BRP BOMBARDIER DS250 2006 Shop Manual
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BRP BOMBARDIER DS250 2006 Shop Manual

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Summary of Contents for BRP BOMBARDIER DS250 2006

  • Page 1 2006-2019...
  • Page 2 2006 -2019 Shop Manual DS 250...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTICE ................... VII INTRODUCTION .................. VIII GENERAL INFORMATION..................VIII VEHICLE SERIAL NUMBER LOCATION .
  • Page 5 TABLE OF CONTENTS MUFFLER ......................38 EXHAUST PIPE .
  • Page 6 TABLE OF CONTENTS OIL SEAL REPLACEMENT ..................102 GEARBOX DISASSEMBLY .
  • Page 7 TABLE OF CONTENTS FUSES....................... 150 HEADLAMP.
  • Page 8 TABLE OF CONTENTS BRAKING SYSTEM 01 – FRONT AND REAR BRAKES................209 ALL MODELS EXCEPT EUROPEAN MODELS .
  • Page 9 TABLE OF CONTENTS REAR FRAME EXTENSION..................250 FRONT FENDER SUPPORT .

  • Page 10: Safety Notice

    The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser- vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read and understand these. It does not include dealer modifications, whether authorized or not by BRP, after manufacturing the product.

  • Page 11: Introduction

    E.I.N. (ENGINE IDENTIFICATION NUMBER) scription and/or specifications in this document. BRP reserves the right at any time to discontinue ARRANGEMENT OF THE or change specifications, designs, features, mod- MANUAL, ILLUSTRATIONS els or equipment without incurring obligation.
  • Page 12 INTRODUCTION As many of the procedures in this manual are inter- related, we suggest, that before undertaking any task, you read and thoroughly understand the en- tire section or subsection concerning the proce- dure. A number of procedures throughout the book re- quire the use of special tools.
  • Page 13 INTRODUCTION vmr2006-060...
  • Page 14 INTRODUCTION vmr2006-060...

  • Page 15: Self-Locking Fasteners Procedure

    INTRODUCTION SELF-LOCKING FASTENERS Blind Holes PROCEDURE The following describes the most common appli- cation procedures when working with self-locking fasteners. Use a metal brush or a screw tap to clean the hole properly then use a solvent, let act during 30 minutes and wipe off.
  • Page 16 INTRODUCTION – Apply drops of proper strength Loctite on un- NOTE: if it is difficult to readjust, heat screw with covered threads. a soldering iron (232°C (450°F)). – Tighten nuts as required. Stripped Thread Repair Preassembled Parts 1. Release agent 2.
  • Page 17 INTRODUCTION Gasket Compound Mounting on Shaft Mounting with a Press 1. Bearing 2. Proper strength Loctite 3. Shaft A00A3SA – Clean shaft external part and element internal part. 1. Proper strength Loctite 2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518 –...
  • Page 18 INTRODUCTION NOTE: Any Loctite product can be used here. A low strength liquid is recommended as normal strength and gap are required. – Install according to standard procedure. – Wipe off surplus. – Allow it to cure for 30 minutes. NOTE: Normally used on worn-out housings to prevent leaking or sliding.

  • Page 19: Tightening Torques

    INTRODUCTION TIGHTENING TORQUES Tighten fasteners to torque mentioned in exploded views and/or text, When they are not specified, refer to following table. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones, where specified.

  • Page 20: Maintenance

    Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) MAINTENANCE CHART NOISE EMISSION CONTROL SYSTEM REGULATION Tampering with noise control system is 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 21: Maintenance Chart

    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: ATV rental operations or intensive use of ATV, will require greater frequency of inspection and maintenance.
  • Page 22 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) INITIAL INSPECTION 10 HOURS OR 30 DAYS OR 200 KM (125 mi) A: ADJUST (The initial maintenance is very important and must not be neglected.) C: CLEAN EVERY 25 HOURS OR 500 KM (310 mi) I: INSPECT EVERY 50 HOURS OR 1000 KM (620 mi) L: LUBRICATE...
  • Page 23 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) INITIAL INSPECTION 10 HOURS OR 30 DAYS OR 200 KM (125 mi) A: ADJUST (The initial maintenance is very important and must not be neglected.) C: CLEAN EVERY 25 HOURS OR 500 KM (310 mi) I: INSPECT EVERY 50 HOURS OR 1000 KM (620 mi) L: LUBRICATE...

  • Page 24: Preseason Preparation

    Section 01 MAINTENANCE Subsection 02 (PRESEASON PREPARATION) PRESEASON PREPARATION SERVICE PRODUCTS Description Part Number Page pulley flange cleaner............. 413 711 809 ..........5 Prior to use vehicle, proper vehicle preparation is required if vehicle was not used for more than four consecutive months or after performing the stor- age procedure.

  • Page 26: Storage Procedures

    Part Number Page BRP Cleaner ................. 293 110 001 ..........8 BRP Vinyl & Plastic Cleaner..........413 711 200 ..........8 fuel stabilizer................. 413 408 600 ..........7 storage oil ................413 711 600 ..........7 storage oil ................413 711 900 ..........7 XP-S Lube ................

  • Page 27: Cvt Transmission

    Remove any dirt or rust. To clean the vinyl or plastic parts, use only flannel clothes with BRP Vinyl & Plastic Cleaner (P/N 413 711 200). CAUTION: It is necessary to use flannel cloths on plastic parts to avoid damaging surfaces.
  • Page 28 Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) vmr2006-063-004 MUFFLER — LH REAR SIDE OF VEHICLE Protection 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 and covered with an opaque tarpaulin.

  • Page 30: Special Procedures

    Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) SPECIAL PROCEDURES SERVICE PRODUCTS Description Part Number Page XP-S Lube ................293 600 016 ........... 11 ATV IMMERSION ATV Submerged for a Long Time (over one hour) Disassemble engine and transmission to clean the internal parts and check if there is no rust or corro- sion on any internal parts.

  • Page 32: Troubleshooting

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

  • Page 33: Lubrication System

    Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE DOES NOT START — NO SPARK. Symptom: (cont’d) 3. Verify condition of trigger coil. Mechanically damaged part. Vibration problem. Electrically damaged part. Replace trigger coil and/or tighten mounting screw(s). Metallic particles caused a short circuit between the soldered connections. Clean trigger coil from metallic dust.

  • Page 34: Cylinder Head

    Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION. Symptom: (cont’d) 5. Check leak indicator hole if oil leaks (under magneto cover). Oil leaking from leak indicator hole means a damaged oil seal and/or O-ring on water pump cover. Replace both oil seals and O-rings (refer to COOLING SYSTEM).

  • Page 35: Crankshaft

    Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) CRANKSHAFT UNUSUAL ENGINE NOISE AND/OR VIBRATIONS. Symptom: 1. Check crankshaft deflection. The crankshaft deflection is out of specification. Replace. 2. Check crankshaft bearings. Ball bearings do not turn smoothly and freely. Replace bearings. 3.

  • Page 36: Cvt

    Symptom: 1. Check items 1 to 3 of THE ATV ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED. 2. Check driven pulley spring tension. Spring tension is too stiff. Replace spring (recommended BRP spring). PULLEY NOISE AT IDLE SPEED. Symptom: 1. Check slide pieces (drive pulley).
  • Page 37 Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) PULLEY NOISE WHEN ACCELERATING/DECELERATING. Symptom: 1. Check items 1 to 5 of PULLEY NOISE AT IDLE SPEED. 2. Check if belt runs in dry conditions. Drive pulley area is wet/contaminated due to water/dirt intrusion. Clean driven pulley area and/or drain water out of CVT cover.

  • Page 38: Engine General

    Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) BELT SIDES WORN CONCAVE. Symptom: (cont’d) 2. Check drive belt identification number. Unspecified type of belt. Replace belt with an appropriate drive belt (refer to TECHNICAL SPEC- IFICATIONS). BELT DISINTEGRATION. Symptom: 1. Check drive belt identification number. Excessive belt speed.
  • Page 39 Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE SUDDENLY TURNS OFF. Symptom: (cont’d) 3. Perform engine leak test. Check for possible piston seizure. Damaged head gasket and/or seal and/or leaking inlet/exhaust valve(s). Replace and/or repair defective parts. 4. Piston seizure. Spark plug heat range is too low.

  • Page 40: Starting System

    Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH Symptom: MAXIMUM OPERATING RPM. (cont’d) 7. Check for water in fuel (wrong fuel). There is water in fuel or wrong fuel. Drain fuel system, search for leakage and refill it with ap- propriate fuel.
  • Page 41 Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) STARTER DOES NOT TURN. Symptom: (cont’d) 3. Poor contact of battery terminal(s) or ground cable connections. Clean and tighten terminal(s). 4. Weak battery. Recharge battery. 5. Poor contact or open circuit of: start button, engine stop switch, ignition switch or starting solenoid.

  • Page 42: Engine

    Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) ENGINE REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number Page engine removal hook ............529 035 829 ........... 26 GENERAL WARNING Before performing any service or inspection operation on the vehicle, wait until the engine and exhaust have cooled down to avoid po- tential burns.
  • Page 43 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) Disconnect engine temperature sensor, bypass hose and coolant outlet hose. mmr2006-066-001_a Remove radiator cap. Drain engine coolant. Drain plug is located on wa- vmr2006-066-003_a ter pump cover. Disconnect engine vent tube. NOTE: Use a container to recover coolant.
  • Page 44 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) Disconnect gearbox switch connectors. vmr2006-066-007_a Remove carburetor from intake manifold and from air intake hose. vmr2006-066-005_a From LH Side of Vehicle: Remove spark plug cap. vmr2006-066-008_a Temporarily attach carburetor to body for engine removal.
  • Page 45 Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) vmr2006-066_a Engine Removal vmr2006-066-011 Remove engine mount bolts. Remove engine mount nuts. Remove LH and RH front engine supports. vmr2006-066-012_a vmr2006-066-010_a Carefully pull out engine from left side. Turn steering on RH side to make room. Install engine removal hook (P/N 529 035 829), in engine hook and lift tool to support engine weight.

  • Page 46: Inspection

    Section 03 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) vmr2006-069-006_b Step 1: Positive first Step 2: Negative last Refill cooling system. Refer to COOLING SYS- TEM. vmr2006-066-013 Refill engine with oil. Refer to LUBRICATION INSPECTION SYSTEM. Check throttle and choke cables adjustment. Re- Check parts for cracks, corrosion or any other de- fer to FUEL SYSTEM.

  • Page 48: Engine Leak Test

    Section 03 ENGINE Subsection 02 (ENGINE LEAK TEST) ENGINE LEAK TEST SERVICE TOOLS Description Part Number Page camshaft locking tool............529 036 055 ........... 30 leak down tester..............529 035 661 ........... 30 GENERAL PROCEDURES Before performing the engine leak test, verify the Preparation following: CAUTION: Perform leak down testing with the...
  • Page 49 Section 03 ENGINE Subsection 02 (ENGINE LEAK TEST) – Unscrew the magneto access plug. mmr2006-073-005_a mmr2006-073-008_a – Turn drive pulley clockwise to bring piston at How to Lock Piston at TDC TDC. Align TDC mark besides the letter “T” as (compression) shown.
  • Page 50 Section 03 ENGINE Subsection 02 (ENGINE LEAK TEST) Connect the tester to an air supply. Set gauge needle to zero (0). NOTE: Each tester will have specific instruction on the gauge operation and required pressure. Connect the tester to the adaptor hose. Supply combustion chamber with air pressure.

  • Page 52: Air Intake System

    Section 03 ENGINE Subsection 03 (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 5150 (silicone sealant) ..........293 800 086 ........... 35 vmr2006-068-001_a vmr2006-068...

  • Page 53: General

    Section 03 ENGINE Subsection 03 (AIR INTAKE SYSTEM) GENERAL If vehicle is used in dusty area, inspect more fre- quently than specified in maintenance chart. CAUTION: Do not start engine when liquid or deposits are found in the drain tube. If you have oil in the air filter housing, check engine oil level.

  • Page 54: Air Injection Valve Filter

    Section 03 ENGINE Subsection 03 (AIR INTAKE SYSTEM) vmr2006-068-003_a 1. Air intake duct 2. Air filter housing 3. Exhaust shield vmo2006-014-044_a Remove air filter, see procedure above. TYPICAL Unscrew bolts holding air filter housing to frame 1. Air filter housing 2.
  • Page 55 Section 03 ENGINE Subsection 03 (AIR INTAKE SYSTEM) vmo2006-014-066_b 1. Air injection valve Remove air injection valve from its supports. While holding one half, turn the other half counter- clockwise to open. Extract filters from air injection valve. vmo2006-014-073_a 1. Air injection valve filters Cleaning Pour cleaning solution (P/N 219 700 341) or an equivalent into a bucket.

  • Page 56: Exhaust System

    Section 03 ENGINE Subsection 04 (EXHAUST SYSTEM) EXHAUST SYSTEM vmr2006-069-001 vmr2006-069...

  • Page 57: General

    Section 03 ENGINE Subsection 04 (EXHAUST SYSTEM) GENERAL WARNING Before performing any service or inspection operation on the vehicle, wait until the engine and exhaust have cooled down to avoid po- tential burns. WARNING Always disconnect battery or starter cables exactly in the specified order, BLACK (-) cable first.

  • Page 58: Spark Arrester

    Section 03 ENGINE Subsection 04 (EXHAUST SYSTEM) vmr2006-069-005_a vmo2006-014-042_a 1. Remove muffler end Inspection 2. Muffler Check part for cracks, rust or any other default. Replace damaged part as necessary. Installation Installation is the reverse procedure of removal. However, pay attention to the following. Loosely install pipe and muffler before tightening all parts.

  • Page 60: Lubrication System

    Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) LUBRICATION SYSTEM vmr2006-070-001_a vmr2006-070...
  • Page 61 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) vmr2006-070-002_a ENGINE LUBRICATION 1. Oil strainer 2. Oil pump 3. Lubrication outlet 4. Connecting rod 5. Lubrication spray 6. Camshaft 7. Valve rocker arm vmr2006-070...

  • Page 62: General

    Oil Viscosity SAE 5W30 is recommended for all seasons. However, during the hottest days of the summer the BRP XP-S 10W40 mineral oil (P/N 219 700 346) can be used. NOTE: For improved overall performance and all vmo2006-007-013_a...
  • Page 63 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) vmo2006-014-035_a LH SIDE UNDERNEATH CVT COVER 1. Oil drain plug TYPICAL Unscrew the oil strainer cover. 1. Full 2. Add Allow enough time for oil to flow out of oil strainer hole. To add oil, remove the dipstick. Place a funnel into the dipstick tube to avoid spillage.

  • Page 64: Engine Oil Pressure

    Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) vmo2006-014-037_a 1. Cover 2. O-ring 3. Spring 4. Strainer vmr2006-070-003_a Reinstall oil strainer, spring, O-ring and torque cov- 1. Bypass hole er to 15 N•m (133 lbf•in). NOTE: If oil pressure is low (as per ENGINE OIL Verify drain plug washer condition and replace it if PRESSURE), check ball of oil pressure relief valve necessary.
  • Page 65 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) Remove oil pump shaft roller and shaft. vmr2006-070-007_a Inspection vmr2006-070-004 Inspect and clean oil passages. Remove circlip. Check inner rotor and oil pump housing for pitting, scratches or other damage. Check side contact surface of rotor and friction plate.
  • Page 66 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) vmr2006-070-011_a vmr2006-070-009 INNER ROTOR AND OUTER ROTOR CLEARANCE 0.15 mm (.006 in) vmr2006-070-012_a SERVICE LIMIT 0.20 mm (.008 in) Properly torque screws. Check clearance between rotor side face and pump housing. vmr2006-070-006_a Make sure oil pump shaft can be turned freely. vmr2006-070-010 Ensure to properly lock sprocket with circlip.
  • Page 67 Section 03 ENGINE Subsection 05 (LUBRICATION SYSTEM) Reinstall magneto flywheel and cover. Refer to MAGNETO AND STARTER DRIVE. Refill engine with the recommended oil. Verify if lubrication system is working properly. Refer to ENGINE OIL PRESSURE. vmr2006-070...

  • Page 68: Cooling System

    Section 03 ENGINE Subsection 06 (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number Page special radiator cap ............... 529 035 991 ........... 52 water pump oil seal installer..........529 036 052 ........... 57 SERVICE PRODUCTS Description Part Number Page Loctite 5910................
  • Page 69 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) WATER PUMP vmr2006-071-001_a vmr2006-071...
  • Page 70 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) COOLING SYSTEM vmr2006-071-002_a vmr2006-071...

  • Page 71: General

    Section 03 ENGINE Subsection 06 (COOLING SYSTEM) GENERAL The engine removal is not necessary when work- ing on water pump, thermostat or thermo-switch. Check general condition of hoses and clamp tight- ness. Air bubbles in radiator when engine is running in- dicates a leaking engine gasket.

  • Page 72: Procedures

    Section 03 ENGINE Subsection 06 (COOLING SYSTEM) PROCEDURES If coolant is added in the coolant reservoir, check also level in radiator. ENGINE COOLANT NOTE: A cooling system that frequently requires coolant is the indication of a leak or an engine prob- Recommended Coolant lem.

  • Page 73: Radiator Cap

    Section 03 ENGINE Subsection 06 (COOLING SYSTEM) vmr2006-071-012_a vmr2006-071-013_a Run engine until air bubbles have all escaped from Pull thermostat out. bleed nipple. Stop engine. Reinstall bleed tube. Carefully remove radiator cap. WARNING Let engine cool down. Otherwise, coolant under pressure will rush out and you might get burned.

  • Page 74: Thermo-Switch

    Section 03 ENGINE Subsection 06 (COOLING SYSTEM) Test Thermostat should open when coolant tempera- ture reaches 82 - 85°C (180 - 203°F). When tem- Thermo-switch is a normally open switch (no con- perature cools down below 82°C (180°F), thermo- tinuity). It controls cooling fan. stat should close.
  • Page 75 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) vmr2006-072-002_a vmr2006-071-018 Remove magneto cover. Refer to MAGNETO Remove inner bearing. AND STARTER DRIVE. Use a claw type hammer puller and pull bearing out from inner race. Remove gasket and dowel pin. Rotate impeller shaft. Bearing must turn smooth- ly and freely.
  • Page 76 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) vmr2006-071-020 vmr2006-071-022 Install inner seal using an appropriate pusher. Inspection Check impeller and impeller shaft for wear and damage. Assembly Assembly is the reverse of disassembly proce- dure. However, pay attention to the following. Apply Loctite 5910 (P/N 293 800 081) on mating surface of seal with its bore.

  • Page 77: Cooling Fan Motor

    Section 03 ENGINE Subsection 06 (COOLING SYSTEM) Install impeller and properly torque. vmr2006-071-024 Install circlip. vmr2006-071-027 Install dowel pin and gasket. Install pump cover. vmr2006-071-025 Install a new seal to impeller shaft. CAUTION: Always install a new seal whenever vmr2006-071-028 mechanical seal is replaced.

  • Page 78: Radiator

    Section 03 ENGINE Subsection 06 (COOLING SYSTEM) vmr2006-071-007_b Use a jumper and connect BLACK/BLUE wire from connector to a good ground. vmr2006-071-006_a Fan should turn. If so, check thermo-switch and Disconnect top hoses from radiator. wiring. If fan does not turn, directly connect wires from a 12 Vdc battery to fan motor connector.
  • Page 79 Section 03 ENGINE Subsection 06 (COOLING SYSTEM) vmr2006-071-009_a vmr2006-071-007_a Pull out radiator with cooling fan. Inspection Check radiator air passage for clogging or damage. Disassembly Remove insects, mud or other obstructions with Remove thermo-switch. compressed air or low pressure water. Remove fan duct screws.

  • Page 80: Magneto And Starter Drive

    Section 03 ENGINE Subsection 07 (MAGNETO AND STARTER DRIVE) MAGNETO AND STARTER DRIVE SERVICE TOOLS Description Part Number Page crankshaft protector ............529 036 051 ........... 66 magneto puller ..............529 036 049 ........... 66 vmr2006-072-001_a vmr2006-072...

  • Page 81: General

    Section 03 ENGINE Subsection 07 (MAGNETO AND STARTER DRIVE) GENERAL Always disconnect battery. WARNING Always disconnect battery cables exactly in the specified order, BLACK (-) cable first. During assembly/installation, use the torque val- ues and service products as in the exploded views.
  • Page 82 Section 03 ENGINE Subsection 07 (MAGNETO AND STARTER DRIVE) vmr2006-072-020_a vmr2006-072-021_a Install magneto cover. Properly torque cover screws. Pay attention to engage water pump shaft end Reinstall water pump cover with a new gasket. onto oil pump shaft. Turn coolant impeller as re- quired.

  • Page 83: Trigger Coil

    Section 03 ENGINE Subsection 07 (MAGNETO AND STARTER DRIVE) TRIGGER COIL Test Refer to IGNITION SYSTEM. Removal Remove magneto cover. Remove trigger coil screws and pull trigger coil out. vmr2006-072-004_b Installation Install stator in magneto cover. Position wiring harness in recess of crankcase. CAUTION: Ensure to route wiring harness un- der trigger coil.

  • Page 84: Flywheel

    Section 03 ENGINE Subsection 07 (MAGNETO AND STARTER DRIVE) Installation Use an appropriate pusher to install magneto cov- er bearing. CAUTION: Always support cover properly when installing bearing. Never use a hammer to install bearing. Use a vmr2006-072-005_a press only. Removal Always heat cover housing up to 100°C (212°F) Remove magneto cover.

  • Page 85: Starter Reduction Gear

    Section 03 ENGINE Subsection 07 (MAGNETO AND STARTER DRIVE) Install crankshaft protector (P/N 529 036 051) on crankshaft end . Use magneto puller (P/N 529 036 049) to remove flywheel. vmr2006-072-017_a Properly torque flywheel nut. CAUTION: Ensure flywheel is well locked to ad- equately apply tightening torque.

  • Page 86: Starting Clutch Gear

    Section 03 ENGINE Subsection 07 (MAGNETO AND STARTER DRIVE) vmr2006-072-016 Installation Installation is essentially the reverse procedure of removal. vmr2006-072-015_a Check outside diameter for hammered surface, STARTING CLUTCH GEAR deformation or scratches. Inspection Measure diameters as follows. Remove magneto cover. STARTING CLUTCH GEAR Remove flywheel.
  • Page 87 Section 03 ENGINE Subsection 07 (MAGNETO AND STARTER DRIVE) vmr2006-072-014 vmr2006-072-011_a Install gear on one way clutch. Turn gear counter- Removal clockwise to ease installation. Remove magneto cover. Remove flywheel. Pull out starting clutch from flywheel. Remove screws then pull out one way clutch. vmr2006-072-015 vmr2006-072-012_a 1.

  • Page 88: Cylinder Head

    Section 03 ENGINE Subsection 08 (CYLINDER HEAD) CYLINDER HEAD SERVICE TOOLS Description Part Number Page valve spring compressor clamp ..........529 035 724 ........74, 80 valve spring compressor cup..........529 035 764 ........74, 80 vmr2006-073-001_a vmr2006-073...

  • Page 89: General

    Section 03 ENGINE Subsection 08 (CYLINDER HEAD) GENERAL Preparation for Adjustment with Engine in Vehicle When diagnosing an engine problem, always per- form a leak test. Refer to ENGINE LEAK TEST. Always place the vehicle on level surface. Always disconnect the negative wire from the bat- tery before working the engine.

  • Page 90: Cylinder Head Removal

    Section 03 ENGINE Subsection 08 (CYLINDER HEAD) mmr2006-073-008_a vmr2006-073-032_a 1. Adjusting screw Adjustment 2. Lock nut When marks are properly aligned, check valve Turn adjustment screw as required. clearance with a feeler gauge. When adjustment is appropriate, hold adjusting NOTE: All valves can be adjusted in this position. screw while tightening locking nut.
  • Page 91 Section 03 ENGINE Subsection 08 (CYLINDER HEAD) mmr2006-073-002_a mmr2006-073-004_a Remove air injection system pipe and spark plug. Remove magneto access plug. mmr2006-073-003_a Remove valve cover. mmr2006-073-005_a Remove CVT cover. Turn drive pulley clockwise to bring piston at TDC. Align TDC mark as shown. mmr2006-073-007_a Remove cylinder head side cover.
  • Page 92 Section 03 ENGINE Subsection 08 (CYLINDER HEAD) mmr2006-073-009_a NOTE: Attach timing chain to prevent it from falling. Remove camshaft locking plate. mmr2006-073-006_a TDC MARK BESIDES THE “T” ALIGNED Screw in a M5 x 0.8 x 75 screw in rocker arm shaft end then pull it out.

  • Page 93: Cylinder Head Disassembly

    Section 03 ENGINE Subsection 08 (CYLINDER HEAD) vmr2006-073-012_a mmr2006-073-011_a CYLINDER HEAD DISASSEMBLY Remove small mounting bolts. Valve Use valve spring compressor clamp (P/N 529 035 724) and valve spring compressor cup (P/N 529 035 764). vmr2006-073-011_a Remove cylinder head retaining nuts. Remove cylinder head.

  • Page 94: Cleaning

    Section 03 ENGINE Subsection 08 (CYLINDER HEAD) TYPICAL — LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF THE VALVE vmr2006-073-017_a 1. Valve cotter CAUTION: To avoid changing spring character- istics, do not compress too much. Compress spring about the length of valve cotter. vmr2006-073-018_a Carefully remove clamp then pull out valves.
  • Page 95 Section 03 ENGINE Subsection 08 (CYLINDER HEAD) Inspect valve condition. Valve blade should not be bent and should rest against its seat. vmr2006-0-73-021_a 1. Bearing 2. Lobe vmr2006-073-050_a 3. Bearing Replace valve as necessary. Measure cam lobe with a micrometer. Cylinder Head Check if spark plug and valve ports are cracked.
  • Page 96 Section 03 ENGINE Subsection 08 (CYLINDER HEAD) A. Valve spring free length VALVE SPRING FREE LENGTH DESCRIPTION INNER OUTER 38.70 mm 40.40 mm vmr2006-073-022 (1.523 in) (1.591 in) 35.20 mm 36.90 mm ROCKER ARM BORE DIAMETER Service limit (1.386 in) (1.453 in) 11.982 - 12.000 mm (.4717 - .4724 in)
  • Page 97 Section 03 ENGINE Subsection 08 (CYLINDER HEAD) VALVE STEM DIAMETER DESCRIPTION INTAKE EXHAUST 4.975 - 4.990 mm 4.950 - 4.975 mm (.1959 - .1965 in) (.1949 - .1959 in) 4.900 mm 4.900 mm Service limit (.1929 in) (.1929 in) Check valve face and seat for burning or pittings. Replace valve or cylinder head if damaged.

  • Page 98: Cylinder Head Assembly

    Section 03 ENGINE Subsection 08 (CYLINDER HEAD) VALVE GUIDE INNER DIAMETER DESCRIPTION INTAKE 5.000 - 5.012 mm (.1968 - .1973 in) Service limit 5.030 mm (.1980 in) If part does not meet requirements, replace cylin- der head. NOTE: Whenever a valve guide is replaced, it must be properly reamed.

  • Page 99: Cylinder Head Installation

    Section 03 ENGINE Subsection 08 (CYLINDER HEAD) vmr2006-073-027_a 1. Tightest coils here 2. Painted area here Use valve spring compressor clamp (P/N 529 035 724) and valve spring compressor cup (P/N 529 035 764) to reinstall valve springs. WARNING vmr2006-073-012_a Install cylinder head and properly torque screws.
  • Page 100 Section 03 ENGINE Subsection 08 (CYLINDER HEAD) To properly perform camshaft timing, do the fol- lowing. – Position crankshaft at TDC. Align TDC mark as shown vmr2006-073-034_a 1. Marks aligned Install and turn rocker arm shafts so that their flat sides align with locking plate. Secure locking plate.
  • Page 101 Section 03 ENGINE Subsection 08 (CYLINDER HEAD) – Torque tensioner screws. – Install tensioner spring and tighten adjuster screw. vmr2006-073-035 vmr2006-073-037 – Recheck camshaft timing marks. NOTE: Ensure crankshaft is still at the proper po- sition. Install remaining components except valve cover and air injection pipe and spark plug.

  • Page 102: Piston And Cylinder

    Section 03 ENGINE Subsection 09 (PISTON AND CYLINDER) PISTON AND CYLINDER SERVICE TOOLS Description Part Number Page piston circlip installer ............529 036 048 ........... 88 vmr2006-074-001_a vmr2006-074...

  • Page 103: General

    Section 03 ENGINE Subsection 09 (PISTON AND CYLINDER) GENERAL When diagnosing an engine problem, always per- form an engine leak test. This will help pinpoint a problem. Refer to the instructions included with your leak tester and ENGINE LEAK TEST section for procedures.

  • Page 104: Inspection

    Section 03 ENGINE Subsection 09 (PISTON AND CYLINDER) vmr2006-073-016_a Clean gasket residues off the contact surfaces. CAUTION: Pay attention not to damage con- tact surface of the gasket. It is better to moist- en the gasket residue for easy scraping. Take care so that no residue falls into crankcase or oil/coolant passages.
  • Page 105 Section 03 ENGINE Subsection 09 (PISTON AND CYLINDER) Measure cylinder head warpage with a straight edge and a feeler gauge. vmr2006-074-050_a vmr2006-074-020 A. 20 mm (.787 in) from top CYLINDER WARPAGE RING END GAP Service limit 0.50 mm (.020 in) 0.15 - 0.30 mm Top ring (.006 - .012 in)
  • Page 106 Section 03 ENGINE Subsection 09 (PISTON AND CYLINDER) PISTON DIAMETER 70.430 - 70.480 mm Nominal (new) (2.773 - 2.775 in) Service limit 70.380 mm (2.771 in) Using a small diameter bore gauge, measure pis- ton pin bore diameter. vmr2006-074-010 PISTON PIN 16.994 - 17.000 mm Nominal (new) (.6691 - .6693 in)

  • Page 107: Assembly

    Section 03 ENGINE Subsection 09 (PISTON AND CYLINDER) ASSEMBLY Assembly is essentially the reverse procedure of disassembly. However, pay attention to the fol- lowing. Carefully install piston ring with their openings on piston as shown. Install oil ring first then other rings going up. Do not align ring openings with piston thrust side axis or piston pin axis.
  • Page 108 Section 03 ENGINE Subsection 09 (PISTON AND CYLINDER) vmr2006-074-006_a TYPICAL Coat cylinder, piston and rings with engine oil. 1. Hold piston while pushing circlip in place 2. Sleeve Use a suitable ring compressor to compress and 3. Circlip installer hold rings while inserting cylinder. 4.

  • Page 110: Crankshaft And Crankcase

    Section 03 ENGINE Subsection 10 (CRANKSHAFT AND CRANKCASE) CRANKSHAFT AND CRANKCASE SERVICE PRODUCTS Description Part Number Page synthetic grease ..............293 550 014 ........... 92 vmr2006-075-020_a vmr2006-075...

  • Page 111: General

    Section 03 ENGINE Subsection 10 (CRANKSHAFT AND CRANKCASE) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded views. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones where specified.
  • Page 112 Section 03 ENGINE Subsection 10 (CRANKSHAFT AND CRANKCASE) vmr2006-075-001_a 1. Locking plate 2. Chain guide vmr2006-075-003_a Remove bolts on the right half crankcase. Place crankcase as shown. vmr2006-075-002_a vmr2006-075-004 NOTE: It is not necessary to remove oil pump cov- Hold up crankcase so that it does not touch the working table and tap the left half crankcase with Remove bolts on the left half crankcase.

  • Page 113: Inspection

    Section 03 ENGINE Subsection 10 (CRANKSHAFT AND CRANKCASE) Drive out left half crankcase oil seal. vmr2006-075-005_a Remove crankshaft from right half crankcase. vmr2006-075-008 INSPECTION Crankshaft NOTE: Crankshaft axial play is took up by a wave washer. If washer is worn, replace with a new one.
  • Page 114 Section 03 ENGINE Subsection 10 (CRANKSHAFT AND CRANKCASE) Crankshaft Gears Measure the radial clearance of connecting rod big end with a dial indicator. vmr2006-075-010 vmr2006-075-025_a Timing Chain Gear RADIAL CLEARANCE Mesh chain in gear and check for excessive radial 0 - 0.008 mm (0 - 0.0003 in) play.

  • Page 115: Crankcase Assembly

    Section 03 ENGINE Subsection 10 (CRANKSHAFT AND CRANKCASE) Balance Shaft Bearing Check bearings on right and left crankcase halves. Manually turn the bearing to see if it turns freely, smoothly and noiselessly. Check for radial and ax- ial play. If any defect is detected, replace bearing with a new one.
  • Page 116 Section 03 ENGINE Subsection 10 (CRANKSHAFT AND CRANKCASE) Clean the crankshaft. Apply a layer of grease on the lip of oil seal. Put seal on crankshaft. vmr2006-075-004 First, torque crankcase bolts in a criss-cross se- quence to half torque value. Ensure crankcase halves are properly aligned.
  • Page 117 Section 03 ENGINE Subsection 10 (CRANKSHAFT AND CRANKCASE) vmr2006-075-001_a 1. Locking plate 2. Chain guide vmr2006-075...

  • Page 118: Gearbox

    Section 03 ENGINE Subsection 11 (GEARBOX) GEARBOX SERVICE TOOLS Description Part Number Page countershaft needle bearing installer ........529 036 053 ......... 105 SERVICE PRODUCTS Description Part Number Page synthetic grease ..............293 550 014 ......... 103 vmr2006-076...
  • Page 119 Section 03 ENGINE Subsection 11 (GEARBOX) vmr2006-076-001_a vmr2006-076...

  • Page 120: General

    Section 03 ENGINE Subsection 11 (GEARBOX) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded views. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be installed or replaced with new ones where specified.

  • Page 121: Gearbox Switch

    Section 03 ENGINE Subsection 11 (GEARBOX) GEARBOX SWITCH If any test fail, check wiring and if good, replace gearbox switch. Remove driven pulley to have Disconnect gearbox switch connectors. access to switch. Refer to CONTINUOUS VARI- ABLE TRANSMISSION. NOTE: Also pay attention to shift drum contact pin condition.

  • Page 122: Gearbox Disassembly

    Section 03 ENGINE Subsection 11 (GEARBOX) Check bearing for contamination and/or metal shavings. Replace if necessary (gearbox disas- sembly is required). Check shaft surface around oil seal friction area for grooves and replace if necessary (gearbox disas- sembly is required). Apply synthetic grease (P/N 293 550 014) inside oil seal lips.
  • Page 123 Section 03 ENGINE Subsection 11 (GEARBOX) vmr2006-076-007_a vmr2006-076-009_a 1. Spindle Remove drive shaft towards inside of case. 2. Shift fork 3. Shift drum Remove output shaft, countershaft and reverse shaft. vmr2006-076-010 Remove gasket and dowel pins. Bearings vmr2006-076-008_a All bearings must turn smoothly and freely. 1.
  • Page 124 Section 03 ENGINE Subsection 11 (GEARBOX) vmr2006-076-004_a Push against inner race to install a bearing on its shaft. To install countershaft needle bearing, use coun- tershaft needle bearing installer (P/N 529 036 053). vmr2006-076-003_a To remove a bearing from a blind bore, use a blind hole bearing puller with a hammer puller.

  • Page 125: Gearbox Inspection

    Section 03 ENGINE Subsection 11 (GEARBOX) GEARBOX INSPECTION Check shift spindle for wear or damage. vmr2006-076-020_a vmr2006-076-021_a TYPICAL A. Claw thickness Check shift drum for wear or damage. B. Bore diameter Push the contact pin. It must move freely and SHIFT FORK remain in its housing.

  • Page 126: Gearbox Assembly

    Section 03 ENGINE Subsection 11 (GEARBOX) SHIFT FORK SHAFT DESCRIPTION BORE DIAMETER 11.982 - 12.000 mm (.4717 - .4724 in) Service limit 11.97 mm (.471 in) min. Check countershaft for wear, damage and free movement of gears. vmr2006-076-027_a GEARBOX ASSEMBLY Assembly is essentially the reverse procedure of disassembly.
  • Page 127 Section 03 ENGINE Subsection 11 (GEARBOX) vmr2006-076-013 Install fork in sliding gear. vmr2006-076-015_a Ensure drum shift catch ball is removed under- neath gearbox. Slightly move fork to allow insertion in drum shaft. Properly mesh fork pin in drum shaft. vmr2006-076-014_a Insert shaft in fork then in gearbox.
  • Page 128 Section 03 ENGINE Subsection 11 (GEARBOX) vmr2006-076-006 vmr2006-076-005_b 1. Bracket here Install shift spindle in gearbox. When meshing teeth, ensure to align dots as shown. Properly torque screws. Install remaining parts. Refill gearbox with the recommended oil. See OIL CHANGE. vmr2006-076-017_a 1.

  • Page 130: Fuel System

    Section 04 FUEL SYSTEM Subsection 01 (CARBURETOR AND FUEL TANK) CARBURETOR AND FUEL TANK SERVICE TOOLS Description Part Number Page cable luber ................529 035 738 ......... 120–121 digital inductive tachometer ..........529 014 500 ......... 117 float level gauge ..............529 035 520 ......... 116 small hose pincher..............
  • Page 131 Section 04 FUEL SYSTEM Subsection 01 (CARBURETOR AND FUEL TANK) FUEL TANK, FUEL VALVE AND FUEL FILTER vmr2006-077-001_a vmr2006-077...
  • Page 132 Section 04 FUEL SYSTEM Subsection 01 (CARBURETOR AND FUEL TANK) CARBURETOR vmr2006-077-002_a vmr2006-077...

  • Page 133: General

    Loosen the choke cable retaining plate then re- When replacing fuel lines, be sure to use hoses move choke cable from its lever. as available from BRP parts department. This will ensure continued proper and safe operation. WARNING Use of improper fuel lines could compromise fuel system integrity.
  • Page 134 Section 04 FUEL SYSTEM Subsection 01 (CARBURETOR AND FUEL TANK) vmr2006-077-005_a vmr2006-077-007_a 1. Choke cable retaining plate 2. Choke lever on carburetor Remove carburetor. Install a small hose pincher (P/N 295 000 076) on Cleaning and Inspection fuel line then disconnect the fuel line from carbu- The entire carburetor should be cleaned with a retor.
  • Page 135 Section 04 FUEL SYSTEM Subsection 01 (CARBURETOR AND FUEL TANK) Carburetor Adjustments Float Level Correct fuel level in float chamber is vital for maxi- mum engine efficiency. To check for correct float level proceed as follows: – Remove carburetor. – Turn the carburetor upside down and remove float bowl.

  • Page 136: Fuel Filter

    Section 04 FUEL SYSTEM Subsection 01 (CARBURETOR AND FUEL TANK) vmr2006-077-011_a vmr2006-077-006_a 1. Pilot screw 1. Small hose pincher 2. Fuel line Idle Speed Unplug fuel line (between filter and valve) from Warm up engine; using a digital inductive fuel valve. tachometer (P/N 529 014 500), adjust idle speed to 1700 ±...

  • Page 137: Fuel Tank

    Section 04 FUEL SYSTEM Subsection 01 (CARBURETOR AND FUEL TANK) vmr2006-077-012_a vmr2006-077-012_a 1. Fuel valve 1. Fuel valve 2. Fuel filter 2. Fuel filter No fuel should leak from fuel valve in this position. Unscrew fuel valve from frame. Turn fuel valve to ON to check if the valve works Unscrew bolts retaining the front of fuel tank to properly.

  • Page 138: Throttle Cable

    Section 04 FUEL SYSTEM Subsection 01 (CARBURETOR AND FUEL TANK) THROTTLE CABLE Removal WARNING Ensure the key is turned OFF, prior to per- forming the throttle cable removal. NOTE: To ease reinstallation, take note cable rout- ing. Throttle Lever Side vmr2006-083-008_a Remove throttle housing cover.

  • Page 139: Choke Cable

    Section 04 FUEL SYSTEM Subsection 01 (CARBURETOR AND FUEL TANK) Place the cable in a vertical position during approx- imately 15 minutes or until no lubricant flows out of cable. Reinstall and adjust cable, see below. Installation For installation, reverse the removal procedure. Adjustment WARNING Ensure the key is turned OFF, prior to perform...
  • Page 140 Section 04 FUEL SYSTEM Subsection 01 (CARBURETOR AND FUEL TANK) Lubrication Carburetor Side Loosen the choke cable retaining plate then re- The choke cable must be lubricated with cable lu- move choke cable from its lever. bricant (P/N 293 600 041) or an equivalent. WARNING Always use a silicone-based lubricant.

  • Page 142: Electrical System

    Section 05 ELECTRICAL SYSTEM Subsection 01 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS Description Part Number Page multimeter Fluke 111 ............529 035 868 ......... 123 SERVICE PRODUCTS Description Part Number Page dielectric grease ..............293 550 004 ......... 126 GENERAL PROCEDURES For best results, use the multimeter Fluke 111 (P/N 529 035 868).

  • Page 143: Stator

    Section 05 ELECTRICAL SYSTEM Subsection 01 (CHARGING SYSTEM) Connect multimeter between fuse pins. TEST ENGINE SPEED VOLTAGE 1500 RPM Max. 13.5 - 15 Vdc If voltage is above specification, replace voltage regulator/rectifier. If voltage is below specification, check wiring and connections.

  • Page 144: Battery

    Section 05 ELECTRICAL SYSTEM Subsection 01 (CHARGING SYSTEM) Read resistance. RESISTANCE @ TERMINAL 20°C (69°F) RESISTANCE @ TERMINAL Any YELLOW wire and 20°C (69°F) Infinity (open circuit) engine ground 1 and 2 If there is a resistance or continuity, the stator coils 1 and 3 0.3 - 0.4 and/or the wiring is grounded and need to be re-...
  • Page 145 Section 05 ELECTRICAL SYSTEM Subsection 01 (CHARGING SYSTEM) vmr2006-078-003_a CURRENT LEAKAGE LIMIT vmr2006-078-001_a 1. Positive cable (RED) Less than 1 mA 2. Negative cable (BLACK) 3. Retaining screws If leakage current is above specification, it may in- Remove battery from vehicle. dicate a short circuit.
  • Page 146 Section 05 ELECTRICAL SYSTEM Subsection 01 (CHARGING SYSTEM) WARNING Ensure to store battery in a safe place, out of reach for children. Installation Reinstall battery in vehicle. Properly secure retaining bracket. Reconnect battery cables. WARNING Connect RED (+) cable first then BLACK (-) ca- ble.

  • Page 148: Ignition System

    Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page digital/inductive type tachometer ......... 529 014 500 ......... 141 multimeter Fluke 111 ............529 035 868 ......... 130 GENERAL Shift Gear Control Module It monitors gearbox position (F, N and R) to allow Overview different predefined engine/vehicle behaviors.

  • Page 149: Troubleshooting

    Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Ignition System Components Location 1. fuse 2. spark plug (spark occurence) 3. battery 4. ignition switch 5. engine stop switch 6. trigger coil 7. ignition coil 8. ignition module 9. shift gear control module. Intermittent Ignition Problems In dealing with intermittent problems there is no easy diagnosis.

  • Page 150: Fuses

    Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) FUSES Fouling Fouling of the spark plug is indicated by irregular Check condition of main fuse and 15 A fuse (sup- running of the engine, decreased engine speed plying ignition module and shift gear control mod- due to misfiring, reduced performance, and in- ule).

  • Page 151: Battery

    Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) All Models If test failed, perform the following tests. Remove front cover. Refer to BODY. Disconnect ignition switch connector with the RED wire. 1. Proper socket 2. Improper socket – Torque spark plug to 12 N•m (106 lbf•in). BATTERY At least 8 V is required for proper operation of the ignition system (however 10.2 V is required for en-...
  • Page 152 Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) vmr2006-079-004_a Push tabs of switch and while holding them squeezed, push switch out. vmr2006-079-010_b All Models except Europe IGNITION SWITCH CONNECTOR POSITION TERMINAL RESISTANCE Infinite (0L.) RED and BROWN wires max. European Models IGNITION SWITCH CONNECTOR POSITION TERMINAL...

  • Page 153: Engine Stop Switch

    Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) ENGINE STOP SWITCH vmr2006-079-012_a vmo2006-014-011_b 1. Engine stop switch 2. RUN position ENGINE STOP SWITCH 3. OFF position POSITION WIRE RESISTANCE Infinite (0L.) Test BLUE/YELLOW and BLUE/YELLOW max. Remove front cover. Refer to BODY. Discon- nect engine stop switch connector with the Replace switch if defective.
  • Page 154 Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) vmr2006-079-013_a vmr2006-079-013_a 2. Use a multimeter and set it to . Read resis- 2. Use a multimeter and set it to Vac. tance as follows. 3. Set engine stop switch to RUN. 4.

  • Page 155: Ignition Coil

    Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) IGNITION COIL vmr2006-079-015_a vmr2006-079-005_a IGNITION COIL NOTE: An ignition coil with good resistance mea- surement can still be faulty. Voltage leak can oc- TERMINALS RESISTANCE @ 20°C (68°F) cur at high voltage level which is not detectable 1 and 2 0.19 - .23 with an ohmmeter.

  • Page 156: Ignition Module

    Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) If there is no voltage, either wiring harness, elec- If resistance is good, continue tests. Otherwise, tronic module or shift gear control module is faulty. replace ignition coil. Secondary Winding Static Test Secondary Winding Dynamic Test The spark plug cap includes a resistance.
  • Page 157 Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) vmr2006-079-018_b vmr2006-079-006_a Use a multimeter and set it to Vdc. IGNITION MODULE Read voltage as follows. 2-PIN 3-PIN VOLTAGE CONNECTOR CONNECTOR Battery BLACK/WHITE Battery ground voltage – If voltage is now adequate, repair ground wire of ignition module.

  • Page 158: Shift Gear Control Module

    Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Installation For the installation, reverse the removal proce- dure. SHIFT GEAR CONTROL MODULE vmr2006-079-022_a SHIFT GEAR CONTROL MODULE WIRES VOLTAGE WHITE/BLACK and Battery voltage GREEN vmr2006-079-008_a If there is no voltage, recheck as follows. Test NOTE: A grounded BLUE/YELLOW wire be- tween trigger coil and shift gear control module...

  • Page 159: Override Switch

    Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Installation For the installation, reverse the removal proce- dure. OVERRIDE SWITCH NOTE: If engine RPM is not limited in reverse op- eration, check GREEN/WHITE wire between gear- box and ignition module. vmr2006-076-052_a OVERRIDE WIRE SWITCH...

  • Page 160: Adjustment

    Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) If test succeeded, check wiring harness going to ignition module. If good, try a new module. Reconnect connectors and reinstall front cover. ADJUSTMENT IGNITION TIMING Ignition timing is not adjustable. However, its in- tegrity can be checked to ensure components are working properly.

  • Page 162: Starting System

    Section 05 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page multimeter Fluke 111 ............529 035 868 ......... 143 SERVICE PRODUCTS Description Part Number Page dielectric grease ..............293 550 004 ......... 147 GENERAL Starting System Components Location Engine Starting The following conditions must be met to allow en-...

  • Page 163: Testing Procedures

    Section 05 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) IGNITION SWITCH Troubleshooting First ensure the problem is not related to engine Refer to IGNITION SYSTEM for testing proce- mechanical components. If not, test the starting dures. system. Causes of problems are not necessarily related ENGINE STOP SWITCH to starter but may be due to a burnt fuse, faulty Refer to IGNITION SYSTEM for testing proce-...

  • Page 164: Starting Solenoid

    Section 05 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) NOTE: On European models, ensure brake switch If switch tests good, check starting solenoid is working properly. Refer to BRAKING SYSTEM. winding. See below. If winding tests good, check power supply to shift gear control module. If voltage is good, continue testing.

  • Page 165: Electrical Cables Or Connections

    Section 05 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) Use a multimeter and set it to . If voltage is out of specification, replace solenoid. Read resistance as follows. If solenoid tests good, continue testing. ELECTRICAL CABLES OR CONNECTIONS Check all connections, cables and wires. Tight- en any loose connections.
  • Page 166 Section 05 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) WARNING Always connect RED (+) cable first then BLACK (-) cable last. Whenever connecting the RED (+) cable to the starter motor, make sure the battery cables are disconnected to prevent electric shock. Test starter operation.

  • Page 168: Lights And Accessories

    Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) LIGHTS AND ACCESSORIES SERVICE TOOLS Description Part Number Page multimeter Fluke 111 ............529 035 868 ......... 149 GENERAL IMPORTANT: When solving an electrical problem, the first thing to do is to check battery condition as well as its cables and connections.

  • Page 169: Procedures

    Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) HEADLAMP Checking for Shorts Between 2 Wires When checking continuity of a wire in a circuit, NOTE: Assuming headlamps are good, failure of wires should be checked for short circuit as fol- both LO or HI beam headlamps may be caused lows.
  • Page 170 Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) LO Beam Relay SWITCH WIRE COLOR VOLTAGE POSITION Disconnect LO beam relay connector. LO beam WHITE Battery voltage GREEN HI beam BLUE If voltage is good, replace headlamp bulb. If there is no voltage, recheck by measuring volt- age as follows.
  • Page 171 Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) vmr2006-079-009_a vmr2006-081-003_a Turn on ignition switch. Using a jumper wire, connect wires as follows. Use a multimeter and set it to Vdc. Read switch supply voltage from main harness as follows. vmr2006-081-006_a RELAY CONNECTOR WIRES RED/WHITE...
  • Page 172 Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) vmr2006-081-009_a WHITE TERMINALS RELAY WINDING RESISTANCE vmr2006-081-003_a WHITE TERMINALS RESISTANCE Turn ignition switch on. Approximately 110 Select LO beam at headlamp switch. Use a multimeter and set it to Vdc. If out of specification, replace relay. Measure relay supply voltage as follows.
  • Page 173 Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) vmr2006-081-008_a RELAY SUPPLY VOLTAGE vmo2006-013-007_a WIRE COLOR VOLTAGE 1. Release locking tab 2. Pull on connector using a wiggle movement BLUE Battery voltage GREEN Unlock bulb holder by turning it counterclockwise. If voltage test failed, check ground wire.

  • Page 174: Turn Signal Lights

    Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) European Models vmo2006-014-057_b vmo2006-014-058_a 1. Bulb holder 2. Unlock (open) 1. Headlamp housing 3. Lock (close) 2. Beam height adjustment Properly reinstall removed parts in the reverse or- der of their removal. TURN SIGNAL LIGHTS Unlock bulb holder by turning it counterclockwise.
  • Page 175 Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) If switch is out of specifications, replace multi- function switch. See STEERING AND FRONT SUSPENSION. If switch is good, continue testing. Reconnect connectors. Hazard Control Module vmr2006-081-011_a REAR There should be pulsating battery voltage. If voltage is good, replace bulb.
  • Page 176 Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) HAZARD CONTROL MODULE SUPPLY VOLTAGE HAZARD CONTROL MODULE SUPPLY VOLTAGE WIRE COLOR VOLTAGE WIRE COLOR VOLTAGE GREEN Battery voltage BLACK GREEN Battery voltage If there is no voltage, recheck as follows. If there is no voltage, recheck as follows.
  • Page 177 Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) HAZARD CONTROL TURN MODULE INPUTS SIGNAL SWITCH WIRE COLOR VOLTAGE Left turn PINK Pulsating battery GREEN Right turn BROWN/WHITE voltage If there is no voltage, recheck as follows. vmr2006-081-015_a HAZARD CONTROL TURN MODULE OUTPUTS SIGNAL...
  • Page 178 Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) Remove front fender. Refer to BODY. If switch test failed, replace the auxiliary multi- function switch. See STEERING AND FRONT Unscrew retaining screw then pull out module. SUSPENSION. Disconnect module. Front Turn Signal Bulb Replacement Use a multimeter and set it to Vdc.

  • Page 179: Position Light

    Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) vmo2006-014-067_a RELEASE HOUSING FROM REAR FENDER Remove lamp lens. vmr2006-081-018_a POSITION LIGHT SOCKET WIRES VOLTAGE Battery voltage BROWN GREEN There should be battery voltage. If so, replace bulb. If there is no voltage, measure voltage between BROWN wire and battery ground.

  • Page 180: Pilot Lamps

    Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) vmo2006-014-070_a 1. Bulb housing vmr2006-081-019_a Validate light works. If there is no voltage, check wire from battery to PILOT LAMPS lamp socket. If battery voltage is present, continue the follow- Tests ing tests.
  • Page 181 Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) vmr2006-079-008_a SHIFT GEAR CONTROL MODULE vmr2006-081-019 PILOT LAMP SWITCH FUNCTION WIRE COLOR If wire test failed, repair/replace wire as neces- Forward BROWN/YELLOW sary. Neutral GREEN/RED If wire tests good, try a new shift gear control Reverse GREEN/WHITE module.
  • Page 182 Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) vmr2006-081-002 Heat coolant to 123 °C (253 °F) and measure re- sistance of sensor. It should be within 15 - 19 . Otherwise, replace sensor. Reinstall and reconnect sensor. vmr2006-081-020_c Refill cooling system. Refer to COOLING SYS- If there is no voltage, check supply wire going to TEM.
  • Page 183 Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) If there is no voltage, check supply wire of socket. Reinstall removed parts. Turn signal Lamp (European models) Use a multimeter and set it to Vdc. Measure voltage at lamp socket as follows. vmr2006-081-020_e If so, check module ground wire .

  • Page 184: Taillight

    Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) TAILLIGHT Install the new bulb by first pushing in while turn- ing clockwise. Reinstall lens. Test HORN Turn ignition switch on. On European models, turn headlamp switch to ei- European Models ther LO or HI beam.

  • Page 185: 12-Volt Power Outlet

    Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) HORN TERMINALS HORN SWITCH WIRE VOLTAGE POSITION Pressed LIGHT GREEN and Battery and held GREEN wires voltage If voltage is adequate, replace horn. Otherwise, recheck voltage as follows. vmr2006-081-022_b HORN SWITCH MAIN HARNESS CONNECTOR WIRE VOLTAGE WHITE/BLACK and...
  • Page 186 Section 05 ELECTRICAL SYSTEM Subsection 04 (LIGHTS AND ACCESSORIES) vmr2006-081-024_a OUTLET CONNECTORS VOLTAGE Battery voltage – No voltage: • Check fuses and wiring condition. – Voltage is good: • Change power outlet. Reconnect terminals. Removal Unplug the connectors of the power outlet. Unscrew the retaining nut.

  • Page 188: Transmission

    Section 06 TRANSMISSION Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) CONTINUOUSLY VARIABLE TRANSMISSION (CVT) SERVICE TOOLS Description Part Number Page blind hole puller kit..............529 036 056 ......... 172 driven pulley holding support..........529 035 864 ......... 176 driven pulley support ............529 035 863 ......... 176 driven pulley support tab kit ..........
  • Page 189 Section 06 TRANSMISSION Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2006-082-001_a vmr2006-082...

  • Page 190: General

    Section 06 TRANSMISSION Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) GENERAL To remove the drive belt, the fixed sheave of the drive pulley and the driven pulley must be During assembly/installation, use the torque val- removed. Refer to DRIVE PULLEY and DRIVEN ues and service products as in the exploded PULLEY.

  • Page 191: Cvt Cover Bearing

    Section 06 TRANSMISSION Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) CVT COVER BEARING Inspection Check if the CVT cover bearing turns smoothly and freely. Otherwise, replace it. Removal Remove CVT cover from engine. Remove both screws retaining the bearing plate to CVT cover. vmr2006-082-002_a Remove all cover screws.
  • Page 192 Section 06 TRANSMISSION Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) vmr2006-082-024_a 1. Pulley holder 2. Fixed sheave of drive pulley Move away the drive belt. TYPICAL 1. Ramp plate 2. Sliding shoes 3. Spacer vmr2006-082-007 Remove drive pulley sliding sheave by placing a finger behind sliding sheave ramp plate and pull.
  • Page 193 Section 06 TRANSMISSION Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Spacer Check if the outer surface of spacer is worn or damaged. Replace as required. Measure the sliding sheave spacer. If the exter- nal diameter is out of specification, replace as re- quired.
  • Page 194 Section 06 TRANSMISSION Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) Insert slider shoes into ramp plate to properly slide SLIDING SHEAVE BUSHING in guides of drive pulley sliding sheave. 30.060 mm SERVICE LIMIT (1.184 in) Installation of Drive Pulley For installation, reverse the removal procedure. Replace sliding sheave if bushing(s) is(are) out of Pay attention to the following details.

  • Page 195: Driven Pulley

    Section 06 TRANSMISSION Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) DRIVEN PULLEY WARNING Centrifugal clutch is spring loaded. Never un- Removal of Driven Pulley screw centrifugal clutch nut without special Remove the drive pulley fixed sheave, see proce- tool. dure in DRIVE PULLEY above. Remove the holding support then remove cen- Using the pulley holder (P/N 529 036 054), remove trifugal clutch from driven pulley.
  • Page 196 Section 06 TRANSMISSION Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) CAUTION: Avoid contact between cleaner and LINING THICKNESS oil seals because damage may occur. 3.00 mm SERVICE LIMIT (.118 in) Inspection of Driven Pulley Bearing Stay Collar If lining thickness is out of specifications, replace centrifugal clutch.
  • Page 197 Section 06 TRANSMISSION Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)) If the outside diameter of shaft is out of specifica- tion, change driven pulley. Assembly of Driven Pulley For assembly, reverse the removal procedure. Pay attention to following details. Lubricate the inner of sliding sheave with Isoflex grease (P/N 293 550 021).

  • Page 198: Steering And Front Suspension

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) STEERING AND FRONT SUSPENSION SERVICE TOOLS Description Part Number Page shock/spring remover ............529 036 007 ......... 190 SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page Smoothflow™ tapered tip ............ (16 ga #511 .........
  • Page 199 Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) vmr2006-083-001_a vmr2006-083...

  • Page 200: General

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) GENERAL During assembly/installation, use torque values as in the exploded view. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be installed or replaced with new ones where specified.

  • Page 201: Auxiliary Multifunction Switch

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) vmr2006-083-004_a vmr2006-083-035_a TYPICAL 1. Multifunction switch pin Remove CVT air inlet hose to reach multifunction 2. Handlebar hole switch connectors. Unplug multifunction switch connectors. AUXILIARY MULTIFUNCTION Unscrew multifunction switch screws. SWITCH European Models Only Replacement...

  • Page 202: Throttle Lever

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) vmr2006-083-012_a 1. Auxiliary switch screw 2. Brake switch on LH brake lever vmr2006-083-006_a 1. Throttle housing cover screws Remove switch. For installation, reverse the removal procedure. Move back rubber cap. THROTTLE LEVER Removal Procedure for Handlebar Replacement...

  • Page 203: Master Cylinder

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) MASTER CYLINDER Refer to BRAKING SYSTEM. HANDLEBAR Removal Procedure if Handlebar is not Replaced All Models except Europe Remove steering cover by unscrewing both retain- ing screws. vmr2006-083-009 Unscrew throttle clamp to separate throttle lever from handlebar.

  • Page 204: Tie-Rod

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) NOTE: When torquing, the gap between lower and upper steering clamps must be equal, on both sides and between rear and front. TIE-ROD Removal Place the vehicle on jack stands and remove ap- propriate front wheel.

  • Page 205: Steering Column

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) Installation For the installation, reverse the removal proce- dure. Install a new nut and a new cotter pin. Both ends of cotter pin must be folded. Perform a steering adjustment. See further in this section.

  • Page 206: Steering Column Bearing

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) Check bearing seals for damages. Replace if nec- essary. Installation For the installation, reverse the removal proce- dure. Apply synthetic grease XP-S (P/N 293 550 010) on both seals when installing half housings. Install a new cotter pin.

  • Page 207: Front Wheel Hub

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) Remove the insert between knuckle shaft and hub seal. vmr2006-083-034_a 1. Washer 2. Large washer vmr2006-083-021 Pull wheel hub strongly. Use a puller if necessary. FRONT WHEEL HUB Installation Removal The installation is the reverse of the removal pro-...

  • Page 208: Knuckle

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) KNUCKLE Torque castle nut and further tighten until one of its grooves is aligned with a cotter pin hole. Removal Install a new cotter pin. Both ends of cotter pin Raise front of vehicle and install jack stands under must be folded.

  • Page 209: Lower A-Arm

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) Disassembly Inspection To remove spring from the shock absorber, use Inspect the spring for damage. Replace if neces- the shock/spring remover (P/N 529 036 007). sary. Inspect shock for oil leakage. Extend and com- press the shock several times over its entire stroke.
  • Page 210 Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) vmr2006-083-036_a vmr2006-083-039_a Detach tie-rod from knuckle. Remove bolts retaining A-arm to frame. vmr2006-083-040_a vmr2006-083-015_a 1. Lower A-arm 2. Bolts and nuts KNUCKLE SIDE 3. Upper A-arm 1. Cotter pin 2.

  • Page 211: Upper A-Arm

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) UPPER A-ARM Inspection Before removing A-arm, do the following: – Move A-arm from side to side. There should be no noticeable looseness. Replace A-arm if necessary. – Move A-arm up and down. There should be no noticeable looseness.

  • Page 212: Adjustment

    Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) ADJUSTMENT STEERING ALIGNMENT Toe-In Adjustment Place vehicle on a level surface (wheels on ground). Check that handlebar is straight. Attach handlebar to make sure it does not move during adjustment. Check pressure in each tires.
  • Page 213 Section 07 STEERING AND FRONT SUSPENSION Subsection 01 (STEERING AND FRONT SUSPENSION) vmr2006-083-049 REAR DISTANCE The perfect front toe-in adjustment is 3 mm (.118 in) each side. Adjust alignment with tie-rod. vmr2006-083...

  • Page 214: Rear Suspension And Axle

    Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) REAR SUSPENSION AND AXLE SERVICE TOOLS Description Part Number Page crankcase support sleeve tool ..........529 036 031 ......... 205 rear axle key ................. 529 036 046 ......... 201 shock/spring remover ............
  • Page 215 Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) vmr2006-084-001_a vmr2006-084...

  • Page 216: General

    Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded views. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic vmr2006-084-003_a stop nuts, self-locking fasteners, cotter pin, TYPICAL...

  • Page 217: Drive Chain

    Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) vmr2006-026-011 Inspection vmo2006-014-048_a Inspect the spring for damage. Replace if neces- TYPICAL 1. Chain tensioner lock bolts sary. Inspect shock for oil leakage. Place shock in ver- tical position. Extend and compress the shock several times over its entire stroke.
  • Page 218 Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) The deflection of the chain should be 20 mm ± 5 mm (13/16 in ± 3/16 in). Tighten the chain tensioner lock bolts to 62 N•m (46 lbf•ft) and caliper support bolt to 12 N•m vmr2006-084-005_a (106 lbf•in).

  • Page 219: Engine Sprocket

    Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) vmr2006-084-007_a ENGINE SPROCKET Removal 1. Good Remove drive chain protector. 2. Replace CAUTION: Replace chain and sprockets togeth- er to prevent premature wear of these compo- nents. Installation The installation is the reverse of the removal pro- cedure.

  • Page 220: Wheel Hub

    Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) Remove axle sprocket from vehicle. Inspection Check the axle sprocket for distortion, excessive wear or other damages. vmr2006-084-010_a 1. Cotter pin 2. Castle nut 3. Wheel hub Remove castle nut and washer. Pull hub to remove it.

  • Page 221: Rear Axle

    Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Apply suspension synthetic grease (P/N 293 550 033) on splines before installing hub. Torque each axle nuts to 140 N•m (103 lbf•ft).

  • Page 222: Sprocket Hub

    Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) Installation Check if the O-ring inside sprocket hub spacer is brittle, hard or damaged. Replace if necessary. Insert the axle into the chain tensioner from the right side. Apply suspension synthetic grease (P/N 293 550 033) on splines before installing hubs.
  • Page 223 Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) If a bearing is seized on the axle, this axle must be replaced. Bearings must be slide fit on the axle, otherwise it will result in a faulty reassembly and a failure may occur.

  • Page 224: Swing Arm

    Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) Assembly To install new bearings, use the crankcase support sleeve tool (P/N 529 036 031) to push them in the chain tensioner. Do not forget the inner sleeve when installing the second bearing.
  • Page 225 Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) Procedure With Rear Axle Removed NOTE: The rear axle must be removed only if the swing arm is replaced. Remove the lower bolt of shock absorber. vmr2006-084-003_a 1. Lower bolt Loosen drive chain.
  • Page 226 Section 08 REAR SUSPENSION AND AXLE Subsection 01 (REAR SUSPENSION AND AXLE) Check bushings and shaft for wear or damages. Replace defective parts. Check if the seals are brittle, hard or otherwise damaged. Assembly Press new bushings into swing arm. Insert swing arm shaft.

  • Page 228: Braking System

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) FRONT AND REAR BRAKES SERVICE TOOLS Description Part Number Page vacuum/pressure pump............529 021 800 ......... 226 SERVICE PRODUCTS Description Part Number Page GTLMA brake fluid..............293 600 062 ......... 212, 225 suspension synthetic grease ..........

  • Page 229: All Models Except European Models

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) ALL MODELS EXCEPT EUROPEAN MODELS FRONT BRAKES vmr2006-085-001_a vmr2006-085...
  • Page 230 Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) REAR BRAKE vmr2006-085-002_a vmr2006-085...

  • Page 231: General

    Clean reservoir cover before removing. Use brake fluid meeting the specification DOT 3 or DOT 4 such as GTLMA brake fluid (P/N 293 600 062) sold by BRP. Fluid Level NOTE: A low level may indicate leaks or worn brake pads.
  • Page 232 Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) To fill front brake circuit do the following: – Make sure reservoir cover and diaphragm are removed. – Connect a clear hose to RH caliper and loosen bleeding screw. Place the other end of hose in a container.
  • Page 233 Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) – Squeeze brake lever. It should be firm. – If yes, install diaphragm and cover on reservoir. – If not, bleed rear brake lever circuit as per pro- cedure in BRAKE SYSTEM BLEEDING. Rear Brake Pedal Circuit To drain and fill the rear brake pedal circuit, use the following procedure:...

  • Page 234: Procedures

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) Rear Brake Lever Circuit – Pump up circuit pressure with brake lever until lever resistance is felt. – Squeeze brake lever, open bleeding screw and then close it. NOTE: Do not release brake lever until bleeding screw has been closed.

  • Page 235: Brake Pads

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) Use new sealing washers when installing Banjo fitting retaining brake hose to caliper. Torque Ban- jo fitting to 35 N•m (26 lbf•ft). Install caliper in its original position. Torque caliper bolt to 27 N•m (20 lbf•ft).

  • Page 236: Master Cylinders Of Brake Levers

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) MASTER CYLINDERS OF BRAKE LEVERS Removal Master Cylinder of LH Rear Brake Lever Drain the rear brake lever circuit. Refer to BRAKE FLUID REPLACEMENT in this section. vmr2006-085-018_a Remove banjo fitting and the sealing washers. 1.

  • Page 237: Rear Brake Pedal

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) Master Cylinder of LH Rear Brake Lever Refill rear brake lever circuit. Bleed rear brake system. WARNING Bleed rear brake lever and rear brake pedal circuits before riding vehicle. Master Cylinder of RH Front Brake Lever Refill and bleed front brake circuit.

  • Page 238: Master Cylinder Of Rear Brake Pedal

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) Apply suspension synthetic grease (P/N 293 550 033) on shaft before installing rear brake pedal. MASTER CYLINDER OF REAR BRAKE PEDAL Removal Drain rear brake pedal circuit. Refer to BRAKE vmr2006-085-024_a FLUID REPLACEMENT in this section.

  • Page 239: Pressure Control Valve

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) Refill rear brake system. Bleed rear brake system. WARNING Bleed rear brake lever and pedal circuits be- fore riding vehicle. BRAKE DISCS Inspection vmr2006-085-028_a Brake discs can be inspected without removing 1.

  • Page 240: Brake Hoses

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) Torque brake disc screws in accordance with the following table. TORQUE FOR BRAKE DISC SCREWS Front brake disc 41 N•m (30 lbf•ft) Rear brake disc 29 N•m (21 lbf•ft) BRAKE HOSES Inspection Brake hoses should be inspected frequently for leaks and damages.
  • Page 241 Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) vmr2006-085-020_a vmr2006-085-033_a LH REAR BRAKE LEVER 1. Brake fluid reservoir 1. Brake pedal switch 2. Brake light switch connectors 2. Brake pedal 3. Choke lever The brake pedal switch cannot be adjusted. Disconnect switch connector.

  • Page 242: European Models

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) EUROPEAN MODELS FRONT BRAKES vmr2006-085-036_a vmr2006-085...
  • Page 243 Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) REAR BRAKE vmr2006-085-037_a vmr2006-085...

  • Page 244: General

    Clean reservoir cover before removing. Use brake fluid meeting the specification DOT 3 or DOT 4 such as GTLMA brake fluid (P/N 293 600 062) sold by BRP. Fluid Level NOTE: A low level may indicate leaks or worn brake pads.

  • Page 245: Procedures

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) – Close bleeding screw and operate brake lever or brake pedal. If it still feels spongy, bleed circuit again. – Repeat the procedures until air bubbles do not appear in hose and lever or pedal is firm. –...

  • Page 246: Calipers

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) On rear caliper, loosen lock nut on adjusting bolt. vmr2006-085-042 Detach cable from swing arm and frame. Unscrew socket screws under lever. vmr2006-085-040_a 1. Adjusting bolt Remove lever plate and parking brake lever. 2.

  • Page 247: Brake Pads

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) Inspection Check piston for scratches, rust or other damages. If so, replace caliper. Check brake pads. Refer to BRAKE PAD further in this section. Installation For the installation, reverse the removal proce- dure, pay attention to the following details.
  • Page 248 Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) vmr2006-085-018_a 1. Wear groove on pad lining BRAKE PAD MINIMUM 2 mm (5/64 in) vmr2006-085-039_a THICKNESS 1. Cable adjuster 2. Parking brake cable Installation 3. Parking brake lever 4. RH handle brake lever Clean the visible portion of piston with clean brake fluid.

  • Page 249: Master-Cylinders Of Brake Levers

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) MASTER-CYLINDERS OF BRAKE LEVERS Removal Master Cylinder of LH Rear Brake Lever Drain the rear brake lever circuit. Refer to BRAKE FLUID REPLACEMENT in this section. Remove banjo fitting and the sealing washers. Unplug brake light switch connectors.

  • Page 250: Rear Brake Pedal

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) Master Cylinder of LH Rear Brake Lever Refill rear brake lever circuit. Bleed rear brake system. WARNING Bleed rear brake lever and rear brake pedal circuits before riding vehicle. vmr2006-085-024_a Master Cylinder of RH Front Brake Lever Then, remove pin to separate yoke and rear brake Refill and bleed front brake circuit.

  • Page 251: Master Cylinder Of Rear Brake Pedal

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) Apply suspension synthetic grease (P/N 293 550 033) on shaft before installing rear brake pedal. MASTER CYLINDER OF REAR BRAKE PEDAL Removal Drain rear brake pedal circuit. Refer to BRAKE FLUID REPLACEMENT in this section.

  • Page 252: Rear Brake Pressure Control Valve

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) Installation The installation is the reverse of the removal pro- cedure. Refill and bleed braking system. WARNING Bleed braking system before riding vehicle. BRAKE DISCS vmr2006-085-045_a Inspection 1. From RH front brake lever 2.

  • Page 253: Brake Hoses

    Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) Installation The installation is the reverse of removal proce- dure. However, pay attention to the following de- tails. Torque brake disc screws in accordance with the following table. TORQUE FOR BRAKE DISC SCREWS Front brake disc 41 N•m (30 lbf•ft) Rear brake disc...
  • Page 254 Section 09 BRAKING SYSTEM Subsection 01 (FRONT AND REAR BRAKES) Rear Brake Pedal The brake pedal switch is located over brake ped- vmr2006-085-020_a LH REAR BRAKE LEVER 1. LH rear brake fluid reservoir 2. Brake light switch connectors 3. Choke lever vmr2006-085-033_a 1.

  • Page 256: Body/Frame

    Section 10 BODY/FRAME Subsection 01 (BODY) BODY BODY vmr2006-086-001_a vmr2006-086...
  • Page 257 Section 10 BODY/FRAME Subsection 01 (BODY) SEAT vmr2006-086-002_a vmr2006-086...

  • Page 258: Parts Replacement

    Section 10 BODY/FRAME Subsection 01 (BODY) PARTS REPLACEMENT DECAL To remove a decal; heat old decal with a heat gun and peel off slowly. Using isopropyl alcohol, clean the surface and dry thoroughly. Apply liquid soap to new decal and carefully po- sition the decal.

  • Page 259: Fuel Tank Cover

    Section 10 BODY/FRAME Subsection 01 (BODY) FUEL TANK COVER Removal Remove screws near handlebar. One on each side. vmr2006-086-006_a Lift until cover is over the fuel tank neck. vmr2006-086-003_a Remove seat. Unscrew bolt securing fuel tank cover and front fender to frame. vmr2006-086-007 Move the fuel tank cover rearward to unlock the tabs.

  • Page 260: Radiator Shield

    Section 10 BODY/FRAME Subsection 01 (BODY) vmr2006-086-013_a Remove screw joining front and rear side panels vmr2006-086-009_a (left side only). Installation The installation is the reverse of removal proce- dure. RADIATOR SHIELD Removal Remove front cover. See procedures above. Unscrew bolt near radiator cap. vmr2006-086-017 Remove screws at the bottom of radiator shield.

  • Page 261: Front Fender

    Section 10 BODY/FRAME Subsection 01 (BODY) Raise bottom of radiator shield to gain access to screw heads and hold to remove them. Pull out radiator shield. vmr2006-086-011_a Unscrew bolt and screw securing front fender to frame and fender support (one on each side). vmr2006-071-004_a Installation The installation is the reverse of the removal pro-...
  • Page 262 Section 10 BODY/FRAME Subsection 01 (BODY) Unscrew bolts holding front fender and rear fender to frame. vmr2006-086-015_a vmr2006-086-018 Remove shifter handle. Remove CVT air inlet hose from the front fender. vmr2006-086-016 vmr2006-086-019_a Remove screw joining front and rear side panels 1.

  • Page 263: Rear Fender

    Section 10 BODY/FRAME Subsection 01 (BODY) vmr2006-086-014_a Unscrew bolts holding front fender and rear fender vmr2006-086-021 to frame. Carefully, remove the front fender. vmr2006-086-015_a vmr2006-086-022 Remove screws under front fender side panels. Installation The installation is the reverse of removal proce- dure.

  • Page 264: Footrest

    Section 10 BODY/FRAME Subsection 01 (BODY) vmr2006-086-024_a vmr2006-086-027_a 1. Starting solenoid connectors Remove battery retaining plate and battery. Refer 2. BLACK wire on solenoid to CHARGING SYSTEM. Remove starting solenoid from vehicle. Unlatch the fuse box from fender. Slide fuse box and wires through the fender open- ing.

  • Page 265: Cleaning

    Section 10 BODY/FRAME Subsection 01 (BODY) CLEANING SEAT It is recommended to clean the seat with a solu- tion of warm soapy water, using a soft clean cloth. CAUTION: Avoid use of harsh detergents such as strong soaps, degreasing solvents, abrasive cleaners, paint thinners, etc.

  • Page 266: Frame

    Section 10 BODY/FRAME Subsection 02 (FRAME) FRAME SERVICE PRODUCTS Description Part Number Page XP-S Lube ................293 600 016 ......... 249 vmr2006-087-014_a vmr2006-087...
  • Page 267 Section 10 BODY/FRAME Subsection 02 (FRAME) vmr2006-087-015_a vmr2006-087...

  • Page 268: General

    Section 10 BODY/FRAME Subsection 02 (FRAME) GENERAL PROCEDURES During assembly/installation, use the torque val- FRONT BUMPER ues and service products as in the exploded views. Removal WARNING Remove bolts that attach front bumper to the frame. Two (2) on each sides. Torque wrench tightening specifications must strictly be adhered to.

  • Page 269: Footrest Support

    Section 10 BODY/FRAME Subsection 02 (FRAME) FOOTREST SUPPORT Installation The installation is the reverse of the removal pro- Removal cedure. Behind footrest, remove bolts that attach footrest support to frame. REAR FRAME EXTENSION Removal Remove protective box bolt. vmr2006-087-003_a Remove bolts located in front of footrest and the screw near engine.

  • Page 270: Front Fender Support

    Section 10 BODY/FRAME Subsection 02 (FRAME) vmr2006-087-010_a 1. Retaining screw vmr2006-087-008_a 2. Retaining bolt LEFT SIDE SHOWN 1. Rear frame extension bolts Remove nuts retaining the support to the frame. Installation To install the rear frame extension, reverse the removal procedure. FRONT FENDER SUPPORT Removal NOTE: Use the same procedure for right or left...
  • Page 271 Section 10 BODY/FRAME Subsection 02 (FRAME) vmr2006-087-013_a Installation The installation is the reverse of the removal pro- cedure. vmr2006-087...
  • Page 272 Section 11 TECHNICAL SPECIFICATIONS Subsection 01 (DS 250) DS 250 DS 250 VEHICLE MODEL NORTH AMERICA MODEL EUROPEAN MODEL ENGINE 4-stroke, Single Over Head Camshaft (SOHC), Engine type liquid cooled Starting system Electric Number of cylinder(s) 4 valves with mechanical adjustment Number of valves Bore mm (in)

  • Page 273: Technical Specifications

    Section 11 TECHNICAL SPECIFICATIONS Subsection 01 (DS 250) DS 250 VEHICLE MODEL NORTH AMERICA MODEL EUROPEAN MODEL ENGINE (con'd) mm (in) 17.002 to 17.008 (.6694 to .6696) nominal Piston pin hole diameter Wear limit mm (in) 17.020 (.6701) mm (in) 16.994 to 17.000 (.6691 to .6693) Piston pin diameter Wear limit...
  • Page 274 Section 11 TECHNICAL SPECIFICATIONS Subsection 01 (DS 250) DS 250 VEHICLE MODEL NORTH AMERICA MODEL EUROPEAN MODEL ENGINE (con'd) mm (in) 0.00 to 0.008 (.000 to .0003) Connecting rod big end axial play Wear limit mm (in) 0.050 (.002) mm (in) 17.016 to 17.034 (.6699 to .6706) Connecting rod small end diameter...

  • Page 275: Ds 250

    Section 11 TECHNICAL SPECIFICATIONS Subsection 01 (DS 250) DS 250 VEHICLE MODEL NORTH AMERICA MODEL EUROPEAN MODEL CARBURETION Type KEHIN with manual choke Carburetor Model PTG-23 Idle engine speed 1700 ± 100 Main jet Pilot jet Needle jet Jet needle NB5G NB5E Clip position...
  • Page 276 41.000 to 41.050 (1.6142 to 1.6161) Sliding sheave inside diameter mm (in) Wear limit 41.070 (1.6169) COOLING BRP premixed coolant or ethyl glycol/water mix (50% coolant, 50% distilled water). Use coolant Coolant specifically designed for aluminum engines Opening temperature Fan (thermostatic switch) 98°C ±...
  • Page 277 Section 11 TECHNICAL SPECIFICATIONS Subsection 01 (DS 250) DS 250 VEHICLE MODEL NORTH AMERICA MODEL EUROPEAN MODEL SUSPENSION • FRONT Independent suspension — double A-arms Suspension type Suspension travel mm (in) 125 (5) Shock absorber Type Spring free length mm (in) 246.3 (9.7) Front preload adjustment —...
  • Page 278 Section 11 TECHNICAL SPECIFICATIONS Subsection 01 (DS 250) DS 250 VEHICLE MODEL NORTH AMERICA MODEL EUROPEAN MODEL CAPACITIES • LIQUID 12 L (3.2 U.S. gal) Fuel tank 2.8 L (2.96 U.S. quarts) Fuel tank reserve Replacement: 1.2 L (1.27 U.S. quarts) Capacity Disassembly: 1.4 L (1.48 U.S.

  • Page 280: Wiring Diagrams

    Section 12 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS SERVICE PRODUCTS Description Part Number Page dielectric grease ..............293 550 004 ......... 261 WIRE COLORS It identifies the color of a wire. When a 2-color scheme is used, the first color is the main color while the second color is the tracer color.
  • Page 282 FRAME GROUND WELDED JOINT EGINE GROUND SHRINKED JOINT DS 250 (ALL MODELS EXCEPT EUROPE MODELS) • CROSSED WIRE -:;:- PHILLIPS SCREW COLOR CODE _,/. WIREBUS NUT CONNECTION GENERAL SYSTEM BEIGE ,& BLACK SPLICE CONNECTION SIMPLE CONDUCTOR WIRE BLUE FEMALE TERMINAL COMPONENT CONNECTION BROWN GREEN...
  • Page 283 COLOR CODE • WELDED JOINT .,,b. FRAME GROUND EGINE GROUND - SHRINKED JOINT :��K BLUE � CROSSED WIRE O PHILLIPS SCREW OS 250 EUROPE MODELS ...J. WIRE BUS O NUT CONNECTION :::: GREY GENERAL SYSTEM - SIMPLE CONDUCTOR WIRE O SPLICE CONNECTION :::GE FEMALE TERMINAL �...

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