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) vmo2008-011-061_a 1. Access cover Install a drain pan under vehicle. vmr2008-013-003_a 1. Drain plug Partially unscrew drain plug on water pump cover. 2. Gasket ring 3. Water pump cover Refilling the System Ensure vehicle is on a flat surface and engine is cold.

  • Page 77: Procedures

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) PROCEDURES COOLANT TANK CAP Coolant Tank Cap Test Using a pressure cap tester, check the efficiency of coolant tank cap. If the efficiency is weak, in- stall a new 110 kPa (16 PSI) cap (do not exceed this pressure).

  • Page 78: Radiator

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Loosen clamps securing hoses underneath coolant tank. Remove coolant tank. Coolant Tank Installation The installation is the reverse of the removal pro- cedure. REFILLING THE Refill coolant tank as described in SYSTEM above in this section. vmr2008-013-035_a RADIATOR 1.

  • Page 79: Radiator Installation

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) vmr2008-013-038_a 1. Cooling fan connector vmr2008-013-043_a 1. Fan relay Remove radiator from vehicle. Install a jumper wire end between pins 3 and 5. COOLING FAN Remove from radiator, see proce- dure further in this section. Radiator Installation The installation is the reverse of the removal pro- cedure.

  • Page 80: Thermostat

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Lift the radiator to disengage the bottom pin and tilt the top of radiator to reach cooling fan screws. Remove and discard screws securing cooling fan to radiator. vmr2008-013-101_b vmr2008-013-041_a 1. Long screw (M6 x 20) Pull out thermostat housing.

  • Page 81: Water Pump Housing

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) vmr2008-013-004_a vmr2008-013-003_b 1. Coolant temperature sensor 1. Cooling drain plug 2. Sealing ring 3. Screws Refer to ELECTRONIC FUEL INJECTION section 4. Water pump cover for testing and replacement procedures of the coolant temperature sensor (CTS). Water Pump Housing Inspection WATER PUMP HOUSING Check if gasket is brittle, hard or damaged and...

  • Page 82: Water Pump Impeller

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) WATER PUMP IMPELLER Water Pump Impeller Removal Remove water pump housing. Use a proper punch to remove spring pin. vmr2008-013-007_a 1. Water pump shaft 2. Clutch cover 3. Clutch cover retaining screws CAUTION: When removing the clutch cover take care not to loose the thrust washers on the water pump shaft and shift shaft.
  • Page 83 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) vmr2008-013-019_a 1. Extractor (10 mm socket) 2. Clutch cover 3. Support (36 mm socket) Check if leak indicator orifice in clutch cover is vmr2008-013-008_a free. If necessary use a parts cleaner, then use 1.
  • Page 84 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) vmr2008-013-023_a 1. Apply Loctite 243 on this surface vmr2008-013-020_a 1. Ball bearing pusher Use press machine only to install outer oil seal. 2. Ball bearing 3. Clutch cover Install outer oil seal with a press and the water pump seal installer (P/N 529 036 077).
  • Page 85 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Water Pump Shaft Installation Apply engine oil on the water pump shaft and install water pump shaft together with distance sleeve into clutch cover. NOTE: Do not drive spring pin into impeller until clutch cover has been installed.

  • Page 87: Magneto/Starter

    Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) MAGNETO/STARTER SERVICE TOOLS Description Part Number Page magneto puller..............529 035 748 ........... 76 Fluke 111 multimeter ............529 035 868 ........... 80 magneto harness adapter............. 529 036 016 ........... 72 crankshaft locking tool............529 036 107 ........... 76 SERVICE PRODUCTS Description Part Number...
  • Page 88 Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) vmr2008-014-001_a vmr2008-015...

  • Page 89: General

    Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) GENERAL WARNING Always disconnect BLACK (-) cable first and reconnect last. The engine removal is not necessary to work on the magneto system. During assembly/installation, use the torque val- ues and service products as in the exploded views.
  • Page 90 Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) Magneto Cover Inspection Check magneto cover for cracks or other damage. Replace if necessary. Clean all metal component in a non-ferrous met- al cleaner. Use Bombardier gasket remover (P/N 413 708 500), or suitable equivalent. WARNING Wear safety glasses and work in a well ventilated area when working with strong...

  • Page 91: Crankshaft Position Sensor (Cps)

    Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) STATOR Stator Continuity Test Test at Voltage Regulator/Rectifier Connector Disconnect the voltage regulator connector. vmr2008-014-004_a 1. Loctite 5910 Follow the shown tightening sequence for the magneto cover screws. vmr2008-025-008_a 1. Disconnect voltage regulator/rectifier Set multimeter to Connect multimeter between each pair of YEL- LOW wires.
  • Page 92 Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) Disconnect the stator connector and connect the STATOR CONTINUITY TEST AT VOLTAGE magneto harness adapter (P/N 529 036 016) to the REGULATOR/RECTIFIER stator side only, not to the rear main harness side. YELLOW WIRES RESISTANCE @ (EACH PAIR) 20°C (69°F)
  • Page 93 Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) STATOR CONTINUITY TEST AT STATOR CONNECTOR RESISTANCE @ TEST PROBES 20°C (69°F) YELLOW and BLACK/YELLOW wires YELLOW and BLACK 0.1 - 1 wires BLACK and BLACK/YELLOW wires vmr2008-025-009_b If a resistance reading is not as specified, replace STATOR INSULATION TEST AT VOLTAGE the stator.
  • Page 94 Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) Start engine. Connect multimeter between each pair of YEL- LOW wires. vmr2008-025-015_c STATOR INSULATION TEST AT STATOR CONNECTOR STATOR INSULATION TEST AT STATOR vmr2008-025-009_c CONNECTOR STATOR OUTPUT VOLTAGE TEST AT VOLTAGE REGULATOR/RECTIFIER CONNECTOR RESISTANCE PROBE POSITIONS @ 20°C (69°F) Read voltage.
  • Page 95 Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) Start engine. Repeat the stator output voltage test measuring the AC voltage between each pair of wires. vmr2008-014-005_a 1. Stator 2. Stator retaining screws 3. CPS 4. CPS retaining screws vmr2008-025-015_d STATOR OUTPUT VOLTAGE TEST AT STATOR CONNECTOR Stator Inspection STATOR OUTPUT VOLTAGE TEST AT Check stator and CPS condition.

  • Page 96: Rotor

    Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) vmr2008-014-005_b vmr2008-014-009_a 1. CPS screws 1. Screw M8 2. Stator wiring harness 2. Washer 3. Rotor Apply Loctite 5910 (P/N 293 800 081) between CPS and magneto cover as shown. Use the screw from the magneto puller (P/N 529 035 748).
  • Page 97 Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) Apply a light coat of Loctite 648 (green) (P/N 413 711 400) to taper on rotor. Apply engine oil on sprag clutch and sprag clutch gear needle bearing. vmr2008-014-010_a 1. Rotor 2. Screw of magneto puller (P/N 529 035 748) Rotor Inspection vmr2008-014-012_a Check inner side of rotor for scratches or other...

  • Page 98: Sprag Clutch

    Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) SPRAG CLUTCH Sprag Clutch Inspection Inspect sprag clutch and sprag clutch housing for Sprag Clutch Removal wear and damage. MAGNETO COV- Remove magneto cover (refer to Check the bushing of the sprag clutch gear. above).

  • Page 99: Sprag Clutch Gear

    Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) Apply Loctite 648 (green) (P/N 413 711 400) on threads of sprag clutch housing screws. Loosely install screws. Apply engine oil on sprag clutch and sprag clutch gear needle bearing. vmr2008-014-012_b 1. Rotor 2. Sprag clutch gear Sprag Clutch Gear Inspection Inspect gear, especially teeth and sprag clutch bushing for wear and other damage.

  • Page 100: Starter

    Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) vmr2008-026-002_c 1. Fuse cover 2. PF1 fuse holder 3. Injector/ignition fuse NOTE: Check engine light will flash when power vmr2008-014-018_a is turned “ON”. Starter will crank engine but with 1. Sprag clutch gear an initial delay of 1 or 2 seconds. 2.
  • Page 101 Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) Press the start button and measure for battery voltage between the starter terminal and engine ground as the starter is cranking. NOTE: Battery voltage will drop approximately 2 Vdc and fluctuate with starter cranking load. STARTER VOLTAGE TEST RED PROBE BLACK PROBE...
  • Page 102 Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) Pull starter out from crankcase. Starter Installation Installation is the reverse of the removal proce- dure. However, pay particular attention to the fol- lowing. Ensure starter and engine mating surfaces are free of debris. Serious problems may arise if the starter is not properly aligned.
  • Page 103 Section 03 ENGINE Subsection 06 (MAGNETO/STARTER) Apply dielectric grease (P/N 293 550 004) on starter terminal and nut before installing the RED protective cover. vmr2008-026-004_d 1. Torque starter mounting screws 2. Apply dielectric grease Connect the BLACK (-) battery cable. WARNING Always connect the RED (+) starter cable first, then the BLACK (-) battery cable last.

  • Page 105: Cylinder Head/Cylinder

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) CYLINDER HEAD/CYLINDER SERVICE TOOLS Description Part Number Page engine leak down test kit ............. 529 035 661 ........... 90 spring compressor..............529 035 724 ......... 102 compressor cup..............529 036 073 ......... 102 valve guide remover .............
  • Page 106 Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) vmr2008-015-002_a vmr2008-015...
  • Page 107 Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) vmr2008-015-001_a vmr2008-015...
  • Page 108 Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) vmr2008-015-003_a vmr2008-015...

  • Page 109: General

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) GENERAL When disassembling parts that are duplicated in the engine, (e.g.: valves, springs, etc.), it is NOTE: When diagnosing an engine problem, al- strongly recommended to note their position ways perform the cylinder leak test. This will help and to keep the parts of the same assembly as a pinpoint a problem.

  • Page 110: Inspection

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) Valve Clearance Adjustment Leak Test Adjust valve clearance by replacing the adjust- Install a gauge adaptor of the engine leak down ment shim of the respective valve. test kit (P/N 529 035 661) into previously cleaned spark plug hole.

  • Page 111: Procedures

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) Diagnosis Listen to for air leaks. – Air escaping on intake port/throttle body means leaking intake valve(s). – Air escaping on exhaust port means leaking ex- haust valve(s). – Air bubbles out of radiator means leaking cylin- der head gasket.
  • Page 112 Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) vmr2008-015-101_b Remove retaining screws of headlight power reg- ulator. vmr2008-015-105_a vmr2008-015-102 vmr2008-015-106 Disconnect engine harness connectors and ECM Disconnect fuel rail quick connector. ELECTRICAL FUEL INJECTI- connector. Refer to ION (EFI) section. vmr2008-015-107_a vmr2008-015-103_a Move headlight power regulator away, toward ECM.
  • Page 113 Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) vmr2008-015-108 vmr2008-015-116 Remove the LH side member. Refer to FRAME Valve Cover Removal section. (Engine Removed) Completely remove valve cover screws. Unscrew cover retaining screws. Remove the cover with the gasket. vmr2008-015-115_a vmr2008-015-007_a Gently pull out valve cover.

  • Page 114: Timing Chain Tensioner

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) TIMING CHAIN TENSIONER Timing Chain Tensioner Removal NOTE: Make sure that the crankshaft is set at TDC compression stroke. Refer to CRANKSHAFT LOCKING PROCEDURE in the CRANKCASE/CRANKSHAFT section. Remove plug screw and gasket ring. Pull out chain tensioner.
  • Page 115 Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) NOTE: Make sure that crankshaft is locked to TDC. Install timing gears on camshafts so that marks “IN” on intake and “EX” on exhaust camshaft are aligned. vmr2008-015-014_a 1. Timing chain guide Remove camshaft timing gear screws. vmr2008-015-004_a 1.
  • Page 116 Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) vmr2008-038-207_a 1. Exhaust timing gear vmr2008-016-007_a 2. Mark “EX” 3. Split line of camshaft holder 1. Intake timing gear 2. Mark “IN” 3. Mark on camshaft timing device Install the camshaft timing device (P/N 529 036 084).

  • Page 117: Camshaft

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) vmr2008-015-015_a vmr2008-015-016_a 1. Timing gear screws 1. Retaining screws 2. Washers 3. Camshaft holder Install upper chain guide and remaining removed parts. Remove exhaust and intake camshafts. CAMSHAFT Camshaft Removal NOTE: Before removing camshaft, measure the decompressor valve lift.
  • Page 118 Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) vmr2008-015-080_a A. Camshaft journal B. Camshaft lobe CAMSHAFT JOURNAL DIAMETER vmr2008-016-066_a 23.967 to 23.980 mm 1. Plastic gauge (.9436 to .9441 in) 2. Camshaft bearing journal SERVICE LIMIT 23.950 mm (.9429 in) Install camshaft holder in the proper position and tighten bearing cover screws to specified torque.

  • Page 119: Valve Lifter Bucket

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) NOTE: Never stretch spring to avoid altering the NOTE: After bearing cover installation check if defined spring force. camshafts turn easily. VALVE CLEARANCE Measure the lift of the decompressor on the valve Check .

  • Page 120: Cylinder Head

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) Valve Lifter Bucket Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. CAUTION: Place adjustment shim properly in place before installing valve lifter bucket. vmr2008-015-025_a 1.

  • Page 121: Cylinder Head Inspection

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) Cylinder Head Inspection Check for cracks between valve seats or other damages, if so, replace cylinder head. Clean oil support through cylinder head from con- tamination. vmr2008-015-025_b Apply Loctite 5910 (P/N 293 800 081) on crankcase sealing surface in the areas crankcase gasket/cylinder base gasket, chain duct and cool- ing circuit as shown in the following illustration.

  • Page 122: Valve Springs

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) First tighten cylinder head nuts M10 by hand, then tighten them according to the following tightening sequence. vmr2008-015-073_a 1. Cylinder head screws M6 vmr2008-015-070_a VALVE SPRINGS Torque cylinder screws M8 underneath intake port. Valve Springs Removal NOTE: Whenever valves are removed, it is recom- mended to replace valve stem seal at the same...

  • Page 123: Valve

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) Install valve cotters. Make sure valve cotters are properly engaged into valve stem grooves. CAUTION: Improperly locked valve springs will cause engine damage. vmr2008-016-031_a 1. Valve spring retainer 2. Outer valve spring 3. Inner valve spring Valve Springs Inspection vmr2008-016-032_a 1.

  • Page 124: Valve Inspection

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) VALVE OUT OF ROUND INTAKE AND EXHAUST VALVE 0.005 mm (.0002 in) SERVICE LIMIT 0.06 mm (.0024 in) Valve Stem Measure valve stem in three places using a mi- crometer. vmr2008-015-033_a 1. Intake valves 38 mm 2.

  • Page 125: Valve Installation

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) VALVE SEAT CONTACT WIDTH INTAKE VALVE 1.00 to 1.40 mm (.0394 to .0551 in) SERVICE LIMIT 1.60 mm (.0630 in) EXHAUST VALVE 1.25 to 1.55 mm (.0492 to .0610 in) SERVICE LIMIT 1.80 mm (.0709 in) If valve seat contact width is too wide, too narrow or has dark spots, replace the cylinder head.

  • Page 126: Valve Guide

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) VALVE GUIDE Disassembly Using procedures described in this section, re- move the following parts: – Cylinder head – Valve springs – Valves (including valve stem seal and shim). Valve Guide Inspection Measure valve guide in three places using a small bore gauge.

  • Page 127: Cylinder

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) Intake and exhaust valve guides are different. In- VALVE GUIDE MEASUREMENT “A” take valve guide has a longer chamfer. 13.10 to 13.50 mm (.5157 to .5315 in) Valve has guide to be adjusted in diameter by us- ing a reamer.

  • Page 128: Piston

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) Cylinder Installation CYLINDER HEAD For cylinder installation refer to INSTALLATION in this section. NOTE: If cylinder replacement is necessary, al- ways replace cylinder and piston at the same time. PISTON Refer to to match cylinder and piston to- gether.
  • Page 129 Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) Piston Inspection Piston/Cylinder Clearance Adjust and lock a micrometer to the piston dimen- Piston sion. Make sure piston is within specification. Inspect piston for scoring, cracking or other dam- ages. Replace piston and piston rings if neces- sary.

  • Page 130: Piston Installation

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) NOTE: Make sure the cylinder bore gauge indica- tor is set exactly at the same dimension as with the micrometer, otherwise the reading will be false. Position the dial bore gauge 20 mm (.787 in) above cylinder base, measuring perpendicularly (90°) to piston pin axis.

  • Page 131: Piston Rings

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) RING/PISTON GROOVE CLEARANCE UPPER COMPRESSION RING 0.025 to 0.070 mm (.0010 to .0028 in) SERVICE LIMIT 0.120 mm (.0047 in) LOWER COMPRESSION RING 0.025 to 0.070 mm (.0010 to .0028 in) SERVICE LIMIT 0.120 mm (.0047 in) vmr2008-015-053_a OIL SCRAPER RING...

  • Page 132: Piston Pin

    Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) Piston Pin Inspection Using a ring expander, install the lower compres- sion ring with the stamping “E” and “TOP “ fac- Using synthetic abrasive woven, clean piston pin ing up, then the upper compression ring with the from deposits.
  • Page 133 Section 03 ENGINE Subsection 07 (CYLINDER HEAD/CYLINDER) Piston Pin Installation For installation, reverse the removal procedure. Pay attention to the following details. NOTE: Take care that the hook of the piston circlip is positioned properly. vmr2008-016-054 CORRECT POSITION OF THE PISTON CIRCLIP vmr2008-015...

  • Page 135: Crankcase/Crankshaft

    Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) CRANKCASE/CRANKSHAFT SERVICE TOOLS Description Part Number Page crankshaft protector ............. 420 876 557 ......... 125 handle ................... 420 877 650 ......... 124 bolt M16 x 1,5 x 65 mm ............529 035 549 ......... 120 oil seal installer ..............
  • Page 136 Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) vmr2008-016-001_a vmr2008-016...

  • Page 137: General

    Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) GENERAL Check bearing behind oil seal for contamination and/or metal shavings. Replace bearing if neces- During assembly/installation, use the torque val- sary. ues and service products as in the exploded views. Main Shaft Oil Seal Installation Clean threads before applying a threadlocker.

  • Page 138: Primary Drive Gear

    Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) PRIMARY DRIVE GEAR Primary Drive Gear Removal Engine removal from vehicle is not necessary. CRANKSHAFT LOCK- Lock crankshaft at TDC, see ING PROCEDURE CRANKSHAFT below. Drain lubrication system, refer to LUBRICATION SYSTEM COOLING SYSTEM Drain cooling system, refer to CLUTCH Remove clutch, refer to...

  • Page 139: Timing Chain Drive Gears

    Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) Timing Chain and Chain Tensioner Guide Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. To adjust the camshaft timing correctly refer to TIMING CHAIN DRIVE GEARS INSTALLATION this section.
  • Page 140 Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) NOTE: When tightening screw, it may be neces- sary to tap on screw head to release control gear from its taper. Timing Chain Drive Gears Inspection Bearing Pin Check bearing pin surface for wear or scoring. Re- place if necessary.

  • Page 141: Crankcase

    Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) Control Gear Inspect the control gear for chipped, worn or bro- ken gear teeth. Replace parts if necessary. Timing Chain Drive Gears Installation Clean tapers of balancer shaft and control gear with pulley flange cleaner (P/N 413 701 809) and put gear on balancer shaft.

  • Page 142: Crankcase Inspection

    Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) Crankcase Inspection Clean crankcase halves from contaminations us- ing a parts cleaner and dry them with compressed air. Clean oil passages with compressed air to make sure that they are not clogged. WARNING Wear safety goggles to avoid eye injuries. vmr2008-016-121_a Place crankcase with magneto side against a wooden rack.
  • Page 143 Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) Ball Bearings Check ball bearings of balancer shaft (no. 1 and no. 2), countershaft (no. 5 and no. 6) and main shaft (no. 7 and no. 8) for excessive play and smooth operation. Replace if necessary. Crankshaft Main Bearings Check crankshaft roller bearings (no.
  • Page 144 Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) 529036117 For all other bearings use a suitable puller and vmr2008-016-131_a press bearings from outside in. 1. Oil seal 2. Oil seal installer Ball Bearings Installation Crankshaft Main Bearings Removal Unless otherwise instructed, never use a hammer Use a suitable puller and press bearings from to install bearings.
  • Page 145 Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) Use a press and press out inner ring. Heat inner ring again if necessary. vmr2008-016-201_a PARTIAL CRANKSHAFT SHOWN 1. Inner ring 2. Bearing splitter Partly tighten splitter to create a pulling force on inner ring. Do not overtighten. vmr2008-016-203_a PARTIAL CRANKSHAFT SHOWN Use a propane torch and heat inner ring to “un-...

  • Page 146: Balancer Shaft

    Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) Crankcase Assembly NOTE: It takes approximately 11 minutes to heat up the inner ring to the recommended tempera- The assembly of the crankcase is essentially the ture. reverse of the disassembly procedure. Turn inner ring upside down several times during However pay attention to following details.

  • Page 147: Crankshaft

    Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) CAUTION: Temporarily secure connecting rod to the front of crankcase. Otherwise connect- ing rod will crush the oil spray nozzle no. 10. vmr2008-015-117_a Use a screwdriver to feel the groove when the crankshaft is aligned with the hole. vmr2008-016-204_a 1.
  • Page 148 Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) Rotate crankshaft until marks on intake and ex- Screw the crankshaft locking tool in and try to ro- haust camshaft timing gear are aligned. This is the tate the crankshaft. If it does not turn, tighten the compression stroke.

  • Page 149: Crankshaft Installation

    Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) Move connecting rod small end upside down and PISTON PIN BORE CLEARANCE measure radial clearance using a dial gauge. 0.050 mm (.0020 in) SERVICE LIMIT Crankshaft Gear Replacement Procedure Crankshaft Gear Removal CAUTION: If crankshaft gear was removed once, replace it by a new one.
  • Page 150 Section 03 ENGINE Subsection 08 (CRANKCASE/CRANKSHAFT) CAUTION: Temporarily secure connecting rod to the front of crankcase. Otherwise connect- ing rod will crush the oil spray nozzle no. 10. vmr2008-016-204_a 1. Oil spray nozzle 2. Secure connecting rod here For installation, refer to BALANCER SHAFT instal- lation.

  • Page 151: Clutch

    Section 03 ENGINE Subsection 09 (CLUTCH) CLUTCH SERVICE TOOLS Description Part Number Page clutch spanner ..............529 035 647 ......... 141, 144 oil seal installer ..............529 036 070 ......... 146 protection sleeve ..............529 036 071 ......... 146 clutch adjustment wrench ............ 529 036 076 ......... 135 SERVICE PRODUCTS Description Part Number...
  • Page 152 Section 03 ENGINE Subsection 09 (CLUTCH) Vmr2008-017-001_a vmr2008-017...
  • Page 153 Section 03 ENGINE Subsection 09 (CLUTCH) Vmr2008-017-002_a vmr2008-017...

  • Page 154: General

    Section 03 ENGINE Subsection 09 (CLUTCH) GENERAL NOTE: For a better understanding, the following illustrations are taken with engine out of vehicle. To perform the following instructions, it is not nec- essary to remove engine from vehicle. Always disconnect the BLACK (-) wire from the battery before working the engine.
  • Page 155 Section 03 ENGINE Subsection 09 (CLUTCH) vmo2008-011-063_c CLUTCH LEVER — PROPER ADJUSTMENT A. 10 to 15 mm (3/8 to 5/8 in) Tighten cable adjuster lock nut when proper ad- justment is obtained. vmo2008-011-042_c LH SIDE OF ENGINE Adjustment at Clutch Cover 1.

  • Page 156: Procedures

    Section 03 ENGINE Subsection 09 (CLUTCH) To confirm proper adjustment, gently push on ad- justment screw using a finger, a small play should be felt, if not, perform adjustment again. CAUTION: A premature clutch disk wear may occur if adjustment is too tight. Apply engine oil on access plug O-ring.
  • Page 157 Section 03 ENGINE Subsection 09 (CLUTCH) vmr2008-017-066_a 1. Clutch release cover screws Discard the clutch release cover gasket. vmr2008-017-008_a Clutch Release Cover Disassembly 1. Screw 2. Leaf spring Disengage clutch cable. 3. Thrust washer 4. Clutch release cam 5. Balls 6.
  • Page 158 Section 03 ENGINE Subsection 09 (CLUTCH) Apply Loctite 243 (blue) (P/N 293 800 060) on threads of the leaf spring screw. When fitting the release cam, make sure that the end of the leaf spring rests neatly on the thrust washer and does not touch the adjustment screw.

  • Page 159: Clutch Cable

    Section 03 ENGINE Subsection 09 (CLUTCH) Tighten clutch release cover screws in a crisscross sequence. Install shifter. CLUTCH ADJUSTMENT Perform the , see proce- dure at the beginning of this section. CLUTCH CABLE Clutch Cable Removal vmo2008-011-063_b At Engine 1. Cable adjuster CLUTCH RELEASE COVER Remove the , see pro-...

  • Page 160: Retaining Plate And Clutch Spring

    Section 03 ENGINE Subsection 09 (CLUTCH) RETAINING PLATE AND CLUTCH SPRING Retaining Plate and Clutch Spring Removal CLUTCH RELEASE COVER Remove , see proce- dure above in this section. Unfasten screws crosswise and remove retaining plate and clutch spring. vmo2008-011-063_a 1.

  • Page 161: Clutch

    Section 03 ENGINE Subsection 09 (CLUTCH) Using the clutch spanner (P/N 529 035 647) and a 27 mm socket, remove clutch hub nut and spring washer. vmr2008-017-015_a 1. Retaining plate 2. Bearing 3. Thrust hub Clutch Spring Measure each clutch spring free length. CLUTCH SPRING FREE LENGTH 33.70 to 34.50 mm (1.327 to 1.358 in)

  • Page 162: Clutch Disassembly

    Section 03 ENGINE Subsection 09 (CLUTCH) vmr2008-017-051 Clutch Disassembly Remove the clutch spring. Remove clutch hub. vmr2008-017-019_a 1. Splines 2. Flat surface Friction Plate Measure friction plate thickness. Even if one friction plate is worn out, replace all friction plates. FRICTION PLATE THICKNESS 2.52 to 2.68 mm (.100 to .106 in)

  • Page 163: Clutch Installation

    Section 03 ENGINE Subsection 09 (CLUTCH) Place clutch plate on a flat surface and tip with a Align the tabs of the friction plates and secure the finger on plate to find maximum warpage. clutch assembly in place with a clutch spring. NOTE: Take care that the inner splines of the inner CLUTCH PLATE WARPAGE plate slip into the outer splines of the clutch hub.

  • Page 164: Clutch Cover

    Section 03 ENGINE Subsection 09 (CLUTCH) Using the clutch spanner (P/N 529 035 647) and a 27 mm socket, tighten clutch hub nut. vmr2008-017-054_a 1. Clutch cover screws 2. Sealing washer Remove clutch cover and discard the gasket. vmr2008-017-017_a 1. Clutch spanner 2.
  • Page 165 Section 03 ENGINE Subsection 09 (CLUTCH) Bearing Sleeve (for Crankshaft) Check if bearing sleeve is in proper position. vmr2008-017-057_a 1. Thrust washer 2. Shift shaft vmr2008-017-058_a Clutch Cover Inspection 1. Bearing sleeve 2. Water pump shaft Check the clutch cover for cracks or other dam- A.

  • Page 166: Clutch Drum

    Section 03 ENGINE Subsection 09 (CLUTCH) 529036071 vmr2008-017-060_a 1. New gasket Apply Loctite 518 (P/N 293 800 038) on gasket as shown in the following illustration. vmr2008-017-039_a 1. Protection sleeve 2. Oil seal 3. Shift shaft Use oil seal installer (P/N 529 036 070) for instal- lation of the oil seal.
  • Page 167 Section 03 ENGINE Subsection 09 (CLUTCH) Remove CLUTCH , see procedure above in this section. Remove thrust washer then the clutch drum. vmr2008-017-035_b 1. O-ring 2. Clutch shaft Replace as required. Check slots of clutch basket for steps, damage or wear caused by friction plates.
  • Page 168 Section 03 ENGINE Subsection 09 (CLUTCH) Clutch Drum Installation Replace the oil pump drive gear if any damage is detected. Perform the following to replace the For installation reverse the removal procedure. gear. Break gear locking tabs then pull gear. vmr2008-017-062_a 1.

  • Page 169: Gearbox

    Section 03 ENGINE Subsection 10 (GEARBOX) GEARBOX SERVICE TOOLS Description Part Number Page oil seal protection sleeve ............529 036 068 ......... 160 SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............293 800 060 ......... 155 Loctite 5910................293 800 081 ......... 152 vmr2008-018...
  • Page 170 Section 03 ENGINE Subsection 10 (GEARBOX) vmr2008-018-001_a vmr2008-018...
  • Page 171 Section 03 ENGINE Subsection 10 (GEARBOX) vmr2008-018-002_a vmr2008-018...

  • Page 172: General

    Section 03 ENGINE Subsection 10 (GEARBOX) GENERAL Unscrew indicator switch. During assembly/installation, use the torque val- Neutral Indicator Switch Installation ues and service products as in the exploded view. For installation reverse the removal procedure. Clean threads before applying a threadlocker. Re- However, pay attention to the following.
  • Page 173 Section 03 ENGINE Subsection 10 (GEARBOX) Unscrew and remove bearing pin. vmr2008-018-024_a 1. Bearing pin Insert a flat screwdriver in the slot of index lever. vmr2008-012-012_a Turn screwdriver counterclockwise and remove in- 1. Bearing bolt 2. Intermediate gear dex washer. Unscrew screws retaining the disengagement gate to the crankcase.
  • Page 174 Section 03 ENGINE Subsection 10 (GEARBOX) vmr2008-018-026_a vmr2008-018-034_a 1. Index lever screw A. 90 ° 2. Step ring 3. Index lever Index Washer 4. Index spring Check engagement slots of index washer for wear or other damages. Shifting Mechanism Inspection Shift shaft Check shift shaft for worn splines or other dam- ages.

  • Page 175: Gearbox

    Section 03 ENGINE Subsection 10 (GEARBOX) Remove both shift fork shafts from shift forks. vmr2008-018-005_a 1. Pawls 2. Tooth segment 3. Spring Apply Loctite 243 (blue) (P/N 293 800 060) on the vmr2008-018-027_a lower threads of the bearing pin. 1. Long shift fork shaft (with a retaining ring) 2.
  • Page 176 Section 03 ENGINE Subsection 10 (GEARBOX) Remove the 5 gear from the main shaft. vmr2008-018-009_a 1. Snap ring vmr2008-018-007_a 2. Thrust washer 3. Free pinion 1. Thrust washer 4. Main shaft assembly 2. Shifting gear, 5 gear Remove: Using a soft hammer, tap main shaft to assist with- –...
  • Page 177 Section 03 ENGINE Subsection 10 (GEARBOX) Remove: – Snap ring (discard) – Thrust washer – Free pinion – Needle bearing. vmr2008-018-014_a 1. Snap ring 2. Thrust washer 3. Free pinion 4. Needle bearing 5. Clutch shaft Gearbox Inspection vmr2008-018-012_a Always verify for the following when inspecting 1.
  • Page 178 Section 03 ENGINE Subsection 10 (GEARBOX) vmr2008-018-016_a vmr2006-022-075_a 1. Engagement dog 1. Micrometer 2. Shift fork engagement groove A. Shift fork claw thickness 3. Inner splines SHIFT FORK CLAW THICKNESS Shift Drum Check shift drum tracks for scouring or heavy 3.54 to 3.60 mm wear, like rounded engagement slots and contact (.1394 to .1417 in)
  • Page 179 Section 03 ENGINE Subsection 10 (GEARBOX) DIAMETER FREE PINION CLUTCH SHAFT 24.007 to 24.020 mm (.9452 to .9457 in) SERVICE LIMIT 24.025 mm (.9458 in) MAIN SHAFT 25.007 to 25.020 mm (.9845 to .9850 in) SERVICE LIMIT 25.025 mm (.9852 in) vmr2008-018-017_a Main Shaft A.
  • Page 180 Section 03 ENGINE Subsection 10 (GEARBOX) Check splines for wear and/or damages. Install NEW snap rings. NOTE: Snap rings should be installed using a re- taining ring pliers only. For gearbox installation, put the oil seal protection sleeve (P/N 529 036 068) on main shaft to avoid damaging main shaft oil seal.

  • Page 181: Engine Management System

    Section 04 ENGINE MANAGEMENT SYSTEM Subsection 01 (OVERVIEW) OVERVIEW Engine Management System (EMS) vmr2008-019-001_aen vmr2008-019...
  • Page 182 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 01 (OVERVIEW) Power Distribution vmr2008-019-004_aen vmr2008-019...
  • Page 183 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 01 (OVERVIEW) ECM Interaction with the Electrical System vmr2008-019-005_aen ECM Inputs/Outputs vmr2008-019-003_aen vmr2008-019...

  • Page 184: System Description

    Section 04 ENGINE MANAGEMENT SYSTEM Subsection 01 (OVERVIEW) SYSTEM DESCRIPTION A highly advanced engine management system (EMS) has been used to ensure a high power out- put with cleaner combustion. There are 4 main systems that are controlled by the engine management system (EMS): 1.

  • Page 185: Power Distribution

    Section 04 ENGINE MANAGEMENT SYSTEM Subsection 01 (OVERVIEW) These performance-reduced modes allow the rid- er to go back home which would not be otherwise possible without this advanced system. Refer to MONITORING SYSTEM/FAULT CODES Diagnostic Mode The ECM features a self-diagnostic mode when ignition key is turned on.

  • Page 187: Communication Tools/B.u.d.s. Software

    Section 04 ENGINE MANAGEMENT SYSTEM Subsection 02 (COMMUNICATION TOOLS/B.U.D.S. SOFTWARE) COMMUNICATION TOOLS/B.U.D.S. SOFTWARE SERVICE TOOLS Description Part Number Page Optional extension cable ............529 035 697 ......... 167 MPI-2 ..................529 036 018 ......... 167 Diagnostic cable ..............710 000 851 ......... 167 MULTI-PURPOSE INTERFACE-2 MPI-2 Power Supply (MPI-2)

  • Page 188: B.u.d.s. Software

    Section 04 ENGINE MANAGEMENT SYSTEM Subsection 02 (COMMUNICATION TOOLS/B.U.D.S. SOFTWARE) For more information pertaining to the use of the B.U.D.S. software, use its help which contains de- tailed information on its functions. Ensure the appropriate connections are done for B.U.D.S. Ensure to use the latest B.U.D.S.
  • Page 189 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 02 (COMMUNICATION TOOLS/B.U.D.S. SOFTWARE) vmr2006-012-100_ben Disconnect MPI connections and reconnect vehi- cle harness in protective cap. NOTE: There is a 120 resistor in protective cap to minimize the possibility of communication error. Changes in ECM Anytime a change is brought in ECM through B.U.D.S., there will be an EMS Tracking mes- sage that will say Remove key from vehicle.

  • Page 191: Monitoring System/Fault Codes

    Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) MONITORING SYSTEM/FAULT CODES MONITORING SYSTEM COMPONENT EMS (TPS, CPS, AAPTS, MAPS, CTS, IACV, neutral The EMS features a monitoring system that self- switch, ignition coil and fuel injector) diagnose its electronic components (control mod- ules, sensors and actuators) to ascertain they are Battery voltage not faulty or defective.
  • Page 192 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) POSSIBLE CAUSES ACTION POSSIBLE CAUSES ACTION Check if connector is Fix. Sensor has been replaced Reset Closed Throttle and Idle Actuator. disconnected from TPS and TPS closed position not reset Check if sensor is loose Tighten and reset Closed Throttle and Idle...

  • Page 193: Fault Code Table

    Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) FAULT CODE TABLE FAULT DESCRIPTION POSSIBLE FAULT ACTION CODE Manifold absolute Make sure sensor's connector is fully Faulty MAPS sensor - pressure sensor signal disconnected connector - inserted. Check for approximately 5 volts shorted to GND or between sensor connector pins 1 and 2.
  • Page 194 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) FAULT DESCRIPTION POSSIBLE FAULT ACTION CODE Coolant temperature Faulty CTS sensor - partially Check for disconnected engine sensor intermittent disconnected connector - faulty temperature sensor. Check sensor fault terminals - cut wires - shorted resistor value between 1800 ohm and wire - change in temperature 2200 at 22°C.
  • Page 195 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) FAULT DESCRIPTION POSSIBLE FAULT ACTION CODE Starter solenoid Faulty solenoid - faulty terminal at Check for damaged or disconnected solenoid or at engine connector shorted to battery starter solenoid, damaged circuit wires, 12 V - Dirt stuck on solenoid blades damaged connectors or damaged ECM...
  • Page 196 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) FAULT DESCRIPTION POSSIBLE FAULT ACTION CODE Idle air control valve Faulty IACV - disconnected Make sure IACV connector is fully inserted. pin(s) disconnected or connector - faulty terminals - cut Check circuits between idle valve motor shorted to GND wires - shorted wire...
  • Page 197 Section 04 ENGINE MANAGEMENT SYSTEM Subsection 03 (MONITORING SYSTEM/FAULT CODES) FAULT DESCRIPTION POSSIBLE FAULT ACTION CODE Indicator lamp Lamp missing, disconnected or Check if lamp is connected. Check for disconnected faulty damaged circuit between pilot lamp and ECM K4. Check for damaged circuit between pilot lamp and battery.

  • Page 199: Fuel System

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) ELECTRONIC FUEL INJECTION (EFI) SERVICE TOOLS Description Part Number Page tachometer ................529 014 500 ......... 182 Fluke 115 multimeter ............529 035 868 ....185–186, 191–192, 198–200, 202–207, 209 ECM adapter.................

  • Page 200: General Recommendations

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Fuel Rail One fuel rail is mounted on the intake manifold. The fuel rail ensures all the time, that enough fuel can be delivered to the fuel injector. The fuel rail is fed by the fuel pump with the properly regulated fuel pressure.
  • Page 201 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) After a problem has been solved, ensure to WARNING clear the fault code(s) in the ECM using the Fuel lines remain under pressure at all times. B.U.D.S. software. Refer to MONITORING Always proceed with care and use appropri- SYSTEM/FAULT CODES...

  • Page 202: Basic Adjustments

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Also remember this validates the operation of the – ECM is replaced. sensor at room temperature. It does not validate CAUTION: An improperly set TPS or idle air the over temperature functionality. To test it, the control valve may lead to poor engine perfor- sensor could be removed from the engine and mance and emission compliance could possi-...

  • Page 203: Procedures

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Start engine and make sure it operates normally through its full engine RPM range. If fault codes appear, refer to MONITORING SYSTEM/FAULT CODES section for more information. PROCEDURES ENGINE CONTROL MODULE (ECM) vmr2008-022-014_a Pull out connector.
  • Page 204 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) CAUTION: Never probe directly on ECM har- ness connector. This could change the shape or enlarge the terminals and create intermittent or permanent contact problems. Power Supply to ECM vmr2008-022-013 _b 1.
  • Page 205 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Check continuity of ground connections as fol- lows. CONNECTOR BATTERY MEASUREMENT Battery Close to 0 ground post (continuity) vmr2008-026-001_a UNDER SEAT 1. Main fuse vmr2008-022-100_a If test succeeded, ECM grounds are adequate. If test failed, ensure wiring and connectors are good and repair or replace as necessary.
  • Page 206 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) 529035868_a vmr2008-022-006_a Check voltage as follows. 1. Harness ground to engine (at starter motor) 2. Wiring harness ground to frame ECM CONNECTOR PIN MEASUREMENT Battery voltage vmr2008-022-005_b If voltage is out of specification, check wiring and vmr2008-025-002_b connectors from battery to ECM.
  • Page 207 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) ECM Removal NOTE: If ECM is removed for replacement, refer ECM REPLACEMENT first to further. BODY. Remove seat. Refer to Disconnect battery cables. WARNING Battery BLACK negative cable must always be disconnected first and connected last.
  • Page 208 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) If a new ECM is installed, transfer/enter data and In B.U.D.S., click the Write Data button to save perform the required resets to the new ECM. Re- the information to ECM. fer to ECM REPLACEMENT below.
  • Page 209 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) NOTE: The file name structure is as follows: B.U.D.S. version_V.I.N._date read (yyyymmdd)_hour read (hhmmss).mpem Example: P2.3.18.3_2BPSMJ9A59V000262_20080201_142322.mpem B.U.D.S. version = P2.3.18.3 V.I.N. = 2BPSMJ9A59V000262 Date file was read = 2008-02-01 Hour file was read = 14h 23m 22s mmr2009-023-081_a Go to the Vehicle tab and record the following Double click on the AutoSave folder.
  • Page 210 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) vmr2006-012-100_aen Go to the Vehicle tab and enter the information you recorded previously. vmo2008-011-026_a – Vehicle (V.I.N.) number 1. Vehicle serial number location – Engine number NOTE: Do not enter the leading “M”. –...

  • Page 211: Fuel Injector

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) FUEL INJECTOR Injector Leakage Test The leakage test is validated when performing the FUEL TANK fuel pump pressure test. Refer to AND FUEL PUMP section. Injector Test with B.U.D.S. Turn ignition key ON and set engine stop switch to RUN.
  • Page 212 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Injector Resistance Test Reconnect the injector connector. Disconnect the ECM connector. Install ECM adapter (P/N 529 036 085) on ECM connector. Using the Fluke 115 multimeter (P/N 529 035 868), check resistance value between terminals as fol- lows.

  • Page 213: Fuel Rail

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Injector Installation For the installation, reverse the removal proce- dure. Pay attention to the following details. Install new O-rings. Apply a thin film of engine oil to O-rings to ease insertion in rail.
  • Page 214 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Remove front body ass'y. Refer to BODY. Remove retaining screw of coolant tank. vmr2008-022-039_A Unplug injector connector. vmr2008-022-036_a NOTE: If connector is hard to unlock, gently use a screwdriver to release connector. Move tank away to make room to reach the fuel hose connection.

  • Page 215: Throttle Body

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) THROTTLE BODY vmr2008-022-040 Fuel Rail Installation vmr2008-022-010_a 1. Throttle body For installation, reverse the removal process but 2. Throttle cable attachment pay attention to the following. 3. Throttle plate 4. TPS Apply a thin film of injection oil to O-rings of fuel 5.
  • Page 216 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) vmr2008-022-044_a vmr2008-022-041_a Pull air intake silencer adaptor from throttle body. Pull each panel to make room. Remove seat guide. vmr2008-022-045 vmr2008-022-042_a Pull out throttle body. Remove air deflector. vmr2008-022-046 vmr2008-022-043_a Remove throttle body cover.

  • Page 217: Throttle Body Installation

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) vmr2008-022-047_a Turn throttle lever and pull out cable barrel. vmr2006-014-063_a Hook cable to throttle lever. vmr2006-014-060_b 1. Throttle lever 2. Cable barrel vmr2006-014-064_a Remove barrel from cable. Pull out throttle cable. Do not reinstall cover yet.

  • Page 218: Throttle Position Sensor (Tps)

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) TPS Wear Test While engine is not running, activate throttle and pay attention for smooth operation without physi- cal stops of the cable. Using the B.U.D.S. software, use the Throttle Opening display under Monitoring.
  • Page 219 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Use the Fluke 115 multimeter (P/N 529 035 868) WIDE OPEN THROTTLE IDLE and select Vdc. THROTTLE ADAPTER POSITION POSITION Check the voltage readings from harness connec- tor as follows. RESISTANCE @ 20°C (68°F) CONNECTOR PIN...

  • Page 220: Idle Air Control Valve

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) vmr2008-022-016_b vmr2008-022-016_c THROTTLE BODY Using the Fluke 115 multimeter (P/N 529 035 868) 1. Throttle position sensor (TPS) and select 2. Screws Check the resistance in both windings. Remove TPS. NOTE: It is easier to remove IACV to measure the TPS Installation resistance.

  • Page 221: Crankshaft Position Sensor (Cps)

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Use a throttle body cleaner such as Gunk Intake Medic or the equivalent. WARNING Only use an appropriate throttle body cleaner that will not damage O-rings, MAPS sensor and idle control valve. Clean idle air bypass in throttle body from contam- ination then use an air gun to dry it.
  • Page 222 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) NOTE: Take into account that a CPS fault If test failed, perform the resistance test. can be triggered by bent or missing encoder CPS Resistance Test wheel teeth. First check fault codes (refer to MONITORING SYSTEM/FAULT CODES ) then Use the Fluke 115 multimeter (P/N 529 035 868)

  • Page 223: Manifold Absolute Pressure Sensor (Maps)

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) MAPS Test with B.U.D.S. If resistance value is incorrect, repair the connec- tors or replace the wiring harness between ECM Start engine. connector and the CPS. Using B.U.D.S. software, read the manifold abso- lute pressure.
  • Page 224 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) vmr2008-022-024_a vmr2008-022-024_c If voltage test failed, check wiring and connectors If continuity is not good, repair or replace the from this wire to the ECM. wiring and connectors between ECM connector and the MAPS.

  • Page 225: Ambient Air Pressure And Temperature Sensor (Aapts)

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) AAPTS Resistance Test (Temperature Function) Detach AAPTS sensor from air filter housing. Re- AAPTS REMOVAL. fer to Disconnect AAPTS connector. vmr2008-022-022_c Disconnect vacuum tube from MAPS sensor. Remove MAPS sensor. MAPS Installation Install the new MAPS sensor.
  • Page 226 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) SENSOR TEMPERATURE TABLE RESISTANCE TEMPERATURE (OHMS) °C °F AAPTS - 30 - 22 26860 - 20 15614 - 10 9425 5587 vmr2008-022-005 Measure resistance as follows. 2510 1715 RESISTANCE TEST PROBES 1200 @ 20°C (68°F) Pin C3...
  • Page 227 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) TEST PROBES MEASUREMENT Pin 3 Battery (AAPTS 5 Vdc ground connector) vmr200-022-200_a If resistance value is incorrect, repair or replace wiring harness between ECM connector and the AAPTS. AAPTS Input Voltage Test vmr200-022-200_b (Pressure Function) If voltage test failed, check wiring and connectors...
  • Page 228 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) RESISTANCE TEST PROBES @ 20°C (68°F) Pin C3 Pin 1 (ECM (AAPTS) adapter) Close to 0 Pin D2 Pin 4 (ECM (AAPTS) adapter) vmr2008-022-049 Pull out sensor and unplug connector. AAPTS Installation Reverse operations for the installation.

  • Page 229: Coolant Temperature Sensor (Cts)

    Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) COOLANT TEMPERATURE Use the Fluke 115 multimeter (P/N 529 035 868) and select SENSOR (CTS) Measure resistance on the ECM adapter. Com- pare result with sensor temperature table. ECM ADAPTER Pin F4 Pin C3 SENSOR TEMPERATURE TABLE...
  • Page 230 Section 05 FUEL SYSTEM Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) vmr2008-022-028_c CTS Installation Install the new CTS. Torque CTS to 17 N•m (150 lbf•in). Reinstall remaining removed parts. Refill and bleed the cooling system. Refer to COOLING SYSTEM subsection. vmr2008-022...

  • Page 231: Fuel Tank/Fuel Pump

    Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) FUEL TANK/FUEL PUMP SERVICE TOOLS Description Part Number Page Oetiker pliers ................ 295 000 070 ......... 216 vacuum/pressure pump............529 021 800 ......... 213 pressure gauge..............529 035 709 ......... 215 Fluke 115 multimeter ............
  • Page 232 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-023-001_a vmr2008-023...

  • Page 233: General

    Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) GENERAL WARNING Do not allow fuel to spill on hot engine parts WARNING or electrical connectors. The evaporating fuel Fuel is flammable and explosive under cer- on the hot components or on the electrical tain conditions.

  • Page 234: Fuel Pump Pressure Test

    Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-024-003_a vmr2008-023-002 RH SIDE TIME WITHOUT PRESSURE PRESSURE DROP 21 kPa (3 PSI) 3 minutes If pressure drops, locate fuel leak(s). Repair or replace leaking component(s). If leak(s) can not be seen, spray soapy water on all hose connections and components;...
  • Page 235 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-023-004_a vmr2008-023-006_a Carefully pull side panels apart just enough to al- FUEL PRESSURE TEST low withdrawal of coolant tank. 1. Fuel hose quick disconnect 2. Fuel hose adapter Move coolant tank aside to make room for access 3.

  • Page 236: Procedures

    Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) PROCEDURES FUEL HOSE AND OETIKER CLAMPS Fuel Hose Replacement When replacing fuel hoses, be sure to use hoses and clamps available from the BRP parts depart- ment. This will ensure continued proper and safe operation.
  • Page 237 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-023-011_a vmr2008-023-018_a FUEL PUMP ACTIVATION IN B.U.D.S. FUEL PUMP CONNECTOR (DISCONNECTED) 1. Fuel pump 2. Fuel pump connector Fuel Pump Input Voltage Test 3. Coolant hose T-fitting From the LH side of the vehicle, locate the fuel Remove the red plastic pin lock from the connec- pump connector.
  • Page 238 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) If fuel pump motor winding resistance is not as FUEL PUMP INPUT VOLTAGE TEST per table, replace the fuel pump. TEST PROBES VOLTAGE READING Fuel Pump Relay Quick Test Pin 3 Pin 4 Battery voltage Locate the fuel pump relay.
  • Page 239 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-023-014_a vmr2008-023-013_b COOLING FAN RELAY MOVED TO FUEL PUMP RELAY SOCKET FUEL PUMP RELAY INPUT VOLTAGE Set ignition switch to ON and listen for the fuel pump. VOLTAGE TEST PROBES READING If the fuel pump functions with the replacement (cooling fan) relay, replace the fuel pump relay.
  • Page 240 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) vmr2008-139-016_a TYPICAL — ECM ADAPTER INSTALLATION 1. ECM connector 2. ECM adapter vmr2008-027-005_a Set the Fluke 115 multimeter (P/N 529 035 868) 1. Fuel pump connector 2. Fuel tank Measure the fuel pump circuity wiring continuity Remove screw securing front of coolant tank.

  • Page 241: Fuel Pump Installation

    Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) Wrap a rag around the fuel hose at the quick dis- CAUTION: While removing fuel pump, pay at- tention to the fuel level sensor (forward end connect fitting. of pump), and fuel filter (bottom of pump) to avoid deforming them.

  • Page 242: Fuel Tank

    Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) Route fuel hose as before removal and connect to fuel rail. FUEL TANK Fuel Tank Draining WARNING Never perform this operation when the en- gine and/or the exhaust system is/are hot. Never use a hose pincher on injection system high pressure hoses.
  • Page 243 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK/FUEL PUMP) WARNING Prior to disconnecting the fuel rail quick dis- connect fitting, ensure engine and exhaust system are not hot. Wrap a rag around the fuel hose at the quick dis- connect fitting. vmr2008-023-010_a TOP LH FUEL TANK MOUNTING SCREW Carefully lower the fuel tank until the filler neck...

  • Page 245: Electrical System

    Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page Fluke 115 multimeter ............529 035 868 ....228, 230, 232, 234 ECM adapter tool..............529 036 085 ......... 231, 233 SERVICE PRODUCTS Description Part Number Page Super Lube ................
  • Page 246 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) vmr2008-026-002_e vmr2008-026-001_a PF1 FUSE HOLDER 1. 20 A cooling fan fuse PF2 FUSE HOLDER 1. 20 A main fuse Ignition switch NOTE: PF2 fuse holder is located under the seat Engine “STOP” switch (RH rear corner).

  • Page 247: Procedures

    Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Intermittent Ignition Problems In dealing with intermittent problems there is no easy diagnosis. Problems that occur only during normal engine operation may be related to vibra- tions, or the engine operating temperature, and have to be tested under similar conditions.
  • Page 248 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Disconnect the ignition switch connector. vmr2008-137-001_a vmr2008-026-001_a DISCONNECT IGNITION SWITCH 1. 20 A main fuse Set the Fluke 115 multimeter (P/N 529 035 868) 5 A ECM fuse to Vdc. Measure the ignition switch input voltage as fol- lows.

  • Page 249: Engine Stop Switch

    Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) IGNITION SWITCH CONTINUITY TEST IGNITION IGNITION SWITCH RESISTANCE SWITCH PINS POSITION Pins A to F Infinite (OL) Pins C to D Pins E to F 0.2 ± 0.2 max. Pins A to F 0.2 ±...
  • Page 250 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Set the Fluke 115 multimeter (P/N 529 035 868) Measure the resistance through the stop switch (steering harness side) as per following table. ENGINE STOP SWITCH CONTINUITY TEST POSITION CONNECTOR RESISTANCE Switch to MG1 pin 3 max.
  • Page 251 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) vmr2008-139-016_a TYPICAL – ECM ADAPTER TOOL INSTALLATION 1. ECM connector 2. Adapter tool vmr2008-026-003_b Carry out the following continuity tests. Disconnect HIC1 connector. ENGINE STOP SWITCH WIRING TEST TEST PROBES RESISTANCE MG1 pin 3 HIC1 pin B (VIOLET/BEIGE) (VIOLET/BEIGE)

  • Page 252: Ignition Coil

    Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) vmr2008-024-013_a vmr2008-024-011_a 1. Front ignition coil CONNECTOR HIC1 PIN-OUT 2. VIOLET/BLUE connector housing 3. BROWN/ORANGE connector housing Repair or replace wiring/connector as applicable. IGNITION COIL The ignition coils are mounted to the top RH side frame member.
  • Page 253 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) vmr2008-139-016_a TYPICAL – ECM ADAPTER TOOL INSTALLATION vmr2008-024-013_b 1. ECM connector 2. Adapter tool IGNITION COIL INPUT VOLTAGE TEST 1. VIOLET/BLUE wire 2. BROWN/ORANGE wire Pull back the plastic connector housing on the BROWN/ORANGE wire of each coil enough to ac- If you did not read battery voltage at the cess the metal terminals.
  • Page 254 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) If the primary winding tests good, test the sec- ondary winding resistance. Secondary Winding Resistance Test Disconnect both spark plug cables from its spark plug. vmr2008-024-013_d COIL GROUND CIRCUIT CONTINUITY TEST 1. BROWN/ORANGE wire terminal Ignition Coil Resistance Tests NOTE: An ignition coil with good resistance mea- vmr2008-024-006_a...
  • Page 255 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Remove the two ignition coil mounting screws RESISTANCE @ SPARK PLUG CAP and relocate the coil outside of the frame to pro- 20°C (68°F) vide access to the two small input connectors. Coil side Spark plug side ±...

  • Page 256: Spark Plug

    Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Press and hold the start button. If nothing happens when the start button is STARTING SYSTEM pressed, refer to the section. If the starter rotates the engine and there is no spark indicated by the tester, follow the ignition system troubleshooting sequence as indicated.
  • Page 257 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Spark Plug Analysis TYPICAL 1. Overheated (light grey, white) 2. Normal (light brown, brown) vmr2008-024-009_a 3. Fouled (black, wet or dry, dark deposits, grey, melted coating) CLEAN AREA AROUND SPARK PLUGS The plug face reveals the condition of the engine, Using an approved spark plug socket, release the operating condition, method of driving and fuel spark plug torque.
  • Page 258 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Apply Super Lube (P/N 293 550 030) to the elec- trical contact inside the spark plug cap before in- stalling it on the spark plug. vmr2008-024...

  • Page 259: Charging System

    Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS Description Part Number Page digital/inductive tachometer ..........529 014 500 ......... 241–242 Fluke 111 multimeter ............529 035 868 ......... 241 SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page Extech inductive ammeter............

  • Page 260: Procedures

    Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) The voltage regulator/rectifier limits voltage to pre- The voltage regulator/rectifier could be the cause vent any damage to electrical components. of a blown fuse. To test this possibility, simply disconnect the voltage regulator/rectifier from the circuit and replace the fuse.
  • Page 261 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Select the Monitoring tab. On Monitoring page 1, read the 12 Vdc system voltage on the Battery Voltage meter and the en- gine RPM on the Engine Speed indicator as per following table. CHARGING SYSTEM VOLTAGE TEST WITH B.U.D.S.
  • Page 262 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) DC Current Test with an Inductive Ammeter Remove seat. Pull main fuse holder out of its storage compart- ment. Push back the fuse holder harness sheath enough to access its wiring for the inductive ammeter in- stallation.

  • Page 263: Battery

    Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Battery Voltage Test (No Load) If readings are not close to specification, check for the following: NOTE: A battery voltage test without a load ap- – Battery condition plied is carried out on a battery without discharg- –...

  • Page 264: Battery Removal

    Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) BATTERY VOLTAGE TEST (load applied) TIME TO MEASURE VOLTAGE INTO TEST 14 seconds Min. 10.5 Vdc If battery voltage has dropped below 10.5 Vdc, battery storage capacity has decreased apprecia- bly and battery should be replaced. Battery Removal Remove the seat.
  • Page 265 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Battery Cleaning Battery Charging With the battery removed from vehicle, clean the WARNING battery support, battery compartment, cables and Always wear safety glasses and charge in a battery posts using a solution of baking soda and well ventilated area.

  • Page 266: Electrical System Main Grounds

    Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) vmr2008-025-012_a 1. Battery support 2. Install battery support screws vmr2008-022-006_a Connect the RED (+) battery cable to the positive MAIN GROUND LOCATIONS (+) battery post. 1. Chassis ground 2. Engine ground Connect the BLACK battery cable to the negative (-) battery post.

  • Page 267: Starting System

    Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page ECM adapter tool..............529 036 085 ......... 252 GENERAL To manually rotate the engine, carry out the fol- lowing. Starting System Operation – Set the ignition switch to the “OFF” position. When the START button is pressed, 12 Vdc is ap- –...

  • Page 268: Procedures

    Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) PROCEDURES STARTER SOLENOID Solenoid Continuity Test Remove the 20 A main fuse and the 20 A charging system fuse for circuit isolation. vmr2008-026-007_a 1. Small solenoid coil wires 2. Small solenoid coil terminals Set multimeter to Measure solenoid coil resistance as follows.
  • Page 269 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) NOTE: A reading other than almost 0 indicates a bad crimp on a terminal, or corrosion within the crimped terminal leading to a high resistance and a voltage drop at the terminal. Solenoid Diode Test Disconnect small terminals from solenoid.
  • Page 270 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) CAUTION: Be sure to respect battery polarity when connecting battery cables. Connecting battery in reverse polarity could result in equip- ment damage. Always connect the RED (+) bat- tery cable first and the BLACK (-) battery cable last.
  • Page 271 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) Solenoid Dynamic Test Remove the injection and ignition fuse to prevent engine from starting. NOTE: Check engine light will flash, starter will crank engine but with an initial delay of 1 or 2 sec- onds.
  • Page 272 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) NOTE: A high voltage drop could indicate a high resistance across the solenoid contacts, or bad connections. Continuity Test of Solenoid Ground Control Circuit BODY Remove the front body assembly, refer to section.

  • Page 273: Start Button

    Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) Set parking brake. Set transmission to neutral “N” position. Set engine stop switch to “RUN”. Turn ignition switch “ON”. Set multimeter to Vdc and measure the start but- ton input voltage as follows: START BUTTON INPUT VOLTAGE TEST MG1 VEHICLE HARNESS VOLTAGE...
  • Page 274 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) MULTIFUNCTION START SWITCH RESISTANCE BUTTON CONNECTOR (MG1) Released Pin 6 Infinite (OL) (RED/VIOLET) and Depressed pin 1 max. and held (YELLOW/BLUE) If start switch does not test as specified, replace the multifunction switch assembly. If start switch tests as specified, remove the 20 A cooling fan and accessories fuse.

  • Page 275: Clutch Switch

    Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) MG1 (vehicle RESISTANCE harness side) Starter Pin 6 solenoid Close to 0 (YELLOW/RED) YELLOW/RED wire Cooling Pin 1 fan/acc. fuse Approx. 1.0 (YELLOW/BLUE) (contact “B”) vmr2008-026-003_c Set multimeter to selection. Connect the multimeter between the two clutch switch connectors (steering side) and measure the resistance as follows: CLUTCH SWITCH CONTINUITY TEST...
  • Page 276 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) vmr2008-026-013_a 1. Pull back rubber protector 2. Press up on locking tab 3. Pull switch out Note routing of clutch switch wiring and remove the switch from the handlebars. Insert new switch in clutch lever housing with alignment keys in a vertical position.

  • Page 277: Lights

    Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) LIGHTS SERVICE TOOLS Description Part Number Page Fluke 115 multimeter ............529 035 868 ....258, 260–261, 264 ECM adapter tool..............529 036 085 ......... 266 GENERAL TROUBLESHOOTING LIGHTS SYSTEM DESCRIPTION LIGHTS SYSTEM TESTING The lights system is composed of the following Lights System Testing Sequence components:...
  • Page 278 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) Measure charging system voltage at battery ter- minals, refer to CHARGING SYSTEM section. Again measure taillight/brake light input voltage. vmr2008-027-001_a 1. Taillight/brake light connector 2. Rear frame extension BODY Remove seat, refer to the section.

  • Page 279: Headlights

    Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) Test for continuity of the RED/VIOLET wire (pin 3) from the headlight power regulator connector to the taillight/brake light connector (pin 2). vmr2008-027-002_a HEADLIGHT POWER REGULATOR CONNECTOR PIN-OUT Test for battery voltage at the RED/VIOLET wire (pin 2).
  • Page 280 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) WARNING Before starting engine, ensure parking brake is set and transmission is selected to neutral “N”. Failure to comply with this procedure may result in equipment damage, severe in- jury and possible loss of life. Set the Fluke 115 multimeter (P/N 529 035 868) to Vdc and measure the headlight input voltage as per following table.

  • Page 281: Headlight Switch

    Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) HEADLIGHT SWITCH vmo2008-011-048_a Reinstall removed parts in the reverse order of their removal. vmo2008-011-008_a Headlight Beam Aiming Adjustment HEADLIGHT SWITCH FUNCTIONS 1. Headlight switch Adjust beam aiming as follows: 2. Low beam 3. High beam Using a long screwdriver, turn the adjusting screw to adjust beam height according to owner prefer- Headlight Switch Continuity Test...

  • Page 282: Taillight/Brake Light

    Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) POSITION WIRES RESISTANCE Pins 4 Switch to LO (RED/YELLOW) max. and 2 (GREEN) Pins 4 Switch to HI (RED/YELLOW) max. and 5 (BLUE) vmr2008-027-001_a 1. Taillight/brake light connector 2. Rear frame extension Set engine stop switch to “RUN”. Set ignition switch to “ON”.

  • Page 283: Neutral Indicator Light (Green)

    Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) Set ignition switch to “ON” and test both the tail- CONTINUITY TEST light and brake light functions. TAILLIGHT/BRAKE LIGHT GROUND CIRCUIT CONTROL TO Taillight/brake NEUTRAL INDICATOR LIGHT Resistance ACTUATE light connector (GREEN) NONE Pin 1 (TAILLIGHT) (BLACK wire)
  • Page 284 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) vmr2008-027-004_a NEUTRAL INDICATOR LIGHT LED TESTING If you do not obtain readings as per table, replace the LED indicator light. If the LED tested good, carry out the following tests. With the transmission set to neutral, measure the ground circuit continuity from the WHITE/GREEN vmr2008-027-003_a wire connector to ground.

  • Page 285: Check Engine Indicator Light (Yellow)

    Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) Repair or replace wiring as required. NOTE: When reconnecting the LED connectors, be sure to connect the RED/VIOLET wire to the positive (+) LED terminal or it will not function as it will be in reverse polarity. Neutral Indicator Light Removal BODY Remove dashboard, refer to...

  • Page 286: Low Fuel Level Indicator Light (Yellow)

    Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) vmr2008-027-004_a If you do not obtain readings as per previous ta- ble, replace the check engine indicator light (LED). NEUTRAL INDICATOR LIGHT Refer to in this sec- tion. vmr2008-139-016_a If you obtained readings as per table, carry out the TYPICAL 1.
  • Page 287 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) Low Fuel Level Indicator Light Testing To test the low fuel indicator light, carry out the following procedures. BODY Remove the dashboard, refer to the sec- tion. Disconnect the two wires from the indicator light. vmo2008-011-028_b 1.
  • Page 288 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) GROUND CIRCUIT CONTINUITY TEST (LOW FUEL LEVEL SENSOR) RESISTANCE PROBE POSITIONS 20°C (68°F) Fuel pump Fuel pump 1000 ± connector pin 1 connector pin 2 Fuel pump wiring BROWN/PINK wire terminal connector pin 1 at light (BROWN/PINK wire)
  • Page 289 Section 06 ELECTRICAL SYSTEM Subsection 04 (LIGHTS) If you do not obtain battery voltage, repair or re- place wiring/connectors as required. vmr2008-027-009_c GROUND CIRCUIT CONTINUITY TEST (LOW FUEL LEVEL SENSOR) 1. Pin 1 (BROWN/BLACK wire) If the low fuel level sensor resistance is not as specified at the indicated temperature, the fuel FUEL pump will have to be replaced.

  • Page 291: Drive System

    Section 07 DRIVE SYSTEM Subsection 01 (DRIVE CHAIN/REAR AXLE) DRIVE CHAIN/REAR AXLE SERVICE TOOLS Description Part Number Page bearing remover/installer tool ..........529 035 918 ......... 282 rear axle key ................. 529 036 082 ......... 279 SERVICE PRODUCTS Description Part Number Page CV grease ................
  • Page 292 Section 07 DRIVE SYSTEM Subsection 01 (DRIVE CHAIN/REAR AXLE) vmr2008-032-001_a vmr2008-032...

  • Page 293: General

    Section 07 DRIVE SYSTEM Subsection 01 (DRIVE CHAIN/REAR AXLE) GENERAL If drive chain free play is constant but out of spec- ification, adjust as follow: During assembly/installation, use the torque val- Loosen rear axle lock bolts. ues and service products as in the exploded views.

  • Page 294: Drive Chain Lubrication

    Section 07 DRIVE SYSTEM Subsection 01 (DRIVE CHAIN/REAR AXLE) Drive Chain Removal Select a level surface and set transmission to NEUTRAL. Loosen rear axle lock bolts. vmr2008-032-002_a 1. Rotated pin Measure elongation or stretching of drive chain as per following procedures: If the chain is installed on the vehicle, tension the top of chain by placing transmission on 1 gear...
  • Page 295 Section 07 DRIVE SYSTEM Subsection 01 (DRIVE CHAIN/REAR AXLE) vmr2008-032-004_a 1. Swing arm protector vmr2008-032-007_a 1. Protector screws Remove drive chain from rear sprocket. 2. Brake pedal Remove bolt securing bell crank lever to swing Remove chain guard. arm. vmr2008-032-008_a vmr2008-032-005_a 1.

  • Page 296: Front Sprocket

    Section 07 DRIVE SYSTEM Subsection 01 (DRIVE CHAIN/REAR AXLE) Position wires from indicator switches on front sprocket protector before installing it. vmr2008-032-008_a 1. Chain guard Remove and discard circlip at the center of front vmr2008-032-010 sprocket. DRIVE CHAIN AD- Adjust drive chain. Refer to JUSTMENT for the proper procedure.

  • Page 297: Rear Sprocket

    Section 07 DRIVE SYSTEM Subsection 01 (DRIVE CHAIN/REAR AXLE) REAR SPROCKET Rear Sprocket Removal Lift the rear of vehicle and install jack stands under the frame to support vehicle off the ground. Remove the RH rear wheel. Remove swing arm protector. Loosen rear sprocket nuts.

  • Page 298: Rear Axle

    Section 07 DRIVE SYSTEM Subsection 01 (DRIVE CHAIN/REAR AXLE) vmr2008-032-016 Rear Sprocket Inspection Check rear sprocket for: vmo2008-011-109_a – Distortion 1. Drive chain 2. Screwdriver pin – Excessive wear 3. Rear sprocket hub 4. Chain tensioner – Other damages. Turn the axle forward to release chain tension. Remove drive chain from rear sprocket and place it on swing arm.

  • Page 299: Rear Axle Inspection

    Section 07 DRIVE SYSTEM Subsection 01 (DRIVE CHAIN/REAR AXLE) Remove brake disc hub. Refer to BRAKE SYS- section. Using the axle key (P/N 529 036 082), unscrew the axle nut. vmr2008-032-031_a Rear Axle Inspection Check axle for: – Bending – Torsion –...

  • Page 300: Rear Sprocket Hub

    Section 07 DRIVE SYSTEM Subsection 01 (DRIVE CHAIN/REAR AXLE) REAR SPROCKET HUB Rear Sprocket Hub Removal CAUTION: Removing rear sprocket hub from rear axle will permanently damage the hub splines. Do not remove hub needlessly. REAR SPROCKET Remove , see procedure in this section.

  • Page 301: Chain Tensioner

    Section 07 DRIVE SYSTEM Subsection 01 (DRIVE CHAIN/REAR AXLE) Apply CV grease (P/N 293 550 019) on O-ring. Remove chain tensioner from the RH side. Insert a NEW hub on axle and align splines. Chain Tensioner Disassembly Using the same steel tube as for removal, press Remove and discard both seals.
  • Page 302 Section 07 DRIVE SYSTEM Subsection 01 (DRIVE CHAIN/REAR AXLE) Using a press and the bearing remover/installer tool (P/N 529 035 918), install NEW bearings. vmr2008-032-040_a 1. Special tool (P/N 529 035 918) NOTE: Sometimes, bearings can be installed with- out tools. Clean Loctite surplus.

  • Page 303: Chassis

    Section 08 CHASSIS Subsection 01 (WHEELS/TIRES) WHEELS/TIRES SERVICE PRODUCTS Description Part Number Page CV grease ................293 550 019 ......... 287–288 vmr2008-028-001_a vmr2008-028...

  • Page 304: General

    Section 08 CHASSIS Subsection 01 (WHEELS/TIRES) GENERAL Check pressure when tires are COLD before using the vehicle. Tire pressure changes with tempera- During assembly/installation, use the torque val- ture and altitude. ues and service products as in the exploded view. Recheck pressure if one of these conditions has Clean threads before applying a threadlocker.

  • Page 305: Wheel

    Section 08 CHASSIS Subsection 01 (WHEELS/TIRES) Clean inner side of wheel with alcohol to remove Using the following sequence, tighten lug nuts to grease and dust. 52 N•m (38 lbf•ft). Balance wheel using a wheel balancer. NOTE: Refer to manufacturer's instructions for wheel balancer operation.
  • Page 306 Section 08 CHASSIS Subsection 01 (WHEELS/TIRES) Remove wheel hub cap. vmr2008-028-010_a 1. Wheel hub 2. Caliper vmr2008-028-007_a Remove the outer brake pad. 1. Wheel hub cap Unfold locking washer. vmr2008-028-011_a 1. Outer brake pad vmr2008-028-008_a 1. Locking washer Pull wheel hub. 2.

  • Page 307: Rear Wheel Hub

    Section 08 CHASSIS Subsection 01 (WHEELS/TIRES) Install the wheel hub. BRAKES Install brake pad and caliper. Refer to section. Install locking washer tab into retaining washer hole. Install washers by inserting the tab into the knuck- le drilled hole. vmr2008-028-013_a 1.
  • Page 308 Section 08 CHASSIS Subsection 01 (WHEELS/TIRES) vmr2008-028-019_a vmr2008-028-022_a 1. Cotter pin 1. Wheel hub 2. Drive axle Unscrew the rear wheel hub nut. Remove the conical washer. vmr2008-028-023_a vmr2008-028-020_a 1. Conical washer 1. 41 mm socket 2. Pry bar Rear Wheel Hub Installation Remove the flat washer.

  • Page 309: Wheel Bearing

    Section 08 CHASSIS Subsection 01 (WHEELS/TIRES) Using a press and a proper extractor, push the wheel bearing out of wheel hub. Wheel Bearing Installation Place the NEW wheel bearing in a freezer for 30 minutes before installing. Clean all grease, outside and inside, from wheel hub.

  • Page 311: Steering

    Section 08 CHASSIS Subsection 02 (STEERING) STEERING SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page Smoothflow™ tapered tip ............ 16 ga ......... 294 #511 rtt-b SERVICE PRODUCTS Description Part Number Page XP-S synthetic grease............293 550 010 ......... 301 Loctite 406 (glue)..............
  • Page 312 Section 08 CHASSIS Subsection 02 (STEERING) vmr2008-029-001_a vmr2008-029...

  • Page 313: General

    Section 08 CHASSIS Subsection 02 (STEERING) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded view. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to APPLICATION at the beginning of this manual for complete procedure.

  • Page 314: Procedures

    Section 08 CHASSIS Subsection 02 (STEERING) Recheck the measurement after torquing tie-rod Install a Smoothflow™ tapered tip (P/N 16 ga lock nuts. #511 rtt-b) from EFD Inc on a bottle of Loctite 406 (glue) (P/N 293 800 100). PROCEDURES Lift a part of the grip using a small screwdriver and inject glue (about 4 spots per side).

  • Page 315: Throttle Lever

    Section 08 CHASSIS Subsection 02 (STEERING) THROTTLE LEVER Throttle Lever Removal Remove the throttle lever housing cover. vmr2008-029-011_a 1. Throttle cable end 2. Throttle lever Underneath throttle lever housing, remove screws securing the housing clamp. vmr2008-029-008_a 1. Cover screws Slide rubber protector back to expose the throttle cable adjuster.
  • Page 316 Section 08 CHASSIS Subsection 02 (STEERING) vmr2008-029-008_a vmr2008-029-011_a 1. Cover screws 1. Throttle cable end 2. Throttle lever Slide rubber protector back to expose the throttle cable adjuster. At Throttle Body BODY Remove front body assembly. Refer to section. Remove the air intake hose deflector. vmr2008-029-009_a 1.

  • Page 317: Throttle Cable Installation

    Section 08 CHASSIS Subsection 02 (STEERING) Detach throttle cable from the throttle body cam. vmr2008-029-009_a 1. Rubber protector vmr2008-029-014_a Loosen lock nut then turn the adjuster to obtain 1. Cable barrel correct throttle lever free play. Unscrew the cable from throttle body. vmr2008-029-010_a 1.

  • Page 318: Handlebar

    Section 08 CHASSIS Subsection 02 (STEERING) To ensure there is no strain in the cable at wide open position: Fully depress throttle lever and hold. Loosen adjuster lock nut/adjuster until it just re- leases lever. vmr2008-029-050_a DS 450 X 1. Leatherette cover with foam Remove the handlebar screws.

  • Page 319: Handlebar Installation

    Section 08 CHASSIS Subsection 02 (STEERING) Handlebar Installation vmr2008-029-022_a 1. LH upper attachment vmr2008-029-040_a 2. Upper brace bolt (one each side) DS 450 TIE- Detach tie-rods from steering column. See 1. Handlebar clamps 2. Reinforcement plate in this section. vmr2008-029-023_a 1.
  • Page 320 Section 08 CHASSIS Subsection 02 (STEERING) Steering Column Bearing Replacement Remove and discard cotter pin. Remove and discard the nut securing the steering column bearing. vmr2008-029-025_a 1. Bearing flanges 2. Steering column Unscrew bolts securing the steering support. vmr2008-029-027_a 1. Steering column bearing nut Remove the washer.

  • Page 321: Tie-Rod

    Section 08 CHASSIS Subsection 02 (STEERING) vmr2008-029-032_a 1. V-shaped section Install all other parts by reversing the previous procedure. However, pay attention to the follow- ing. vmr2008-029-029_a Install a NEW bearing nut. 1. Steering column bearing Install a NEW cotter pin. Both ends of cotter pins must be folded.

  • Page 322: Knuckle

    Section 08 CHASSIS Subsection 02 (STEERING) vmr2008-029-039_a A. Preliminary adjustment: 439 mm (17-9/32 in) B. Unengaged threads: 20 mm (25/32 in) vmr2008-029-033_a TIE-ROD FROM KNUCKLE Preliminary length 1. Cotter pin 2. Tie-rod end nut adjustment — dimension 439 mm (17-9/32 in) 3.
  • Page 323 Section 08 CHASSIS Subsection 02 (STEERING) Verify steering alignment. Refer to ADJUST- MENT at the beginning of this section. vmr2008-029-036_a 1. Tie-rod end 2. Knuckle Remove protective plate by removing the central screw. vmr2008-029-037_a 1. Protective plate screw 2. Knuckle Separate lower ball joint from knuckle.

  • Page 325: Front Suspension

    Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) FRONT SUSPENSION SERVICE TOOLS Description Part Number Page ball joint remover ..............529 036 121 ......... 312–315 SERVICE PRODUCTS Description Part Number Page suspension grease..............293 550 033 ......... 309 Loctite 609................413 703 100 ......... 313, 315 Loctite Chisel (gasket remover)..........
  • Page 326 Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) vmr2008-030-001_a vmr2008-030...

  • Page 327: General

    Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) GENERAL FACTORY SETTINGS During assembly/installation, use the torque val- FACTORY SETTINGS ues and service products as in the exploded view. Spring length 282 mm (11 in) Hoses or cables removed or disconnected must be installed and routed at the same place.

  • Page 328: Adjusting Suspension

    Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) ADJUSTING SUSPENSION DS 450 X Spring Preload Adjustment Shorten the spring for a firmer ride on rough trail condition. Lengthen the spring for a softer ride on smooth trail condition. Lift the front of the vehicle. Measure springs length.

  • Page 329: Maintenance

    Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) Compression (low speed) Use a flat screwdriver to adjust it. vmo2008-011-075_a 1. Rebound adjuster Turning it clockwise (H) increases shock damping vmo2008-011-057_c action (stiffer). 1. Compression adjuster Turning it counterclockwise (S) decreases shock Turning it clockwise (H) increases shock damping damping action (softer).

  • Page 330: Procedures

    Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) Remove shock absorber from vehicle. Shock Absorber Disassembly Loosen the top locking ring. Unscrew adjusting ring. vmr2008-030-020_a LOWER ARM 1. Grease fittings PROCEDURES SHOCK ABSORBER vmr2008-030-005_a Shock Absorber Removal 1. Locking ring 2. Adjusting ring Lift the front of vehicle.

  • Page 331: Upper Suspension Arm

    Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) Completely push down the shock rod then re- SHOCK ABSORBER BOLT HEAD POSITION lease. Upper shock absorber bolt Forward NOTE: Because of gas pressure, strong resis- Lower shock absorber bolt Rearward tance is felt when compressing shock. The shock should extend unassisted.

  • Page 332: Upper Ball Joint

    Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) UPPER BALL JOINT Upper Ball Joint Inspection Inspect ball joint end for damage. Ensure it's moving freely without play. Replace ball joint as required. Upper Ball Joint Removal UPPER SUSPENSION ARM Remove , see proce- dure above.

  • Page 333: Lower Suspension Arm

    Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) Apply a thin layer of Loctite 609 (P/N 413 703 100) If necessary, remove suspension arm and inspect on ball joint head and inside the suspension arm pivot bushings and sleeves for wear or damages. bore.

  • Page 334: Lower Ball Joint

    Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) vmr2008-030-017_a 1. Shock absorber lower bolt vmr2008-030-026_a 2. Lower suspension arm 1. Front suspension plate 2. Lower suspension arm front bolt Separate ball joint from knuckle. 3. Lower suspension arm Remove bolts retaining lower suspension arm to CAUTION: Do not omit this plate.
  • Page 335 Section 08 CHASSIS Subsection 03 (FRONT SUSPENSION) Wipe any excess of adhesive product. Install the circlip. LOWER SUSPENSION ARM Install , see proce- dure in this section. vmr2008-030-022_a 1. Ball joint remover 2. Press Lower Ball Joint Installation Cured product on suspension arm can be removed using a combination of Loctite Chisel (gasket re- mover) (P/N 413 708 500) and a brass wire brush.

  • Page 337: Rear Suspension

    Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) REAR SUSPENSION SERVICE TOOLS Description Part Number Page needle bearing installer............529 036 109 ......... 324 SERVICE PRODUCTS Description Part Number Page dielectric grease ..............293 550 004 ......... 322 suspension grease..............293 550 033 ......320, 325–326 vmr2008-031...
  • Page 338 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) vmr2008-031-001_a vmr2008-031...

  • Page 339: General

    Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) GENERAL Shock Absorber Compression Damping During assembly/installation, use the torque val- ues and service products as in the exploded views. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to APPLICATION at the beginning of this manual for complete procedure.

  • Page 340: Maintenance

    Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) vmo2008-011-076_a vmo2008-011-077_a PRELOAD ADJUSTMENT 1. Rebound adjuster (flat screwdriver) Step 1: Loosen top locking ring Step 2: Turn adjusting ring accordingly Step 3: Tighten top locking ring MAINTENANCE Shock compression and Rebound Adjustment LUBRICATION Perform adjustments one position (click) at a time.

  • Page 341: Procedures

    Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) PROCEDURES SHOCK ABSORBER Shock Absorber Removal Remove seat. Remove screws securing both rear ends of fascia. vmr2008-031-002_a UNDERNEATH SWING ARM 1. Cotter pin 2. Lower bolt 3. Shock absorber 4. Bell crank lever Remove bolt securing bell crank lever to swing arm.

  • Page 342: Spring

    Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) – Dents Apply dielectric grease (P/N 293 550 004) on O-rings. – Abnormal wear. Check piston rod for: SPRING – Straightness – Wear Spring Removal – Nicks WARNING – Burrs. SPRING Remove , see procedure in this section. –...

  • Page 343: Swing Arm

    Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) SWING ARM Remove front sprocket. Refer to FRONT SPROCKET DRIVE TRAIN section for the Swing Arm Removal procedure. NOTE: Wheel hubs, brake disc, rear sprocket, rear Remove bolt securing bell crank lever to swing axle and chain tensioner should be removed on- arm.
  • Page 344 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) – Cracks – Other damages. Replace swing arm with a new one if damaged. With your finger nail, feel bearing contact surfaces of bushing. If any irregular surface is found, re- place bushing and needle bearings. Check needle bearings.

  • Page 345: Bell Crank Lever

    Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) vmr2008-031-020_a SECOND BEARING 1. Needle bearing vmr2008-031-014_a 2. Needle bearing installer UNDERNEATH SWING ARM 1. Pivot arm Apply suspension grease (P/N 293 550 033) on the 2. Bell crank lever 3. Remove bolt and nut inner face of needle bearings.

  • Page 346: Pivot Arm

    Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) WITH GREASE FITTING (SEAL LIPS FACE OUTWARD) vmr2008-031-023_a 1. Bushing WITHOUT GREASE FITTING (SEALS LIPS TOWARD NEEDLE BEARINGS) Remove and discard seals. Insert bushing. vmr2008-031-024_a Bell Crank Lever Installation 1. Seal Position the longest radius of bell crank lever up- Remove and discard needle bearing(s) by using ward.
  • Page 347 Section 08 CHASSIS Subsection 04 (REAR SUSPENSION) vmr2008-031-033_a 1. Seal Remove and discard needle bearings by using the vmr2008-031-014_a SWING ARM DISASSEM- procedure described in UNDERNEATH SWING ARM 1. Pivot arm 2. Bell crank lever 3. Remove bolt and nut BODY Remove the RH footrest.

  • Page 349: Brakes

    Section 08 CHASSIS Subsection 05 (BRAKES) BRAKES SERVICE TOOLS Description Part Number Page vacuum/pressure pump............529 021 800 ......... 334 axle key................. 529 036 082 ......... 345 blind hole puller kit..............529 036 117 ......... 343 SERVICE PRODUCTS Description Part Number Page CV grease ................

  • Page 350: Front Brakes

    Section 08 CHASSIS Subsection 05 (BRAKES) FRONT BRAKES vmr2008-033-001_a vmr2008-033...

  • Page 351: Rear Brake

    Section 08 CHASSIS Subsection 05 (BRAKES) REAR BRAKE vmr2008-033-003_a vmr2008-033...

  • Page 352: General

    Section 08 CHASSIS Subsection 05 (BRAKES) GENERAL Parking Brake To engage mechanism: Squeeze front brake During assembly/installation, use the torque val- lever and maintain while moving lever lock with a ues and service products as in the exploded view. finger. Front brake lever is now compressed and Clean threads before applying a threadlocker.
  • Page 353 Section 08 CHASSIS Subsection 05 (BRAKES) Brake Fluid Replacement Add brake fluid when required. Do not overfill. Clean reservoir cover before removing. To replace brake fluid, drain the brake circuit com- pletely then refill and bleed. Immediately wipe out any spills. Brake Fluid Draining Front Brake Fluid Reservoir Turn handlebar in the straight-ahead position to en-...

  • Page 354: Procedures

    Section 08 CHASSIS Subsection 05 (BRAKES) vmr2008-033-062_a vmr2008-033-062_a 1. Good position 1. Good position 2. To avoid 2. To avoid Check brakes operation carefully before riding the Check brakes operation carefully before riding the vehicle. vehicle. Bleeding Procedure Using a Vacuum Pump: PROCEDURES Install the vacuum/pressure pump (P/N 529 021 800) to bleeder.
  • Page 355 Section 08 CHASSIS Subsection 05 (BRAKES) vmr2008-033-008_a 1. Guide pins vmr2008-033-005_a Rear Caliper 1. Protector 2. Caliper Park the vehicle on a firm level surface. NOTE: If the caliper is not replaced, omit the next Unscrew caliper screws. steps concerning the brake system draining and brake hose removal.

  • Page 356: Brake Pads

    Section 08 CHASSIS Subsection 05 (BRAKES) Caliper Inspection Check pistons for: – Rust – Scratches – Leaks. vmr2008-033-016_a Check caliper support for: 1. Groove on pad lining – Cracks A. Brake pad minimum thickness 1 mm (1/32 in) – Wear. SERVICE LIMIT Replace caliper support if required.
  • Page 357 Section 08 CHASSIS Subsection 05 (BRAKES) vmr2008-033-018_a vmr2008-033-015_a 1. Caliper screws PULL BRAKE PAD PIN Remove brake pad screws. Depress pistons into their bores. CAUTION: It's very important to clean remain- ing O.D. of pistons out from caliper with brake fluid before pushing pistons back in.

  • Page 358: Brake Disc

    Section 08 CHASSIS Subsection 05 (BRAKES) Replace brake disc as required. Measure thickness of the disc. BRAKE DISC THICKNESS Minimum thickness 3.5 mm (.13 in) CAUTION: Brake discs should never be ma- chined. Replace disc if not within specifications. vmr2008-033-021_a Turn the disc by hand and check run out.

  • Page 359: Brake Lever

    Section 08 CHASSIS Subsection 05 (BRAKES) BRAKE LEVER Brake Lever Replacement NOTE: The removal of master cylinder is not nec- essary to disassemble it. Remove brake lever pivot by removing the circlip underneath lever. vmr2008-033-042_a 1. Inner lever 2. Circlip 3.

  • Page 360: Front Master Cylinder

    Section 08 CHASSIS Subsection 05 (BRAKES) Unscrew master cylinder screws. vmr2008-033-045_a 1. Apply grease here vmr2008-033-028_a 1. Master cylinder screws FRONT MASTER CYLINDER Remove BRAKE LEVER , see procedure in this sec- Front Master Cylinder Removal tion. NOTE: If the master cylinder is not replaced, omit Front Master Cylinder Installation the next step concerning the parking brake lever and the brake system draining.
  • Page 361 Section 08 CHASSIS Subsection 05 (BRAKES) vmr2008-033-033_a vmr2008-033-030_a 1. Cotter pin (discard) 1. Brake light switch connector 2. Brake pedal 2. Air filter housing 3. Retaining pin 4. Hook Drain brake fluid from rear brake circuit. See BRAKE FLUID DRAINING Disconnect reservoir hose from master cylinder.

  • Page 362: Rear Master Cylinder Installation

    Section 08 CHASSIS Subsection 05 (BRAKES) Rear Master Cylinder Assembly The assembly is the reverse of the disassembly procedure. However, pay attention to the follow- ing. Apply brake fluid on both seals. Apply lithium grease such as the jet pump bearing grease (P/N 293 550 032) on the end of master piston.
  • Page 363 Section 08 CHASSIS Subsection 05 (BRAKES) vmr2008-033-052_a vmr2008-033-049_a NOTE: If the inner bearing outer race stays inside 1. Brake pedal spring the frame, the swing arm removal is necessary. Use a blind hole puller from the blind hole puller Remove pin securing brake pedal to master cylin- kit (P/N 529 036 117) to extract the outer race.

  • Page 364: Brake Disc Hub

    Section 08 CHASSIS Subsection 05 (BRAKES) CAUTION: Do not let the caliper hang by the hose and do not stretch or twist the hose. Unfold locking washer. Remove brake hub screws. vmr2008-033-054_a 1. Bolt 2. Large washer 3. Bearing 4. Washer (bearing diameter) 5.

  • Page 365: Front Brake Light Switch

    Section 08 CHASSIS Subsection 05 (BRAKES) Using the axle key (P/N 529 036 082), unscrew the axle nut. vmr2008-033-057_a 1. Rear caliper bracket 529036082 Rear Caliper Bracket Installation For installation, reverse the removal procedure. FRONT BRAKE LIGHT SWITCH Front Brake Light Switch Test BODY Refer to section to remove the front body...

  • Page 366: Rear Brake Light Switch

    Section 08 CHASSIS Subsection 05 (BRAKES) vmr2008-033-025_a 1. Brake light switch connector vmr2008-033-030_a 1. Brake light switch connector Unscrew brake light switch and discard the sealing 2. Air filter housing washers. Check switch operation as follows. BRAKE LIGHT RESISTANCE @ SWITCH POSITION 20°C (68°F) Firmly pushed...

  • Page 367: Flexible Brake Hose

    Section 08 CHASSIS Subsection 05 (BRAKES) Support vehicle securely on jack stands. Remove front wheels. BRAKE FLUID DRAINING Drain brake fluid, see this section. Remove the front body assembly. Refer to BODY section. Unplug the brake light switch connector. vmr2008-033-030_a 1.
  • Page 368 Section 08 CHASSIS Subsection 05 (BRAKES) Wipe brake fluid spillage. Discard sealing washers. Empty hose into a drain pan. Unscrew bolt securing the T-union to frame. vmr2008-033-030_a 1. Brake light switch connector 2. Air filter housing Drain brake fluid from rear brake circuit. See BRAKE FLUID DRAINING at the beginning of this section.
  • Page 369 Section 08 CHASSIS Subsection 05 (BRAKES) vmr2008-033-061_a 1. Brake hose 2. Caliper recess 3. Front caliper After front brake hoses installation, turn handlebar fully right and fully left to be sure that the brake hose does not rub against wheel hub or suspen- sion arm.

  • Page 371: Body

    Section 08 CHASSIS Subsection 06 (BODY) BODY BODY PARTS vmr2008-035-001_a vmr2008-035...
  • Page 372 Section 08 CHASSIS Subsection 06 (BODY) vmr2008-035-002_a vmr2008-035...
  • Page 373 Section 08 CHASSIS Subsection 06 (BODY) SEAT vmr2008-035-003_a vmr2008-035...

  • Page 374: General

    Section 08 CHASSIS Subsection 06 (BODY) GENERAL PROCEDURES During assembly/installation, use the torque val- DECALS ues and service products as in the exploded views. Decal Removal Clean threads before applying a threadlocker. Re- Using a heat gun (low heat setting) warm up one SELF-LOCKING FASTENERS LOCTITE fer to...

  • Page 375: Seat Installation

    Section 08 CHASSIS Subsection 06 (BODY) vmo2008-011-026_c vmo2008-011-031_a 1. Seat latch 1. Upper slot 2. Middle tab Pull latch rearward while gently lifting rear of seat. Continue lifting movement until you can release WARNING seat retaining devices, then completely remove Make sure seat is securely latched before rid- seat.

  • Page 376: Access Cover

    Section 08 CHASSIS Subsection 06 (BODY) ACCESS COVER FRONT BUMPER Access Cover Removal Front Bumper Removal Remove seat. Remove bolts securing front bumper to frame. Unscrew fuel tank cap. Lift front edge of access cover. Release access cover tabs from front fascia. vmr2008-035-006_a TYPICAL 1.
  • Page 377 Section 08 CHASSIS Subsection 06 (BODY) vmr2008-035-011_a vmr2008-035-008_a 1. Headlamp connector 2. Screw to remove 1. Remove these screws 2. Coolant reservoir Remove headlamp support screw. Remove screws at the rear end of front fascia (two on each sides). vmr2008-035-012_a 1.

  • Page 378: Front Fender

    Section 08 CHASSIS Subsection 06 (BODY) Remove front fender. Front Fender Installation The installation is the reverse of removal proce- dure. FRONT GRILLE Front Grille Removal Remove the bottom screw of front grille. vmr2008-035-014_a Remove both screws holding front grille to side Step 1: Move the ends of fascia away panels.

  • Page 379: Front Fascia

    Section 08 CHASSIS Subsection 06 (BODY) vmr2008-035-019_a Side Panel Installation vmr2008-035-021_a Remove footrest. Installation is the reverse order of removal. Footrest Installation FRONT FASCIA Installation is the reverse order of removal. Front Fascia Removal NOTE: Install all bolts before torquing. Remove the following components as detailed elsewhere in this section: FOOTREST SUPPORT...

  • Page 380: Rear Bumper

    Section 08 CHASSIS Subsection 06 (BODY) Rear Bumper Installation Installation is the reverse order of removal. NOTE: Install all bolts before torquing. ENGINE SKID PLATE DS 450 X Skid Plate Inspection vmr2008-035-023_a The skid plate protects the engine and the frame. 1.

  • Page 381: Nerf Bar

    Section 08 CHASSIS Subsection 06 (BODY) NERF BAR Nerf Bar Installation Installation is essentially the reverse of removal DS 450 X procedure but pay attention to the following: Nerf Bar Removal After installing the net strap on the frame, make sure to tight it properly.

  • Page 383: Frame

    Section 08 CHASSIS Subsection 07 (FRAME) FRAME vmr2008-036-100_a vmr2008-036...

  • Page 384: General

    Section 08 CHASSIS Subsection 07 (FRAME) GENERAL CAUTION: Never direct high-pressure water jet towards decals. They will peel off. During assembly/installation, use the torque val- Clean frame with a special cleaner specially for- ues and service products as in the exploded view. mulated for anodized aluminum (follow manufac- turer's instructions).

  • Page 385: Rear Engine Supports

    Section 08 CHASSIS Subsection 07 (FRAME) On both sides, remove bolts securing the rear CAUTION: Make sure do not use elastic stop nuts to secure rear frame extension bolts. The frame extension to frame. plastic inside elastic stop nuts could melt due to the exhaust system heat and their efficiency could be reduced.

  • Page 386: Side Member

    Section 08 CHASSIS Subsection 07 (FRAME) Unscrew and discard bolts securing footrest sup- port to footpeg. vmr2008-036-009_a 1. Side member front bolt 2. Shock absorber upper bracket Remove front fender support screw. vmr2008-036-007_a 1. Footrest support bolts 2. Footrest support 3.

  • Page 387: Lower Suspension Arm Attachments

    Section 08 CHASSIS Subsection 07 (FRAME) CAUTION: A special fastener grade is used for this assembly. Make sure to use the proper bolts when installing suspension arm attach- ments. vmr2008-036-012_a Step 1: Slide forward Step 2: Move the end outside Step 3: Move rearward to remove Side Member Installation...
  • Page 389 1.8 L (1.9 quarts) (oil change with filter) XP-S 5W40 synthetic oil. Engine oil Do not use other synthetic oil, synthetic Recommended blend oil or additive in Can-Am ATV wet clutch equipped vehicles Intake valve opening 12° BTDC Intake valve closing 48° ABDC Exhaust valve opening 64°...
  • Page 390 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (DS 450/DS 450 X) MODEL DS 450 DS 450 X ENGINE (cont'd) mm (in) 33.459 to 33.475 (1.3173 to 1.3179) Valve lifter bucket diameter Service limit mm (in) 33.440 (1.3165) Valve lifter bucket radial clearance Service limit mm (in) 0.08 (.0032)
  • Page 391 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (DS 450/DS 450 X) MODEL DS 450 DS 450 X ENGINE (cont'd) mm (in) 23.967 to 23.980 (.9436 to .9441) Camshaft bearing journal Service limit mm (in) 23.950 (.9429) mm (in) 24.007 to 24.020 (.9452 to .9457) Camshaft bearing journal bore Service limit mm (in)
  • Page 392 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (DS 450/DS 450 X) MODEL DS 450 DS 450 X ENGINE (cont'd) GEARBOX (cont'd) mm (in) 3.54 to 3.60 (.139 to .142) Shift fork claw thickness Service limit mm (in) 3.40 (.134) mm (in) 24.007 to 24.020 (.9452 to .9457) Diameter of free pinion on clutch shaft and 5...
  • Page 393 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (DS 450/DS 450 X) MODEL DS 450 DS 450 X ELECTRICAL SYSTEM (cont'd) Taillight 5/21 Indicator lights LEDS, 0.7 V approximately (each) Charging system Main Cooling fan and Fuses accessories Injector and ignition Engine control module (ECM) FUEL SYSTEM Electronic Fuel Injection (EFI), Dell'Orto 46 mm...
  • Page 394 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (DS 450/DS 450 X) MODEL DS 450 DS 450 X SUSPENSION (cont'd) REAR Suspension type Rigid swing arm Suspension travel mm (in) 267 (10.5) Shock absorber Type Spring free length mm (in) 274.3 (10.8) White/Black/White Spring color code Rear preload adjustment...
  • Page 395 Section 09 TECHNICAL SPECIFICATIONS Subsection 01 (DS 450/DS 450 X) MODEL DS 450 DS 450 X DIMENSION Overall length m (in) 1.83 (72) Overall width m (in) 1.17 (46) Overall height m (in) 1.06 (42) Wheel base m (in) 1.27 (50) Front mm (in) 1000 (39.5)

  • Page 397: Wiring Diagram

    Section 10 WIRING DIAGRAM Subsection 01 (DS 450/DS 450 X) DS 450/DS 450 X WIRING DIAGRAM Connector Identification Indicates the connector individually. If there are NOTE: The wiring diagram is on the last page of many connectors in the same area this helps to the manual.
  • Page 399 NOTES...
  • Page 400 NOTES...

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Ds 450 x 2008

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