Bombardier Traxter 7401 Manuals

Manuals and User Guides for Bombardier Traxter 7401. We have 1 Bombardier Traxter 7401 manual available for free PDF download: Shop Manual

Bombardier Traxter 7401 Shop Manual (228 pages)

Bombardier 1999 ATV Shop manual

Brand: Bombardier | Category: Offroad Vehicle | Size: 15.07 MB

Table of Contents

1
- Introduction
  3
- 01 Service Tools and Service Products
  5
  - General Information
    8
  - Tightening Torques
    9
Table of Contents

11
- Service Tools
  
  12
  - Engine - Mandatory Service Tools
    13
    
    Engine - Recommended Service Tools
    14
    
    Electrical - Mandatory Service Tools
    16
    
    Electrical - Recommended Service Tools
    17
    
    Suspension - Mandatory Service Tools
    18
    
    Suspension - Recommended Service Tools
    19
    
    Drive - Mandatory Service Tools
    20
    
    Drive - Recommended Service Tools
    21
    
    Vehicle - Mandatory Service Tools
    22
    
    Vehicle - Recommended Service Tools
    23
- Service Products
  
  24
  - Mandatory Service Products
    24
    
    Recommended Service Products
    25
Maintenance

26
- Table of Contents
  
  26
- Noise Emission Control System Regulation
  
  27
  - Tampering with Noise Control System Prohibited
    27
  - Among those Acts Presumed to Constitute Tampering Are the Acts Listed below
    27
- Maintenance Chart
  
  27
- Maintenance Chart
  
  28
  - Maintenance and Lubrication
    30
- Maintenance/Lubrication
  
  30
  - Air Filter Cleaning/Draining
    30
  - Bolts, Fasteners and Nuts
    31
  - Engine Oil and Filter
    31
  - Spark Arrester
    32
  - Tires and Wheels
    33
  - Engine Compartment
    34
  - Storage and Pre-Season Preparation
    35
- Storage/Pre-Season Preparation
  
  35
- Storage
  
  35
  - Fuel Stabilizer
    35
  - Engine Lubrication
    35
  - Rags in Air Intake and Exhaust System
    35
  - Vehicle Cleaning and Protection
    35
  - Coolant Density
    36
- Pre-Season Preparation
  
  37
Engine

38
- Table of Contents
  
  38
- Removal and Installation
  
  40
  - Engine Removal
    41
    
    Engine Installation
    43
    
    Anti-Vibration System
    43
    
    Exhaust System
    44
    
    Shifting System
    45
- Cooling System
  
  47
  - Cooling System Leak Test
    48
    
    Inspection
    48
    
    Draining the System
    48
    
    Cooling System Refilling
    48
    
    Pressure Cap
    49
    
    Radiator
    49
    
    Thermostat
    49
    
    Coolant Tank
    50
    
    Fan and Outlet Deflector
    50
    
    Temperature Sender
    50
- Rewind Starter
  
  51
  - Rewind Starter
    52
    
    Starting Pulley
    54
- Magneto System
  
  55
  - Magneto
    56
  - Rotor
    56
  - Sparg Clutch
    57
- Cylinder and Head
  
  58
  - 1, Cylinder Head
    59
  - 2, Push Rod
    59
  - 3, Rocker Arm
    59
  - 4, Valve Spring
    60
  - 5, Valve
    61
  - 6, Valve Stem Seal
    61
  - 7, Cylinder
    62
  - 8, Lifter
    63
  - 9, Piston
    63
  - 10, Piston Rings
    64
- Crankshaft/Balancer Shaft
  
  66
  - 1, Camshaft
    67
  - 2, Balancer Shaft
    68
  - 3, Crankshaft
    68
- Lubrication System
  
  69
  - Troubleshooting
    70
  - Engine Pressure Test
    70
  - Oil Change and Oil Filter Replacement
    70
  - Oil Strainer
    71
  - Engine Oil Pressure Regulator
    71
  - Oil Pump
    72
  - Clutch Oil Pressure Regulator
    72
- Clutch
  
  73
  - Clutch Drum, Clutch Weight and Sprag Clutch
    74
  - Friction Drive Plate, Steel Driven Plate and Clutch Basket
    75
- Gear Shift System
  
  79
- Transmission
  
  79
- Transmission
  
  80
  - Gear Shift Mechanism
    81
  - Transmission
    82
Fuel System

84
- Table of Contents
  
  84
- Fuel Circuit
  
  85
  - Fuel Lines
    86
    
    Fuel Tank Strainer
    86
    
    Fuel Valve
    87
    
    Fuel Tank
    87
    
    Fuel Gauge
    88
    
    Fuel System Pressurization
    88
- Carburetor
  
  90
  - Removal
    90
  - Cleaning and Inspection
    91
  - Carburetor Float Level Adjustment
    91
  - Installation
    92
  - Carburetor Adjustments
    93
  - Pilot Screw Adjustment
    94
- Carburetor and Fuel Pump
  
  90
- Fuel Pump
  
  96
  - Removal
    96
  - Verification
    96
  - Cleaning and Inspection
    96
  - Installation
    96
- Air Intake Silencer
  
  97
  - Air Filter Box
    98
    
    Rear Air Intake Tube
    98
    
    Front Air Intake Tube
    98
    
    Pcv Valve
    98
Electrical

100
- Table of Contents
  
  100
- Overview
  
  103
- General Operation Information
  
  103
  - Mpem (Multi-Purpose Electronic Module)
    103
  - Charging System
    103
  - Starting System
    104
  - Ignition System
    104
  - Electric Shift System
    105
  - Gauges/Accessories
    105
- General Testing/Troubleshooting Information
  
  106
- Charging System
  
  114
  - Testing Procedure
    114
- Battery
  
  116
  - Troubleshooting
    116
  - Battery Testing
    116
  - Removal
    117
  - Cleaning
    117
  - Inspection
    117
  - Battery Storage
    117
  - Activation of a New Battery
    118
  - Tips for Charging a Used Battery
    119
  - Charging 2 or more Batteries at a Time
    120
  - Installation
    120
- Starting System
  
  116
- Starting System Troubleshooting
  
  121
- Starting System Tests
  
  122
- Electric Starter
  
  124
  - Removal
    124
  - Installation
    124
- Ignition System
  
  125
- Ignition System Testing Procedure
  
  125
  - General
    125
  - Ignition System Test
    125
  - Ignition Coil
    127
  - Other Ignition System Problems
    128
  - Ignition Timing
    128
- Spark Plug
  
  129
  - Disassembly
    129
  - Heat Range
    129
  - Fouling
    129
  - Spark Plug Analysis
    129
  - Spark Plug Installation
    130
- Ngk Spark Plug Symbol Explanation
  
  131
- General
  
  132
- Electric Shift System
  
  132
- Troubleshooting
  
  132
- Diagnostic/Calibration Mode
  
  132
  - Preparation
    133
  - Testing
    134
- Valve Removal/Installation
  
  140
  - Shifting Valve
    140
  - Clutching Valve
    140
  - Clutch Modulator Valve
    141
- Sensor Removal/Installation
  
  142
- Valves/Solenoids Tests
  
  144
  - Clutching Valve and Clutch Modulator Valve Tests
    144
  - Upshift/Downshift Solenoids Tests
    144
- Sensor Tests
  
  146
  - Stps (Sub-Transmission Position Sensor) and Gbps (Gear Box Position Sensor) Tests
    146
  - Vss (Vehicle Speed Sensor) Tests
    146
- Upshift/Downshift Switch Tests
  
  147
  - Upshift/Downshift Switch
    147
- Instruments and Accessories
  
  148
- Removal and Installation
  
  148
  - 12-Volt Auxiliary Power Outlet
    148
  - 12-Volt Power Outlet
    148
  - Headlight
    148
  - Ignition Switch
    149
  - Indicator Lights
    150
  - Mpem
    150
  - Speedometer
    150
- Tests
  
  152
  - 12-Volt Auxiliary Power Outlet
    152
  - 12-Volt Power Outlet
    152
  - Cooling Fan Operation Test
    152
  - Headlight
    152
  - Hi-Lo Switch
    152
  - Indicator Lights
    153
  - Speedometer
    153
Drive Train

154
- Table of Contents
  
  154
- Front Differential
  
  155
  - Front Drive Shaft
    156
    
    Front Differential
    157
    
    Front Propeller Shaft
    158
- Rear Axle
  
  161
  - Rigid Axle
    162
    
    Rear Propeller Shaft
    164
Table of Contents

166
- Steering/Control
  167
  - Steering/Control Systems
    167
    
    Handle Bar
    168
    
    Steering Column
    168
    
    Tie-Rod
    168
    
    Steering Column Bearing
    169
    
    Multi-Function Switch
    169
    
    Throttle Handle
    170
    
    Lh Handle Brake
    170
    
    Rh Handle Brake
    171
Suspension

172
- Table of Contents
  
  172
- Front Suspension
  
  173
  - Shocks Assembly
    174
    
    Upper A-Arm
    175
    
    Lower A-Arm
    176
    
    Knuckle
    177
    
    Wheel Bearing Condition
    178
- Rear Suspension
  
  179
  - Rear Shock
    180
    
    Swing Arm
    181
Brakes

185
- Table of Contents
  
  185
- Front Brakes
  
  186
- Hydraulic Brakes
  
  186
- Rear Brake
  
  187
  - General
    188
  - Master Cylinder
    188
  - Caliper
    189
  - Brake Pads
    190
  - Brake Disc
    191
  - Brake Pedal
    192
  - Brake Cable
    193
  - Interlock Cable
    193
  - Brake Hoses and Brake Tubes
    194
  - Brake System Bleeding
    196
  - Brake Light Switch
    197
Table of Contents

198
- Body Parts
  
  199
- Seat
  
  201
  - Seat/Engine Cover
    202
  - Storage/Steering/Shifter Guide Cover
    203
  - Front Skid Plate/Bumper/Luggage Rack
    203
  - Front Fender/Mudguard/Facia
    204
  - Inner Fender
    206
  - Fuel Tank Cover/Side Panel
    206
  - Rear Luggage Rack
    207
  - Rear Fender/Rear Fender Cover
    208
  - Rear Mudguard/Facia
    209
  - Skid Plate
    210
  - Arm Protector
    210
  - Latch Lever/Latch Base/Spring
    210
  - Seat Adjustment
    211
  - Seat Cover Replacement
    211
  - Storage Cover Latch
    211
  - Seat Cleaning
    212
  - Decals Replacement
    212
  - Hitch/Trailer Ball
    212
- Plastic Maintenance
  
  213
  - Maintenance
    213
- Plastic Repair
  
  214
  - Repair
    214
- Frame
  
  215
  - 1, Footrest
    216
  - 2, Removable Brace
    216
  - 3, Rear Extension Frame
    216
  - 4, Winch Plate
    217
  - 5, Frame
    217
    
    Technical Data
    219
    
    Wiring Diagram
    225

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Bombardier Traxter 7401 Manuals

Bombardier Traxter 7401 Shop Manual (228 pages)

Table of Contents

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