BOMBARDIER Traxter 7400 Shop Manual

Bombardier 1999 atv shop manual

Hide thumbs

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

166

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

188

189

190

191

192

193

194

195

196

197

198

199

200

201

202

203

204

205

206

207

208

209

210

211

212

213

214

215

216

217

218

219

220

221

222

223

224

225

226

227

228

Table of Contents

Quick Links

SECTION

SAFETY NOTICE ...................................................................................................................................

WHAT'S NEW .......................................................................................................................................

INTRODUCTION ..................................................................................................................................

SYSTEM

SUBSECTION

01 - Table of contents...................................................................... 01-01-1

02 - Service tools............................................................................. 01-02-1

03 - Service products....................................................................... 01-03-1

01 - Table of contents...................................................................... 02-01-1

02 - Maintenance chart.................................................................... 02-02-1

03 - Maintenance and lubrication .................................................... 02-03-1

04 - Storage and pre-season preparation......................................... 02-04-1

01 - Table of contents...................................................................... 03-01-1

02 - Removal and installation........................................................... 03-02-1

03 - Cooling system......................................................................... 03-03-1

04 - Rewind starter.......................................................................... 03-04-1

01 - Table of contents...................................................................... 04-01-1

02 - Fuel circuit ................................................................................ 04-02-1

03 - Carburetor and fuel pump ........................................................ 04-03-1

04 - Air intake silencer ..................................................................... 04-04-1

01 - Table of contents...................................................................... 05-01-1

02 - Overview .................................................................................. 05-02-1

03 - Charging system ...................................................................... 05-03-1

04 - Starting system ........................................................................ 05-04-1

05 - Ignition system......................................................................... 05-05-1

06 - Electric shift system................................................................. 05-06-1

07 - Instruments and accessories ................................................... 05-07-1

01 - Table of contents...................................................................... 06-01-1

02 - Front differential ....................................................................... 06-02-1

03 - Rear axle................................................................................... 06-03-1

01 - Table of contents...................................................................... 07-01-1

02 - Steering/control systems ......................................................... 07-02-1

01 - Table of contents...................................................................... 08-01-1

02 - Front suspension...................................................................... 08-02-1

03 - Rear suspension....................................................................... 08-03-1

01 - Table of contents...................................................................... 09-01-1

02 - Hydraulic brakes ....................................................................... 09-02-1

TABLE OF CONTENTS

PAGE

III

Chapters

Table of Contents

Troubleshooting

Need help?

Do you have a question about the Traxter 7400 and is the answer not in the manual?

Questions and answers

Summary of Contents for BOMBARDIER Traxter 7400

Page 1: Table Of Contents
TABLE OF CONTENTS SECTION SUBSECTION PAGE SAFETY NOTICE ........................... WHAT’S NEW ............................INTRODUCTION ..........................SERVICE TOOLS AND 01 – Table of contents..............01-01-1 SERVICE PRODUCTS 02 – Service tools................01-02-1 03 – Service products............... 01-03-1 MAINTENANCE 01 – Table of contents..............02-01-1 02 –...
Page 2 TABLE OF CONTENTS SECTION SUBSECTION PAGE BODY/FRAME 01 – Table of contents ..............10-01-1 02 – Body..................10-02-1 03 – Frame..................10-03-1 TECHNICAL DATA 01 – SI metric information guide............11-01-1 02 – Engine and vehicle ..............11-02-1 WIRING DIAGRAM 01 –...
Page 3: Introduction
TRAXTER* (Canada) ........ 7400 TRAXTER* (Canada) ........ 7413 TRAXTER* (Canada) ........ 7415 TRAXTER* (Canada) ........ 7417 TRAXTER* (U.S.)........7401 TRAXTER* (U.S.)........7414 TRAXTER* (U.S.)........7416 TRAXTER* (U.S.)........7418 *Trademark of Bombardier Inc. 1. Engine 2. Vehicle 1. Model number http://ReadManuals.com...
Page 4 INTRODUCTION Serial Number Meaning 10 11 12 13 14 15 16 17 10 11 12 13 14 15 16 17 http://ReadManuals.com...
Page 5: 01 Service Tools And Service Products
INTRODUCTION ARRANGEMENT OF THE inch MANUAL in² square inch The manual is divided into 12 major sections: in³ cubic inch 01 SERVICE TOOLS AND SERVICE PRODUCTS kilo (thousand) 02 MAINTENANCE kilogram 03 ENGINE km/h kilometer per hour 04 FUEL SYSTEM kilo pascal 05 ELECTRICAL liter...
Page 6 INTRODUCTION This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. Page heading indicates section and subsection detailed. Section 03 ENGINE REMOVAL AND INSTALLATION Subsection title indicates beginning of the subsection. Exploded view assists you in identifying parts and Ti ghtening torque...
Page 7 INTRODUCTION Section 03 ENGINE Title indicates main procedure Place the vehicle on jackstands and place the shifter to be carried out. on park position Remove front wheels Drain engine oil and engine coolant Remove seat, front and rear fenders, inner fend- ers, side panels, steering cover, shifter guide cov- er and skid plate Refer to the section 09-02 BODY Disconnect BLACK negative cable from battery,...
Page 8: General Information
(when sitting on tion and/or specifications in this document. vehicle). Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation.
Page 9: Tightening Torques
INTRODUCTION TIGHTENING TORQUES N•m FASTENER SIZE (8.8) Lbf•ft Tighten fasteners to torque mentioned in explod- ed views and text. When they are not specified refer to following table.The table also gives the metric conversion. N•m FASTENER SIZE (8.8) Lbf•in http://ReadManuals.com...
Page 10 INTRODUCTION N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS http://ReadManuals.com...
Page 11: Table Of Contents
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS SERVICE TOOLS 01-02-1 ENGINE — MANDATORY SERVICE TOOLS ..............01-02-2 ENGINE — RECOMMENDED SERVICE TOOLS .............. 01-02-3 ELECTRICAL — MANDATORY SERVICE TOOLS ............01-02-5 ELECTRICAL — RECOMMENDED SERVICE TOOLS ............01-02-6 SUSPENSION —...
Page 12: Service Tools
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) SERVICE TOOLS This is a list of tools to properly service ATV vehicle. If you need to replace or add to your tool inventory these items can be ordered through the regular parts channel. Following mention points out new tool: 01-02-1 http://ReadManuals.com...
Page 13: Engine - Mandatory Service Tools
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) ENGINE — MANDATORY SERVICE TOOLS Lifting bar Spanner tool for clutch basket Magneto puller (P/N 529 035 610) (P/N 529 035 647) (P/N 529 035 547) V01B094 V01B0B4 Small hose pincher F01B294 (P/N 529 009 900) Crankshaft locking bolt...
Page 14: Engine - Recommended Service Tools
Subsection 02 (SERVICE TOOLS) ENGINE — RECOMMENDED SERVICE TOOLS Sub-transmission positioner Ring compressor Handle for insertion jig (P/N 529 035 651) Not sold by Bombardier (P/N 420 877 650) Snap-on RCW60 V01B0E4 Oil pressure gauge (1 to 8 bar) (P/N 529 035 652)
Page 15 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) ENGINE — RECOMMENDED SERVICE TOOLS (continued) Engine stand (P/N 529 035 646) V01B0J4 01-02-4 http://ReadManuals.com...
Page 16: Electrical - Mandatory Service Tools
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) ELECTRICAL — MANDATORY SERVICE TOOLS Six-pin magneto harness (P/N 529 035 654) F01B284 T-Harness for diagnoses of solenoids (P/N 529 035 653) V01B0L4 Jumper for self-diagnoses (P/N 529 035 605) V01B0M4 01-02-5 http://ReadManuals.com...
Page 17: Electrical - Recommended Service Tools
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) ELECTRICAL — RECOMMENDED SERVICE TOOLS Crimping tool (P/N 295 100 164) F00B0E4 Terminal remover Not sold by Bombardier Snap-on TT 600-4 F01B1J4 Multimeter (P/N 529 022 000) F01B1O4 01-02-6...
Page 18: Suspension - Mandatory Service Tools
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) SUSPENSION — MANDATORY SERVICE TOOLS Front suspension space bar (P/N 529 035 611) V01B0N4 01-02-7 http://ReadManuals.com...
Page 19: Suspension - Recommended Service Tools
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) SUSPENSION — RECOMMENDED SERVICE TOOLS Shock spring removal kit (P/N 529 027 100) Replacement clevis pin: (P/N 414 528 400) A01B4O4 01-02-8 http://ReadManuals.com...
Page 20: Drive - Mandatory Service Tools
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) DRIVE — MANDATORY SERVICE TOOLS Pliers (P/N 295 000 069) Oetiker 1090 F01D184 Pliers (P/N 295 000 054) Caillau F01B1T4 Hub puller (P/N 529 035 612) V01B0O4 01-02-9 http://ReadManuals.com...
Page 21: Drive - Recommended Service Tools
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) DRIVE — RECOMMENDED SERVICE TOOLS Differential spanner socket (P/N 529 035 649) V01B0S4 01-02-10 http://ReadManuals.com...
Page 22: Vehicle - Mandatory Service Tools
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) VEHICLE — MANDATORY SERVICE TOOLS 41 mm socket for swing arm nut (P/N 529 035 650) V01B0T4 01-02-11 http://ReadManuals.com...
Page 23: Vehicle - Recommended Service Tools
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) VEHICLE — RECOMMENDED SERVICE TOOLS Flexible spout for oil container (P/N 414 837 300) F04B044 01-02-12 http://ReadManuals.com...
Page 24: Service Products
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 03 (SERVICE PRODUCTS) SERVICE PRODUCTS MANDATORY SERVICE PRODUCTS ® Loctite is a trademarks of Loctite Corporation. ® Permatex is a trademark of Loctite™ Corporation. ® Dow Corning is a trademarks of Dow Corning Corporation. Primer for gasket eliminator Medium strength The Right Stuff (sealant)
Page 25: Recommended Service Products
236 mL (8 oz) Loctite anti-seize Permatex ® 48 TA lubricant 454 g (16 oz) 433 g (15 oz) F01B174 Bombardier storage oil (P/N 413 711 600) A00B3V4 A00B3K4 (12 x 350 g) Paste gasket Plastic & vinyl cleaner (P/N 413 702 700)
Page 26: Maintenance
Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS MAINTENANCE CHART ......................02-02-1 NOISE EMISSION CONTROL SYSTEM REGULATION ........... 02-02-1 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! ........02-02-1 AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: ....................02-02-1 MAINTENANCE CHART ....................
Page 27: Maintenance Chart
Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART) MAINTENANCE CHART NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law and Canadian provincial laws may prohibit the following acts or the causing there of: 1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2.
Page 28: Maintenance Chart
Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART) MAINTENANCE CHART LUBRICATION AND MAINTENANCE CHART Engine/transmission oil level Engine/transmission oil and filter replacement 02-02 Spark arrester (cleaning) Engine mount fasteners 03-02 Exhaust system (leak) Condition of seals N.A. Coolant density 02-04 ENGINE/ Coolant level TRANSMISSION Coolant replacement...
Page 29 Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART) LUBRICATION AND MAINTENANCE CHART Throttle condition 04-03 Choke condition Handlebar fastener tightness Steering system mechanism 07-02 STEERING/ Tie rod ends inspection CONTROL Steering adjustment SYSTEMS Tire pressure Wheel mount tightness and stud lubrication 02-02 Wear and condition of tires Front wheel alignment...
Page 30: Maintenance And Lubrication
Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) MAINTENANCE/LUBRICATION AIR FILTER CLEANING/DRAINING When water/deposits are found, air filter must be inspected/dried/replaced depending on its condi- tion. Air Filter Box Draining Remove air filter as explained below. Periodically inspect air filter box drain plugs for wa- ter or deposits.
Page 31: Bolts, Fasteners And Nuts
Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) Properly reinstall removed parts in the reverse or- der of their removal. BOLTS, FASTENERS AND NUTS Check that all fasteners, bolts and nuts are tight- ened to the proper torque. ENGINE OIL AND FILTER Oil Viscosity SAE 10W40 is recommended for general use.
Page 32: Spark Arrester
Discard filter. Be sure that the old filter O-ring is removed. CAUTION: Only use Bombardier high pressure filter. The Bombardier filter is specifically de- signed for this engine. This filter does not op- erate at the same pressure than other brands.
Page 33: Tires And Wheels
Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) WARNING TIRE PRESSURE Never run engine in an enclosed area. FRONT REAR RECOMMENDED 48 kPa 38 kPa Never perform this operation immediately af- (7 PSI) (5.5 PSI) ter the engine has been run because exhaust system is very hot.
Page 34: Engine Compartment
Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) Wheel Removal Untighten nuts then lift vehicle where needed. Place a support under vehicle. Remove nuts then withdraw wheel. At installation, it is recommended to apply anti- seize lubricant on threads. Gently tighten nuts in a criss-cross sequence then apply a final torque of 75 N•m (55 lbf•ft).
Page 35: Storage And Pre-Season Preparation
Bristol Myers, available at hardware stores or supermarkets. – Inject storage oil until the engine stalls or until CAUTION: Do not use Bombardier Cleaner on a sufficient quantity of oil has entered the en- decals, plastic parts or vinyl.
Page 36: Coolant Density
Inspect the vehicle and repair any damage. Touch up all metal spots where paint has been scratched off. Spray all metal parts with BOMBARDIER LUBE (P/N 293 600 016). NOTE: Protect the vehicle with a cover to prevent dust accumulation during storage.
Page 37: Pre-Season Preparation
Section 02 MAINTENANCE Subsection 04 (STORAGE/PRE-SEASON PREPARATION) PRE-SEASON PREPARATION TO BE PERFORMED BY SYSTEM PRE-SEASON OPERATIONS REFER TO CUSTOMER DEALER ENGINE/ Test Run Vehicle. Check Clutch and Transmission Operation N.A. TRANSMISSION Engine Oil and Filter Oil Replacement Section 02-02 Coolant Replacement and Pressurization of System Section 03-04 Condition of Seals N.A.
Page 38: Engine
Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS REMOVAL AND INSTALLATION ..................03-02-1 ENGINE REMOVAL ......................03-02-2 ENGINE INSTALLATION ....................03-02-4 ANTI-VIBRATION SYSTEM....................03-02-4 EXHAUST SYSTEM ......................03-02-5 SHIFTING SYSTEM......................03-02-6 COOLING SYSTEM ....................... 03-03-1 COOLING SYSTEM LEAK TEST ..................03-03-2 INSPECTION ........................
Page 39 Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) CRANKSHAFT/BALANCER SHAFT ..................03-07-1 1, CAMSHAFT........................03-07-2 2, BALANCER SHAFT......................03-07-3 3, CRANKSHAFT ........................ 03-07-3 LUBRICATION SYSTEM......................03-08-1 TROUBLESHOOTING......................03-08-2 ENGINE PRESSURE TEST ....................03-08-2 OIL CHANGE AND OIL FILTER REPLACEMENT .............. 03-08-2 OIL STRAINER ........................
Page 40: Removal And Installation
Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION 32 26 30 2 03-02-1 VMR9932_03_02.FM http://ReadManuals.com...
Page 41: Engine Removal
Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION) ENGINE REMOVAL FRONT VIEW UNDER ENGINE 1. Clutching and clutch modulator solenoids connector 2. STPS (Sub Transmission Position Sensor) 1. Engine oil plug 3. VSS (Vehicle Speed Sensor) 2. Engine coolant plug 4.
Page 42 Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION) Engine Preparation Remove fuse box. Remove shifting valve. Refer to ELECTRIC SHIFT Unplug spark plug cables. SYSTEM 05-06. Unplug oil pressure sensor. Disconnect the interlock cable no. 6 from rear Remove exhaust pipe no. 4. Refer to Exhaust Sys- brake pedal.
Page 43: Engine Installation
Anti-Vibration System Installation DRAULIC BRAKES 09-02. Insert support bushing in engine support. Before Reattach cables, hoses, harness wiring, etc. insert support bushing, spray BOMBARDIER LUBE (P/N 293 600 016) in support. Install a new O-ring in anti-vibration bushing grooves. Before to start the engine, remove spark plugs and Apply grease on anti-vibration bushings and insert ground them on engine or frame.
Page 44: Exhaust System
Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION) EXHAUST SYSTEM Exhaust Pipe Removal Remove the exhaust pipe nuts no. 15. WARNING Never touch exhaust system components im- mediately after the engine has been run be- cause these components are very hot. Heat Shield Removal Remove the rear fender.
Page 45: Shifting System
Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION) Exhaust Pipe Installation For installation, reverse the removal procedure, paying attention to the following details. Use a new exhaust pipe gasket no. 19 and make sure that it is properly installed. 1. Muffler 2.
Page 46 Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION) Shifter Column Removal Remove shifter lever no. 1. Remove shifter tie-rod no. 23. Shifter Column Installation For installation, reverse the removal procedure. Shifting Rod Removal Remove fuel tank. Refer to FUEL CIRCUIT 04-02. NOTE: Separate fuel tank from frame, do not re- move tank completely.
Page 47: Cooling System
Section 03 ENGINE Subsection 03 (COOLING SYSTEM) COOLING SYSTEM 11 12 03-03-1 VMR9933_03_03.FM http://ReadManuals.com...
Page 48: Cooling System Leak Test
Section 03 ENGINE Subsection 03 (COOLING SYSTEM) COOLING SYSTEM LEAK TEST Install special plug (radiator cap) (P/N 529 021 400) and hose pincher (P/N 529 009 900) on overflow hose no. 8. Pressurize all system through coolant reservoir to 103 kPa (15 PSI). Check all hoses, radiator and cylinder/base for cool- ant leaks.
Page 49: Pressure Cap
Section 03 ENGINE Subsection 03 (COOLING SYSTEM) When engine has completely cooled down, re- Installation check coolant level in radiator no. 1 and coolant For installation, reverse the removal procedure. tank no. 9 and top up if necessary. Paying attention to the following detail. Check coolant concentration (freezing point) with Install hose pincher on coolant hose at thermostat proper tester.
Page 50: Coolant Tank
Section 03 ENGINE Subsection 03 (COOLING SYSTEM) COOLANT TANK Overflow Coolant Tank The coolant expands as the temperature (up to 100 - 110°C (212 - 230°F)) and pressure rise in the system. If the limiting system working pressure cap is reached 90 kPa (13 PSI), the pressure relief valve in the pressure cap is lifted from its seat and allows coolant to flow through the overflow hose into the overflow coolant tank.
Page 51: Rewind Starter
Section 03 ENGINE Subsection 04 (REWIND STARTER) REWIND STARTER 03-04-1 VMR9934_03_04A.FM http://ReadManuals.com...
Page 52: Rewind Starter
Section 03 ENGINE Subsection 04 (REWIND STARTER) REWIND STARTER Removal Remove fuel tank cover and skid plate. Refer to BODY 10-02. Remove seat pivot bar and unplug clutching and clutch modulator valve connector. Remove rewind mounting bolts no. 15 and pull re- wing starter.
Page 53 Section 03 ENGINE Subsection 04 (REWIND STARTER) CAUTION: The use of standard multi-purpose grease could result in rewind starter malfunc- tion. To install a new rope no. 5, insert rope into sheave orifice and lock it with the key no. 4 as illustrated. TYPICAL 1.
Page 54: Starting Pulley
Section 03 ENGINE Subsection 04 (REWIND STARTER) STARTING PULLEY Removal Remove rewind starter. Remove screw no. 12 and O-ring no. 13 retaining starting pulley no. 14 to crankshaft. Installation For installation, reverse the removal procedure. Paying attention to the following detail. Check O-ring for damage and change if necessary.
Page 55: Magneto System
Section 03 ENGINE Subsection 05 (MAGNETO SYSTEM) MAGNETO SYSTEM 03-05-1 VMR9956_03-05A.FM http://ReadManuals.com...
Page 56: Magneto
– ignition cover no. 2 NOTE: Clean all metal component in a non-ferrous – pawl no. 6 and needle pin no. 7 metal cleaner. Use Bombardier gasket remover Unscrew nut no. 8 retaining rotor no. 9. (P/N 413 708 500) or suitable equivalent.
Page 57: Sparg Clutch
Section 03 ENGINE Subsection 05 (MAGNETO SYSTEM) SPARG CLUTCH Removal Remove rotor no. 9. Unscrew all socket screws no. 12 retaining rotor and sparg clutch housing no. 13. Remove sparg clutch from sparg clutch housing. Installation For installation, reverse the removal procedure. NOTE: Apply engine oil on sparg clutch.
Page 58: Cylinder And Head
Section 03 ENGINE Subsection 06 (CYLINDER AND HEAD) CYLINDER AND HEAD NOTE: For cylinder head, cylinder and piston removal, it is not necessary to remove engine from vehicle. 03-06-1 VMR9957_03-06A.FM http://ReadManuals.com...
Page 59: 1, Cylinder Head
Section 03 ENGINE Subsection 06 (CYLINDER AND HEAD) 1, CYLINDER HEAD Installation For installation, reverse the removal procedure. Removal Install a new gasket no. 15 between cylinder head Remove engine oil and coolant. and cylinder base no. 7. Disconnect temperature sensor. Install the flanged nuts no.
Page 60: 4, Valve Spring
Section 03 ENGINE Subsection 06 (CYLINDER AND HEAD) Any area worn excessively will require part replace- ment. Installation For installation, reverse the removal procedure. NOTE: Apply engine oil on rocker arm shaft. 4, VALVE SPRING Removal Remove: – cylinder head no. 1 –...
Page 61: 5, Valve
Section 03 ENGINE Subsection 06 (CYLINDER AND HEAD) Installation Measure valve seat width, using a caliper. For installation, reverse the removal procedure. VALVE SEAT CONTACT WIDTH mm (in) 5, VALVE SERVICE LIMIT Exhaust 2 mm (0.078 in) Removal Intake 1.8 mm (0.07 in) Remove valve spring no.
Page 62: 7, Cylinder
Section 03 ENGINE Subsection 06 (CYLINDER AND HEAD) Cylinder Taper Measure cylinder diameter 16 mm (5/8 in) from top of cylinder then half-way through and finally at 13 mm (1/2 in) from bottom. 1. Circlip 2. Valve stem seal 1. Measure at three points Inspection Difference between measurements should not exceed 0.10 mm (0.004 in).
Page 63: 8, Lifter
Section 03 ENGINE Subsection 06 (CYLINDER AND HEAD) Installation 9, PISTON For installation, reverse the removal procedure. Removal Paying attention to the following details. Remove cylinder no. 7. Apply engine oil in cylinder bore. Remove both piston pin circlips no. 21 then push Using a ring compressor, slide piston into cylinder.
Page 64: 10, Piston Rings
Section 03 ENGINE Subsection 06 (CYLINDER AND HEAD) Position the dial bore gauge at 16 mm (5/8 in) be- low cylinder top edge, measuring perpendicularly (90°) to piston pin axis. Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance.
Page 65 Section 03 ENGINE Subsection 06 (CYLINDER AND HEAD) A31C2NA 1. Top ring (rectangular, black/gray color) 2. Second ring (scraper, chrome/stainless steel looking ring) 3. Oil ring CAUTION: Ensure that top and second rings are not interchanged. A. Measure here NOTE: Use a ring expander to prevent breakage Ring End Gap during installation.
Page 66: Crankshaft/Balancer Shaft
Section 03 ENGINE Subsection 07 (CRANKSHAFT/BALANCER SHAFT) CRANKSHAFT/BALANCER SHAFT 03-07-1 VMR9958_03-07A.FM http://ReadManuals.com...
Page 67: 1, Camshaft
Section 03 ENGINE Subsection 07 (CRANKSHAFT/BALANCER SHAFT) 1, CAMSHAFT Rear Side Remove: Removal – starter, water pump, magneto and ring gear Remove engine from vehicle (refer to INSTALLA- (refer to MAGNETO SYSTEM 03-05) TION AND REMOVAL 03-02). – shifting system (refer to TRANSMISSION 03-10) Front Side Separate crankcase housings.
Page 68: 2, Balancer Shaft
Section 03 ENGINE Subsection 07 (CRANKSHAFT/BALANCER SHAFT) Installation For installation reverse the removal procedure. NOTE: Always install a new crankcase gasket. 2, BALANCER SHAFT Removal Refer to CAMSHAFT REMOVAL section above. Use the same procedure. Remove balancer shaft. Inspection Check balancer shaft bearing in the front and rear housing for excessive play and smooth operation.
Page 69: Lubrication System
Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) LUBRICATION SYSTEM 03-08-1 VMR9959_03-08A.FM http://ReadManuals.com...
Page 70: Troubleshooting
Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) TROUBLESHOOTING When the hydraulic shifter is used, the engine pressure must increase up to about 810 kPa (118 PSI). Oil Level Low If the engine pressure is out of specifications, – external oil leak check the points described in LOW OR NO OIL –...
Page 71: Oil Strainer
Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) CAUTION: Only use Bombardier high pressure ENGINE OIL PRESSURE filter or suitable equivalent. The Bombardier filter REGULATOR is specifically designed for this engine. This filter does not operate at the same pressure as other The engine oil pressure regulator is located near brands.
Page 72: Oil Pump
Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) OIL PUMP OIL PUMP ROTOR AND INNER ROTOR CLEARANCE mm (in) The oil pump is located on the clutch side of the SERVICE LIMIT crankcase housing. Removal 0.25 mm (0.009 in) Remove engine. Refer to REMOVAL AND IN- STALLATION 03-02.
Page 73: Clutch
Section 03 ENGINE Subsection 09 (CLUTCH) CLUTCH 03-09-1 VMR9960_03-09A.FM http://ReadManuals.com...
Page 74: Clutch Drum, Clutch Weight And Sprag Clutch
Section 03 ENGINE Subsection 09 (CLUTCH) CLUTCH DRUM, CLUTCH WEIGHT Inspect sparg clutch no. 5 for smooth operation and roller for excessive wear. Change sparg clutch AND SPRAG CLUTCH if necessary. Disassembly Weight Lining Measure weight lining thickness. The weight lin- Remove: ing thickness must have 2.0 mm (5/64 in).
Page 75: Friction Drive Plate, Steel Driven Plate And Clutch Basket
Section 03 ENGINE Subsection 09 (CLUTCH) Assembly For installation, reverse the removal procedure. Paying attention to the following details. Install weight springs with the open ends down. Install sparg clutch in clutch drum with its OUT SIDE mark facing out. Apply engine oil on sprag clutch.
Page 76 Section 03 ENGINE Subsection 09 (CLUTCH) Remove: STEEL DRIVEN PLATE 0.25 mm (0.01 in) – clutch hub no. 11 MAXIMUM WARPAGE – friction drive plates no. 12 – steel driven plates no. 13 – inner plate no. 14 – thrust washer no. 15 –...
Page 77 Section 03 ENGINE Subsection 09 (CLUTCH) Clutch Hub Clutch Spring Check grooves of clutch hub for damage or wear Measure each clutch springs free length. caused by steel driven plates. CLUTCH SPRING 32.5 mm (1.28 in) MINIMUM LENGTH Pressure Plate Bearing Assembly Check the pressure plate bearing no.
Page 78 Section 03 ENGINE Subsection 09 (CLUTCH) Install 2 clutch springs. Remove clutch hub as- Install clutch hub. Move the output shaft slowly sembly from clutch basket. and push clutch hub. 1. Output shaft NOTE: Do not remove shift shaft. If the shift shaft is removed, refer to TRANSMISSION 03-10 for CAUTION: Do not use clutch lock nut when you proper installation.
Page 79: Transmission
Section 03 ENGINE Subsection 10 (TRANSMISSION) TRANSMISSION GEAR SHIFT SYSTEM 03-10-1 VMR9961_03-10A.FM http://ReadManuals.com...
Page 80: Transmission
Section 03 ENGINE Subsection 10 (TRANSMISSION) TRANSMISSION 03-10-2 VMR9961_03-10A.FM http://ReadManuals.com...
Page 81: Gear Shift Mechanism
Section 03 ENGINE Subsection 10 (TRANSMISSION) GEAR SHIFT MECHANISM Remove the tension spring no. 13 then pull shift shaft with pawl no. 14 out of housing. Disassembly Front Side Remove: – engine from vehicle (refer to REMOVAL AND INSTALLATION 03-02) –...
Page 82: Transmission
Section 03 ENGINE Subsection 10 (TRANSMISSION) After clutch housing installation, align mark on Inspection shift shaft with mark on indicator shaft. Turn the inner race of each bearing with your fin- ger. The bearings should turn smoothly and quiet- ly. Replace if necessary. During and after transmission disassembly, in- spect the condition of each parts closely.
Page 83 Section 03 ENGINE Subsection 10 (TRANSMISSION) 1. Shaft pin 2. Shift drum Install the shift fork shafts. NOTE: Make sure all of the shift fork pins are aligned with the grooves in the shift drum. Install the index gear on end of shift drum. At the same time, turn the sub-transmission shaft no.
Page 84: Fuel System
Section 04 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL CIRCUIT........................04-02-1 FUEL LINES........................04-02-2 FUEL TANK STRAINER ..................... 04-02-2 FUEL VALVE ........................04-02-3 FUEL TANK ........................04-02-3 FUEL GAUGE........................04-02-4 FUEL SYSTEM PRESSURIZATION ................... 04-02-4 CARBURETOR AND FUEL PUMP..................04-03-1 CARBURETOR ........................
Page 85: Fuel Circuit
Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) FUEL CIRCUIT 04-02-1 http://ReadManuals.com...
Page 86: Fuel Lines
Replace any damaged, leaking or deteri- orated fuel lines. When replacing fuel lines, be sure to use hoses as available from Bombardier parts department. This will ensure continued proper and safe operation. WARNING Use of improper fuel lines could compromise USE SCREWDRIVER ONLY IF GROMMET IS TOO TIGHT fuel system integrity.
Page 87: Fuel Valve
Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Installation Reinstall fuel valve by positioning rubber washer inside and nut outside vehicle. See next photo. 1. Grommet properly position for tank insertion 2. Fitting recess Once grommet is inserted in tank hole, push fitting until its recess properly sits in grommet.
Page 88: Fuel Gauge
Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Unplug fuel hoses from tank and disconnect fuel vent line no. 5. Remove both fuel tank top screws, as shown in the next photo. 1. Nut 2. Frame bracket 3. Fuel tank holding tab 4.
Page 89 Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Install hose pinchers (P/N 295 000 076) on fuel Using air pump from engine leak test kit (P/N 861 tank vent line and fuel pump outlet hose no. 2 at 749 100) inject air into fuel tank. See next photo. carburetor(s), as shown in the following photos.
Page 90: Carburetor And Fuel Pump
Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND FUEL PUMP) CARBURETOR AND FUEL PUMP CARBURETOR CAUTION: Although some jets be replaced by other jets from other carburetors, such modifica- tions shouldn’t be performed. They can greatly affect engine calibration and can cause severe damage to engine.
Page 91: Cleaning And Inspection
Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND FUEL PUMP) Separate cable end bushing from throttle cable Carburetor body and jets should be cleaned in a end, as shown in the next photo. Keep bushing. carburetor cleaner following manufacturer’s in- structions.
Page 92: Installation
Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND FUEL PUMP) GAUGE ALIGNED WITH MAIN JET To adjust height H, bend the contact tab of float CARBURETOR SIDE — RUBBER FLANGE INSTALLATION arm until the specified height is reached. 1. Flange recess aligned with carburetor notch CAUTION: When adjusting lever, do not pry it.
Page 93: Carburetor Adjustments
Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND FUEL PUMP) CARBURETOR ADJUSTMENTS BOTTOM VIEW 1. Idle speed screw 2. Pilot screw 3. Drain plug and screw Pilot Screw Preliminary Adjustment NOTE: The pilot screw is factory pre-set. Adjust- ment is not necessary unless the carburetor is 1.
Page 94: Pilot Screw Adjustment
Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND FUEL PUMP) Choke Pilot Screw Adjustment Remove top cover from carburetor. NOTE: The pilot screw is factory pre-set. Adjust- ment is not necessary unless the carburetor is Detach diaphragm from carburetor body, then pull overhauled or replaced.
Page 95 Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND FUEL PUMP) FULLY OPENED POSITION 1. Plunger end must be here Plunger Adjustment Throttle If plunger needs to be adjusted use cable adjuster, WARNING as shown in the next photo. Ensure the key is turned OFF, prior to per- forming the throttle cable adjustment.
Page 96: Fuel Pump
Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND FUEL PUMP) FUEL PUMP REMOVAL Check impulse diaphragm and gasket on high- supply fuel pump with twin outlets as follows: Close fuel valve. Connect a clean plastic tubing to the impulse nip- Lift coolant tank.
Page 97: Air Intake Silencer
Section 04 FUEL SYSTEM Subsection 04 (AIR INTAKE SILENCER) AIR INTAKE SILENCER 04-04-1 http://ReadManuals.com...
Page 98: Air Filter Box
Section 04 FUEL SYSTEM Subsection 04 (AIR INTAKE SILENCER) AIR FILTER BOX Inspection Inspect air intake tube for cracks, blisters or any Removal other damage. Change if necessary. Remove: Installation – seat For installation, reverse the removal procedure. – air filter box cover no. 1 –...
Page 99 Section 04 FUEL SYSTEM Subsection 04 (AIR INTAKE SILENCER) Removal Remove and discard clamps no. 14 and no. 15. Separate PCV valve no. 13 from breather hose no. 6 and from connecting tube no. 16. 1. PCV valve 2. Clamps 3.
Page 100: Electrical
Section 05 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OVERVIEW..........................05-02-1 GENERAL OPERATION INFORMATION................05-02-1 MPEM (MULTI-PURPOSE ELECTRONIC MODULE)............05-02-1 CHARGING SYSTEM......................05-02-1 STARTING SYSTEM ......................05-02-2 IGNITION SYSTEM......................05-02-2 ELECTRIC SHIFT SYSTEM ....................05-02-3 GAUGES/ACCESSORIES ....................05-02-3 GENERAL TESTING/TROUBLESHOOTING INFORMATION ..........
Page 101 Section 05 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) IGNITION SYSTEM ........................ 05-05-1 IGNITION SYSTEM TESTING PROCEDURE..............05-05-1 GENERAL..........................05-05-1 IGNITION SYSTEM TEST ....................05-05-1 OTHER IGNITION SYSTEM PROBLEMS ................05-05-4 IGNITION TIMING ......................05-05-4 SPARK PLUG ........................05-05-5 DISASSEMBLY ........................05-05-5 HEAT RANGE........................
Page 102 Section 05 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) INSTRUMENTS AND ACCESSORIES .................. 05-07-1 REMOVAL AND INSTALLATION..................05-07-1 12-VOLT AUXILIARY POWER OUTLET................05-07-1 12-VOLT POWER OUTLET ....................05-07-1 HEADLIGHT ........................05-07-1 IGNITION SWITCH ......................05-07-2 INDICATOR LIGHTS ......................05-07-3 MPEM..........................05-07-3 SPEEDOMETER .........................
Page 103: Overview
Section 05 ELECTRICAL Subsection 02 (OVERVIEW) OVERVIEW GENERAL OPERATION INFORMATION The electrical system consist of different sub- The MPEM is equipped with an automatic power systems where some are inter-related: shut-down. This feature prevents the battery from losing its charge if ignition switch is left turned ON •...
Page 104: Starting System
Section 05 ELECTRICAL Subsection 02 (OVERVIEW) Voltage Regulator/Rectifier IGNITION SYSTEM A 3-phase full-wave shunt-type voltage regulator/ An IDI (Induction Discharge Ignition) system is uti- rectifier receives the AC voltage and rectifies (con- lized. The ignition system is made up of the follow- verts) it into DC.
Page 105: Electric Shift System
Section 05 ELECTRICAL Subsection 02 (OVERVIEW) Magneto Flywheel/Trigger Coil Upshift/Downshift Switch The magneto flywheel features six protrusions When the upshift or downshift button is pressed, that are working with the trigger coil. The trigger the MPEM activates the proper solenoid (up or coil sends the signals to the MPEM to be pro- down) that moves the shared hydraulic valve.
Page 106: General Testing/Troubleshooting Information
Section 05 ELECTRICAL Subsection 02 (OVERVIEW) GENERAL TESTING/TROUBLESHOOTING INFORMATION The following gives general electrical-related prob- It is recommended to always disconnect the bat- lems. For specific system-related problems, refer tery when replacing the any electric or electronic to proper system section. part(s).
Page 107: Servicing Deutsch Connectors
Section 05 ELECTRICAL Subsection 02 (OVERVIEW) SERVICING DEUTSCH – Insert a 4.8 mm (0.189 in) wide screwdriver blade inside the front of the contact cavity. CONNECTORS – Pry back the retaining tab while gently pulling wire back until contact is removed. Waterproof Connector Housing Female and Male Connector Housing To remove:...
Page 108 Section 05 ELECTRICAL Subsection 02 (OVERVIEW) Identification Each plug assembly is mechanically keyed to mate only with identical mechanical keyed header on Parts the MPEM. F00H0WA 1. Plug assembly 2. Cover assembly 3. Mating seal 4. Wedge lock 5. Header assembly 6.
Page 109 Section 05 ELECTRICAL Subsection 02 (OVERVIEW) Contact Crimping CAUTION: Do not pierce the diaphragm with a sharp point for electrical troubleshooting. The All contacts in AMP plug connectors must be resulting pin holes in the insulation will allow crimped using the crimping tool (P/N 295 100 164). moisture to penetrate the system and possibly CAUTION: If contacts are not crimped using result in system failure.
Page 110 Section 05 ELECTRICAL Subsection 02 (OVERVIEW) While rotating the wire back and forth over a half Insert a 4.8 mm (0.189 in) wide screwdriver blade turn (1/4 turn in each direction), gently pull the wire inside the front of the contact cavity. until the contact is removed.
Page 111: Identification Of Fuse Block On Vehicle
Section 05 ELECTRICAL Subsection 02 (OVERVIEW) Apply a thin coat of DEOXIT contact lubricant to the pins of the header on the MPEM only. 1. Ignition system 2. Accessories (power outlet and auxiliary supply) 3. Solenoids 4. Fan F00H11A 5. MPEM (Multi-Purpose Electronic Module) TYPICAL 6.
Page 112 Section 05 ELECTRICAL Subsection 02 (OVERVIEW) AMP Connectors of Wiring Harness F04H6GA 05-02-10 http://ReadManuals.com...
Page 113 Section 05 ELECTRICAL Subsection 02 (OVERVIEW) Other Deutsch and Packard Connectors Pin-Out 05-02-11 http://ReadManuals.com...
Page 114: Charging System
Section 05 ELECTRICAL Subsection 03 (CHARGING SYSTEM) CHARGING SYSTEM TESTING PROCEDURE NOTE: If it is continually necessary to add distilled water to the battery, this indicates an over voltage NOTE: First, ensure that battery is in good condi- situation, requiring replacement of the voltage tion prior to performing the following test using a regulator/rectifier.
Page 115 Section 05 ELECTRICAL Subsection 03 (CHARGING SYSTEM) Stator STATIC TEST: INSULATION With the stator leads disconnected, insert either STATIC TEST: CONTINUITY meter test probe onto AC-1 and ground the other 1. Disconnect the magneto wiring harness con- meter test probe to the engine or the stator iron nector.
Page 116: Starting System
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) STARTING SYSTEM BATTERY TROUBLESHOOTING SYMPTOM: DISCHARGED OR WEAK BATTERY CAUSE REMEDY 1. Battery posts and/or Clean and coat with cable terminal oxidized. dielectric grease. 2. Loose or bad Check wiring and connections. connector cleanliness, damaged or short circuit.
Page 117: Removal
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) Load Test INSPECTION This is the best test of battery condition under a Visually inspect battery casing for cracks or other starting load. Use a load testing device that has an possible damage. If casing is damaged, replace adjustable load.
Page 118: Activation Of A New Battery
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) During the storage period, recheck electrolyte lev- 2. Remove caps and fill battery to UPPER LEVEL el and specific gravity readings at least every 40 line with electrolyte (specific gravity: 1.260 at days. As necessary, keep the battery at its upper 20°C (68°F)).
Page 119: Tips For Charging A Used Battery
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) – State of charge: Because the electrolyte is near- ly pure water in a completely discharged bat- tery, it cannot accept current as well as electro- lyte. This is the reason the battery will not accept current when the charging cycle first begins.
Page 120: Charging 2 Or More Batteries At A Time
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) INSTALLATION – If the charging current is measurable before the end or at the end of about 10 hours, the battery Reinstall battery and fasten making sure to rein- is good and charging should be completed in stall the vent tube.
Page 121: Starting System Troubleshooting
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY Starter does not turn. Ignition switch is in the OFF position. Turn switch in the ON position. Burnt fuse. Check solenoid fuse, MPEM fuse and wiring condition. Transmission is not set on the Park or Set transmission either in Park or Neutral.
Page 122: Starting System Tests
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) STARTING SYSTEM TESTS GENERAL STPS (Sub-Transmission Position Sensor) First ensure the problem is not related to engine mechanical components. Try cranking the engine Ensure the transmission lever is either in PARK or with the rewind starter. If it does not turn, perform in NEUTRAL.
Page 123 Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) Starting Solenoid If solenoid test good, check the electric starter. If starter test good, the MPEM can be suspected. NOTE: Solenoid is located on frame, behind fuse See MPEM below. block. Ensure the solenoid receives electric current as fol- Electrical Cables or Connections lows.
Page 124: Electric Starter
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) ELECTRIC STARTER REMOVAL Turn OFF ignition switch. Disconnect BLACK cable ground connection from battery. WARNING Always disconnect ground cable first and re- connect last. Disconnect RED cable connection from battery. Clean starter area. Remove LH side panel.
Page 125: Ignition System
Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) IGNITION SYSTEM IGNITION SYSTEM TESTING PROCEDURE GENERAL IGNITION SYSTEM TEST Ignition Problems Safety Precautions When dealing with ignition problems, the follow- WARNING ing items should be checked in this order. After one item has been checked and it is found not to To prevent powerful electric shocks while be the problem, continue with the next item.
Page 126 Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) Ignition switch A quick test to validate it is working. If the lights turn on in the cluster display just after turning on the key, the ignition switch is good. Test Ensure the MPEM fuse no. 5 is in good condition. Disconnect ignition switch.
Page 127: Ignition Coil
Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) Ignition Coil 1. Multimeter IGNITION COIL 2. 6-pin magneto harness adapter 1. Primary side 3. WHITE wire 2. Secondary side 4. BLACK wire Primary Winding DYNAMIC TEST Disconnect the wire connector on the primary side 1.
Page 128: Other Ignition System Problems
Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) Measure resistance between ignition coil outlet caps and spark plug caps. The obtained value should be between 5.4 and 5.7 Ω. If resistance is good, continue check. If not, change spark plug wires. DYNAMIC TEST An ignition coil tester available from after-market tool/equipment suppliers can be used.
Page 129: Spark Plug
Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) SPARK PLUG DISASSEMBLY A too “hot” plug will result in overheating pre- ignition, etc. First unscrew the spark plug one turn. A too “cold” plug will result in fouling (shorting the Clean the spark plug and cylinder head with pres- spark plug) or may create carbon build up which surized air then completely unscrew.
Page 130: Spark Plug Installation
Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) SPARK PLUG INSTALLATION Prior to installation make sure that contact surfac- es of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap ac- cording to the following chart.
Page 131: Ngk Spark Plug Symbol Explanation
Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) NGK SPARK PLUG SYMBOL EXPLANATION WIDE GAP PREFIX SUFFIX 10: 1.0 mm (.040") B P 5 E S 11: 1.1 mm (.044") 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080") Thread Heat rating...
Page 132: Electric Shift System
Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) ELECTRIC SHIFT SYSTEM GENERAL The electric shift system controls several valves/solenoids that control the shifting and also allow an ad- justment to the clutch pressure to modify the gear change. It is possible to calibrate the clutch for the hardness or smoothness of shifting action. This calibration is to be used when the clutch is slippery or is too hard.
Page 133: Preparation
Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) PREPARATION Before going into the diagnostic/calibration mode, the ignition switch needs to be on position OFF, the transmission in FIRST gear and shifter lever on NEUTRAL position. To set the MPEM into the diagnostic/calibration mode, the following sequence needs to be done: –...
Page 134: Testing
Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) TESTING The following tasks are performed in this order by the MPEM in the diagnostic/calibration mode: – Task 1: Indicator lights test. – Task 2: Clutch modulator calibration. – Task 3: Sensors and solenoids verification. –...
Page 135 Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) Task 2: Clutch Modulator Calibration The LED “Check Engine” blinks for a maximum time of 5 seconds or until the user begins the calibration process or removes the jumper. The upshift/downshift button is used to change the calibration of the clutch modulator valve. When one of these buttons is activated, the LED “Check Engine”...
Page 136 Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) Task 3: Sensors and Solenoids Verification The MPEM reads all sensors and solenoids and displays the information with the LED “Hi-Lo beam” . The LED “Reverse” is ON during all the time the MPEM is verifying the components. Each abnormal components is represented by a coded number (see table below) and each code number correspond to the number of blinks that the LED “Hi-Lo bean”...
Page 137 Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) Table 3: Abnormality Conditions CODE ABNORMALITY CONDITION ACTION – Short circuit to battery is detected. Refer to STARTING SYSTEM 05-04. – Operating current on the starter output has exceeded the overload threshold. –...
Page 138 Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) Task 4: GBPS (Gear Box Position Sensor) Calibration The LEDS “1” and “Hi-Lo beam” are ON during a maximum of 5 seconds or until the user sets the calibration. This calibration mode sets the nominal position of sensor. The GBPS calibration is automati- cally set when the Start/Stop button and the Hi/Lo beam button are activated at the same time.
Page 139 Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) Resetting the Diagnostic Components Register Before resetting the diagnostic components registers, the MPEM needs to be in the diagnostic/calibration mode. The register is automatically reset when the following sequence is performed: – The jumper on the diagnostic connector is removed while the START/STOP button is activated. The MPEM will reset the register (See table ABNORMALITY-DIAGNOSIS COMPONENTS and table AB- NORMALITY CONDITIONS) and after it will turn off itself.
Page 140: Valve Removal/Installation
Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) VALVE REMOVAL/INSTALLATION CAUTION: It is recommended to always discon- Remove screws on top of shifting valve. nect the battery when replacing any electric or Pull shifting valve. electronic part(s). Installation SHIFTING VALVE For the installation, reverse the removal proce- dure, paying attention to the following details: The upshift/downshift solenoids are installed on...
Page 141: Clutch Modulator Valve
Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) Removal CLUTCH MODULATOR VALVE Remove fuel tank cover. Refer to BODY 10-02. The clutch modulator valve is located in front of en- Unplug connector on seat pivot bar. gine. 1. Clutch modulator valve 1.
Page 142: Sensor Removal/Installation
Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) SENSOR REMOVAL/INSTALLATION CAUTION: It is recommended to always discon- Installation nect the battery when replacing any electric or For installation, reverse the removal procedure. electronic part(s). Pay attention to the following details: –...
Page 143 Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) Installation For installation, reverse the removal procedure. Pay attention to the following detail: – Check O-ring and change if necessary. – Install VSS and secure with screw. Torque to 9 N•m (80 lbf•in). NOTE: Don’t apply Loctite on threads.
Page 144: Valves/Solenoids Tests
Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) VALVES/SOLENOIDS TESTS CLUTCHING VALVE AND CLUTCH – Install a new clutching valve. Refer to VALVES REMOVAL/INSTALLATION section. MODULATOR VALVE TESTS – Check AMP connectors on MPEM. Refer to CAUTION: It is recommended to always dis- OVERVIEW 05-02.
Page 145 Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) – Check wiring condition. – Check upshift/downshift switch, refer to UPSHIFT/ DOWNSHIFT BUTTON TESTS section. – Install a new shifting valve, refer to VALVES REMOVAL/INSTALLATION section. – Check AMP connectors on MPEM. Refer to OVERVIEW 05-02.
Page 146: Sensor Tests
Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) SENSOR TESTS STPS VSS (Vehicle Speed Sensor) (Sub-Transmission Position Sensor) TESTS AND GBPS If VSS is not working properly, the speedometer (Gear Box Position Sensor) TESTS will not indicate vehicle speed. Check the follow- ing details: NOTE: The reverse vehicle speed limiter doesn’t –...
Page 147: Upshift/Downshift Switch Tests
Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM) UPSHIFT/DOWNSHIFT SWITCH TESTS UPSHIFT/DOWNSHIFT SWITCH Open multi-function switch box. Using a multimeter, measure resistance between the following wires. POSITION WIRE RESISTANCE UPSHIFT Switch released Infinite (0.L) BLACK and Switch 0.4 Ω max. depressed and held DOWNSHIFT...
Page 148: Instruments And Accessories
Section 05 ELECTRICAL Subsection 07 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES REMOVAL AND INSTALLATION CAUTION: It is recommended to always dis- connect the battery when replacing any electric or electronic parts. 12-VOLT AUXILIARY POWER OUTLET The 12-volt auxiliary power outlet is located on the LH rear part of the rear extension frame.
Page 149: Ignition Switch
Section 05 ELECTRICAL Subsection 07 (INSTRUMENTS AND ACCESSORIES) HEADLIGHT BEAM AIMING Select high intensity. Beam aiming is correct when center of high beam is 131 mm (5 in) below the headlight horizontal center line, scribed on a test surface, 5 m (17 ft) away.
Page 150: Indicator Lights
Section 05 ELECTRICAL Subsection 07 (INSTRUMENTS AND ACCESSORIES) INDICATOR LIGHTS Installation For the installation, reverse the removal proce- Test dure. Refer to TESTS section. SPEEDOMETER Removal Test Remove the steering cover. Refer to BODY 10-02. Refer to TESTS section. NOTE: Do not unplugged all connectors. Lift up the steering cover and unplug the indicator lights Removal connector(s) only.
Page 151 Section 05 ELECTRICAL Subsection 07 (INSTRUMENTS AND ACCESSORIES) Speedometer Bulbs Replacement Each bulb can be replaced individually. Proceed as follows: Using a small screwdriver, pry cap out to expose bulb socket. 1. Speedometer Insert a small screwdriver in socket slot and turn counterclockwise until stopped.
Page 152: Tests
Section 05 ELECTRICAL Subsection 07 (INSTRUMENTS AND ACCESSORIES) TESTS 12-VOLT AUXILIARY POWER COOLING FAN OPERATION TEST OUTLET Unplug the temperature sender connectors. Using a multimeter, measure the voltage between Install a jumper wire end in each connector. Re- RED/BLACK and BLACK wires. place the fan if it does not work.
Page 153: Indicator Lights
Section 05 ELECTRICAL Subsection 07 (INSTRUMENTS AND ACCESSORIES) INDICATOR LIGHTS SPEEDOMETER Remove steering cover. If switch tests good, Using a multimeter, measure the voltage between check wiring condition and MPEM. RED/GREY and BLACK/BROWN wires. Unplug indicator light connector. Turn ignition switch to ON. The obtained value should be between 12 and 14.5 Vdc.
Page 154: Drive Train
Section 06 DRIVE TRAIN Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FRONT DIFFERENTIAL......................06-02-1 FRONT DRIVE SHAFT ....................... 06-02-2 FRONT DIFFERENTIAL...................... 06-02-3 FRONT PROPELLER SHAFT ....................06-02-4 REAR AXLE ..........................06-03-1 RIGID AXLE ........................06-03-2 REAR PROPELLER SHAFT....................06-03-4 06-01-1 http://ReadManuals.com...
Page 155: Front Differential
Section 06 DRIVE TRAIN Subsection 02 (FRONT DIFFERENTIAL) FRONT DIFFERENTIAL 17 18 06-02-1 http://ReadManuals.com...
Page 156: Front Drive Shaft
Section 06 DRIVE TRAIN Subsection 02 (FRONT DIFFERENTIAL) FRONT DRIVE SHAFT Separate knuckle no. 8, with hub and disk brake no. 9, from lower and upper suspension arms. Removal Separate knuckle from the drive shaft no. 7 or no. 14. Raise the front of vehicle, support it securely on jack stands and remove front wheel(s).
Page 157: Front Differential
Section 06 DRIVE TRAIN Subsection 02 (FRONT DIFFERENTIAL) Drive Shaft Boot FRONT DIFFERENTIAL Removal Removal Remove: Raise front of vehicle, support it securely on jack – clamps from rubber boot using boot clamp pli- stands and remove front wheels. ers (P/N 295 000 069 and 295 000 054) Remove: –...
Page 158: Front Propeller Shaft
Section 06 DRIVE TRAIN Subsection 02 (FRONT DIFFERENTIAL) Front Differential Oil Change On RH side, remove drive shaft. Unscrew propeller shaft bolt no. 19. Differential Place vehicle on a level surface. Set transmission side only. in park position. Remove vent tube no. 15 on the top from the front Lift LH side of vehicle.
Page 159 Section 06 DRIVE TRAIN Subsection 02 (FRONT DIFFERENTIAL) Pull differential forward then separate propeller shaft from differential and engine. Inspection Check propeller shaft for wear or damage, replace if necessary. Installation Installation is the reverse of removal procedure. 1. Snap ring Support inner yoke in vice and drive other yoke down with a soft hammer.
Page 160 Section 06 DRIVE TRAIN Subsection 02 (FRONT DIFFERENTIAL) Tighten vise to force bearing caps in. Using a suitable arbor, fully seat bearing cap in one side. Continually, check for free movement of bearing cross as bearing caps are assembled. Install snap ring. Repeat procedure for other sides.
Page 161: Rear Axle
Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) REAR AXLE 06-03-1 http://ReadManuals.com...
Page 162: Rigid Axle
Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) RIGID AXLE Remove the M10 x 25 socket screws no. 7 retain- ing rigid axle center section to swing arm. Removal Lift rear of the vehicle until rear shock absorbers are fully extended. Install jack stands under frame to support vehicle.
Page 163 Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) Secure rear axle tube to swing arm with bolts. Do Unfasten TORX head screws no. 16 retaining axle not tighten yet. housing from rear rigid axle center section no. 17. When all bolts are installed, torque in a criss-cross Remove axle housing then pull out axle no.
Page 164: Rear Propeller Shaft
Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) Rear Rigid Axle Center Section Oil Level Lift back of vehicle. Place swing arm to the hori- zontal position. Clean filler plug prior to check oil level. Check oil level by removing filler plug. Oil level must reach lower edge.
Page 165 Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) Installation Installation is essentially the reverse of removal procedure. Apply grease (P/N 293 550 019) to spring and splines before insert the end of the propeller shaft into swing arm. Apply grease to splines from engine. Grease U-joint from rear propeller shaft.
Page 166 Section 07 STEERING/CONTROL SYSTEMS Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING/CONTROL SYSTEMS..................07-02-1 HANDLE BAR........................07-02-2 STEERING COLUMN ......................07-02-2 TIE-ROD..........................07-02-2 STEERING COLUMN BEARING..................07-02-3 MULTI-FUNCTION SWITCH ..................... 07-02-3 THROTTLE HANDLE......................07-02-4 LH HANDLE BRAKE......................07-02-4 RH HANDLE BRAKE ......................07-02-5 07-01-1 http://ReadManuals.com...
Page 167: Steering/Control
Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS) STEERING/CONTROL SYSTEMS 07-02-1 http://ReadManuals.com...
Page 168: Handle Bar
Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS) HANDLE BAR Inspection Inspect steering column for damage, cracks or bend- Removal ing, replace if any problems is detected. Remove: Installation – steering cover (refer to BODY 10-02) For the installation, reverse the removal procedure. –...
Page 169: Steering Column Bearing
Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS) Toe Adjustment Place vehicle on level surface. Check that handlebar is straight. Use a long rule and check if the rear and front wheels are aligned. Adjust alignment with tie-rod. Adjust toe to 0º ± 0.3º. STEERING COLUMN BEARING Removal Place vehicle on jack stands and remove front...
Page 170: Throttle Handle
Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS) Separate multi-function switch no. 5 from handle bar no. 7. Remove steering cover. Refer to BODY 10-02. Unplug multi-function switch connector. The con- nector is located under steering cover. 1. Throttle handle housing 2.
Page 171: Rh Handle Brake
Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS) Cable Removal Refer to HYDRAULIC BRAKES 09-02 for specifics instructions. Installation For installation, reverse the removal procedure. RH HANDLE BRAKE Removal Remove screws. 1. Remove the screws Separate handle brake no. 2 from handle bar no. 7. If necessary, unplug connectors under steering cov- er and cut locking tie.
Page 172: Suspension
Section 08 SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FRONT SUSPENSION ......................08-02-1 SHOCKS ASSEMBLY ......................08-02-2 UPPER A-ARM ........................08-02-3 LOWER A-ARM........................08-02-4 KNUCKLE ........................... 08-02-5 WHEEL BEARING CONDITION ..................08-02-6 REAR SUSPENSION......................08-03-1 REAR SHOCK........................08-03-2 SWING ARM ........................
Page 173: Front Suspension
Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION ) FRONT SUSPENSION 08-02-1 http://ReadManuals.com...
Page 174: Shocks Assembly
Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION ) SHOCKS ASSEMBLY Removal Loosen wheel nuts. Lift front of vehicle and install a jack stand under the frame to support the vehicle off the ground. NOTE: Lift up vehicle high enough to have the wheel off the ground and shock absorber no.
Page 175: Upper A-Arm
Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION ) Installation Remove cotter pin and castellated nut from upper ball joint no. 4. For assembly, reverse the disassembly and re- moval procedures. NOTE: Do not interchange left and right tires. Check direction of rotation mark on tires. 1.
Page 176: Lower A-Arm
Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION ) Inspection Torque nuts to 67 N•m (49 lbf•ft). Attach upper A-arm to knuckle. Install castellated Check ball joint rubber on upper A-arm for crack or nut and torque to 75 N•m (55 lbf•ft). any other damage.
Page 177: Knuckle
Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION ) Use a suitable ball joint remover and detach knuckle from the lower A-arm. Remove nuts and bolts no. 8 retaining lower A-arm to frame. DIRECTION OF ROTATION Torque wheel nuts to 75 N•m (55 lbf•ft) in a criss- cross sequence.
Page 178: Wheel Bearing Condition
Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION ) Installation For installation, reverse the removal procedure. Pay attention to the following details. For hub installation, refer to HYDRAULIC BRAKE 09-02. Reinstall front wheel(s) and torque nuts to 75 N•m (55 lbf•ft) in a criss-cross sequence. NOTE: Do not interchange left and right tires.
Page 179: Rear Suspension
Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) REAR SUSPENSION 08-03-1 http://ReadManuals.com...
Page 180: Rear Shock
Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) REAR SHOCK Push down on handle until it locks. Remove spring stopper and cap then release handle. Removal Lift rear of vehicle until rear shock absorbers no. 1 are fully extended. Install a jack or a block under the frame to support the vehicle.
Page 181: Swing Arm
Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) Inspection Secure the shock body end no. 2 in a vise with its rod upward. TYPICAL 1. Clamp here CAUTION: Do not clamp directly on shock body. Examine each shock for leaks. Extend and com- 1.
Page 182 Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) Remove M8 flanged screws retaining master cyl- Unscrew and remove RH pivot bolt no. 14. inder. CAUTION: Don’t let caliper hang by the hose and don’t stretch or twist brake hose. 1. Swing arm bellows 2.
Page 183 Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) Installation Remove M10 nuts and bolts retaining swing arm to rear axle tube. Installation is essentially the reverse of removal procedure. However, pay attention to the follow- ing details. Secure rear rigid axle center section to swing arm with socket screws.
Page 184 Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) Apply grease (P/N 293 550 019) to spring and Install LH pivot bolt. splines before insert the end of the propeller shaft Move the swing arm up and down several times into swing arm. and tighten LH pivot bolt.
Page 185: Brakes
Section 09 BRAKES Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS HYDRAULIC BRAKES......................09-02-1 FRONT BRAKES ........................ 09-02-1 REAR BRAKE ........................09-02-2 GENERAL ........................... 09-02-3 MASTER CYLINDER ......................09-02-3 CALIPER ..........................09-02-4 BRAKE PADS ........................09-02-5 BRAKE DISC........................09-02-6 BRAKE PEDAL ........................09-02-7 BRAKE CABLE ........................
Page 186: Hydraulic Brakes
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) HYDRAULIC BRAKES FRONT BRAKES 09-02-1 http://ReadManuals.com...
Page 187: Rear Brake
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) REAR BRAKE 09-02-2 http://ReadManuals.com...
Page 188: General
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) GENERAL Hydraulic Brakes System The brake system consists of two separate cir- cuits. Each system has its own master cylinder and reservoir. Both front and rear brakes are disc type. Parking Device The parking device operates the rear brake only. It is activated by a locking mechanism on LH brake lever.
Page 189: Caliper
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Installation Remove bolt no. 12 and sealing washers no. 11 retaining brake hose no. 23 to master cylinder For the installation, reverse the removal proce- no. 19. dure, paying attention to the following details. Discard sealing washers.
Page 190: Brake Pads
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Disassembly Only brake pads are available as spare parts. If cal- iper is damaged, replace as an assembly. Installation For the installation, reverse the removal proce- dure, paying attention to the following details. Use new sealing washers when installing bolt re- taining brake hose to caliper.
Page 191: Brake Disc
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Remove brake pads no. 3 from caliper. Check for leaks and make sure the brakes operate normally before driving. CAUTION: Don’t let the caliper hang by the hose and don’t stretch or twist the hose. BRAKE DISC Inspection Inspection...
Page 192: Brake Pedal
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) BRAKE PEDAL Using a suitable puller, pull out wheel hub with disc. Removal Remove RH side panel with foot peg. Refer to section 10-02 BODY for removal proce- dure. Unhook the return spring no. 21. Unhook the brake cable no.
Page 193: Brake Cable
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Brake Handle Unscrew the bolt retaining the parking lever lock from brake lever no. 18 and remove the lever. Release the tension on brake lever. Rotate cable end bushing so that cable aligns with the brake lever recess, then lift cable end.
Page 194: Brake Hoses And Brake Tubes
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Remove the LH and RH side panels. Refer to Adjust cable so that the pin end from interlock ca- BODY 10-02. ble is flush with the shifter lever plate. Use the interlock cable adjustment. Disconnect the interlock cable under shift lever.
Page 195 Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) LEFT HAND SIDE 1. Flexible hose 2. Tube clip Rear Flexible Brake Hose 1. Vertical brake tube Remove bolt no. 12 retaining flexible hose no. 23 2. Brake hose on top of rear master cylinder no. 19. 3.
Page 196: Brake System Bleeding
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Inspection Remove bolt no. 12 and washers no 11 retaining hose to rear caliper. Periodically inspect flexible brake hoses for cracks, leaks, blisters and any other damage. If any sign of deterioration is found, replace the defective part with a new one.
Page 197: Brake Light Switch
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) BRAKE LIGHT SWITCH NOTE: Check the fluid level often in the reservoir. Add brake fluid when level is low. Removal Repeat procedure until no air appears in hose. Front Brake Light Switch Proceed the same way with the left side front cal- iper.
Page 198 Section 10 BODY/FRAME Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS BODY............................10-02-1 BODY PARTS ........................10-02-1 SEAT........................... 10-02-3 SEAT/ENGINE COVER....................... 10-02-4 STORAGE/STEERING/SHIFTER GUIDE COVER .............. 10-02-5 FRONT SKID PLATE/BUMPER/LUGGAGE RACK ............10-02-5 FRONT FENDER/MUDGUARD/FACIA ................10-02-6 INNER FENDER........................10-02-8 FUEL TANK COVER/SIDE PANEL ..................
Page 199: Body Parts
Section 10 BODY/FRAME Subsection 02 (BODY) BODY BODY PARTS 10-02-1 http://ReadManuals.com...
Page 200 Section 10 BODY/FRAME Subsection 02 (BODY) 10-02-2 http://ReadManuals.com...
Page 201: Seat
Section 10 BODY/FRAME Subsection 02 (BODY) SEAT 10-02-3 http://ReadManuals.com...
Page 202: Seat/Engine Cover
Section 10 BODY/FRAME Subsection 02 (BODY) SEAT/ENGINE COVER 2, Engine Cover Remove seat and screws no. 24. Removal 1, Seat Pull latch upward while gently lifting rear of seat. Continue lifting movement until you can release the front retaining devices, then, completely re- move seat.
Page 203: Storage/Steering/Shifter Guide Cover
Section 10 BODY/FRAME Subsection 02 (BODY) STORAGE/STEERING/SHIFTER Inspection GUIDE COVER Check latches no. 27 from storage cover for cracks or other damages. Change if necessary. Removal Installation 3, Storage Cover Installation is the reverse order of removal. Unlatch cover, lift then remove cover. 4, Steering Cover FRONT SKID PLATE/BUMPER/ Remove screws under handle bar.
Page 204: Front Fender/Mudguard/Facia
Section 10 BODY/FRAME Subsection 02 (BODY) Cut locking tie holding the cable of the sealed beam. NOTE: Install a new locking tie at the time of lug- gage rack installation. Pull upside. Installation Installation is in the reverse order of removal. FRONT FENDER/MUDGUARD/ FACIA Removal...
Page 205 Section 10 BODY/FRAME Subsection 02 (BODY) 10, Front Mudguard Remove screws no. 34 and no. 35. Remove screw no. 36 near the front facia. V01L16A Remove bolts no. 28, no. 29 and no. 30. V01L1PA 11, Front Facia Remove sealed beams. Remove the screws no.
Page 206: Inner Fender
Section 10 BODY/FRAME Subsection 02 (BODY) INNER FENDER Removal 12, Inner Fender Remove front wheel. Remove screws no. 39, two on bottom side and one behind shock. V01L17A Installation Install in first, the upper screw; secondly, the low- er front screw and then the lower rear screw. NOTE: Install all screws before torque.
Page 207: Rear Luggage Rack
Section 10 BODY/FRAME Subsection 02 (BODY) Remove latches no. 40. Three by side. V01L1DA V01L14A Installation 14, Side Panel Installation is the reverse order of removal. Remove seat. Remove footpeg. REAR LUGGAGE RACK Remove plastic pin and screws retaining the side Removal panel with front and rear fender.
Page 208: Rear Fender/Rear Fender Cover
Section 10 BODY/FRAME Subsection 02 (BODY) REAR FENDER/REAR FENDER Under rear fender, remove bolts no. 43. One on each side. COVER Removal 16, Rear Fender Remove seat and rear luggage rack. Remove screws no. 44 under rear facia and screws no. 45 on the top. V01L1FA Pivot the bottom of rear luggage rack toward in- side of ATV.
Page 209: Rear Mudguard/Facia
Section 10 BODY/FRAME Subsection 02 (BODY) REAR MUDGUARD/FACIA Rear Fender Cover Remove rear luggage rack. Removal Remove screws no. 44 under rear facia. 18, Rear Mudguard Remove screws no. 47 retaining mudguard and rear fender. Remove screws retaining mudguard and side pan- V01L1HB Lift the rearward of the rear fender and remove V01L1IB...
Page 210: Skid Plate
Section 10 BODY/FRAME Subsection 02 (BODY) Installation ARM PROTECTOR Installation is the reverse order of removal. How- Removal ever, pay attention to the following details. Remove the bolts. For the rear facia installation, install the flat wash- ers between rear fender and rear facia with a nee- dle nose pliers.
Page 211: Seat Adjustment
Section 10 BODY/FRAME Subsection 02 (BODY) SEAT ADJUSTMENT For latch stud no. 56 adjustment, unscrew the latch stud nut no. 57 and screw or unscrew the latch stud to the best height. See the following illustration. 1. Lock pin 2. Adjustment nut (apply Loctite 271) F01L3YA A.
Page 212: Seat Cleaning
Section 10 BODY/FRAME Subsection 02 (BODY) SEAT CLEANING Using a pencil and the decal as a template, mark the area where decal will be located. It is recommended to clean the seat with a solu- Remove half of the decal back protective film and tion of warm soapy water, using a soft clean align decal with marks.
Page 213: Plastic Maintenance
Section 10 BODY/FRAME Subsection 02 (BODY) PLASTIC MAINTENANCE MAINTENANCE Clean the vehicle thoroughly, removing all dirt and grease accumulation. To clean use a soft clean cloth and either soapy water or isopropyl alcohol. To remove grease, oil or glue use isopropyl alco- hol.
Page 214: Plastic Repair
Section 10 BODY/FRAME Subsection 02 (BODY) PLASTIC REPAIR REPAIR The very first step before repairing plastic materials is to find out exactly which type of material is involved. Refer to following chart. CAUTION: Consult the plastic maintenance chart carefully, some maintenance products are not com- patible with certain plastics.
Page 215: Frame
Section 10 BODY/FRAME Subsection 03 (FRAME) FRAME 10-03-1 http://ReadManuals.com...
Page 216: 1, Footrest
Section 10 BODY/FRAME Subsection 03 (FRAME) 1, FOOTREST 3, REAR EXTENSION FRAME Removal Removal Remove footpeg and side panel. Refer to BODY Remove rear fender. Refer to BODY 10-02. 10-02. Remove: Remove M8 x 20 mounting flanged bolts no. 6 and –...
Page 217: 4, Winch Plate
Section 10 BODY/FRAME Subsection 03 (FRAME) Remove M10 x 55 mounting flanged bolts no. 10 and the flanged nuts no. 11. 1. Remove M8 x 20 flanged bolts Inspection Check for crack or other damage. Change if neces- sary. Installation Installation is the reverse of removal procedure.
Page 218 Section 10 BODY/FRAME Subsection 03 (FRAME) CAUTION: Before performing electrical weld- ing anywhere on the vehicle, unplug the multi- ple connector at the MPEM. Also unplug the negative cable and the voltage regulator. This will protect the MPEM and battery against damage caused by flowing current when weld- ing.
Page 219: Technical Data
Section 11 TECHNICAL DATA Subsection 01 (SI METRIC INFORMATION GUIDE) TECHNICAL DATA SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length ..............meter ............. mass ..............kilogram ..........force ..............newton ........... liquid ..............liter ............temperature ............Celsius ........... °C pressure ..............
Page 220 Subsection 02 (ENGINE AND VEHICLE) ENGINE AND VEHICLE VEHICLE MODEL 7400/7401 7413/7414 7415/7416/7417/7418 Engine type BOMBARDIER-ROTAX 511, longitudinal mount, liquid cooled Starting system Electric and manual Number of cylinder(s) Number of valves 2 valves with hydraulic lifters (no adjustment) Decompressor type...
Page 221 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) VEHICLE MODEL 7400/7401 7413/7414 7415/7416/7417/7418 Thermostatic Opening temperature 96°C (205°F) Fan thermostat Closing temperature 102°C (221°F) Opening temperature 85°C (185°F) Engine thermostat Closing temperature 75°C (167°F) Radiator cap opening pressure 90 kPa (13 PSI) Type Dual range (HI-LO) with park, neutral and reverse Transmission...
Page 222 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) VEHICLE MODEL 7400/7401 7413/7414 7415/7416/7417/7418 TIRE Recommended 48 kPa (7 PSi) Front Minimum 45 kPa (6.5 PSi) Pressure Recommended 38 kPa (5.5 PSi) Rear Minimum 34.5 kPa (5 PSi) Minimum tire thread depth 4 mm (0.16 in) Front 635 x 203 x 305 mm (25 x 8 x 12 in)
Page 223 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) VEHICLE MODEL 7400/7401 7413/7414 7415/7416 7417/7418 Material Steel Frame Color Black Material Steel Front/rear rack Color Black Material Steel Front bumper Color Silver Material High density polyethylene Front/rear fender Color Green Material High density polyethylene Fuel tank cover...
Page 224 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) VEHICLE MODEL 7400/7401 7413/7414 7415/7416 7417/7418 WHEEL Wheel nuts 75 N•m (55 lbf•ft) STEERING/CONTROL Upper/lower A-arm lock nut 75 N•m (55 lbf•ft) Tie rod ends 75 N•m (55 lbf•ft) Steering arm (castellated nut) 75 N•m (55 lbf•ft) Steering column support screws 24 N•m (17 lbf•ft)
Page 225: Wiring Diagram
Section 12 WIRING DIAGRAM Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) Subsection 01 (WIRING DIAGRAM) WIRING DIAGRAM WIRING CONNECTORS CODING CONNECTOR HOUSING AREA WARNING Ensure all terminals are properly crimped on the wires and all connector housings are properly fastened. XX/XX 1-02D THE SHADED PART INDICATES THE CONNECTOR HOUSING...
Page 226 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) CONNECTOR LOCATION IN HOUSING This is the wire position in the connector. The number or letter given refers to the physical identification stamped on the connector. THE SHADED PART INDICATES THE CONNECTOR LOCATION IN HOUSING A00E4WB TYPICAL...
Page 227 (Electric Components) REFER TO Is emergency sh fter shaft mov ng wh e Prob em w th the press ng upsh ft/downsh ft button ? sh ft ng system (Hydraulic/Mechanical Components) Check fuse(s) Recheck e ectr c sh ft system Change fuse Is fuse burned ? Is the prob em...
Page 228 ANNEX 2 (Hydraulic/Mechanical Components) (Electric Components) SERVICE REPRESENTATIVE.

This manual is also suitable for:

Traxter 7415 Traxter 7417 Traxter 7414 Traxter 7416 Traxter 7413 Traxter 7401 ... Show all

BOMBARDIER Traxter 7400 Shop Manual

Table of Contents

Table of Contents

Service Tools

Service Products

Maintenance

Table of Contents

Noise Emission Control System Regulation

Maintenance Chart

Maintenance Chart

Maintenance/Lubrication

Storage/Pre-Season Preparation

Storage

Pre-Season Preparation

Engine

Table of Contents

Removal and Installation

Cooling System

Rewind Starter

Magneto System

Cylinder and Head

Crankshaft/Balancer Shaft

Lubrication System

Clutch

Gear Shift System

Transmission

Transmission

Fuel System

Table of Contents

Fuel Circuit

Carburetor

Carburetor and Fuel Pump

Fuel Pump

Air Intake Silencer

Electrical

Table of Contents

Overview

General Operation Information

General Testing/Troubleshooting Information

Charging System

Battery

Starting System

Starting System Troubleshooting

Starting System Tests

Electric Starter

Ignition System

Ignition System Testing Procedure

Spark Plug

Ngk Spark Plug Symbol Explanation

General

Electric Shift System

Troubleshooting

Diagnostic/Calibration Mode

Valve Removal/Installation

Sensor Removal/Installation

Valves/Solenoids Tests

Sensor Tests

Upshift/Downshift Switch Tests

Instruments and Accessories

Removal and Installation

Tests

Drive Train

Table of Contents

Front Differential

Rear Axle

Table of Contents

Suspension

Table of Contents

Front Suspension

Rear Suspension

Brakes

Table of Contents

Front Brakes

Hydraulic Brakes

Rear Brake

Table of Contents

Body Parts

Seat

Plastic Maintenance

Plastic Repair