2001 Bombardier Traxter XT XL Auto Footshift Atv Shop Manual by www.heydownloads.com

2001 Shop Manual TRAXTER TRAXTER AUTO TRAXTER FOOTSHIFT TRAXTER XL TRAXTER XT

Legal deposit: National Library of Quebec 4th trimester 2000 National Library of Canada 2000 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. ©Bombardier Inc. 2000 Technical Publications Bombardier Inc. Valcourt (Quebec) Canada Printed in Canada ®*Registered trademarks of Bombardier Inc. This document contains the trademarks of the following companies: Kimtowels® is a trademark of Kimberly-Clark Loctite® is a trademark of Loctite Corporation Molykote® is a trademark of Dow Corning Corporation Snap-on® is a trademark of Snap-on Tools Corporation

TABLE OF CONTENTS

SECTION

SUBSECTION

PAGE

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

III

WHAT’S NEW .......................................................................................................................................

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

SERVICE TOOLS AND SERVICE PRODUCTS

01 – Table of contents...................................................................... 01-01-1 02 – Service tools............................................................................. 01-02-1 03 – Service products....................................................................... 01-03-1

MAINTENANCE

01 – Table of contents...................................................................... 02 – Maintenance chart.................................................................... 03 – Maintenance/lubrication ........................................................... 04 – Storage/pre-season preparation ...............................................

02-01-1 02-02-1 02-03-1 02-04-1

ENGINE

01 – Table of contents...................................................................... 02 – Removal and installation........................................................... 03 – Cooling system......................................................................... 04 – Rewind starter.......................................................................... 05 – Magneto system ...................................................................... 06 – Cylinder and head..................................................................... 07 – Crankshaft/balancer shaft......................................................... 08 – Lubrication system ................................................................... 09 – Clutch ....................................................................................... 10 – Transmission ............................................................................

03-01-1 03-02-1 03-03-1 03-04-1 03-05-1 03-06-1 03-07-1 03-08-1 03-09-1 03-10-1

FUEL SYSTEM

01 – Table of contents...................................................................... 02 – Fuel circuit ................................................................................ 03 – Carburetor and fuel pump ........................................................ 04 – Air intake silencer .....................................................................

04-01-1 04-02-1 04-03-1 04-04-1

ELECTRICAL

01 – Table of contents...................................................................... 02 – Overview .................................................................................. 03 – Charging system ...................................................................... 04 – Starting system ........................................................................ 05 – Ignition system......................................................................... 06 – Electric shift system................................................................. 07 – Instruments and accessories ...................................................

05-01-1 05-02-1 05-03-1 05-04-1 05-05-1 05-06-1 05-07-1

DRIVE TRAIN

01 – Table of contents...................................................................... 06-01-1 02 – Front drive ................................................................................ 06-02-1 03 – Rear axle................................................................................... 06-03-1

STEERING/CONTROL SYSTEMS

01 – Table of contents...................................................................... 07-01-1 02 – Steering/control systems ......................................................... 07-02-1

SUSPENSION

01 – Table of contents...................................................................... 08-01-1 02 – Front suspension...................................................................... 08-02-1 03 – Rear suspension....................................................................... 08-03-1

VMR2001_032_00_02A.FM

TABLE OF CONTENTS

SECTION

SUBSECTION

PAGE

BRAKES

01 – Table of contents ..................................................................... 09-01-1 02 – Hydraulic brakes....................................................................... 09-02-1

BODY/FRAME

01 – Table of contents ..................................................................... 10-01-1 02 – Body......................................................................................... 10-02-1 03 – Frame....................................................................................... 10-03-1

TECHNICAL DATA

01 – SI metric information guide...................................................... 11-01-1 02 – Engine and vehicle ................................................................... 11-02-1

WIRING DIAGRAMS

01 – Wiring diagrams ....................................................................... 12-01-1

VMR2001_032_00_02A.FM

SAFETY NOTICE

This manual has been prepared as a guide to correctly service and repair 2001 ATVs. This edition was primarily published to be used by ATV mechanical technicians who are already familiar with all service procedures relating to Bombardier made vehicles. Mechanical technicians should attend continuous training courses given by Bombardier Training Department. Please note that the instructions will apply only if proper hand tools and special service tools are used. This shop manual uses technical terms which may be slightly different from the ones used in parts catalog. It is understood that this manual may be translated into another language. In the event of any discrepancy, the english version shall prevail. The content depicts parts and/or procedures applicable to the particular product at time of writing. Service 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 Bombardier, after manufacturing the product. In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas of the parts. The use of Bombardier parts is most strongly recommended when considering replacement of any component. Dealer and/or distributor assistance should be sought in case of doubt. The engines and the corresponding components identified in this document should not be utilized on product(s) other than those mentioned in this document. Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab, elastic stop nut, self-locking fasteners, etc.) must be installed or replaced with new ones, where specified. If the efficiency of a locking device is impaired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols:

î°? WARNING Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death. CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components. NOTE: Indicates supplementary information needed to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your understanding of the information will promote its correct use. Always use common shop safety practice. This information relates to the preparation and use of Bombardier ATV and has been utilized safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing federal, provincial and state regulations.

VMR2001_032_00_02A.FM

III

WHAT’S NEW

SERVICE TOOLS AND SERVICE PRODUCTS • New oil pressure gauge.

MAINTENANCE/LUBRICATION • New air filter on some models.

REMOVAL AND INSTALLATION • Removal and installation procedure for FOOTSHIFT model.

MAGNETO SYSTEM • New section included in the shop manual.

CYLINDER AND HEAD • New section included in the shop manual.

CRANKSHAFT/BALANCER SHAFT • New section included in the shop manual.

LUBRICATION SYSTEM • New section included in the shop manual.

CLUTCH • New section included in the shop manual.

TRANSMISSION • New section included in the shop manual.

CARBURETOR AND FUEL PUMP • New pilot screw adjustment.

AIR INTAKE SILENCER • New air intake silencer on some models.

ELECTRIC SHIFT SYSTEM • Change in diagnostic mode for the new AUTO model.

INSTRUMENTS AND ACCESSORIES • Complete new winch removal and installation procedure.

VMR2001_032_00_02A.FM

WHAT’S NEW

FRONT DRIVE • Complete new inner differential removal and installation procedure.

REAR AXLE • Complete new inner differential removal and installation procedure.

FRONT SUSPENSION • Ball joints removal and installation procedure.

BODY • New procedure for XL model.

FRAME • New procedure for XL model.

TECHNICAL DATA • New technical data for all models.

WIRING DIAGRAMS • New wiring diagrams for all models.

VMR2001_032_00_02A.FM

INTRODUCTION

This Shop Manual covers the following Bombardier made 2001 ATV: Models TRAXTER* (Canada/Red) ....................... 7425 TRAXTER* (Canada/Green).................... 7427 TRAXTER* (USA/Red) ............................ 7426 TRAXTER* (USA/Green)........................ 7428 TRAXTER AUTO* (Canada/Red) ........... 7431 TRAXTER AUTO* (Canada/Green) ....... 7433 TRAXTER AUTO* (USA/Red) ................ 7432 TRAXTER AUTO* (USA/Green) ............ 7434

TRAXTER FOOTSHIFT* (Canada/Red).. 7439 TRAXTER FOOTSHIFT* (Canada/Green) ...................................... 7441 TRAXTER FOOTSHIFT* (USA/Red)....... 7440 TRAXTER FOOTSHIFT* (USA/Green)... 7442

V01A17A

TYPICAL 1. Model number

TRAXTER XL* (Green)........................... 7448 TRAXTER XT* (Canada) ........................ 7423 TRAXTER XT* (USA) ............................. 7424 *Trademark of Bombardier Inc.

VMR2001_032_00_02A.FM

INTRODUCTION

VEHICLE AND ENGINE SERIAL NUMBER LOCATION 1

2 V01A16A

1. Engine 2. Vehicle

VMR2001_032_00_02A.FM

VII

INTRODUCTION

Serial Number Meaning

SECTION 1

SECTION 2

1 2 3

4 5 6 7 8

SECTION 3

SECTION 4

9 10 11 12 13 14 15 16 17

SECTION 1

1 2 3 Class Make Manufacturer SECTION 2

4 5 6 7 8 Factory use Engine type II Engine type I Product line Type of drive SECTION 3

9 Check digit SECTION 4

10 11 12 13 14 15 16 17 Number sequentially assigned by the manufacturer in the production process Plant of manufacture Model year V01A0PS

VIII

VMR2001_032_00_02A.FM

INTRODUCTION

ARRANGEMENT OF THE MANUAL

inch

in²

square inch

The manual is divided into 12 major sections: 01 SERVICE TOOLS AND SERVICE PRODUCTS 02 MAINTENANCE 03 ENGINE 04 FUEL SYSTEM 05 ELECTRICAL 06 DRIVE TRAIN 07 STEERING/CONTROL SYSTEMS 08 SUSPENSION 09 BRAKES 10 BODY/FRAME 11 TECHNICAL DATA 12 WIRING DIAGRAMS Each section is divided in various subsections, and again, each subsection has one or more division.

in³

cubic inch

kilo (thousand)

kilogram

km/h

kilometer per hour

kPa

kilo pascal

liter

pound

lbf

pound (force)

lbf/in²

pound per square inch

left hand

meter

MAG

magneto

Max.

maximum

Min.

minimum

LIST OF ABBREVIATIONS USED IN THIS MANUAL

milliliter

millimeter

MPEM

multi-purpose electronic module

MPH

mile per hour

newton

N.A.

not applicable

no.

number

00.0

continuity

0.L

overload (open circuit)

O.D.

outside diameter

OPT

optional

ounce

P/N

part number

PSI

pound per square inch

PTO

power take off

RPM

revolution per minute

Sp. Gr.

specific gravity

TDC

top dead center

U.S. oz

ounce (United States)

volt

Vac

volt (alternative current)

ampere

amp

ampere

A•h

ampere-hour

alternate current

BDC

bottom dead center

BTDC

before top dead center

°C

degree Celsius

centimeter

cm²

square centimeter

cm³

cubic centimeter

direct current

°F

degree Fahrenheit

fl. oz

fluid ounce

foot

GRD

ground

hal.

halogen

I.D.

inside diameter

IDI

induction discharge ignition

imp. oz

imperial ounce

VMR2001_032_00_02A.FM

INTRODUCTION

This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog.

TYPICAL PAGE

Page heading indicates section and subsection detailed. Subsection 02

Section 03 ENGINE (REMOVAL AND INSTALLATION)

REMOVAL AND INSTALLATION 10 N m (97 lbf in) 21 22

Therma Lube grease

5 9

48 N m 8 (35 lbf ft) 3

3 17

18 20

Tightening torque nearby fastener. In this case, nut must be torqued to 24 N m or 17 lbf ft.

17 9

10 N m 15 (97 lbf in)

24 N m (17 lbf ft) 7

Exploded view assists you in identifying parts and related positions.

Therma Lube grease

Subsection title indicates beginning of the subsection.

1324 N m (17 lbf ft) 7

31 10 7

48 N m (35 lbf ft)

10 12

Therma Lube grease

32 26

30 2 32 29

24 N m (17 lbf ft) 7

48 N m (35 lbf ft) 8

Bold face number indicates special procedure concerning this part.

25 25

25 24

Illustration number for publishing process.

V01C15S

VMR2001-037_03-02A.FM

CAUTION: Pay attention to torque specifications. Some of these are in lbf in instead of lbf ft. Use appropriate torque wrench.

Document number for publishing process.

03-02-1

Drop represents a liquid product to be applied to a surface.

Page numbering system: 03: ENGINE section 02: REMOVAL AND INSTALLATION subsection 1: First page of this subsection

V01A33S

VMR2001_032_00_02A.FM

INTRODUCTION

TYPICAL PAGE

Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION)

Title indicates main procedure to be carried-out.

ENGINE REMOVAL

Vehicle Preparation

Place the vehicle on jackstands and place the shifter no. 1 on park position. Remove front wheels. Drain engine oil and engine coolant. Remove seat, front and rear fenders, inner fenders, side panels, steering cover, shifter guide cover and skid plate. Refer to the section BODY. Disconnect BLACK negative cable from battery, then RED positive cable.

m WARNING

V01C0DA

Call-outs for above illustration.

1. 2. 3. 4. 5. 6.

Always disconnect battery or starter cables exactly in the specified order, BLACK negative cable first. It is recommended to disconnect electrical connections prior to disconnecting fuel lines.

Clutching and clutch modulator valves connector STPS (Sub Transmission Position Sensor) VSS (Vehicle Speed Sensor) Shifting engine rod Oil pressure sensor Engine coolant hose

Front Part Preparation Remove fuel tank and fuel valve. Refer to the section FUEL CIRCUIT. Disconnect the interlock cable no. 2 under shifter lever. Remove seat pivot bar and unplug the clutching and clutch modulator valves connector. Remove the STPS (Sub Transmission Position Sensor). Remove shifting rod no. 3. Refer to the SHIFTING ROD REMOVAL section. Remove front propeller shaft. Refer to the section FRONT DIFFERENTIAL. Unplug the VSS (Vehicle Speed Sensor), located under engine drive shaft.

V01C0EA

1. 2. 3. 4.

Shifting valve GBPS (Gear Box Position Sensor) Magneto/trigger plug Engine coolant hose

03-02-2

Bold face number following part name refers to exploded view at beginning of subsection.

Engine Preparation Unplug spark plug cables. Unplug oil pressure sensor. Remove exhaust pipe no. 5. Refer to the EXHAUST SYSTEM section. Remove radiator inlet hose. Remove breather hose. Unplug the temperature sensor.

Reference to look up a certain section and subsection. In this case it concerns exhaust system.

VMR2001-037_03-02A.FM

V01A34S

VMR2001_032_00_02A.FM

INTRODUCTION

GENERAL INFORMATION The information and component/system descriptions contained in this manual are correct at time of publication. Bombardier Inc. however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured. Due to late changes, it may have some differences between the manufactured product and the description and/or specifications in this document. Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation.

ILLUSTRATIONS AND PROCEDURES Illustrations and photos show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function. CAUTION: Most components of those vehicles are built with parts dimensioned in the metric system. Most fasteners are metric and must not be replaced by customary fasteners or viceversa. Mismatched or incorrect fasteners could cause damage to the vehicle or possible personal injury. As many of the procedures in this manual are interrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or subsection in which the procedure is contained. A number of procedures throughout the book require the use of special tools. Before commencing any procedure, be sure that you have on hand all the tools required, or approved equivalents. The use of RIGHT and LEFT indications in the text, always refers to driving position (when sitting on vehicle).

XII

V01L25A

1. Left 2. Right

SELF-LOCKING FASTENERS PROCEDURE The following describes the most common application procedures when working with self-locking fasteners. Use a metal brush or a screwtap to clean the hole properly then use a solvent (Methyl-Chloride), let act during 30 minutes and wipe off. The solvent utilization is to ensure the adhesive works properly.

LOCTITE APPLICATION PROCEDURE The following describes the most common application procedures when working with Loctite products. NOTE: Always use proper strength Loctite product as recommended in this Shop Manual.

VMR2001_032_00_02A.FM

INTRODUCTION

Threadlocker Uncovered Holes (bolts and nuts)

1. Clean threads (bolt and hole) with solvent. 2. Apply Loctite Primer N (P/N 293 800 041) on threads (bolt and nut) and allow to dry for 30 seconds. 3. Choose proper strength Loctite threadlocker. 4. Apply several drops along the threaded hole and at the bottom of the hole. 5. Apply several drops on bolt threads. 6. Tighten as required. Stud in Blind Holes

A00A3LA

1. Apply here 2. Do not apply

1. Clean threads (bolt and nut) with solvent. 2. Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry. 3. Choose proper strength Loctite threadlocker. 4. Fit bolt in the hole. 5. Apply a few drops of threadlocker at proposed tightened nut engagement area. 6. Position nut and tighten as required. Blind Holes

1 2

A00A5RA

1. On threads 2. On threads and in the hole 3. Onto nut threads

1. Clean threads (stud and hole) with solvent. 2. Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry. 3. Put several drops of proper strength Loctite threadlocker on female threads and in hole. 4. Apply several drops of proper strength Loctite on stud threads. 5. Install stud. 6. Install cover, etc. 7. Apply drops of proper strength Loctite on uncovered threads. 8. Tighten nuts as required.

A00A3MA

1. On threads 2. On threads and at the bottom of hole

VMR2001_032_00_02A.FM

XIII

INTRODUCTION

Preassembled Parts

NOTE: If it is difficult to readjust, heat screw with a soldering iron (232Â°C (450Â°F)).

Stripped Thread Repair Stripped Threads

5 1

6 8

2 A00A3OA

1. Apply here 2. Do not apply

A00A3QA

1. Clean bolts and nuts with solvent. 2. Assemble components. 3. Tighten nuts. 4. Apply drops of proper strength Loctite on bolt/nut contact surfaces. 5. Avoid touching metal with tip of flask. NOTE: For preventive maintenance on existing equipment, retighten nuts and apply proper strength Loctite on bolt/nut contact surfaces. Adjusting Screw 2 1

1. 2. 3. 4. 5. 6. 7. 8.

Release agent Stripped threads Form-A-Thread Tape Cleaned bolt Plate New threads Threadlocker

Standard Thread Repair 1. Follow instructions on Loctite FORM-A-THREAD (P/N 413 708 600) package. 2. If a plate is used to align bolt: a. Apply release agent on mating surfaces. b. Put waxed paper or similar film on the surfaces. 3. Twist bolt when inserting it to improve thread conformation. NOTE: NOT intended for engine stud repairs. Repair of Small Holes/Fine Threads Option 1: Enlarge damaged hole, then follow Standard Thread Repair procedure. Option 2: Apply FORM-A-THREAD on the screw and insert in damaged hole.

A00A3PA

1. Apply here 2. Plunger

1. Adjust screw to proper setting. 2. Apply drops of proper strength Loctite threadlocker on screw/body contact surfaces. 3. Avoid touching metal with tip of flask.

XIV

Permanent Stud Installation (light duty) 1. Use a stud or thread on desired length. 2. DO NOT apply release agent on stud. 3. Do a Standard Thread Repair. 4. Allow to cure for 30 minutes. 5. Assemble.

VMR2001_032_00_02A.FM

INTRODUCTION

Mounting on Shaft

Case-In Components

Mounting with a Press

Metallic Gaskets

1 2 3 A00A3UA

1. Bearing 2. Proper strength Loctite 3. Shaft

Standard 1. Clean shaft external part and element internal part. 2. Apply a strip of proper strength Loctite on shaft circumference at insert or engagement point. NOTE: Retaining compound is always forced out when applied on shaft. 3. DO NOT use anti-seize Loctite or any similar product. 4. No curing period is required. Mounting in Tandem 1. Apply retaining compound on internal element bore. 2. Continue to assemble as shown above.

VMR2001_032_00_02A.FM

A00A3VA

1. Proper strength Loctite

1. Clean inner housing diameter and outer gasket diameter. 2. Spray housing and gasket with Loctite Primer N (P/N 293 800 041). 3. Apply a strip of proper strength Loctite on leading edge of outer metallic gasket diameter. NOTE: Any Loctite product can be used here. A low strength liquid is recommended as normal strength and gap are required. 4. Install according to standard procedure. 5. Wipe off surplus. 6. Allow it to cure for 30 minutes. NOTE: Normally used on worn-out housings to prevent leaking or sliding. It is generally not necessary to remove gasket compound applied on outer gasket diameter.

INTRODUCTION

TIGHTENING TORQUES Tighten fasteners to torque mentioned in exploded views and text. When they are not specified refer to following table.The table also gives the metric conversion.

XVI

N•m 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

FASTENER SIZE (8.8)

N•m 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

FASTENER SIZE (8.8)

M4 M5

Lbf•in 9 18 27 35 44 53 62 71 80 89 97 106 115 124 133 142 150 159 168 Lbf•ft 15 15 16 17 18 18 19 20 21 21 22 23 24 24 25 26 27 27 28

N•m 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83

FASTENER SIZE (8.8)

M10

M12

Lbf•ft 29 30 30 31 32 32 33 34 35 35 36 37 38 38 39 40 41 41 42 43 44 44 45 46 46 47 48 49 49 50 51 52 52 53 54 55 55 56 57 58 58 59 60 60 61

VMR2001_032_00_02A.FM

INTRODUCTION

N•m 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127

FASTENER SIZE (8.8)

VMR2001_032_00_02A.FM

Lbf•ft 62 63 63 64 65 66 66 67 68 69 69 70 71 72 72 73 74 74 75 76 77 77 78 79 80 80 81 82 83 83 84 85 86 86 87 88 89 89 90 91 91 92 93 94

N•m 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150

FASTENER SIZE (8.8)

M14

Lbf•ft 94 95 96 97 97 98 99 100 100 101 102 103 103 104 105 105 106 107 108 108 109 110 111

TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS

XVII

Bombardier SERVICE PUBLICATIONS REPORT

We would be pleased if you could communicate to Bombardier any suggestions you may have concerning our publications.

Publication title and year ________________________ Page______ Machine___________________ Report of error ❏ Suggestion ❏ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ____________________________________________________ City and State/Prov. ________________________ Date___________ Zip code/Postal code ________________________________________

Bombardier SERVICE PUBLICATIONS REPORT Publication title and year ________________________ Page______ Machine___________________ Report of error ❏ Suggestion ❏ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ____________________________________________________ City and State/Prov. ________________________ Date___________ Zip code/Postal code ________________________________________

Bombardier SERVICE PUBLICATIONS REPORT

✁

AFFIX PROPER POSTAGE

Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0

AFFIX PROPER POSTAGE

Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0

AFFIX PROPER POSTAGE

Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

SERVICE TOOLS.................................................................................................................... ENGINE — MANDATORY SERVICE TOOLS .................................................................... ENGINE — RECOMMENDED SERVICE TOOLS ............................................................... ENGINE (CONTINUED) — RECOMMENDED SERVICE TOOLS ...................................... ELECTRICAL — MANDATORY SERVICE TOOLS ............................................................ ELECTRICAL — RECOMMENDED SERVICE TOOLS ....................................................... SUSPENSION — MANDATORY SERVICE TOOL ............................................................ SUSPENSION — RECOMMENDED SERVICE TOOL ....................................................... DRIVE — MANDATORY SERVICE TOOLS ....................................................................... DRIVE — RECOMMENDED SERVICE TOOL .................................................................... VEHICLE — MANDATORY SERVICE TOOL ..................................................................... VEHICLE — RECOMMENDED SERVICE TOOL ................................................................

01-02-1 01-02-1 01-02-2 01-02-3 01-02-4 01-02-4 01-02-5 01-02-5 01-02-6 01-02-6 01-02-7 01-02-7

SERVICE PRODUCTS ............................................................................................................ MANDATORY SERVICE PRODUCTS ................................................................................ RECOMMENDED SERVICE PRODUCTS ..........................................................................

01-03-1 01-03-1 01-03-2

VMR2001_065_01_01ATOC.FM

01-01-1

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS)

SERVICE TOOLS

This is a list of tools to properly service ATV vehicles. If you need to replace or add to your tool inventory, these items can be ordered through the regular parts channel. NEW Following mention points out new tool:

ENGINE â&#x20AC;&#x201D; MANDATORY SERVICE TOOLS Lifting bar (P/N 529 035 610)

Magneto puller (P/N 420 976 235)

Spanner tool for clutch basket (P/N 529 035 647)

V01B094

V01B0B4

Small hose pincher (P/N 295 000 076) F01B294

Crankshaft locking bolt (P/N 529 035 645)

Fuel system pressure tester (P/N 529 033 100)

A01B2I4 V01B0C4

Large hose pincher (P/N 529 032 500)

A01B5E4

Crankshaft protector (P/N 420 876 557)

46 mm socket for crankshaft (P/N 529 035 648)

F01B234 V01B0D4 V01B0A4

VMR2001_033_01_02A.FM

01-02-1

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS)

ENGINE â&#x20AC;&#x201D; RECOMMENDED SERVICE TOOLS Lifting ring (P/N 529 035 644)

Float level gauge (P/N 529 035 520)

Valve spring compressor clamp (P/N 529 035 724)

NEW

V01B0F4

A00B4N4

Choke nut tool (P/N 529 035 660)

V00B044

Digital/induction type tachometer (P/N 529 014 500)

Valve spring compressor cap (P/N 529 035 725) NEW

V01B0G4 F01B1G4

Ring compressor Not sold by Bombardier Snap-on RCW60 or Lisle 21700

Exhaust spring installer/remover (P/N 529 035 401)

V00B054

Oil pressure gauge (1 to 8 bars) (P/N 529 035 709) NEW

V01B0H4

A01B584

Carburetor tool kit (P/N 404 112 000)

V00B064

A00B2F4

01-02-2

VMR2001_033_01_02A.FM

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS)

ENGINE (continued) â&#x20AC;&#x201D; RECOMMENDED SERVICE TOOLS Engine oil pressure adapter (P/N 529 035 652)

Connection tool (oil gauge) (P/N 529 035 714) NEW

NEW

F12B0G4

V00B074

VMR2001_033_01_02A.FM

01-02-3

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS)

ELECTRICAL — MANDATORY SERVICE TOOLS Six-pin magneto harness (P/N 529 035 604)

T-Harness for diagnoses of solenoids (P/N 529 035 653)

Jumper for self-diagnoses (P/N 529 035 605)

F01B284 V01B0M4

V01B0L4

ELECTRICAL — RECOMMENDED SERVICE TOOLS Crimping tool (P/N 295 100 164)

Terminal remover Not sold by Bombardier

Multimeter (P/N 529 022 000)

Snap-on TT 600-4

F01B1J4

F00B0E4

F01B1O4

01-02-4

VMR2001_033_01_02A.FM

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS)

SUSPENSION — MANDATORY SERVICE TOOL Front suspension space bar (P/N 529 035 611)

V01B0N4

SUSPENSION — RECOMMENDED SERVICE TOOL Shock spring removal kit (P/N 529 035 504) Replacement clevis pin: (P/N 414 528 400)

A01B4O4

VMR2001_033_01_02A.FM

01-02-5

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS)

DRIVE — MANDATORY SERVICE TOOLS Pliers (P/N 295 000 069)

Pliers (P/N 295 000 054)

Oetiker 1090

Hub puller (P/N 529 035 612)

Caillau

F01B1T4 F01D184

V01B0O4

DRIVE — RECOMMENDED SERVICE TOOL Differential spanner socket (P/N 529 035 649)

V01B0S4

01-02-6

VMR2001_033_01_02A.FM

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS)

VEHICLE — MANDATORY SERVICE TOOL 41 mm socket for swing arm nut Not sold by Bombardier Proto 5541

V01B0T4

VEHICLE — RECOMMENDED SERVICE TOOL Flexible spout for oil container (P/N 414 837 300)

F04B044

VMR2001_033_01_02A.FM

01-02-7

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 03 (SERVICE PRODUCTS)

SERVICE PRODUCTS

MANDATORY SERVICE PRODUCTS Loctite® is a trademarks of Loctite Corporation. Permatex® is a trademark of Loctite™ Corporation. Dow Corning® is a trademarks of Dow Corning Corporation. Primer for gasket eliminator (P/N 293 800 041)

Medium strength threadlocker (P/N 293 800 060)

Loctite 764 128 g (5 oz)

The Right Stuff (sealant) (P/N 293 800 053) Permatex® (198 g)

Loctite 243 (blue) (10 mL)

A00B3N4 F00A0O4

Gasket stripper (P/N 413 508 500) (500 mL)

Gasket/paint remover (P/N 413 708 500) Loctite® 79040 Chisel 510 g (18 oz)

F00B0V4

High strength threadlocker (P/N 293 800 005) Loctite 271 (red) (10 mL)

F01B1W4 A00B3L4

Dielectric grease (P/N 293 550 004) Dow Corning (150 g)

Premixed coolant - 52°C (- 62°F) (P/N 413 711 802) (16 x 1 L)

A00B2U4

F01B164

A00B5E4

VMR2001_034_01_03A.FM

01-03-1

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 03 (SERVICE PRODUCTS)

RECOMMENDED SERVICE PRODUCTS Anti-seize lubricant (P/N 413 701 000)

Degreaser (P/N 413 708 400)

Fuel stabilizer (P/N 413 408 600) 236 mL (8 oz)

Permatex® 48 TA 433 g (15 oz)

Loctite anti-seize lubricant 454 g (16 oz)

F01B174

Bombardier storage oil (P/N 413 711 600) (12 x 350 g)

A00B3V4

A00B3K4

Plastic & vinyl cleaner (P/N 413 711 200)

Paste gasket (P/N 413 702 700) Loctite® 515: Gasket eliminator (50 mL)

(6 x 1 L)

A00B2T4

BOMBARDIER LUBE (P/N 293 600 016) (12 x 14 oz)

A02B054

Silicone compound (P/N 420 897 061) Dow Corning® MS4 A00B4V4

Stripped threads repair kit (P/N 413 708 600)

A00B3R4

F01B0S4

Loctite 81668 Form-A-thread

Molykote PG 54 (P/N 420 899 763) (10 g)

A00B5F4

01-03-2

A00A1J4

VMR2001_034_01_03A.FM

Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

MAINTENANCE CHART ........................................................................................................ NOISE EMISSION CONTROL SYSTEM REGULATION ................................................... TAMPERING WITH NOISE CONTROL SYSTEM IS PROHIBITED!.................................. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: .............................................................................................. MAINTENANCE CHART ....................................................................................................

02-02-1 02-02-1 02-02-1

MAINTENANCE/LUBRICATION ........................................................................................... AIR FILTER CLEANING/DRAINING................................................................................... BOLTS, FASTENERS AND NUTS ..................................................................................... ENGINE OIL AND FILTER.................................................................................................. SPARK ARRESTER ............................................................................................................ TIRES AND WHEELS ......................................................................................................... ENGINE COMPARTMENT.................................................................................................

02-03-1 02-03-1 02-03-3 02-03-3 02-03-4 02-03-5 02-03-6

STORAGE/PRE-SEASON PREPARATION ........................................................................... STORAGE........................................................................................................................... FUEL STABILIZER .............................................................................................................. ENGINE LUBRICATION ..................................................................................................... VEHICLE CLEANING AND PROTECTION......................................................................... COOLANT DENSITY .......................................................................................................... PRE-SEASON PREPARATION...........................................................................................

02-04-1 02-04-1 02-04-1 02-04-1 02-04-1 02-04-2 02-04-3

VMR2001_065_02_01ATOC.FM

02-02-1 02-02-2

02-01-1

Section 02 MAINTENANCE Subsection 02 (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. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases. 2. Removal or alteration or the puncturing of any part of the intake system. 3. Replacing any moving parts of the vehicle or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. 4. Lack of proper maintenance.

VMR2001_035_02_02A.FM

02-02-1

Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART)

MAINTENANCE CHART Some items may not apply to your particular model.

Engine/transmission oil level Engine/transmission oil and filter replacement Spark arrester (cleaning) Engine mount fasteners Exhaust system (leak) Condition of seals Engine oil strainer cleaning Coolant density Coolant level Coolant replacement Cooling system condition Radiator cap pressure test Radiator condition/cleanliness (air ducts) Rewind starter rope condition

02-02-2

✔ ✔ ✔ ✔

Removal/ installation

✔ ✔ ✔ ✔

✔

REFER TO THE SUBSECTION Maintenance/ lubrication

✔

N.A. Transmission Storage

✔ ✔

✔

Cooling system ✔

✔

✔ ✔ ✔

Clutch and transmission operation PCV valve (inspection) Footshift mechanism adjustment Air filter cleaning/draining Air filter and foam replacement Fuel lines and connections Fuel tank strainer replacement Carburetor adjustment Spark plug inspection/replacement Battery electrolyte level and vent condition Battery connections Wiring harness, cables and lines Condition of ignition switch and start/stop button Condition of lighting system (hi/lo intensity, brake light, etc.) Headlight beam aiming Winch connection

200 HOURS OR 5000 KM (3107 m.) OR 2 YEARS

✔

100 HOURS OR 2500 KM (1553 m.) OR ONCE A YEAR

✔ ✔

50 HOURS OR 1250 KM (777 m.)

25 HOURS OR 625 KM (388 m.)

LUBRICATION AND MAINTENANCE CHART

INITIAL 10 HOURS OR 250 KM (150 m.)

EVERY

✔ ✔ ✔

Maintenance/ lubrication

✔ ✔

✔

✔ ✔ ✔ ✔

✔ ✔ ✔

✔ ✔

✔ ✔ ✔

✔

✔ ✔

Rewind starter Clutch, transmission and/or electric shift system Air intake silencer Transmission

Fuel circuit Carburetor Ignition system Starting system

Instruments/ accessories

✔ ✔

VMR2001_035_02_02A.FM

Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART)

Drive shaft boot inspection and protector condition Front propeller shaft joint lubrication (grease fitting) Drive shaft joint inspection Wheel bearing condition Rear propeller shaft joint lubrication (grease fitting) Front differential and rear rigid axle oil level, seals and vent condition Front differential and rear rigid axle oil replacement Throttle condition Choke condition Handlebar fastener tightness Steering system mechanism Tie rod ends inspection Front wheel alignment Steering adjustment Tire pressure Wheel mount tightness and stud lubrication Wear and condition of tires

✔

Front differential ✔

✔ ✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔

Rear axle

✔

✔ ✔ ✔ ✔ ✔

Front differential/ rear axle Carburetor

Steering/ control systems

Maintenance/ lubrication

✔

Swing arm condition Shock absorber condition

✔

A-arm lubrication

✔

Brake fluid level front/rear Brake fluid replacement front/rear Brake cable condition Brake cable adjustment Brake system condition (discs, hoses, etc.) Brake pads condition Engine compartment Fastener condition/tightness Skid plate condition Hitch/trailer ball condition (if installed) Seat latch Frame inspection Vehicle cleaning and protection Storage cover latchs Rear cargo box release lever condition Rear cargo box latches condition Rear cargo box gate latches condition

REFER TO THE SUBSECTION

✔

100 HOURS OR 2500 KM (1553 m.) OR ONCE A YEAR 200 HOURS OR 5000 KM (3107 m.) OR 2 YEARS

✔

50 HOURS OR 1250 KM (777 m.)

25 HOURS OR 625 KM (388 m.)

LUBRICATION AND MAINTENANCE CHART

INITIAL 10 HOURS OR 250 KM (150 m.)

EVERY

✔

Front and rear suspension

✔ ✔ ✔

✔ ✔

✔

Hydraulic brakes

✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔

Maintenance/ lubrication

✔ ✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔

Body and frame

The initial maintenance is very important and must not be neglected. NOTE: Some riding conditions and hauling loads may result in requiring more frequent maintenance. Some items are part of the pre-operation checks and must always be performed prior to operating the vehicle. VMR2001_035_02_02A.FM

02-02-3

Subsection 03

Section 02 MAINTENANCE (MAINTENANCE/LUBRICATION)

MAINTENANCE/LUBRICATION AIR FILTER CLEANING/DRAINING Air Filter Box Draining Periodically inspect air filter box drain plugs for water or deposits. Refer to the maintenance chart.

If water/deposits are found, squeeze the clamp and remove. Pull drain tube out. Proceed with each drain plug. CAUTION: Do not start engine when water is found in the drain tubes. When water/deposits are found, air filter must be inspected/dried/replaced depending on its condition. Remove air filter as explained below.

Air Filter Removal CAUTION: Never remove or modify any component in the air box. Always use genuine parts when replacing air filter and foam. The engine carburetion is calibrated to operate specifically with these components. Otherwise, engine performance degradation or damage can occur. Remove seat. NOTE: On the XL model, lift the rear cargo box to access the air filter box. Release clamps and remove air filter box cover. 1 1 3 2

V01F04A

TYPICAL 1. Air filter box 2. Drain plugs 3. Clamp

NOTE: If vehicle is used in dusty area, inspect more frequently than specified in maintenance chart.

VMR2001_035_02_03A.FM

V01F05A

1. Release clamps 2. Lift to remove

02-03-1

Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION)

All Models except XL NOTE: Some TRAXTER and XT are equipped with the same air filter as the XL model. See which air filter is installed on the vehicle and use the proper removal procedure. Loosen clamp and remove air filter. 1

XL Model Remove air baffles, air filter and foam.

V03F01A

1. Air baffle V01F1LA

1. Clamp 2. Air filter

Pour cleaning solution into a bucket, dunk the filter in multiples times until clean. Rinse with warm water. NOTE: Products like Simple Green, dish soap or mild solvents can be used to clean the air filter. Simple GreenÂŽ from Sunshine Makers Inc. is available at hardware stores or at automotive parts retailer. While filter soaks, clean inside of air box. Next, let the filter dry completely. When the filter is dried, re-oil with air filter oil. If air filter foam is dirty, replace with a new one. Properly reinstall removed parts in the reverse order of their removal.

02-03-2

V03F02A

1. Air filter

VMR2001_035_02_03A.FM

Subsection 03

Section 02 MAINTENANCE (MAINTENANCE/LUBRICATION)

ENGINE OIL AND FILTER Oil Viscosity

BOLTS, FASTENERS AND NUTS Check that all fasteners, bolts and nuts are tightened to the proper torque.

SAE 20W50

SAE 15W50

SAE 15W40

Clean inside of air box. Wash air filter and foam with warm water and a mild detergent as necessary. Squeeze foam to remove excess water. Let air filter and foam dry thoroughly. If air filter element or foam is dirty, replace with a new one. NOTE: Slight dust may be cleaned using a lowpressure airgun. Blow compressed air backward of operating air flow. Properly reinstall removed parts in the reverse order of their removal.

SAE 10W40

1. Foam

°C

°F

140

SAE 10W30

V03F03A

SAE 5W30

BOMBARDIER SYNTHETIC OIL / HUILE SYNTHÉTIQUE BOMBARDIER

SAE 10W40 is recommended for summer time. SAE 5W30 is recommended for winter time. Other viscosity should be used if the average temperature is outside the range of the recommended oil. See chart below.

120

100

30 80 20 60 10 40 0

-10

-20

-30

-20

V01A35A

Oil and Oil Filter Change

 WARNING The engine oil can be very hot. Wait until engine oil is warm. NOTE: Oil and filter are to be replaced at the same time. Oil change should be done with a warmed up engine.

VMR2001_035_02_03A.FM

02-03-3

Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION)

Ensure vehicle is on a level surface. Clean the drain plug area. Remove dipstick. Place a drain pan under the engine drain plug area. Unscrew drain plug.

NOTE: The same oil lubricates both engine and transmission. For improve overall performance and wear protection use Bombardier synthetic oil (P/N 293 600 040). This is a special synthetic oil formulated for clutch type gear box. Donâ&#x20AC;&#x2122;t use synthetic oil, synthetic blend oil or special additive, other than Bombardier brand name. As they could affect the clutching performance. Start engine and let idle for a few minutes. Ensure oil filter area and drain plug areas are not leaking. Stop engine. Wait a while to allow oil to flow down to crankcase then check oil level. Refill as necessary. Dispose oil as per your local environmental regulations.

SPARK ARRESTER 1

The muffler must be periodically purged of accumulated carbon. Select a well-ventilated area and make sure the muffler is cool. Place transmission on park position. Remove the clean out plug.

V01A0AB

1. Oil drain plug

Wait a while to allow oil to flow out of oil filter (10 minutes approximately). Carefully unscrew oil filter and as soon as it can leave the engine, turn it upright. Discard filter. Be sure that the old filter O-ring is removed. CAUTION: Only use Bombardier high pressure filter. The Bombardier filter is specifically designed for this engine. This filter does not operate at the same pressure than other brands. Using a non-recommended filter may cause serious engine damage. Lubricate the O-ring on the filter with engine oil. Install the new filter then screw one full turn after O-ring contact. Wipe out any oil spillage on engine. Inspect gasket on drain plug and replace as necessary. Clean gasket area on engine and drain plug then reinstall plug. Refill engine at the proper level with the recommended oil. Refer to TECHNICAL DATA for capacity. Do not overfill.

02-03-4

V01C05A

TYPICAL 1. Clean out plug 2. Muffler

Block the end of muffler with a shop rag and start engine.

VMR2001_035_02_03A.FM

Subsection 03

Momentarily increase engine RPM several time to purge accumulated carbon out the muffler. Stop engine and allow muffler to cool. Remove shop rag and reinstall the clean out plug.

î°? WARNING Never run engine in an enclosed area. Never perform this operation immediately after the engine has been run because exhaust system is very hot. Make sure that there are no combustible materials in the area. Wear eye protector and gloves. Never stand behind the vehicle while purging exhaust system. Respect all applicable laws and regulations.

Section 02 MAINTENANCE (MAINTENANCE/LUBRICATION)

TIRE PRESSURE TRAXTER, AUTOSHIFT AND FOOTSHIFT MODELS

RECOMMENDED

MINIMUM

FRONT

REAR

38 kPa (5.5 PSI)

35 kPa (5 PSI)

31 kPa (4.5 PSI)

FRONT

REAR

48 kPa (7 PSI)

45 kPa (6.5 PSI)

FRONT

REAR

35 kPa (5 PSI)

38 kPa (5.5 PSI)

31 kPa (4.5 PSI)

35 kPa (5 PSI)

XL MODEL

RECOMMENDED

MINIMUM XT MODEL

Check the exhaust system for damage, crack or leak (exhaust pipe). Repair or change if necessary.

RECOMMENDED

TIRES AND WHEELS Tire Pressure CAUTION: Underpressure may cause tire to deflate and rotate on wheel. Overpressure might burst the tire. Always follow recommended pressure. Since tires are low-pressure type, a manual pump should be used. Check pressure when tires are cold before using the vehicle. NOTE: Tire pressure changes with temperature and altitude. Recheck pressure if one of these conditions has changed. For your convenience, a pressure gauge is supplied in tool box.

MINIMUM

Tire/Wheel Condition Check tire for damage and wear. Measure thread height. It should be 4 mm (5/32 in) minimum. Replace if damaged or worn. A

V01A05A

A. 4 mm (5/32 in)

NOTE: Do not make a tire rotation. The front and rear tires have a different size. Besides, these tires are directional and their rotation must be kept in a specific direction for proper operation.

VMR2001_035_02_03A.FM

02-03-5

Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION)

Wheel Removal Untighten nuts then lift vehicle where needed. Place a support under vehicle. Remove nuts then withdraw wheel. At installation, it is recommended to apply antiseize lubricant on threads. Gently tighten nuts in a criss-cross sequence then apply a final torque of 75 N•m (55 lbf•ft).

V01A08A

1. Taper side of nut

ENGINE COMPARTMENT Check in the engine compartment, for leak or other damage. Clean mud, leafs, etc. from engine compartment.

02-03-6

VMR2001_035_02_03A.FM

Subsection 04

Section 02 MAINTENANCE (STORAGE/PRE-SEASON PREPARATION)

STORAGE/PRE-SEASON PREPARATION STORAGE If the ATV is to be stored for an extended period of time more than 1 month, be sure to thoroughly check the vehicle for needed repairs and have them performed.

FUEL STABILIZER A fuel stabilizer (P/N 413 408 600) can be added in fuel tank to prevent fuel deterioration and avoid draining fuel system for storage. Follow manufacturer’s instructions for proper use. If above fuel stabilizer is not used, drain fuel system including fuel tank and carburetor. CAUTION: Fuel stabilizer should be added prior to engine lubrication to ensure carburetor protection against varnish deposit.

ENGINE LUBRICATION Engine internal parts must be lubricated to protect them from possible rust formation during the storage period. Proceed as follows: – Place the vehicle on blocks to raise all four tires off the ground. – Start the engine and allow it to run at idle speed until the engine reaches its operating temperature. – Stop the engine. – Change engine oil and filter. Refer to MAINTENANCE/ LUBRICATION. – Remove air box cover and air filter to spray storage oil (P/N 413 711 600) into carburetor bore. NOTE: On some TRAXTER and XT as well as XL model, remove foam and baffles too. Refer to MAINTENANCE/LUBRICATION. – Restart engine and run at idle speed. – Inject storage oil until the engine stalls or until a sufficient quantity of oil has entered the engine (approximately a quarter of can). – Reinstall all parts in the air box.

VMR2001_036_02_04A.FM

– Stop the engine and remove the battery. Store it in dry and cool place out of the sun, refer to BATTERY. Remove the spark plugs and spray storage oil into cylinder. – Crank slowly 2 or 3 revolutions to lubricate cylinder. Reinstall the spark plugs. – Turn the fuel valve to OFF and drain carburetor.

 WARNING This procedure must only be performed in a well-ventilated area. Do not run engine during storage period. – Block air intake inlet using clean rag. The air intake hole is located in the air box. – Install a clean rag in the muffler opening to block the exhaust system outlet. CAUTION: Remove those rags at pre-season preparation.

VEHICLE CLEANING AND PROTECTION Wash and dry the vehicle. Remove any dirt or rust. To clean the plastic parts, use only flannel clothes or Kimtowels® wipers no. 58-380 from KimberlyClark. CAUTION: It is necessary to use flannel cloths or Kimtowels wipers on plastic parts to avoid damaging further surfaces to clean. To clean the entire vehicle, including metallic parts with a thick coat of grease, use Endust® imported by Bristol Myers, available at hardware stores or supermarkets. CAUTION: Do not use Bombardier Cleaner on decals, plastic parts or vinyl. To clean the entire vehicle, including metallic parts with a thin coat of grease, use Simple Green® from Sunshine Makers Inc., available at hardware stores or at automotive parts retailer. For vinyl and plastic parts, use Vinyl & Plastic Cleaner (P/N 413 711 200 (6 x 1 L)).

02-04-1

Section 02 MAINTENANCE Subsection 04 (STORAGE/PRE-SEASON PREPARATION)

NOTE: 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. This will prevent sun rays and grime from affecting plastic components and vehicle finish.

COOLANT DENSITY Test the density of the coolant using an antifreeze hydrometer. NOTE: Follow manufacturerâ&#x20AC;&#x2122;s instructions for proper use. A 60/40 mixture of antifreeze and distilled water will provide the optimum cooling, corrosion protection and antifreeze protection. Do not use tap water, straight antifreeze or straight water in the system. Tap water contains minerals and impurities which build up in the system. Straight water or antifreeze will cause the system to freeze. Change coolant if necessary.

02-04-2

VMR2001_036_02_04A.FM

Subsection 04

Section 02 MAINTENANCE (STORAGE/PRE-SEASON PREPARATION)

PRE-SEASON PREPARATION SYSTEM

PRE-SEASON OPERATIONS

TO BE PERFORMED BY CUSTOMER

Test Run Vehicle. Check Clutch and Transmission Operation

REFER TO SECTION

✔

N.A.

✔

Maintenance

Coolant Replacement and Pressurization of System

✔

Cooling system

Condition of Seals

✔

N.A.

Exhaust System Condition

✔

Removal/installation

Rewind Starter, Rope Condition

✔

Rewind starter

Fuel Line and Connectors Condition

✔

Fuel circuit

Carburetor Adjustment

✔

Throttle and Choke Cable Inspection/Adjustment

✔

Engine Oil and Filter Oil Replacement ➀

✔

Spark Arrester Rags Removal (Intake and Exhaust) ➁

✔

Air Filter Cleaning/Replacement

✔

Spark Plug Replacement ➂

✔

Ignition system ✔

Starter Connections and Routing

✔

Drive Shaft Boot Inspection

✔

Front Propeller Shaft Lubrication

✔

Front Differential and Rigid Axle Oil Level and Vent Tube Condition

✔

Steering System Inspection and Adjustment

✔

Handle Bar Fastener Tightness

✔ ✔

Tire Pressure

✔

Tire Condition

✔

Starting system Instruments/ accessories

✔

Wheel Tightness

Carburetor Maintenance

Battery Condition/Charging and Installation

Operation of Lighting System

DEALER

Front differential/ rear axle

Steering/ control systems Maintenance

Suspension System Inspection

✔

Bearing Condition

✔

Swing Arm Condition

✔

Brake Fluid Change

✔

Brake Condition

✔

Brake Cable Adjustment

✔

Front/rear suspension

Hydraulic brakes

✔

Frame and Skid Plate Condition Hitch/Trailer Ball Condition

✔

Front Cover Compartment Cover Latch Condition

✔

Rear Cargo Box Release Lever Condition

✔

Rear Cargo Box Latches Condition

✔

Rear Cargo Box Gate Latches Condition

✔

Body

➀ Replace oil and filter only if it has not been previously performed at the storage. ➁ Remove rags in intake and exhaust that were installed at the storage. ➂ Before installing new spark plugs at pre-season preparation, it is suggested to burn excess storage oil by starting the engine with the old spark plugs. Only perform this operation in a well-ventilated area. VMR2001_036_02_04A.FM

02-04-3

Subsection 01

Section 03 ENGINE (TABLE OF CONTENTS)

TABLE OF CONTENTS

REMOVAL AND INSTALLATION .......................................................................................... ENGINE REMOVAL ........................................................................................................... ENGINE INSTALLATION ................................................................................................... ANTI-VIBRATION SYSTEM............................................................................................... EXHAUST SYSTEM .......................................................................................................... SHIFTING SYSTEM............................................................................................................

03-02-1 03-02-2 03-02-4 03-02-4 03-02-5 03-02-7

COOLING SYSTEM ............................................................................................................... COOLING SYSTEM ........................................................................................................... WATER PUMP.................................................................................................................... COOLING SYSTEM LEAK TEST ....................................................................................... INSPECTION ...................................................................................................................... DRAINING THE SYSTEM .................................................................................................. COOLANT REPLACEMENT ............................................................................................... PRESSURE CAP ................................................................................................................. RADIATOR ......................................................................................................................... THERMOSTAT ................................................................................................................... COOLANT TANK ............................................................................................................... FAN AND OUTLET DEFLECTOR....................................................................................... TEMPERATURE SENDER.................................................................................................. WATER PUMP HOUSING ................................................................................................. WATER PUMP IMPELLER ................................................................................................. WATER PUMP SHAFT....................................................................................................... WATER PUMP BEARINGS ................................................................................................

03-03-1 03-03-1 03-03-2 03-03-3 03-03-3 03-03-3 03-03-3 03-03-4 03-03-4 03-03-5 03-03-5 03-03-5 03-03-6 03-03-6 03-03-6 03-03-6 03-03-7

REWIND STARTER ................................................................................................................ REWIND STARTER ............................................................................................................ STARTING PULLEY ...........................................................................................................

03-04-1 03-04-2 03-04-4

MAGNETO SYSTEM ............................................................................................................. MAGNETO ......................................................................................................................... ROTOR ............................................................................................................................... SPRAG CLUTCH ................................................................................................................

03-05-1 03-05-2 03-05-2 03-05-3

VMR2001_065_03_01ATOC.FM

03-01-1

Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS)

CYLINDER AND HEAD ........................................................................................................... 1, CYLINDER HEAD ............................................................................................................ 2, PUSH ROD ...................................................................................................................... 3, ROCKER ARM................................................................................................................. 4, VALVE SPRING............................................................................................................... 5, VALVE ............................................................................................................................. 6, VALVE STEM SEAL ........................................................................................................ 7, CYLINDER ....................................................................................................................... 8, LIFTER ............................................................................................................................. 9, PISTON ........................................................................................................................... 10, PISTON RINGS .............................................................................................................

03-06-1 03-06-2 03-06-2 03-06-2 03-06-3 03-06-4 03-06-5 03-06-5 03-06-6 03-06-6 03-06-8

CRANKSHAFT/BALANCER SHAFT ....................................................................................... 1, CAMSHAFT..................................................................................................................... 2, BALANCER SHAFT......................................................................................................... 3, CRANKSHAFT ................................................................................................................ RECENTRE CRANKSHAFT.................................................................................................

03-07-1 03-07-2 03-07-2 03-07-3 03-07-4

LUBRICATION SYSTEM......................................................................................................... TROUBLESHOOTING......................................................................................................... ENGINE PRESSURE TEST ................................................................................................. OIL CHANGE AND OIL FILTER REPLACEMENT .............................................................. OIL STRAINER .................................................................................................................... ENGINE OIL PRESSURE REGULATOR ............................................................................. OIL PUMP ........................................................................................................................... MAIN OIL PRESSURE REGULATOR .................................................................................

03-08-1 03-08-2 03-08-2 03-08-2 03-08-3 03-08-3 03-08-4 03-08-4

CLUTCH .................................................................................................................................. 03-09-1 CLUTCH DRUM, CLUTCH WEIGHT AND SPRAG CLUTCH............................................. 03-09-2 FRICTION DRIVE PLATE, STEEL DRIVEN PLATE AND CLUTCH BASKET ..................... 03-09-3 TRANSMISSION .................................................................................................................... GEAR SHIFT SYSTEM........................................................................................................ TRANSMISSION ................................................................................................................. GEAR SHIFT MECHANISM................................................................................................ TRANSMISSION .................................................................................................................

03-01-2

03-10-1 03-10-1 03-10-2 03-10-3 03-10-4

VMR2001_065_03_01ATOC.FM

Section 03 ENGINE (REMOVAL AND INSTALLATION)

Subsection 02

REMOVAL AND INSTALLATION 10 N m 20 (89 lbf in) 21

13 12

Synthetic grease

19 19

7 48 N m (35 lbf ft)

6 24 N m (17 lbf ft)

14 11 N m (97 lbf in)

18 16 19

Synthetic grease

15 4

6 24 N m (17 lbf ft)

10 11

7 48 N m (35 lbf ft)

30 9

7 48 N m 6 24 N m (35 lbf ft) (17 lbf ft) 9 11 Synthetic 6 24 N m grease (17 lbf ft)

10 11

31 2

25 28

1 26

8 9

24 24

24 V01C2NS

VMR2001_037_03_02A.FM

23 24

PARTS

FLAT RATE

03-02-1

Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION)

Front Part Preparation

ENGINE REMOVAL Vehicle Preparation Place the vehicle on jack stands and place the shifter no. 1 on park position. Remove front wheels. Drain engine oil and engine coolant by drain plug.

Remove fuel tank and fuel valve. Refer to FUEL CIRCUIT. Remove seat pivot bar and unplug solenoid(s) connector. Remove sub transmission position sensor. NOTE: Do not unplug only, remove sensor completely. Remove shifting rod no. 2. Refer to Shifting Rod Removal section. Separate front propeller shaft from engine. Refer to FRONT DIFFERENTIAL. Unplug vehicle speed sensor located under engine drive shaft.

Engine Preparation

1 2

Unplug spark plug cables. Unplug oil pressure sensor. Remove exhaust pipe no. 4. Refer to Exhaust System section. Remove radiator inlet hose. Disconnect breather hose. Unplug temperature sensor.

V01A0AC

UNDER ENGINE 1. Engine oil plug 2. Engine coolant plug

Remove seat, front fender, inner fenders, side panels, shifter guide cover and skid plate. Refer to BODY. Disconnect BLACK negative cable from battery, then RED positive cable.

î°? WARNING Always disconnect battery or starter cables exactly in the specified order, BLACK negative cable first. It is recommended to disconnect electrical connections prior to disconnecting fuel lines.

V01C16B

1. 2. 3. 4. 5.

Spark plug cables Exhaust pipe Radiator inlet hose Breather hose Temperature sensor

Remove carburetor no. 5. Refer to FUEL PUMP AND CARBURETOR.

03-02-2

VMR2001_037_03_02A.FM

Subsection 02

Remove engine impulse line.

Section 03 ENGINE (REMOVAL AND INSTALLATION)

Remove fuse box. Remove shifting valve (except FOOTSHIFT model). Refer to ELECTRIC SHIFT SYSTEM. Unplug the clutch activation switch connector (FOOTSHIFT model). Remove brake pedal, rear master cylinder and brake switch. Refer to HYDRAULIC BRAKES.

Rear Part Preparation Unplug gear box position sensor (except FOOTSHIFT model). Remove the rear link rod as well as the shift block (FOOTSHIFT model). V01C0FA

1. Engine impulse line

1 2

V01C2OS

1. Shift block 2. Rear link rod

VMR2001_037_03_02A.FM

03-02-3

Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION)

Separate rear propeller shaft from engine. Refer to REAR SUSPENSION. NOTE: Do not separate swing arm from rear axle. Unplug magneto/trigger wiring harness connector. Remove radiator outlet hose. Remove starter. Install engine lifting tool (P/N 529 035 610) then install a hoist. Remove engine bracket mounting bolts no. 6. Pull down engine lifting tool arm and lift engine.

V01C17A

Before starting the engine, remove spark plugs no. 3 and ground them on engine or frame. Run starter about thirty seconds. This operation activated the oil pump. Reinstall spark plug and check if vehicle run correctly. Let the engine idle for one minute to ensure full charge of hydraulic valve lifter. Calibrate STPS, GBPS (except FOOTSHIFT) and TPS (AUTOMATIC model). Refer to ELECTRIC SHIFT SYSTEM.

ANTI-VIBRATION SYSTEM V01C0HA

TYPICAL

ENGINE INSTALLATION For installation, reverse the removal procedure, paying attention to the following details. NOTE: At the time of seat pivot bar installation, it is possible that the frame is too wide or too restricted. According to your needs, close or widen the frame slightly. On the FOOTSHIFT model, the rear link rod length must be 300 mm (11.8 in). Reattach cables, hoses, harness wiring, etc.

03-02-4

Anti-Vibration System Removal Remove flanged bolt no. 7, elastic nut no. 8 and engine brackets no. 9. RH Anti-Vibration System Remove support bushing no. 10, push out with a punch. Insert a punch in hole of anti-vibration bushing no. 11 and push other anti-vibration bushing out housing. Use punch to remove the other bushing. CAUTION: Do not use a screwdriver for antivibration bushing removal. LH Anti-Vibration System Insert a punch in hole of anti-vibration bushing no. 12 and push support bushing no. 13 and antivibration bushing out the housing. Use punch to remove the other bushing.

VMR2001_037_03_02A.FM

Subsection 02

Section 03 ENGINE (REMOVAL AND INSTALLATION)

Anti-Vibration System Installation

Heat Shield Removal

Insert support bushing in engine support. Before insert support bushing, spray BOMBARDIER LUBE (P/N 293 600 016) in support.

All Models except XL Remove the rear fender. Refer to BODY. Remove screws no. 20 retaining heat shield no. 21. XL Model Heat Shield Pipe Tip up the rear cargo box. Remove screws retaining heat shields to muffler.

1 V01C0SA

Install a new O-ring in anti-vibration bushing grooves. Apply grease on anti-vibration bushings and insert in engine support, one on each side. For installation, use a 152 mm (6 in) bolt for LH side and 102 mm (4 in) for RH side, three washers and a nut. Refer to the following illustration. 1 2

V03C01A

1. Heat shield pipe 2. Heat shield screws V01C0TA

1. Bolt 2. Washers (3) 3. Nut

EXHAUST SYSTEM

 WARNING Never touch exhaust system components immediately after the engine has been run because these components are very hot.

VMR2001_037_03_02A.FM

Heat Shield Remove: – muffler, see below NOTE: Remove the muffler with the heat shields pipe installed. – screws retaining heat shield to rear extension frame.

03-02-5

Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION)

Heat Shield Installation For installation, reverse the removal procedure.

Remove springs no. 16 retaining exhaust pipe and muffler no. 17.

All Models except XL In first, install bottom screw then rear screw, do not tighten yet. Install the screws on top of heat shield. Torque all screws to 10 N•m (89 lbf•in).

3 2 V01C19A

TYPICAL — TRAXTER SHOWN 1. Retaining springs

Pull exhaust pipe forward.

Exhaust Pipe Installation V01C18A

Step 1 : Bottom screw Step 2 : Rear screw Step 3 : Screws on top

For installation, reverse the removal procedure, paying attention to the following details. Use a new exhaust pipe gasket no. 18 and make sure that it is properly installed.

Exhaust Pipe Removal Remove the exhaust pipe nuts no. 14.

V01C0JA

Remove screw from exhaust pipe bracket no. 15.

V01C0LA

TYPICAL 1. Exhaust pipe gasket 03-02-6

VMR2001_037_03_02A.FM

Section 03 ENGINE (REMOVAL AND INSTALLATION)

Subsection 02

With muffler secured in its rubber mounts, fit exhaust pipe, securing it loosely at its flange and on engine. Tighten flange nuts, making sure exhaust pipe is properly aligned inside muffler ball socket then install retaining springs after pushing muffler forward in exhaust pipe. Tighten exhaust pipe support bolt.

Muffler Removal All Models except XL Remove heat shield no. 21 and exhaust pipe no. 4. Pull muffler no. 17 forward, pull out retaining rod from supports and remove muffler.

NOTE: Separate fuel tank from frame only, do not remove tank completely. Do not remove fuel lines. Remove elastic nuts of shifter tie-rod no. 22, one on LH ball joint and one on RH ball joint.

Shifter Tie-Rod Installation For installation, reverse the removal procedure, paying attention to the following details. Pre-adjust shifter tie-rod to 150 mm (5-29/32 in). NOTE: Shifter tie-rod must have 20 mm (25/32 in) maximum between center from ball joint and jam nut. See the following illustration.

A B

V01I0IA

V01C1MA

1. Muffler 2. Retaining rod

XL Model Remove the retaining springs then pull out muffler with heat shields pipe.

1. 2. 3. A. B.

Shifter tie-rod Jam nut Ball joint Shifter tie-rod length 150 mm (5-29/32 in) Ball joint length 20 mm (25/32 in) maximum

Install shifter tie-rod.

Lever Removal

For the installation, reverse the removal procedure. NOTE: Check rubber bushings no. 19 for cracks or other damages, change if necessary.

Remove fuel tank. Refer to FUEL CIRCUIT. Remove upper and lower retaining clamps no. 23 and half rings no. 24. Unscrew lever button no. 25. Remove shifter lever no. 1 from shifter guide. Unscrew lever retaining bolt no. 26 and pull lever.

SHIFTING SYSTEM

Lever Installation

NOTE: Always set the PARK position before remove any parts from shifting system.

For installation, reverse the removal procedure, paying attention to the following details. Place nylon bushing no. 27 in shifter lever. Place lever spring no. 28 properly.

Muffler Installation

Shifter Tie-Rod Removal Remove fuel tank. Refer to FUEL CIRCUIT.

VMR2001_037_03_02A.FM

03-02-7

Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION)

V01I0JA

LEVER SPRING INSTALLATION

Shifter Column Removal

Remove shifter lever no. 1. Remove shifter tie-rod no. 22.

Shifter Column Installation For installation, reverse the removal procedure.

Shifting Rod Removal Remove fuel tank. Refer to FUEL CIRCUIT. NOTE: Separate fuel tank from frame, do not remove tank completely. Separate shifting rod no. 2 from shifting engine rod. Unscrew bolt no. 29 and pull shifting rod forward.

V01I0KA

1. Shifting rod

Unscrew elastic nuts from RH ball joint. Remove retaining clamp no. 30 and half rings no. 31.

Shifting Rod Installation For installation, reverse the removal procedure.

03-02-8

VMR2001_037_03_02A.FM

Section 03 ENGINE Subsection 03 (COOLING SYSTEM)

COOLING SYSTEM

COOLING SYSTEM 2

10 1

11 12

4 5

7 6

9 V01C2AS

VMR2001_038_03_03A.FM

PARTS

FLAT RATE

03-03-1

Section 03 ENGINE Subsection 03 (COOLING SYSTEM)

WATER PUMP

20 19

Molykote 111 23

Engine oil

Engine oil 22 18

17 15

21 14

16 10 N m (89 lbf in)

10 N m (89 lbf in) 13

V01C2BS

03-03-2

PARTS

FLAT RATE

VMR2001_038_03_03A.FM

Section 03 ENGINE Subsection 03 (COOLING SYSTEM)

COOLING SYSTEM LEAK TEST Install special plug (radiator cap) (P/N 529 021 400) and hose pincher (P/N 295 000 076) on overflow hose no. 8. Pressurize all system through coolant reservoir to 103 kPa (15 PSI). Check all hoses, radiator no. 1 and cylinder/base for coolant leaks. Spray a soap/water solution and look for air bubbles.

V01A0AA

1. Cooling plug

COOLANT REPLACEMENT

V01C09A

NOTE: The rear fender removal is not necessary.

INSPECTION Check general condition of hoses and clamp tightness.

DRAINING THE SYSTEM

î°? WARNING Never drain or refill cooling system when engine is hot. To drain cooling system, unscrew plug under engine and remove pressure cap no. 2.

Recommended Coolant Use a blend of 60% antifreeze with 40% water. Do not reinstall pressure cap. CAUTION: To prevent rust formation or freezing condition, always replenish the system with 60% antifreeze and 40% water. Pure antifreeze without water freezes. Always use ethylene glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines.

System Capacity Refer to TECHNICAL DATA.

Replacement Procedure

î°? WARNING To prevent burning yourself do not remove the radiator cap or loosen the engine drain plug if the engine is hot.

VMR2001_038_03_03A.FM

03-03-3

Section 03 ENGINE Subsection 03 (COOLING SYSTEM)

Use hose pincher on coolant hose at thermostat outlet. Unscrew bleeder on top of thermostat housing. NOTE: On XL model, lift the rear of vehicle, about 2 or 3 inches, before install the hose pincher.

V01C0AA V01C0BB

1. Cooling system bleed screw

With vehicle on a flat surface (except XL model), engine cold, refill radiator no. 1. When the coolant comes out by the thermostat housing hole, install the bleeder and remove the hose pincher. Install the pressure cap. Refill coolant tank no. 9 up to cold level mark. Install the coolant tank cap. Run engine until thermostat opens then stop engine. When engine has completely cooled down, recheck coolant level in radiator no. 1 and coolant tank no. 9 and top up if necessary. Once a year, check coolant concentration (freezing point) with proper tester.

PRESSURE CAP Check if cap pressurizes the system. If not, install a new 110 kPa (16 PSI) cap (do not exceed this pressure).

RADIATOR

TYPICAL 1. Radiator inlet hose 2. Radiator outlet hose

Remove overflow hose no. 8. Remove mounting bolts no. 10 on the top. Unplug temperature sender no. 3.

Inspection Check radiator air passage for clogging or damage. Remove insects, mud or other obstructions with compressed air or low pressure water. Check for any coolant leakage from radiator and hoses.

Installation For installation, reverse the removal procedure. Paying attention to the following detail. Install hose pincher on coolant hose at thermostat outlet. Unscrew bleeder on top of thermostat housing. Refill radiator and when coolant overflows by the thermostat cover hole, reinstall the screw.

Removal Drain cooling system. Remove rear fender. Refer to BODY. Remove inlet no. 6 and outlet no. 7 hoses.

03-03-4

VMR2001_038_03_03A.FM

Section 03 ENGINE Subsection 03 (COOLING SYSTEM)

THERMOSTAT

Installation

The thermostat is a single action type.

The installation is the reverse of the removal procedure.

Removal The thermostat is located on the top of engine. Remove screws and pull thermostat cover with hose.

FAN AND OUTLET DEFLECTOR Test Refer to INSTRUMENTS AND ACCESSORIES.

Fan Removal

Remove rear fender. Refer to BODY. Remove bolts no. 12 and fan supports no. 11. Discard bolts. 1

V01C0BA

1. Remove screws

Remove gasket.

Test To check thermostat, put in water and heat water. Thermostat should open when water temperature reaches 75째C (167째F). V01G0AA

Installation For installation, reverse the removal procedure, paying attention to the following details. Install thermostat with a new gasket.

1. Remove bolts 2. Fan supports

Unplug fan connector. 1

COOLANT TANK Overflow Coolant Tank The coolant expands as the temperature (up to 100 - 110째C (212 - 230째F)) and pressure rise in the system. If the limiting system working pressure cap is reached 110 kPa (16 PSI), the pressure relief valve in the pressure cap is lifted from its seat and allows coolant to flow through the overflow hose into the overflow coolant tank.

Removal Remove overflow hose no. 8. Pull coolant tank no. 9 upward. Empty coolant tank. VMR2001_038_03_03A.FM

V01G0BA

TYPICAL 1. Fan connector

03-03-5

Section 03 ENGINE Subsection 03 (COOLING SYSTEM)

Fan Installation

Inspection

For the installation, reverse the removal procedure. NOTE: When fan is reinstalled, use new self-locking bolts.

Check housing for crack or spot of rust. Change housing if necessary.

Outlet Deflector Removal Remove fan no. 5. Remove radiator. Pull outlet deflector upward no. 4.

Outlet Deflector Installation The installation is the reverse of the removal procedure.

TEMPERATURE SENDER Test Refer to INSTRUMENTS AND ACCESSORIES for proper procedure.

Removal Unplug temperature sender connectors. Unscrew temperature sender no. 3.

Installation

Installation The installation is the opposite of the removal procedure.

WATER PUMP IMPELLER Removal Remove the water pump housing. Unscrew the water pump impeller no. 18. Turn clockwise.

Inspection Check impeller for cracks or other damage. Change the impeller if necessary.

Installation The installation is the opposite of the removal procedure.

WATER PUMP SHAFT Removal

The installation is the reverse of the removal procedure, paying attention to the following detail. Check O-ring and change if necessary. CAUTION: Don’t apply any product on the threads or on the O-ring.

Remove: – magneto housing no. 24 – water pump impeller no. 18 – needle pin no. 19 and distance sleeve no. 20. Extract the water pump shaft no. 21.

WATER PUMP HOUSING

Inspection

Removal Drain cooling system. Remove: – radiator outlet hose no. 7 – formed tube no. 13 between fitting inlet no. 14 and water pump housing no. 15 – screws no. 16. Withdraw the water pump housing with rubber ring no. 17.

03-03-6

Inspect shaft for wear, scratch or other damage. Change it if necessary. Check oil seal no. 22 for wear or crack. If so, change seal.

Installation For installation, reverse the removal procedure. NOTE: Drive oil seal carefully, do not use hammer.

VMR2001_038_03_03A.FM

Section 03 ENGINE Subsection 03 (COOLING SYSTEM)

WATER PUMP BEARINGS Inspection Water pump bearing no. 23 must have full freedom of movement. If not, change the bearing. NOTE: Change both bearing at the same time.

Removal Remove water pump shaft no. 21. Using a suitable puller, remove bearings no. 23.

Installation For installation, reverse the removal procedure.

VMR2001_038_03_03A.FM

03-03-7

Section 03 ENGINE Subsection 04 (REWIND STARTER)

REWIND STARTER

Loctite 243

Molykote PG 54 3 4

6 7

8 10 12

5 9

11 13 Loctite 243

V01C1BT

VMR2001_039_03_04A.FM

PARTS

FLAT RATE

03-04-1

Section 03 ENGINE Subsection 04 (REWIND STARTER)

REWIND STARTER Removal

Remove fuel tank cover and skid plate. Refer to BODY. Remove seat pivot bar and unplug clutching and clutch modulator valve connector. Remove rewind mounting bolts no. 15 and pull rewing starter.

Disassembly To remove rope from rewind starter mechanism: – First remove flat washer and screw no. 10 and 11, locking spring no. 9, locking spring washer no. 8, pawl lock no. 7 and pawl no. 6. – Remove sheave no. 3 from starter housing no. 1. – Disengage key no. 4 and pull out rope no. 5.

V01C0WA

TYPICAL 1. Outer end into guide notch

NOTE: Due to dust accumulation, rewind starter must be periodically cleaned, inspected and relubricated. CAUTION: It is of the utmost importance that the rewind starter spring(s) be lubricated periodically using specific lubricants. Otherwise, rewind starter component life will be shortened and/or rewind starter will not operate properly under very cold temperatures. Lubricate spring assembly with Molykote PG 54 (P/N 420 899 763) and position into starter housing as illustrated. CAUTION: This lubricant must NOT be used on rewind starter locking spring as it does not stay on under vibration.

A01C12A

TYPICAL — GENTLY TAP ON KEY

Assembly At assembly, position spring no. 2 outer end into spring guide notch then wind the spring clockwise into guide.

 WARNING Since the spring is tightly wound inside the guide it may fly out when rewind is handled. Always handle with care.

03-04-2

V01C0XA

TYPICAL 1. Apply Molykote PG 54 inside spring guide

VMR2001_039_03_04A.FM

Section 03 ENGINE Subsection 04 (REWIND STARTER)

CAUTION: The use of standard multi-purpose grease could result in rewind starter malfunction. To install a new rope no. 5, insert rope into sheave orifice and lock it with the key no. 4 as illustrated.

V01C0ZA

1 V01C10A

TYPICAL 1. Push to lock

To adjust rope tension: Wind rope on sheave and place rope sheave into starter housing making sure that the sheave hub notch engages in the rewind spring hook. Rotate the sheave counterclockwise until rope end is accessible through starter housing orifice. Pull the rope out of the starter housing and temporarily make a knot to hold it. One turn preload will give 7 turns of tension when fully extended.

TYPICAL 1. Spring coated with Molykote G-n paste

Install locking ring. CAUTION: This lubricant must NOT be used on rewind springs as it does not stay on when dry.

Installation Thread starter rope no. 5 through rope guide when applicable. Reinstall rewind starter assembly on engine. NOTE: Before torque mounting bolts no. 15, apply Loctite 243 on threads. Prior to installing starter grip on new rope, it is first necessary to fuse the rope end with a lit match. Pass rope through starter grip and tie a knot in the rope end. Fuse the knot with a lit match then insert rope end down and pull the starter grip over the knot.

V01C0YA

TYPICAL

Position pawl no. 6, pawl lock no. 7 and locking spring washer no. 8. Install locking spring no. 9 and lubricate with Molykote G-n paste from Dow CorningÂŽ.

A01C18A

TYPICAL

VMR2001_039_03_04A.FM

03-04-3

Section 03 ENGINE Subsection 04 (REWIND STARTER)

STARTING PULLEY Removal Remove rewind starter. Remove screw no. 12 and O-ring no. 13 retaining starting pulley no. 14 to crankshaft.

Installation For installation, reverse the removal procedure. Paying attention to the following detail. Check O-ring for damage and change if necessary. Apply Loctite 243 on threads and torque the screw to 21 N•m (15 lbf•in).

03-04-4

VMR2001_039_03_04A.FM

Section 03 ENGINE Subsection 05 (MAGNETO SYSTEM)

MAGNETO SYSTEM

12 10

8 Loctite 243 9

Engine oil

11 7 140 N m (103 lbf ft)

3 9 N m (80 lbf in)

7 N m (62 lbf in)

2 1

9 N m (80 lbf in)

V01C2HS

VMR2001-040_03-05A.FM

PARTS

FLAT RATE

03-05-1

Section 03 ENGINE Subsection 05 (MAGNETO SYSTEM)

MAGNETO Removal NOTE: To reach the magneto, the engine removal is not necessary. However, on some vehicles it may be necessary to raise the left side of the engine, about 50 mm (2 in), to remove the cover. Remove the left side engine mount. Refer to REMOVAL/INSTALLATION. Remove: – water pump housing (refer to COOLING SYSTEM) – GBPS (Gear Box Position Sensor) (all models except FOOTSHIFT)

V01C2IA

NOTE: Clean all metal component in a non-ferrous metal cleaner. Use Bombardier gasket remover (P/N 413 708 500) or suitable equivalent. Remove all socket screws no. 3 retaining magneto no. 4 to ignition cover then pull magneto.

Installation For installation, reverse the removal procedure. Paying attention to the following details. Apply Loctite 243 on threads of socket screws no. 4 retaining magneto. Torque to 9 N•m (80 lbf•in). Install a new gasket on ignition cover. Place hydraulic piston properly before install ignition cover. If it has a space between ignition cover and crankcase, remove ignition cover and re-align the hydraulic piston.

1. Gear Box Position Sensor

– gear shift block (FOOTSHIFT model only)

V01D0JA

1. Hydraulic piston

ROTOR Removal

V01C2JA

1. Gear shift block

– all bolts retaining ignition cover – ignition cover no. 1 – gasket no. 2.

03-05-2

Lock crankshaft with locking bolt (P/N 529 035 645). Refer to CRANKSHAFT/BALANCER SHAFT. Remove: – ignition cover no. 1 – pawl no. 5 and needle pin no. 6. Unscrew nut no. 7 retaining rotor no. 8. Remove serrated washer no. 9. Install magneto puller (P/N 420 976 235) and crankshaft protector (P/N 420 876 557) then remove rotor.

VMR2001-040_03-05A.FM

Section 03 ENGINE Subsection 05 (MAGNETO SYSTEM)

Installation For installation, reverse the removal procedure. Paying attention to the following details. Insert ring gear in sprag clutch no. 10. Install nut on crankshaft end. Apply Loctite 243 on threads. Torque to 140 Nâ&#x20AC;˘m (103 lbfâ&#x20AC;˘ft).

SPRAG CLUTCH Removal Remove rotor no. 8. Unscrew all socket screws no. 11 retaining rotor and sprag clutch housing no. 12. Remove sprag clutch from sprag clutch housing.

Installation For installation, reverse the removal procedure. NOTE: Apply engine oil on sprag clutch. Install sprag clutch with the arrow on the top.

VMR2001-040_03-05A.FM

03-05-3

Subsection 06

Section 03 ENGINE (CYLINDER AND HEAD)

CYLINDER AND HEAD

10 N m (89 lbf in) 11

12 3

Multi-purpose grease 2 10 N m (89 lbf in)

19 4

17 22 N m (16 lbf ft) 14

Engine oil

50 N m (37 lbf ft) 13

10 N m (89 lbf in)

15 Engine oil

Engine oil

21 9 Engine oil

V01C1CS

NOTE: For cylinder head, cylinder and piston removal, it is not necessary to remove engine from vehicle.

VMR2001_041_03-06A.FM

PARTS

FLAT RATE

03-06-1

Section 03 ENGINE Subsection 06 (CYLINDER AND HEAD)

1, CYLINDER HEAD

Inspection

NOTE: When diagnosing an engine problem, always perform a cylinder leak test. This will help pin-point a problem. Refer to the instructions included with your leak tester, for procedure.

Check for crack between valve seats, if so, replace cylinder head.

Removal Remove engine oil and coolant. Disconnect temperature sensor. Unplug radiator inlet hose. Remove screws retaining air box. Unscrew the clamp retaining carburetor adaptor to engine. Pull back the air box with carburetor assembly. Remove: – exhaust pipe (refer to REMOVAL AND INSTALLATION) – valve cover no. 11 and gasket no. 12 – flanged bolts no. 14 retaining cylinder head to cylinder base – flanged nuts no. 13 retaining cylinder head to the engine.

Installation For installation, reverse the removal procedure. Install a new gasket no. 15 between cylinder head and cylinder base no. 7. Install the flanged nuts no. 13 in first then flanged bolts no. 14.

2, PUSH ROD Removal Remove cylinder head no. 1. Pull the push rods out of cylinder base no. 7.

Inspection Check push rod end for wear or damage. Check push rod for bends by placing the rod on a flat metal plate. Rotate rod and measure the deflection with a dial indicator. If the rod is bent, it should be replaced.

PUSH ROD BEND SERVICE LIMIT

0.2 mm (.008 in)

Installation For installation, reverse the removal procedure. NOTE: Apply engine oil on push rod.

3, ROCKER ARM Removal

V01C1DA

1. Flanged nuts

Remove: – cylinder head no. 1 – holding strip no. 16. Extract rocker arm shaft no. 17 using a M8 x 53.5 screw.

Pull up cylinder head.

03-06-2

VMR2001_041_03-06A.FM

Subsection 06

NOTE: Use a flanged bolt no. 14 retaining cylinder head to cylinder base.

Section 03 ENGINE (CYLINDER AND HEAD)

Rocker Arm Shaft Check for scored friction surfaces, if so, replace parts. Insert shaft in rocker arm and check for excessive play. Measure of shaft diameter. ROCKER ARM SHAFT DIAMETER NEW MINIMUM

13.694 (.5391 in)

NEW MAXIMUM

13.683 (.5386 in)

SERVICE LIMIT

13.67 mm (.5382 in)

Any area worn excessively will require part replacement. 3

V01C1EA

1. Rocker arm shaft 2. Flanged bolt 3. Rocker arm

Installation For installation, reverse the removal procedure. NOTE: Apply engine oil on rocker arm shaft.

Inspection Rocker Arm Inspect each rocker arm for cracks and scored friction surfaces. If so, replace parts. Measure rocker bore diameter. If diameter is out of specification, change the rocker arm. A

V01C1FA

4, VALVE SPRING Removal Remove: – cylinder head no. 1 – rocker arm no. 3. Compress valve spring. Use valve spring compressor (P/N 529 035 724) and valve spring compressor cap (P/N 529 035 725). Remove valve cotters no. 18. Remove spring compressor, valve spring retainer no. 19 and valve spring.

Inspection

A. Rocker arm bore diameter

ROCKER ARM BORE DIAMETER NEW MINIMUM

13.715 (.540 in)

NEW MAXIMUM

13.740 (.541 in)

SERVICE LIMIT

13.765 mm (.542 in)

Check valve spring for rust or corrosion, free length and squareness. VALVE SPRING FREE LENGTH SERVICE LIMIT

VALVE SPRING MAXIMUM SQUARENESS SERVICE LIMIT

VMR2001_041_03-06A.FM

39 mm (1-1/2 in)

1.1 mm (.043 in)

03-06-3

Section 03 ENGINE Subsection 06 (CYLINDER AND HEAD)

Installation For installation, reverse the removal procedure.

5, VALVE

Measure valve face contact width. NOTE: The location of contact area should be in center of valve face. Measure valve seat width, using a caliper. VALVE SEAT CONTACT WIDTH mm (in)

Removal Remove valve spring no. 4. Push the valve stem then pull valve out of valve guide.

NEW

Inspection Valve Inspect valve surface, check for abnormal stem wear and bending. If so, replace by a new one. Valve Stem and Valve Guide Clearance Check valve stem and valve guide for wear or friction surfaces, if so, replace parts. Measure valve stem and valve guide in three places, using a micrometer and a small hole gauge. NOTE: Clean valve guide to remove carbon deposits before measuring. VALVE STEM DIAMETER mm (in)

Exhaust

1.25 to 1.55 mm (.049 to .061 in)

Intake

1.45 to 1.75 mm (.057 to .069 in) SERVICE LIMIT

Exhaust

2 mm (.078 in)

Intake

1.8 mm (.07 in)

If valve seat contact width is too wide, too narrow or has spots, the seat must be ground or cylinder head replaced.

SERVICE LIMIT Exhaust 6.95 mm (.274 in) Intake VALVE GUIDE CLEARANCE mm (in) SERVICE LIMIT Exhaust 0.13 mm (.005 in) Intake

Change valve if valve stem is out of specification.

V01C1HA

A. Valve face contact width B. Valve seat contact width

Valve Face and Seat Check valve face and seat for burning, pitting, and other signs of damage. Apply some lapping compound to valve face and work valve on its seat with a lapping tool.

03-06-4

VMR2001_041_03-06A.FM

Subsection 06

Installation

7, CYLINDER

For installation, reverse the removal procedure. NOTE: Apply engine oil on valve stem.

Removal

6, VALVE STEM SEAL Removal Remove valve. Remove circlip on the bottom of valve stem seal.

Section 03 ENGINE (CYLINDER AND HEAD)

Remove: – flanged bolts no. 23 retaining cylinder to crankcase housing – cylinder head no. 1 – water cooling hose from cylinder no. 20 – push rods no. 2 – all flanged screws retaining cylinder to the crankcase housing. Pull cylinder.

Inspection Cylinder Check cylinder for cracks, scoring, rust and wear ridges on the top and bottom of the cylinder. 2

V01C1IA

Cylinder Taper Measure cylinder diameter 16 mm (5/8 in) from top of cylinder then half-way through and finally at 13 mm (1/2 in) from bottom.

1. Circlip 2. Valve stem seal

Inspection

Inspection of valve stem seals is not needed as new seals should always be installed whenever a cylinder head is diassembled.

Installation For installation, reverse the removal procedure.

V01C1JA

1. Measure at three points

CYLINDER TAPER mm (in)

VMR2001_041_03-06A.FM

NEW MAXIMUM

0.035 mm (.001 in)

SERVICE LIMIT

0.090 mm (.004 in)

03-06-5

Section 03 ENGINE Subsection 06 (CYLINDER AND HEAD)

Cylinder Out of Round Measure cylinder diameter in piston axis direction from top of cylinder. Take an other measurement 90Â° from first one and compare.

8, LIFTER Removal Remove cylinder no. 7. Pull lifter out of crankcase.

Inspection A B

Check for excessive clearance between lifter and its bore or straightness. A telescoping gauge and micrometer are used to check the lifter bore clearance. Subtract lifter diameter from lifter bore diameter to determine clearance. LIFTER AND LIFTER BORE mm (in) SERVICE LIMIT

V01C1KA

Lifter

22.19 mm (.874 in)

Lifter bore

22.27 mm (.876 in)

A. Perpendicular to crankshaft axis B. Parallel to crankshaft axis

LIFTER BORE CLEARANCE

CYLINDER OUT OF ROUND mm (in) NEW MAXIMUM

0.005 mm (.0002 in)

SERVICE LIMIT

0.015 mm (.006 in)

SERVICE LIMIT

0.08 mm (.003 in)

If the clearance is out of specified tolerance change lifter and/or crankcase.

Installation Installation For installation, reverse the removal procedure. Paying attention to the following details. Apply engine oil in cylinder bore. Using a ring compressor, slide piston into cylinder. Install bolts no. 23 in first, then flanged bolts no. 14, then flanged nuts no. 13.

03-06-6

For installation, reverse the removal procedure.

9, PISTON Removal Remove cylinder no. 7. Remove both piston pin circlips no. 21 then push piston pin no. 22 out of piston. Detach piston from connecting rod.

VMR2001_041_03-06A.FM

Subsection 06

Section 03 ENGINE (CYLINDER AND HEAD)

Inspection

Inspect piston for scoring, cracking or other damages. Using a micrometer, measure piston at 16 mm (5/8 in) perpendicularly (90°) to piston pin axis.

A F00B08A

1. Micrometer set to the piston dimension

With the micrometer set to the dimension, adjust a cylinder bore gauge to the micrometer dimension and set the indicator to 0 (zero).

F01D0NA

TYPICAL 1. Measuring perpendicularly (90°) to piston pin axis A. 16 mm (5/8 in)

1 2

The measured dimension should be as described in the previous table. If not, replace piston. PISTON MEASUREMENT SERVICE LIMIT

88.9 mm (3.5 in)

Piston/Cylinder Clearance

F00B09A

PISTON/CYLINDER CLEARANCE NEW

0.016 to 0.044 mm (.0006 to .002)

SERVICE LIMIT

0.090 mm (.004 in)

1. Use the micrometer to set the cylinder bore gauge 2. Dial bore gauge

NOTE: Make sure used piston is not worn. See PISTON MEASUREMENT TABLE above. Adjust and lock a micrometer to the piston dimension.

1 F00B0AA

TYPICAL 1. Indicator set to 0 (zero)

VMR2001_041_03-06A.FM

03-06-7

Section 03 ENGINE Subsection 06 (CYLINDER AND HEAD)

Position the dial bore gauge at 16 mm (5/8 in) below cylinder top edge, measuring perpendicularly (90Â°) to piston pin axis. Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. If clearance exceeds specified tolerance, replace cylinder or rebore. See previous table. NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the micrometer, otherwise the reading will be false.

Installation For installation, reverse the removal procedure. Paying attention to the following details. Apply engine oil on the piston pin. Insert piston pin into piston and connecting rod. Secure piston pin with both piston pin circlips. NOTE: Do not align the end gap of the piston pin circlips with the cutout in the piston bore.

V01C1LA

A. Measure here

Ring End Gap

10, PISTON RINGS

RING END GAP mm (in)

Inspection

NEW MINIMUM

Ring/Piston Groove Clearance Using a feeler gauge measure each ring/piston groove clearance. If the clearance is too large, the piston should be replaced.

RECTANGULAR

0.15 mm (.006 in)

TAPER-FACE

0.15 mm (.006 in)

OIL SCRAPER RING

0.15 mm (.006 in)

NEW MAXIMUM

RING/PISTON GROOVE CLEARANCE mm (in) NEW MINIMUM

RECTANGULAR

0.35 mm (.014 in)

RECTANGULAR

0.03 mm (.001 in)

TAPER-FACE

0.40 mm (.016 in)

TAPER-FACE

0.03 mm (.001 in)

OIL SCRAPER RING

0.35 mm (.014 in)

OIL SCRAPER RING

0.02 mm (.0008 in)

NEW MAXIMUM RECTANGULAR

0.062 mm (.0024 in)

TAPER-FACE

0.062 mm (.0024 in)

OIL SCRAPER RING

0.055 mm (.0022 in)

SERVICE LIMIT ALL

03-06-8

SERVICE LIMIT ALL

1.5 mm (.06 in)

Position ring 16 mm (5/8 in) from top of cylinder. NOTE: In order to correctly position the ring in the cylinder, use piston as a pusher. Using a feeler gauge, check ring end gap. Replace ring, if gap exceeds specified tolerance. See above table.

0.15 mm (.006 in)

VMR2001_041_03-06A.FM

Subsection 06

Installation For installation, reverse the removal procedure. Paying attention to the following details. Install the oil ring first, then the middle ring with the word TOP facing up, then the top ring with a dot facing up.

Section 03 ENGINE (CYLINDER AND HEAD)

Check that rings rotate smoothly after installation. Space the piston ring end gaps 120Â° apart and do not align the gaps with the piston pin bore or the thrust side axis. A A

1 2

A31C2NA

1. Rectangular ring (black/gray color) 2. Taper-face ring (chrome/stainless steel looking ring) 3. Oil ring or oil scraper ring

A31C2OA

1. DO NOT align ring gap with piston trust side axis 2. DO NOT align ring gap with piston pin bore axis A. 120Â°

CAUTION: Ensure that top and second rings are not interchanged. NOTE: Use a ring expander to prevent breakage during installation. The oil ring must be installed by hand.

VMR2001_041_03-06A.FM

03-06-9

Subsection 07

Section 03 ENGINE (CRANKSHAFT/BALANCER SHAFT)

CRANKSHAFT/BALANCER SHAFT

240 N m (178 lbf ft) 4 Loctite 243 22 N m (16 lbf ft) 6 7

150 N m (111 lbf ft) 11

Loctite 243 12

Anti-seize lubricant

Engine oil

Loctite 243

Engine oil

Anti-seize lubricant 14

Anti-seize lubricant 9

2 Anti-seize lubricant

Anti-seize lubricant

V01C2DS

VMR2001-042_03-07A.FM

PARTS

FLAT RATE

03-07-1

Section 03 ENGINE Subsection 07 (CRANKSHAFT/BALANCER SHAFT)

1, CAMSHAFT

CAMSHAFT ENDS mm (in) SERVICE LIMIT

Removal NOTE: To remove camshaft, the engine removal is not necessary. But, if you removed balancer shaft or crankshaft, remove engine from vehicle. Remove engine from vehicle (refer to INSTALLATION AND REMOVAL). Remove: – rewind starter (refer to REWIND STARTER) – clutch (refer to CLUTCH) – sub-transmission system (refer to TRANSMISSION) – cylinder head, cylinder and piston (refer to CYLINDER AND HEAD) – bolt no. 6, lock washer no. 7 and washer no. 8 retaining cam shaft gear no. 9 with centrifugal weight no. 10.

Clutch side

31.95 mm (1.258 in)

Magneto side

17.96 mm (.707 in)

V01C1ZA

1. Measure here

Measure the camshaft bore in both housing. CAMSHAFT BORE mm (in) SERVICE LIMIT Clutch housing

32.036 mm (1.261 in)

Magneto housing

18.035 mm (.71 in)

Subtract the camshaft end diameter from the proper bore diameter to find clearance. CAMSHAFT END CLEARANCE mm (in) SERVICE LIMIT

V01C1XA

1. 2. 3. 4. 5. 6.

Crankshaft gear nut Crankshaft gear Cam shaft gear Control gear Balancing shaft gear Oil pump gear

Clutch side

0.086 mm (.0034 in)

Magneto side

0.075 mm (.0029 in)

If necessary, change camshaft and/or camshaft housing and/or crankcase.

Installation

Unscrew the hexagonal flanged screws retaining the camshaft housing then remove the housing. Remove camshaft.

For installation reverse the removal procedure. Paying attention to the following details. Align the dot on the camshaft gear with the dot on the control gear. Always install a new housing gasket.

Inspection

2, BALANCER SHAFT

Check each lobe for scoring, scuffing, cracks, or other sign of wear. Measure each end of camshaft.

Removal

03-07-2

Refer to CAMSHAFT REMOVAL section above. Use the same procedure.

VMR2001-042_03-07A.FM

Subsection 07

Remove: – crankshaft gear nut no. 4, use 46 mm socket (P/N 529 035 648), then remove crankshaft gear no. 5 – nut no. 11 and lock washer no. 12 retaining control gear no. 13 and balancing shaft gear no. 14. Remove both gears – oil pump gear – holding strip retaining oil pipe – starter, water pump, magneto and ring gear (refer to MAGNETO SYSTEM) – shifting system (refer to TRANSMISSION) – all bolts and socket screws retaining crankcase. Separate crankcase housings. Remove balancer shaft.

Inspection Check balancer shaft bearing in the front and rear housing for excessive play and smooth operation. Replace if necessary.

Section 03 ENGINE (CRANKSHAFT/BALANCER SHAFT)

V01C2EA

1. Measure here

Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. If the distance exceeds specified tolerance, replace the crankshaft. CONNECTING ROD BIG END mm (in)

Installation

SERVICE LIMIT

For installation, reverse the removal procedure. Do not forget, align the camshaft gear dot with the control gear dot as well as the dot on crankshaft gear with the balancing shaft gear dot.

1.3 mm (.05 in)

Radial play

0.08 mm (.003 in)

Connecting Rod/Piston Pin Clearance Measure piston pin. Compare to inside diameter of connecting rod.

3, CRANKSHAFT Removal Use the same removal procedure that camshaft and balancer shaft. Remove crankshaft and adjusting washer no. 14.

CONNECTING ROD SMALL END DIAMETER SERVICE LIMIT

22.07 mm (.869 in)

PISTON PIN DIAMETER

Inspection

SERVICE LIMIT

Crankshaft Deflection Crankshaft deflection is measured with a dial indicator. Check crankshaft deflection on V-shaped blocks. If deflection exceeds the specified tolerance, change it. CRANKSHAFT DEFLECTION mm (in) SERVICE LIMIT Clutch side

0.08 mm (.003 in)

Magneto side

0.05 mm (.002 in)

VMR2001-042_03-07A.FM

Axial play

21.99 mm (.866 in)

PISTON PIN BORE CLEARANCE SERVICE LIMIT

0.08 mm (.003 in)

Installation For installation, reverse the removal procedure. Do not forget, align the camshaft gear dot with the control gear dot as well as the dot of crankshaft gear with the balancing shaft gear dot.

03-07-3

Section 03 ENGINE Subsection 07 (CRANKSHAFT/BALANCER SHAFT)

NOTE: Recentre the crankshaft in the crankcase if the crankshaft or the crankcase are replaced.

RECENTRE CRANKSHAFT

Determine dimension between case and inner ring of bearing. Place a compressed gasket on front crankcase housing (clutch side). This is the dimension “A”.

NOTE: Only fit spacer on the magneto end. Place crankshaft into rear crankcase housing (magneto side). Do not install spacer on clutch side at this time. Using depth gauge, measure distance between crank web and housing edge. This is the dimension “B”.

V01C2GA

Subtract dimension “B” from dimension “A”, the result is the end float of crankshaft plus spacer thickness. Select suitable spacer to ensure the correct end float is obtained. V01C2FA

03-07-4

END FLOAT OF CRANKSHAFT

0.1 to 0.4 mm (.004 to .016 in)

VMR2001-042_03-07A.FM

Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM)

LUBRICATION SYSTEM

10 N m (89 lbf in)

Engine oil

11 12

Engine oil

14 15

7 16 N m (142 lbf in)

16 17

Loctite 243 18

5 4 3 6 2 1 10 N m (89 lbf in)

Loctite 243

21 21 N m (15 lbf ft)

Engine oil V01C2CS

VMR2001_043_03-08A.FM

PARTS

FLAT RATE

03-08-1

Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM)

TROUBLESHOOTING Oil Level Low – – – –

external oil leak worn or incorrect piston rings installation worn valve seal oil pump worm or damaged

OIL CHANGE AND OIL FILTER REPLACEMENT

Low or No Oil Pressure – – – – –

clogged oil orifice(s) incorrect oil being used defective oil pump leaking oil seal oil strainer

Oil and filter are to be replaced at the same time. Oil change should be done with a warm engine.

 WARNING The engine oil can be very hot. Wait until engine oil is warm.

Oil Contamination (white appearance) – – – –

When the hydraulic shifter is used, the engine oil pressure must increase up to about 810 kPa (118 PSI). If the engine oil pressure is out of specifications, check the points described in LOW OR NO OIL PRESSURE section above. NOTE: Use annexes 1 and 2 at the end of manual to also diagnose.

coolant mixing with oil faulty water pump seal faulty head gasket water leak in crankcase

Ensure vehicle is on a level surface. Clean the drain plug area. Remove dipstick. Place a drain pan under the engine drain plug area. Unscrew drain plug.

ENGINE PRESSURE TEST NOTE: The engine pressure test should be done with a warm engine and the recommended oil. Remove the oil pressure switch under oil filter and install the oil pressure gauge (P/N 529 035 652).

1 2 1

V01A0AB V01C1TA

1. Oil drain plug 1. Oil pressure gauge 2. Oil filter

The oil pressure should be checked with a warm engine. The engine oil pressure should be between 101 kPa (14.7 PSI) and 608 kPa (88 PSI). 03-08-2

Wait a while to allow oil to flow out of oil filter. Carefully unscrew oil filter and as soon as it can be removed from the engine, turn it upright. Discard filter. NOTE: Be sure that the old filter O-ring is removed. VMR2001_043_03-08A.FM

Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM)

CAUTION: Only use Bombardier high pressure filter or suitable equivalent. The Bombardier filter is specifically designed for this engine. This filter does not operate at the same pressure as other brands. Using a non-recommended filter may cause serious engine/transmission damage. Lubricate the O-ring on the filter with engine oil. Install the new filter then screw one full turn after O-ring contact. Wipe out any oil spillage on engine. Change gasket on drain plug. Clean gasket area on engine and drain plug then reinstall plug. Refill engine at the proper level with the recommended oil. Refer to TECHNICAL DATA for capacity. Start engine and let idle for a few minutes. Ensure oil filter area and drain plug areas are not leaking. Stop engine. Wait a while to allow oil to flow down to crankcase then check oil level. Refill as necessary. Dispose oil as per your local environmental regulations.

OIL STRAINER Removal Ensure vehicle is on a level surface. Remove: – skid plate under vehicle – engine oil – screws no. 1 retaining oil strainer cover no. 2 – oil collector no. 3 and O-ring no. 4 – oil strainer no. 5.

Cleaning and Inspection Clean oil strainer with the parts cleaner then use an air gun to dry it. Inspect O-ring and oil strainer gasket no. 6 for damage. Change if necessary.

Installation

ENGINE OIL PRESSURE REGULATOR The engine oil pressure regulator is located near exhaust pipe bracket. It is used when not shifting.

V01C1UA

1. Engine oil pressure regulator

The pressure should be between 101 kPa (14.7 PSI) and 500 kPa (72.5 PSI).

Removal Remove the plug screw no. 7, sealing ring no. 8, compression spring no. 9 and piston no. 10.

Inspection Inspect piston for scoring or other damages. Check compression spring for free length, squareness or other damage. COMPRESSION SPRING FREE LENGTH NEW NOMINAL

43.5 mm (1.71 in)

SERVICE LIMIT

42 mm (1.65 in)

Installation For installation, reverse the removal procedure. NOTE: Always install a new sealing ring when the oil pressure regulator is removed.

For installation, reverse the removal procedure.

VMR2001_043_03-08A.FM

03-08-3

Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM)

OIL PUMP The oil pump is located on the clutch side of the crankcase housing.

Removal Remove: – engine (refer to REMOVAL AND INSTALLATION) – clutch cover and clutch housing (refer to CLUTCH) – snap ring no. 11 – oil pump gear no. 12 – needle pin no. 13 – thrust washer no. 14 – oil pump cover no. 15 – oil pump shaft no. 16 – oil pump outer rotor no. 17 – oil pump inner rotor no. 18 – oil pump housing no. 19 – rubber ring no. 20.

Inspection Inspect oil pump for marks or other damages. Using a feeler gauge, measure the clearance between oil pump outer rotor and oil pump inner rotor. 2

Measure oil pump rotor thickness and oil pump rotor bore depth. Difference between measurements should not exceed 0.2 mm (.007 in). If so, replace oil pump rotors and/or oil pump housing and/or oil pump cover. Check the inside of oil pump housing for scoring or other damages. If so, change the ring housing. Check rubber ring for damage. Change if necessary.

Installation For installation, reverse the removal procedure.

MAIN OIL PRESSURE REGULATOR The regulator works when shifting. The pressure should be between 600 kPa (87 PSI) and 800 kPa (116 PSI).

Removal Remove water pump and ignition cover. Refer to MAGNETO SYSTEM. Unscrew plug no. 21. Remove compression spring no. 22, valve piston no. 23 and valve seat sleeve no. 24.

Inspection Inspect piston for scoring or other damages. Check O-ring no. 25 for damage. Change if necessary. Check compression spring for free length, squareness or other damage.

B C V01C1VA

1. Oil pump rotor 2. Inner rotor

COMPRESSION SPRING FREE LENGTH NEW NOMINAL

61.5 mm (2.42 in)

SERVICE LIMIT

59.5 mm (2.34 in)

Installation

OIL PUMP ROTOR AND INNER ROTOR CLEARANCE mm (in)

For installation, reverse the removal procedure.

SERVICE LIMIT A B

0.25 mm (.009 in)

03-08-4

VMR2001_043_03-08A.FM

Section 03 ENGINE Subsection 09 (CLUTCH)

CLUTCH

Loctite 243 270 N m (199 lbf ft)

Engine oil

Loctite 243

Engine oil

150 N m (111 lbf ft) 20

6 7 N m (62 lbf in)

Engine oil

21 15

9 7

Engine oil

11 13

Engine oil

V01D0PS

VMR2001_044_03-09A.FM

PARTS

FLAT RATE

03-09-1

Section 03 ENGINE Subsection 09 (CLUTCH)

CLUTCH DRUM, CLUTCH WEIGHT AND SPRAG CLUTCH

Inspect sparg clutch no. 5 for smooth operation and roller for excessive wear. Change sparg clutch if necessary.

Disassembly

Weight Lining Measure weight lining thickness. The weight lining thickness must be at least 2.0 mm (5/64 in).

Remove: – engine oil and coolant – rewind starter – drive shaft (refer to FRONT DRIVE) – clutch cover. Install the crankshaft locking bolt (P/N 529 035 645).

1 V01D03A

A. Weight lining

If weight lining thickness is out of specification, replace the clutch weight assembly. V01D02A

1. Crankshaft locking bolt

Unscrew nut no. 1 retaining clutch weight assembly no. 4 to crankshaft. Pull clutch drum no. 2 out of housing and remove thrust washer no. 3. Separate clutch weight assembly from clutch drum.

Weight Spring Remove E-clips, washer, clutch spring and washer. Remove clutch weights and weight springs from plate. Measure length of weight springs. If they are longer than 21.6 mm (.85 in), change the clutch weight assembly. A

Inspection Clutch Drum Check inside of drum clutch for excessive wear or scratches.Change if necessary. Measure the inside diameter of clutch drum. If the I.D. is over to 140.4 mm (5-17/32 in) change clutch drum. Sparg Clutch Hold clutch drum and rotate clutch weight. The clutch weight should only turn counterclockwise. If it rotates both directions, replace the sprag clutch. 03-09-2

V01D0EA

A. 21.6 mm (.85 in)

VMR2001_044_03-09A.FM

Section 03 ENGINE Subsection 09 (CLUTCH)

Check weight springs for wear or other damage. Replace the clutch weight assembly if necessary.

– circlip – output gear

Assembly

7 2 6

8 4

For installation, reverse the removal procedure. Paying attention to the following details. Install weight springs with the open ends down. Install sparg clutch in clutch drum with its OUT SIDE mark facing out. Apply engine oil on sprag clutch.

V01D05A

9 10 5 3 1

1. Front output shaft 2. Collar sleeve 3. Helical spring 4. Parking locking lever 5. Shaft 6. Tension spring 7. Indicator shaft 8. Actuating lever 9. Circlip 10. Output gear

– clutch housing. Install the crankshaft locking bolt (P/N 529 035 645). V01D04A

1. Out side mark

FRICTION DRIVE PLATE, STEEL DRIVEN PLATE AND CLUTCH BASKET Disassembly Remove: – engine oil and coolant – rewind starter – clutch cover – front output shaft – collar sleeve – helical spring – parking locking lever – shaft – tension spring – indicator shaft – actuating lever and thrust washer VMR2001_044_03-09A.FM

V01D06A

1. Crankshaft locking bolt 2. Clutch drum 3. Oil pump gear

Remove clutch drum no. 2 and thrust washer no. 3. Remove clutch bolts no. 6, pressure plate no. 7 and clutch spring no. 8. Unlock the tab washer no. 9 then install spanner tool for clutch basket (P/N 529 035 647). Unscrew the clutch lock nut no. 10 then remove tab washer. 03-09-3

Section 03 ENGINE Subsection 09 (CLUTCH)

Remove: – clutch hub no. 11 – friction drive plates no. 12 – steel driven plates no. 13 – inner plate no. 14 – thrust washer no. 15 – O-ring no. 21 – clutch basket no. 16 – needle bearings no. 18 and no. 19 – large thrust washer no. 17.

STEEL DRIVEN PLATE MAXIMUM WARPAGE

0.25 mm (.01 in)

Inspection Friction Drive Plate Measure each friction drive plate thickness. Friction drive plates must be replaced when lining is 2.7 mm (.11 in) thick or less. FRICTION DRIVE PLATE MINIMUM THICKNESS

2.7 mm (.11 in)

V01D07A

Steel Driven Plate Using a feeler gauge, check each steel driven plate for warpage on a plate surface. Change if the warpage is over to 0.25 mm (.01 in) or if they show signs of discoloration.

03-09-4

V01D08A

Clutch Basket Check slots of clutch basket for damage or wear caused by friction drive plates. Change if necessary.

V01D09A

Clutch Hub Check grooves of clutch hub for damage or wear caused by steel driven plates.

VMR2001_044_03-09A.FM

Section 03 ENGINE Subsection 09 (CLUTCH)

Clutch Spring Measure each clutch springs free length. CLUTCH SPRING MINIMUM LENGTH

32.5 mm (1.28 in)

V01D0AA

Pressure Plate Bearing Check the pressure plate bearing no. 20. Turn the bearing with your finger. The bearing should turn smoothly and donâ&#x20AC;&#x2122;t have excessive play. Replace if necessary.

V01D0CA

Assembly For assembly, reverse the disassembly procedure. Paying attention to the following details. Assemble friction drive plates, steel driven plates, inner plate and clutch hub in clutch basket. Apply engine oil on each friction drive plate. NOTE: Place the last friction drive plate in short slots of clutch basket. 2 1

V01D0BA

1. Retaining plate bearing V01D0DA

1. Last friction drive plate 2. Retaining plate 3. Clutch basket

VMR2001_044_03-09A.FM

03-09-5

Section 03 ENGINE Subsection 09 (CLUTCH)

Install a new tab washer and clutch lock nut. Fold up tab washer on nut. CAUTION: Do not use clutch lock nut to install clutch hub in clutch basket.

V01D0IA

03-09-6

VMR2001_044_03-09A.FM

Section 03 ENGINE Subsection 10 (TRANSMISSION)

TRANSMISSION

GEAR SHIFT SYSTEM

10 N m (89 lbf in) 4 5

Engine oil

Engine oil 6

7 22

2 10 N m (89 lbf in)

Engine oil 23 Engine oil

Engine oil

17 Engine oil 8

Engine oil 16

21 Engine oil

Loctite 243

18 20

12 13

Engine oil 14

9 10 N m (89 lbf in) 10 N m (89 lbf in)

V01E0LS

VMR2001_045_03-10A.FM

PARTS

FLAT RATE

03-10-1

Section 03 ENGINE Subsection 10 (TRANSMISSION)

TRANSMISSION 17

Anti-seize Loctite lubricant 243

Anti-seize lubricant

19 16 21

Anti-seize lubricant

Anti-seize lubricant Molykote G-n Loctite 243

10 N m (89 lbf in) 15

Anti-seize lubricant

23 22

Anti-seize lubricant

V01E0MS

03-10-2

PARTS

FLAT RATE

Anti-seize lubricant

VMR2001_045_03-10A.FM

Section 03 ENGINE Subsection 10 (TRANSMISSION)

GEAR SHIFT MECHANISM Disassembly

Remove the tension spring no. 13 then pull shift shaft with pawl no. 14 out of housing. 4

Front Side Remove: – engine from vehicle (refer to REMOVAL AND INSTALLATION) – rewind starter (refer to REWIND STARTER) – clutch (refer to CLUTCH) – shift shaft no. 1 – socket screw no. 2 and lock washer retaining index gear no. 3 – socket screw no. 4, washer no. 5, index lever no. 6 and index spring no. 7. V01E0DA

3 2

1. 2. 3. 4.

Shift drum gear Index lever Tension spring Shift shaft with pawl

Assembly Front Side Reassemble in the reverse order of disassembly. Paying attention to the following detail. Align mark on index gear with mark on shift shaft. 1

V01C1RA

1. Shift shaft 2. Index gear 3. Index lever

NOTE: Insert a flat screw driver in the index lever slot and twist the screw driver clockwise then pull index gear. Rear Side Remove: – water pump and magneto cover – nut no. 8 retaining shift drum gear – socket screw no. 9, washer no. 10, index lever no. 11 and index spring no. 12. NOTE: Insert a flat screw driver in the index lever slot and twist the screw driver clockwise then pull index gear.

VMR2001_045_03-10A.FM

V01E0EA

1. Index gear 2. Shift shaft

03-10-3

Section 03 ENGINE Subsection 10 (TRANSMISSION)

After clutch housing installation, align mark on shift shaft with mark on indicator shaft. 1

V01E0FA

1. Indicator shaft 2. Shift shaft 3. Transmission actuating lever

Rear Side Reassemble in the reverse order of disassembly.

TRANSMISSION Disassembly Remove gear shift mechanism. Separate both housing of crankcase. Remove the shift fork shafts no. 15, no. 16 and no. 17. Remove shift fork no. 18 then pull shift drum no. 19. At the same time, pull all gears and shafts.

Inspection Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Replace if necessary. During and after transmission disassembly, inspect the condition of each parts closely. In particular, check for: – gear teeth damage – worn or scored bearing surfaces – worn or scored shifting fork – worn or scored shift fork shaft – rounded engagement dogs and slots – bent shift forks – bent shift fork shaft – worn shift fork engagement pins – worn tracks on shift drum – worn splines on shafts and gears.

Assembly Reassemble in the reverse order of disassembly. Paying attention to the following details. NOTE: Install all shafts and gears together. Place the shift forks no. 20, no. 21, no. 22 and no. 23 in the proper shift drum tracks before install the transmission in half housing. When the transmission is installed, place the last shift fork no. 18. Install the shift drum.

V01E0GA

03-10-4

VMR2001_045_03-10A.FM

Section 03 ENGINE Subsection 10 (TRANSMISSION)

NOTE: Check if the shaft pin is properly installed in drum slot before housing installation. 1

V01E0IA

1. Shaft pin 2. Shift drum

Install the shift fork shafts. NOTE: Make sure all of the shift fork pins are aligned with the grooves in the shift drum. Install the index gear on end of shift drum. At the same time, turn the sub-transmission shaft no. 24 and the index gear no. 3. The transmission should turn smoothly.

VMR2001_045_03-10A.FM

03-10-5

Section 04 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

FUEL CIRCUIT........................................................................................................................ FUEL LINES........................................................................................................................ FUEL TANK STRAINER ..................................................................................................... FUEL VALVE ...................................................................................................................... FUEL TANK ........................................................................................................................ FUEL GAUGE ..................................................................................................................... FUEL SYSTEM PRESSURIZATION ...................................................................................

04-02-1 04-02-2 04-02-2 04-02-3 04-02-4 04-02-4 04-02-5

CARBURETOR AND FUEL PUMP......................................................................................... CARBURETOR ................................................................................................................... CARBURETOR ................................................................................................................... FUEL PUMP .......................................................................................................................

04-03-1 04-03-1 04-03-2 04-03-6

AIR INTAKE SILENCER.......................................................................................................... AIR FILTER BOX ................................................................................................................ REAR AIR INTAKE ADAPTOR ........................................................................................... REAR AIR INTAKE TUBE................................................................................................... FRONT AIR INTAKE TUBE ................................................................................................ PCV VALVE ........................................................................................................................

04-04-1 04-04-2 04-04-3 04-04-3 04-04-3 04-04-3

VMR2001_065_04_01ATOC.FM

04-01-1

Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

FUEL CIRCUIT

0 5 4 6

Body

8 V01F1MS

VMR2001_046_04_02A.FM

PARTS

FLAT RATE

04-02-1

Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

FUEL LINES

 WARNING

NOTE: In the case that grommet is too tight, use a flat screwdriver and carefully pull out grommet, as shown in the next photo.

Whenever working on fuel system, always verify for water or dust infiltration in reservoir. Replace any damaged, leaking or deteriorated fuel lines. When replacing fuel lines, be sure to use hoses as available from Bombardier parts department. This will ensure continued proper and safe operation.

 WARNING Use of improper fuel lines could compromise fuel system integrity.

 WARNING When draining a fuel tank or whenever a fuel line is disconnected, obstruct line with a hose pincher (P/N 295 000 076) or equivalent device. Fuel is flammable and explosive under certain conditions. Ensure work area is well ventilated. Do not smoke or allow open flames or sparks in the vicinity.

V01N02A

USE SCREWDRIVER ONLY IF GROMMET IS TOO TIGHT

Inspection Ensure that fuel tank strainer no. 7 and fuel line are clean and not damaged, as per following photo. 1

FUEL TANK STRAINER Removal Close fuel valve no. 1. Remove fuel tank cover. Refer to BODY. Disconnect BLACK negative cable from battery. Drain fuel tank no. 3 by unplugging reserve fuel hose no. 8 on fuel valve (top hose). NOTE: To accelerate fuel tank draining and ensure complete draining, remove cap no. 6. Manually pull grommet no. 9 out of fuel tank.

04-02-2

A31I03A

TYPICAL 1. Fuel tank strainer 2. Fuel line

VMR2001_046_04_02A.FM

Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

Installation NOTE: To ease grommet insertion, apply BOMBARDIER LUBE (P/N 293 600 016 (12 x 14 oz)). Position grommet on fuel line, as shown in the next photo then insert grommet in tank hole.

V01N03A

Unplug all 3 hoses from fuel valve. Remove valve.

Installation Reinstall fuel valve by positioning rubber washer inside and nut outside vehicle. See next photo.

1. Grommet properly position for tank insertion 2. Fitting recess

Once grommet is inserted in tank hole, push fitting until its recess properly sits in grommet. Refuel tank and ensure there are no leaks.

V01N05A

1. Rubber washer inside 2. Nut outside

Replug all hoses according to the following illustration. 4

FUEL VALVE

Removal NOTE: To ease reinstallation, mark all hoses before removing fuel valve no. 1. From outside body, remove plastic cap from fuel valve. Unscrew valve nut, as shown in the next photo. 1 2

V01F1NA

1. 2. 3. 4. 5.

Fuel tank top hose To fuel pump Fuel tank bottom hose Fuel pump Carburetor

V01N04A

UNSCREW VALVE NUT

VMR2001_046_04_02A.FM

04-02-3

Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

FUEL TANK

Pressure Test Refer to next section FUEL SYSTEM PRESSURIZATION for complete detailed procedure.

Removal Disconnect BLACK negative cable from battery. Drain fuel tank no. 3 by unplugging reserve fuel hose no. 8 on fuel valve (top hose). NOTE: To accelerate fuel tank draining and ensure complete draining, remove cap no. 6. Remove following items from body. Refer to BODY for complete detailed procedure: – steering cover – shifter guide indicator – front inner fenders – seat – fuel tank cover – front bumper – front fender with rack. Unplug fuel hoses from tank and disconnect fuel vent line no. 5. Remove both fuel tank top screws, as shown in the next photo.

Installation Reverse removal procedure, however pay attention to the following: Ensure that main fuel tank hose no. 10 and reserve fuel tank hose no. 8 are not inverse. Refer to FUEL VALVE table. Position top screws/nuts, washers and spacers as shown in the next photo. 2

V01N07A

1. 2. 3. 4. 5. 6.

4 5 6

Nut Frame bracket Fuel tank holding tab Spacer Washer Screw head

Perform fuel system pressurization as described in the following procedure.

FUEL GAUGE V01N06A

1. Remove both top fuel tank screws

Removal

Remove fuel tank bottom nut located beside rewind starter.

Remove front fender. Refer to BODY. Pull out fuel gauge no. 4 from fuel tank. At the same time, remove the fuel gauge gasket.

Inspection

Installation

Visual Inspect fuel tank for any damage or cracks which may result in fuel leaks. If so, replace tank with new one.

The installation is the reverse of the removal procedure. NOTE: Check gasket for crack or other damage. Change if necessary.

04-02-4

VMR2001_046_04_02A.FM

Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

FUEL SYSTEM PRESSURIZATION Fill up fuel tank no. 3. Remove seat, fuel tank cover and right side inner fender. Install on fuel tank special cap of leak testing kit (P/N 529 033 100). Install hose pinchers (P/N 295 000 076) on fuel tank vent line and fuel pump outlet hose no. 2 at carburetor(s), as shown in the following photos.

Using air pump from engine leak test kit (P/N 861 749 100) inject air into fuel tank. See next photo.

V01N0AA

1. Special cap on tank 2. Air pump

V01N08A

HOSE PINCHER INSTALLED ON FUEL TANK VENT LINE

Pressurize fuel system to 21 kPa (3 PSI). That pressure must not drop during 3 minutes. If pressure drops, locate fuel leak(s) and repair/ replace leaking component(s). To ease locating leak(s) at fuel tank vent fitting, fuel gauge or fuel cap spray soapy water on components, bubbles will indicate leak location(s).

V01N09A

HOSE PINCHER INSTALLED ON FUEL PUMP OUTLET

VMR2001_046_04_02A.FM

04-02-5

Subsection 03

Section 04 FUEL SYSTEM (CARBURETOR AND FUEL PUMP)

CARBURETOR AND FUEL PUMP

CARBURETOR TRAXTER, FOOTSHIFT, XL and XT Models

V01F1OS

VMR2001_047_04_03A.FM

PARTS

FLAT RATE

04-03-1

Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND FUEL PUMP)

CARBURETOR CAUTION: Although some jets can be replaced by other jets from other carburetors, such modifications shouldnâ&#x20AC;&#x2122;t be performed. They can greatly affect engine calibration and can cause severe damage to engine. Use only recommended jetting specific for this carburetor.

Removal Carburetor Removal Disconnect BLACK negative cable from battery. Remove seat. Unplug the TPS sensor connector (AUTOSHIFT model only). Unplug all fuel hoses from carburetor. NOTE: To ease reinstallation, mark all hoses before unplugging. Loosen both carburetor and air box clamps. Loosen air box bolts and move backward. Pull out carburetor.

V01F0AA

1. Release tension on throttle lever 2. Cable end bushing 3. Throttle lever recess

Separate cable end bushing from throttle cable end, as shown in the next photo. Keep bushing.

Choke Cable Removal Put carburetor on a clean rag. Unscrew choke plastic nut from carburetor, use choke nut tool (P/N 529 035 660). Pull choke cable to remove choke plunger from carburetor. Throttle Cable Removal With carburetor on a clean rag, remove carburetor side cover. Using thumb, release tension on throttle lever. With long nose pliers, rotate cable end bushing so that cable aligns with throttle lever recess, then lift cable end. See next photo.

04-03-2

V01F0BA

REMOVE CABLE END BUSHING

VMR2001_047_04_03A.FM

Subsection 03

Loosen throttle cable nut, as shown in the next photo.

Section 04 FUEL SYSTEM (CARBURETOR AND FUEL PUMP)

With carburetor chamber up side down: – Measure height H between bowl seat and the top edge of float arm. Use float level gauge (P/N 529 035 520). – Keep float level gauge perfectly vertical and in line with main jet hole. Ensure that both float level gauge tips are properly positioned on carburetor body and that “L” arm is leaning on float while compressing valve spring. Refer to following photos for proper float level gauge positioning.

V01F0CA

1. Loosen this nut 2. Side cover removed

Pull cable out from carburetor.

Cleaning and Inspection The entire carburetor should be cleaned with a general solvent and dried with compressed air before disassembly. CAUTION: Heavy duty carburetor cleaner may be harmful to the float material and to the rubber parts, O-rings, etc. Therefore, it is recommended to remove those parts prior to cleaning. Carburetor body and jets should be cleaned in a carburetor cleaner following manufacturer’s instructions.

V01F0TA

1. Gauge tips 2. “L” arm A. Height H

 WARNING Solvent with a low flash point such as gasoline, naphtha, benzol, etc., should not be used as they are flammable and explosive.

90°

Carburetor Float Level Adjustment Correct fuel level in float chamber is vital toward maximum engine efficiency. To check for correct float level proceed as follows: – Remove float bowl and gasket from carburetor. – Make sure that float arm is symmetric, not distored.

V01F0EA

GAUGE ALIGNED WITH MAIN JET

VMR2001_047_04_03A.FM

04-03-3

Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND FUEL PUMP)

To adjust height H, bend the contact tab of float arm until the specified height is reached. CAUTION: When adjusting lever, do not pry it. This will apply pressure on needle and damage valve seat/needle.

Install rubber flange on air box side so that its recess aligns with air box notch, as shown in the next photo.

Installation NOTE: On the AUTOSHIFT model, the TPS sensor calibration is necessary. Adjust the idle speed in first, then, calibrate the TPS sensor. Refer to ELECTRIC SHIFT SYSTEM. To install carburetor on engine, inverse removal procedure, as described: – Inspect throttle and choke cable housing prior to installation. – Reinstall throttle and choke cables, at the same time adjust the throttle cable, then install the side cover. Refer to CARBURETOR ADJUSTMENTS below in this section. – Reinstall carburetor on engine. When reinstalling carburetor on engine, pay attention to the following: CAUTION: The rubber flanges must be checked for cracks and/or damage. At assembly, the rubber flanges must be perfectly matched with the air box, carburetor and engine or severe engine damage will occur. Do not use screwdriver or other tool to install the rubber flanges. Install clamps in a way that their tightening bolts are staggered — not aligned.

V01F0GA

AIR BOX SIDE — RUBBER FLANGE INSTALLATION 1. Notch aligned with recess

Carburetor Adjustments

2 V01F0HA

BOTTOM VIEW 1. Idle speed screw 2. Pilot screw 3. Drain plug and screw

V01F0FA

CARBURETOR SIDE — RUBBER FLANGE INSTALLATION 1. Flange recess aligned with carburetor notch 04-03-4

VMR2001_047_04_03A.FM

Subsection 03

Idle Speed Preliminary Adjustment Adjust throttle screw to 1-1/2 turn or so that throttle valve closes bypass hole by half, as shown in the next photo.

Section 04 FUEL SYSTEM (CARBURETOR AND FUEL PUMP)

Turn the pilot screw clockwise until you hear the engine misses or decreases idle speed, then turn counterclockwise until the engine again misses or decreases idle speed. Center the pilot screw exactly between these two extreme positions then unscrew the pilot screw of 3/8 turn. If idle speed changes after adjustment of the pilot screw, readjust the idle speed screw. Diaphragm Installation Carefully replace diaphragm in its original position. Make sure spring is located properly in carburetor cover before screwing. NOTE: Check and place correctly the indexation lob.

Throttle

î°? WARNING Ensure the key is turned OFF, prior to performing the throttle cable adjustment. 1

V01F0WA

1. Bypass hole closes to halfway

Before adjusting the throttle cable, adjust idle speed (preliminary adjustment) and choke. On the carburetor, loosen lock nut and adjust throttle cable. Make sure the throttle lever, at the full position, doesnâ&#x20AC;&#x2122;t lean against carburetor body.

Idle Speed Adjustment Start engine and allow it to warm then adjust idle speed to specifications by turning idle speed screw clockwise to increase engine speed or counterclockwise to decrease it. NOTE: Use the digital induction tachometer (P/N 529 014 500). Turn tachometer wire around spark plug wire, about 4 or 5 turns, for the best measure. CAUTION: Do not attempt to set the idle speed by using the pilot screw. Refer to TECHNICAL DATA for idle speed specifications.

Pilot Screw Adjustment NOTE: The pilot screw is factory pre-set. Warm the engine to operating temperature. V01F0RA

THROTTLE LEVER AT THE FULL POSITION A. 1 mm (1/32 in)

Retorque lock nut. VMR2001_047_04_03A.FM

04-03-5

Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND FUEL PUMP)

Verification

FUEL PUMP Removal Close fuel valve. Lift coolant tank. Unplug fuel hose coming from fuel valve. NOTE: It may be easier to unplug fuel hose coming from fuel valve at fuel valve location. Unplug fuel hose going to carburetor. Disconnect impulse hose. 1

Connect a clean plastic tubing to the inlet nipple and alternately apply pressure and vacuum with pump of leak test kit. The inlet valve should release with pressure and hold under vacuum. Repeat the same procedure at the outlet nipple. This time the outlet valve should hold with pressure and release under vacuum. Check impulse diaphragm and gasket on highsupply fuel pump with twin outlets as follows: Connect a clean plastic tubing to the impulse nipple and plug vent hole on top cover. Either apply pressure or vacuum. The diaphragm/gasket must not leak.

Cleaning and Inspection The entire pump should be cleaned with general purpose solvent before disassembly. Fuel pump components should be cleaned in general purpose solvent and dried with compressed air.

î°? WARNING V01F0NA

1. Fuel hose coming from fuel valve 2. Fuel hose going to carburetor 3. Impulse hose

Remove fuel pump.

Solvent with a low flash point such as gasoline, naphtha, benzol, etc., should not be used as each is flammable and explosive. Inspect diaphragm. The pumping area should be free of holes, tears or imperfections. Replace pump as needed.

Installation To install fuel pump, reverse removal procedure. However, pay attention to fuel hose position. Refer to arrows on fuel pump.

04-03-6

VMR2001_047_04_03A.FM

Section 04 FUEL SYSTEM Subsection 04 (AIR INTAKE SILENCER)

AIR INTAKE SILENCER

XL Model and some TRAXTER and XT

1 2

6 14 13 15 16

Engine Valve Cover

Engine 7

11 V01C13S

VMR2001_048_04_04A.FM

PARTS

FLAT RATE

04-04-1

Section 04 FUEL SYSTEM Subsection 04 (AIR INTAKE SILENCER)

All other Models

1 3 8

To carburetor

To valve cover

10 9

To engine

V01C2PS

AIR FILTER BOX Removal XL Model and some TRAXTER and XT Remove: – seat – air filter box cover no. 1 – air baffle no. 2, air filter no. 3 and foam no. 4. Detach: – breather hose no. 6 – rear air intake tube no. 7 – intake adaptor no. 8 from carburetor.

04-04-2

Unfasten bolts no. 5 and remove drain tubes no. 9 under air filter box no. 10. Pull out the air filter box. All other Models Remove seat. Unsnap the rigid intake from the rear fender. Remove: – rear fender (refer to BODY) – air filter box cover no. 1 – air filter no. 3.

VMR2001_048_04_04A.FM

Section 04 FUEL SYSTEM Subsection 04 (AIR INTAKE SILENCER)

Detach: – breather hose no. 6 – rear air intake adaptor no. 17 – carburetor vent hose no. 18 – intake adaptor no. 8 from carburetor. Unfasten bolts retaining air filter box no. 10 to the frame. Pull out air filter box.

Inspection

Installation

Removal

For installation, reverse the removal procedure.

Remove: – front fender – LH inner fender. Refer to BODY. Disconnect front air intake tube no. 12 from the sleeve no. 11. NOTE: Before removing front air intake tube from vehicle, note tube routing for reinstallation. Remove front air intake tube from vehicle.

REAR AIR INTAKE ADAPTOR All Models except XL and some TRAXTER and XT Models

Removal Remove: – seat – radiator access plug – air filter box cover. Unsnap the rigid intake from the rear fender. Press the air intake adaptor to make it come out of air filter box.

REAR AIR INTAKE TUBE

Inspect air intake tube for cracks, blisters or any other damage. Change if necessary.

Installation For installation, reverse the removal procedure.

FRONT AIR INTAKE TUBE XL Model and some TRAXTER and XT

Inspection Inspect air intake tube for cracks, blisters or any other damage. Change if necessary.

Installation For installation, reverse the removal procedure.

XL Model and some TRAXTER and XT

Removal

PCV VALVE

Remove: – front fender – LH inner fender – LH side panel. NOTE: For all body parts removal, refer to BODY. Detach rear air intake tube no. 7 from air filter box no. 10. In front of vehicle, disconnect rear air intake tube from sleeve no. 11. Remove rear air intake tube from vehicle. NOTE: Before removing rear air intake tube from vehicle, note tube routing for reinstallation.

XL Model and some TRAXTER and XT The positive crankcase ventilation (PCV) valve is used to reduce the signal for pulsation coming from crankcase so that the pressure in the air intake circuit stays constant.

VMR2001_048_04_04A.FM

Test If idle speed engine is not constant, remove the breather hose from PCV valve. When a finger is placed over PCV valve inlet, a strong vacuum should be felt immediately. If not, replace the PCV valve.

04-04-3

Section 04 FUEL SYSTEM Subsection 04 (AIR INTAKE SILENCER)

Removal Remove and discard clamps no. 14 and no. 15. Separate PCV valve no. 13 from breather hose no. 6 and from connecting tube no. 16. 3

V01C14A

1. 2. 3. 4.

PCV valve Clamps Breather hose Connecting tube

Installation For installation, reverse the removal procedure. NOTE: Install PCV valve with the new clamps.

04-04-4

VMR2001_048_04_04A.FM

Section 05 ELECTRICAL Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

OVERVIEW............................................................................................................................. 05-02-1 GENERAL OPERATION INFORMATION ........................................................................... 05-02-1 MPEM (MULTI-PURPOSE ELECTRONIC MODULE)............................................................ 05-02-1 CHARGING SYSTEM......................................................................................................... 05-02-1 STARTING SYSTEM .......................................................................................................... 05-02-2 IGNITION SYSTEM............................................................................................................ 05-02-3 ELECTRIC SHIFT SYSTEM ................................................................................................ 05-02-4 GAUGES/ACCESSORIES .................................................................................................. 05-02-4 GENERAL TESTING/TROUBLESHOOTING INFORMATION .......................................... 05-02-5 SERVICING PACKARD CONNECTORS ............................................................................ 05-02-5 SERVICING DEUTSCH CONNECTORS ............................................................................ 05-02-6 SERVICING AMP CONNECTORS (26 PINS)..................................................................... 05-02-7 IDENTIFICATION OF FUSE BLOCK ON VEHICLE ............................................................ 05-02-10 IDENTIFICATION OF MAJOR CONNECTOR PINS .......................................................... 05-02-11 CHARGING SYSTEM............................................................................................................. TESTING PROCEDURE .....................................................................................................

05-03-1 05-03-1

STARTING SYSTEM.............................................................................................................. BATTERY ............................................................................................................................ TROUBLESHOOTING ........................................................................................................ BATTERY TESTING ........................................................................................................... REMOVAL........................................................................................................................... CLEANING ......................................................................................................................... INSPECTION ...................................................................................................................... BATTERY STORAGE.......................................................................................................... ACTIVATION OF A NEW BATTERY................................................................................... TIPS FOR CHARGING A USED BATTERY ........................................................................ CHARGING 2 OR MORE BATTERIES AT A TIME ............................................................ INSTALLATION .................................................................................................................. STARTING SYSTEM TROUBLESHOOTING ..................................................................... STARTING SYSTEM TESTS ............................................................................................. GENERAL ........................................................................................................................... ELECTRIC STARTER .......................................................................................................... REMOVAL .......................................................................................................................... INSTALLATION..................................................................................................................

05-04-1 05-04-1 05-04-1 05-04-1 05-04-2 05-04-2 05-04-2 05-04-2 05-04-3 05-04-4 05-04-5 05-04-5 05-04-6 05-04-7 05-04-7 05-04-9 05-04-9 05-04-9

VMR2001_065_05_01ATOC.FM

05-01-1

Section 05 ELECTRICAL Subsection 01 (TABLE OF CONTENTS)

IGNITION SYSTEM ................................................................................................................ IGNITION SYSTEM TESTING PROCEDURE..................................................................... GENERAL............................................................................................................................ IGNITION SYSTEM TEST .................................................................................................. OTHER IGNITION SYSTEM PROBLEMS .......................................................................... IGNITION TIMING .............................................................................................................. SPARK PLUG ...................................................................................................................... DISASSEMBLY ................................................................................................................... HEAT RANGE...................................................................................................................... FOULING............................................................................................................................. SPARK PLUG ANALYSIS ................................................................................................... SPARK PLUG INSTALLATION ........................................................................................... NGK SPARK PLUG SYMBOL EXPLANATION ..................................................................

05-05-1 05-05-1 05-05-1 05-05-1 05-05-4 05-05-4 05-05-5 05-05-5 05-05-5 05-05-5 05-05-5 05-05-6 05-05-7

ELECTRIC SHIFT SYSTEM ..................................................................................................... GENERAL............................................................................................................................ TROUBLESHOOTING ......................................................................................................... DIAGNOSTIC/CALIBRATION MODE ................................................................................ PREPARATION ................................................................................................................... TESTING ............................................................................................................................. VALVE REMOVAL/INSTALLATION .................................................................................. SHIFTING VALVE ............................................................................................................... CLUTCHING VALVE ........................................................................................................... CLUTCH MODULATOR VALVE ......................................................................................... CLUTCH ACTIVATION SWITCH ........................................................................................ SENSOR REMOVAL/INSTALLATION............................................................................... STPS (SUB-TRANSMISSION POSITION SENSOR) .................................................................. GBPS (GEAR BOX POSITION SENSOR)........................................................................... VSS (VEHICLE SPEED SENSOR) ....................................................................................... TPS (THROTTLE POSITION SENSOR).............................................................................. VALVES/SOLENOIDS TESTS............................................................................................ CLUTCHING VALVE AND CLUTCH MODULATOR VALVE TESTS ................................. UPSHIFT/DOWNSHIFT SOLENOIDS TESTS .................................................................... SENSORS TESTS ............................................................................................................... STPS (SUB-TRANSMISSION POSITION SENSOR), GBPS (GEAR BOX POSITION SENSOR) AND TPS (THROTTLE POSITION SENSOR) TESTS ........................................................ VSS (VEHICLE SPEED SENSOR) TESTS........................................................................... UPSHIFT/DOWNSHIFT SWITCH TESTS .......................................................................... UPSHIFT/DOWNSHIFT SWITCH .......................................................................................

05-06-1 05-06-1 05-06-1 05-06-1 05-06-2 05-06-3 05-06-11 05-06-11 05-06-12 05-06-13 05-06-13 05-06-14 05-06-14 05-06-14 05-06-14 05-06-15 05-06-15 05-06-15 05-06-16 05-06-16

05-01-2

05-06-16 05-06-17 05-06-17 05-06-17

VMR2001_065_05_01ATOC.FM

Section 05 ELECTRICAL Subsection 01 (TABLE OF CONTENTS)

INSTRUMENTS AND ACCESSORIES .................................................................................. REMOVAL AND INSTALLATION................................................................................................. 12-VOLT AUXILIARY POWER OUTLET............................................................................ 12-VOLT POWER OUTLET ................................................................................................ HEADLIGHT ....................................................................................................................... IGNITION SWITCH ............................................................................................................ INDICATOR LIGHTS .......................................................................................................... MPEM ................................................................................................................................. SPEEDOMETER (if so equipped)...................................................................................... WINCH................................................................................................................................ WINCH CONTROL SWITCH .............................................................................................. TESTS................................................................................................................................. 12-VOLT AUXILIARY POWER OUTLET............................................................................ 12-VOLT POWER OUTLET ................................................................................................ COOLING FAN OPERATION TEST ................................................................................... HEADLIGHT ....................................................................................................................... HI-LO SWITCH ................................................................................................................... MULTI-FUNCTION SWITCH ............................................................................................. INDICATOR LIGHTS .......................................................................................................... SPEEDOMETER (if so equipped)...................................................................................... WINCH CONTROL SWITCH (if so equipped)...................................................................

VMR2001_065_05_01ATOC.FM

05-07-1 05-07-1 05-07-1 05-07-1 05-07-1 05-07-2 05-07-3 05-07-3 05-07-3 05-07-4 05-07-4 05-07-5 05-07-5 05-07-5 05-07-5 05-07-5 05-07-5 05-07-5 05-07-6 05-07-6 05-07-6

05-01-3

Section 05 ELECTRICAL Subsection 02 (OVERVIEW)

OVERVIEW GENERAL OPERATION INFORMATION The electrical system consist of different subsystems where some are inter-related: • MPEM (Multi-Purpose Electronic Module) • Charging System • Starting System • Ignition System • Electric Shift System • Gauges and Accessories The following gives an outline of each components.

MPEM (Multi-Purpose Electronic Module) The MPEM itself is not a system, it is rather part of other systems in the electrical system. Therefore, the MPEM functions will be described specifically in the system into which it belongs. See below in the specific system for more information. The MPEM includes a micro-controller. It is basically responsible for interpreting/computing information, distribution of information, as a timed/untimed power source, managing the starting system, ignition system, the engine RPM limiter, the vehicle speed limiter and the transmission shifting timing and clutch modulation. It reads information through many external sensors to then compute the output actions to the related systems. The MPEM stores engine RPM limiter parameters that are applied to all the 5 gears in EACH High, Lo and Reverse. It also limits the vehicle speed to 15 km/h (9 MPH) in reverse operation whatever the gear. The MPEM controls the indicator lights display. It uses many sensors to acquaint the different system condition and THEN turns on the proper light. Besides monitoring the shifting system sensors, it also monitors the engine oil pressure and the coolant temperature. When oil pressure is too low, the engine light turns on and remain on. When the engine overheats, the engine light flashes. The MPEM features a diagnostic/setting mode with coded light display to troubleshoot and set the shifting system. VMR2001_049_05_02A.FM

0 The MPEM is equipped with an automatic power shut-down. This feature prevents the battery from losing its charge if ignition switch is left turned ON when the engine is not running. NOTE: If parking brake is set and the MPEM shuts down, the brake light will remain ON. The MPEM also controls the accessories such as the cluster display, headlight intensity dimming and taillight. The module doesn't contain fuses since it is not easily accessible to the user. The module includes an internal overload protection device to supply circuits. An external fuse (in the fuse block) is used to protect the module supply circuit. The module does not control the loads connected directly to the battery, such as the fan, the DC accessory outlet, brake light and the optional winch.

CHARGING SYSTEM It is the source of electrical energy to charge the battery and keep it at a full state of charge. The magneto is coupled to the engine and it transforms magnetic field into electric current through a 3 phase, “Y” wound stator on 18 poles. The magneto supplies unregulated AC current (alternative current) to the voltage regulator/rectifier. 1 2

V01G0IA

1. 2. 3. 4.

Magneto flywheel Stator Voltage regulator/rectifier Battery

05-02-1

Section 05 ELECTRICAL Subsection 02 (OVERVIEW)

Voltage Regulator/Rectifier A 3-phase full-wave series-type voltage regulator/ rectifier receives the AC voltage and rectifies (converts) it into DC. The voltage is also regulated to a maximum of 14.5 volts (DC).

FOOTSHIFT Model When ignition switch is turned on and start button is pressed, the MPEM sends a signal to the starting solenoid. The battery then supplies the starter through the starting solenoid to start the engine.

Battery

The battery supplies the entire vehicle and particularly the MPEM which then distributes the current to many components. Therefore, DC current only is used in the entire electrical system.

STARTING SYSTEM 4

All Models except FOOTSHIFT When ignition switch is turned on and start/stop switch is pressed, the MPEM sends a signal to the starting solenoid. The battery then supplies the starter through the starting solenoid to start the engine.

6 V01G1CA

4 5

TYPICAL 1. Battery 2. Ignition switch 3. Start button 4. MPEM 5. Solenoid 6. Electric starter

Engine can be started in any gear (from 1 to 5). Transmission lever must be on PARK or NEUTRAL to allow engine starting. However, an override mode allows to start the engine with the transmission lever in any position when holding any brake lever while pressing the start button.

6 V01G0JA

TYPICAL 1. Battery 2. Ignition switch 3. Start/stop switch 4. MPEM 5. Solenoid 6. Electric starter

05-02-2

VMR2001_049_05_02A.FM

Section 05 ELECTRICAL Subsection 02 (OVERVIEW)

IGNITION SYSTEM

Battery/Ignition Switch

All Models except FOOTSHIFT An IDI (Induction Discharge Ignition) system is utilized. The ignition system is made up of the following components:

The ignition switch allows battery to supply the MPEM for the ignition system.

FOOTSHIFT Model Besides enabling the starting system, the start button enables the ignition system through the MPEM while the engine stop switch disables the ignition system.

MPEM (Multi-Purpose Electronic Module)

V01G0KA

The MPEM is fed by the battery but the ignition is activated by the ignition switch. The MPEM receives the signals from the start/stop switch as well as from the trigger coil and takes action to the ignition system. The MPEM feeds the ignition coil so that a spark is produced at the proper moment. The MPEM controls the spark advance according to different pre-defined parameters.

TYPICAL 1. Battery 2. Ignition switch 3. Start/stop switch 4. MPEM 5. Magneto flywheel 6. Trigger coil 7. Ignition coil 8. Spark plugs

FOOTSHIFT Model

VMR2001_049_05_02A.FM

TYPICAL 1. Battery 2. Ignition switch 3. Start button 4. MPEM 5. Magneto flywheel 6. Trigger coil 7. Ignition coil 8. Spark plugs

V01G1DA

All Models except FOOTSHIFT Besides enabling the starting system, the start/stop switch enables/disables the ignition system through the MPEM.

Start Button

Start/Stop Switch

Magneto Flywheel/Trigger Coil The magneto flywheel features six protrusions that are working with the trigger coil. The trigger coil sends the signals to the MPEM to be processed for the ignition system. The MPEM also uses these signals to accurately calculate the engine RPM and among other things, control the maximum engine RPM.

Ignition Coil/Spark Plugs The ignition coil receives its signal from the MPEM. The ignition coil steps up the input voltage for the IDI system and the end result is firing of the spark plugs. It is a double coil that provides a separate spark to each spark plug. The double control circuit in the MPEM works separately on each part of the ignition coil so, one ignition coil still could work while the other might be defective.

05-02-3

Section 05 ELECTRICAL Subsection 02 (OVERVIEW)

ELECTRIC SHIFT SYSTEM All Models except FOOTSHIFT An electronically controlled hydraulic shift system is utilized. It is made up of the following components: 3

MPEM

5 2 6 V01G0LA

1. 2. 3. 4. 5. 6.

Battery Ignition switch Upshift/downshift switch Sensor MPEM Solenoid/valve

Battery/Ignition Switch The ignition switch allows battery to supply the MPEM. The MPEM then supplies the solenoids for the shifting system.

Upshift/Downshift Switch When the upshift or downshift button is pressed, the MPEM activates the proper solenoid (up or down) that moves the shared hydraulic valve.

Sensor Many sensors are used to assist the MPEM to acquire the conditions where the vehicle is operated to allow the MPEM to compute and select the proper parameters accordingly.

05-02-4

The VSS (vehicle speed sensor) supplies the MPEM with the vehicle speed. The GBPS (gearbox position sensor) supplies the MPEM with the gear position (1, 2, 3, 4, 5). The STPS (sub-transmission position sensor) supplies the MPEM with the sub-transmission position (P, R, N, H, L). The brake light switch is also used by the MPEM to allow engine starting in other position than PARK and NEUTRAL. Other sensors are utilized but they are not related to the shifting system.

The MPEM is responsible to properly engage/ disengage/modulate the clutch and to shift gears. Although the shift system is performed by hydraulic valves on mechanical components, it is electronically-controlled through the MPEM. The MPEM uses pre-defined parameters to change engine RPM, modify the engine timing curve, control the shift timing and modulation depending on the sensors reading to accomplish an accurate shifting adapted to each specific condition.

Solenoid/Valve The solenoids/valves combo are the electro-hydraulic devices that actually activate the mechanical operations. Besides the shifting valve (upshift/downshift), there is a clutching valve that pushes an actuator to open and close the clutch and at last, a clutch modulator valve that regulates the oil pressure to control the speed at which the clutch is re-engaged (modulation). The hydraulic system is enclosed in the engine/transmission case and the same oil as the engine is used for the hydraulic valves.

GAUGES/ACCESSORIES The battery supplies the DC current to all accessories. Some are fed directly by the battery or through the fuse block and some are fed through the MPEM.

VMR2001_049_05_02A.FM

Section 05 ELECTRICAL Subsection 02 (OVERVIEW)

GENERAL TESTING/ TROUBLESHOOTING INFORMATION The following gives general electrical-related problems. For specific system-related problems, refer to proper system section. It is possible that a component seems to operate in static condition but in fact, it is defective. In this case, the best way to solve this problem is to remove the original part and replace it with one which is in good condition. IMPORTANT: When having to solve an electrical problem, the first thing to do is to check battery condition as well as its cables and connections. Never use a battery charger to replace temporarily the battery, as it may cause the MPEM to work erratically or not to work at all. Also ensure the ignition switch is turned on. Check related-circuit fuse condition with an ohmmeter — visual inspection could lead to false results — and solidity (close to battery). Also visually examine harness and connections. CAUTION: It is recommended to always disconnect the battery when replacing any electric or electronic parts. To perform verifications, a good quality multimeter such as Fluke 73 (P/N 529 022 000) should be used. Pay particular attention to ensure that pins are not out of their connectors or out of shape. The troubleshooting procedures cover problems not resulting from one of these causes.

 WARNING Ensure all terminals are properly crimped on wires and connector housings are properly fastened. Before replacing a MPEM, always check electrical connections. Make sure that they are very tight and they make good contact and that they are corrosionfree. A “defective module” can be repaired simply by unplugging and replugging the MPEM. The voltage and current might be too weak to go through dirty wire pins. Check carefully if posts show signs of moisture, corrosion or if they look dull. Clean pins properly and then coat them with silicon-based dielectric grease or other appropriate lubricant (except if otherwise specified) when reassembling them. See connectors information below. VMR2001_049_05_02A.FM

It is recommended to always disconnect the battery when replacing the any electric or electronic part(s). IMPORTANT: In usual electric circuit, the battery supplies a switch which then supplies the electric consumer. Therefore the switch opens and closes the positive side of the circuit. However, in our electrical system, the battery supplies the electric consumer then the switch completes the circuit to the ground. So the switch opens and closes the negative side of the circuit. This is particularly true with the MPEM. The MPEM switches the ground to complete the electrical circuits it controls. Take this into account when troubleshooting the electrical system. Pay attention to grounding wires. Do not mix grounds. It may affect the MPEM operation.

Checking for Shorts Between 2 Wires When checking continuity of a wire in a circuit, wires should be checked for short circuit as follows. Make sure to isolate circuit wires by unplugging connectors. Let’s suppose that the circuit to be checked has a RED and a BLACK wire. Using an ohmmeter, measure the resistance between the RED and the BLACK wire. The resistance should be infinite (0 L). Otherwise, there is a short circuit between both wires. We must therefore identify and correct the fault.

SERVICING PACKARD CONNECTORS To remove terminal from Packard connector housing, use Snap-on TT600-4 tool.

F01B1JA

05-02-5

Section 05 ELECTRICAL Subsection 02 (OVERVIEW)

SERVICING DEUTSCH CONNECTORS Waterproof Connector Housing Female and Male Connector Housing To remove: – Using a long nose pliers, pull out the lock.

NOTE: Before extraction, push wire forward to relieve pressure on retaining tab. – Insert a 4.8 mm (0.189 in) wide screwdriver blade inside the front of the contact cavity. – Pry back the retaining tab while gently pulling wire back until contact is removed. 1

V01G0QA

FEMALE CONNECTOR HOUSING 1. Retaining tab V01G0OA

FEMALE HOUSING 1. Female lock

V01G0PA

To install: – For insertion of signal contact, make sure the lock is removed. – Insert contact into appropriate circuit cavity and push as far as it will go. – Pull back on the contact wire to be sure the retention fingers are holding the contact. – After all required contacts have been inserted, the lock must be installed. CAUTION: Never apply dielectric grease on contacts in plug connector. The use of dielectric grease will make the seal swollen and move out of the connector. Do not lubricate.

MALE HOUSING 1. Male lock

05-02-6

VMR2001_049_05_02A.FM

Section 05 ELECTRICAL Subsection 02 (OVERVIEW)

SERVICING AMP CONNECTORS (26 pins)

2 1

When servicing electrical system, special care must be taken when working with AMP plug connectors in order to prevent any malfunction of the system.

Identification Parts 5 9 1

V01G0MA

TYPICAL 1. AMP connectors 2. Identification numbers

Each plug assembly is mechanically keyed to mate only with identical mechanical keyed header on the MPEM.

F00H0WA

1. 2. 3. 4. 5. 6. 7. 8. 9.

Plug assembly Cover assembly Mating seal Wedge lock Header assembly Seal plug Power wire Signal wire Locking tabs

Connectors Each connector is identified by a unique number from 2 to 3, number 2 being the upper connector. The number is found on the MPEM close to the connector. NOTE: There is no number 1.

F00H12A

TYPICAL 1. Mechanically keyed

To remove plug connector from the header assembly on the MPEM, press both tabs and pull plug. VMR2001_049_05_02A.FM

05-02-7

Section 05 ELECTRICAL Subsection 02 (OVERVIEW)

Wire Selection and Preparation

The size of the wires must be 20 to 16 AWG with a wire insulation diameter having a minimum dimension of 1.7 mm (0.067 in) and a maximum dimension of 2.78 mm (0.106 in). The wire strip length shall be 5.1 mm (13/64 in). NOTE: When stripping wires, ensure conductor is not nicked, scrapped or cut. Wire stripping tool jaws may leave marks on the surface of the wire insulation. If these marks occur at the location of the wire seal, leakage may result. Insulation surface within 25 mm (1 in) from the tip of the contact must be smooth.

Contact Crimping All contacts in AMP plug connectors must be crimped using the crimping tool (P/N 295 100 164). CAUTION: If contacts are not crimped using the proper crimping tool, the wire seal may be damaged.

F00H10A

1. Seal plug 2. Wire seal

CAUTION: Do not pierce the diaphragm with a sharp point for electrical troubleshooting. The resulting pin holes in the insulation will allow moisture to penetrate the system and possibly result in system failure.

Contact Removal

F00B0EA

CRIMPING TOOL (P/N 295 100 164)

Signal Contact Insert a screwdriver blade between the mating seal and the wedge lock tab. Release the plug locking tab and at the same time, pry open the wedge lock to the open position. CAUTION: The wedge lock should never be removed from the housing for insertion or removal of the signal wire contacts.

All circuits are sealed by a diaphragm in the rubber wire seal. When installing wire contacts in plug connector, the diaphragm is pierced as the contact passes through it. If the diaphragm is pierced and the cavity is not used, install a seal plug, large end first, into circuit cavity as far as it will go. NOTE: It is suggested that all unused circuit cavities be sealed with a seal plug, even if they are not pierced.

F00H0OB

1. Wedge lock 2. Locking tab

05-02-8

VMR2001_049_05_02A.FM

Section 05 ELECTRICAL Subsection 02 (OVERVIEW)

F00H0PA

1. Wedge lock in open position

While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed.

F00H0RA

1. Pull locking tab (both sides)

Before extraction, push wire forward to relieve pressure on retaining tab. Insert a 4.8 mm (0.189 in) wide screwdriver blade inside the front of the contact cavity.

1 2

F00H0QA

1. Rotate wire back and forth 2. Pull wire

Power Contact NOTE: The wedge lock must be removed to extract power contact. Pull both locking tabs and remove wedge lock from plug assembly.

F00H0ZA

Pry back the retaining tab while gently pulling wire back until contact is removed.

VMR2001_049_05_02A.FM

05-02-9

Section 05 ELECTRICAL Subsection 02 (OVERVIEW)

Contact Installation For insertion of signal contact, make sure the wedge lock is in the open position. NOTE: For insertion of power contact, the wedge lock may or may not be on the open position. Insert contact into appropriate circuit cavity and push as far as it will go. Pull back on the contact wire to be sure the retention fingers are holding the contact. After all required contacts have been inserted, the wedge lock must be closed to its locked position. CAUTION: Never apply dielectric grease on contacts in plug connector. The use of dielectric grease will create hydrolock and poor sealing. Apply a thin coat of DEOXIT contact lubricant to the pins of the header on the MPEM only.

IDENTIFICATION OF FUSE BLOCK ON VEHICLE Fuses are located in engine compartment on LH side of battery.

V01G04A

1. Battery 2. Fuse holder

Fuses are identified by a number located beside the fuses.

1 4

1 F00H11A

TYPICAL 1. Apply a thin coat of DEOXIT contact lubricant

CAUTION: Do not apply lubricant excessively. Care must be taken so that the lubricant will not come in contact with the mating seal; the seal may loose its sealing capacities. Do not apply lubricant on contacts inside plug connector.

05-02-10

2 5

3 6

V01G02A

1. 2. 3. 4. 5. 6.

Ignition system Accessories (power outlet and auxiliary supply) Solenoids Fan MPEM (Multi-Purpose Electronic Module) Charging system

VMR2001_049_05_02A.FM

Section 05 ELECTRICAL Subsection 02 (OVERVIEW)

IDENTIFICATION OF MAJOR CONNECTOR PINS AMP Connectors of MPEM

F04H6FA

AMP Connectors of Wiring Harness

F04H6GA

VMR2001_049_05_02A.FM

05-02-11

Section 05 ELECTRICAL Subsection 02 (OVERVIEW)

Other Deutsch and Packard Connectors Pin-Out DEUTSCH

A C

A B

C B

B C

B 1 2

A A D

1 2

PACKARD A C

V01G0ES

05-02-12

B FE

A B

C B A

4 3 4 3

1 2

1 2 3

C D

B C

A B

A C

85 87 87a 86 30 A

A D

A CB

6 5 4

1 2 3

1 2 3 4 5 6

6 5 4

A CB

12 11 10 9 8 7

1 2 3 4 5 6

VMR2001_049_05_02A.FM

Section 05 ELECTRICAL Subsection 03 (CHARGING SYSTEM)

CHARGING SYSTEM TESTING PROCEDURE NOTE: First, ensure that battery is in good condition prior to performing the following test using a current inductive ammeter such as Snap-on MT 110. If the battery is regularly discharged, check charging system fuse no. 6 condition. The voltage regulator/rectifier could be the culprit of a blown fuse. To check, simply disconnect the voltage regulator/rectifier from the circuit. If the fuse still burns, check for a defective wire. CAUTION: Do not use a higher rated fuse as this can cause severe damage.

Voltage Regulator/Rectifier STATIC TEST: CONTINUITY 1. Due to internal circuitry, there is no static test available. DYNAMIC TEST

0 NOTE: If it is continually necessary to add distilled water to the battery, this indicates an over voltage situation, requiring replacement of the voltage regulator/rectifier. If, on the other hand, the battery will not stay charged, the problem can be any of the charging circuit components. If these all check good, you would be accurate in assuming the problem to be in the voltage regulator/rectifier. If there is no charging at the battery with the preceding voltage test, the following test can also be performed. Voltage Regulator/Rectifier Output Test Remove the charging system fuse. Connect the negative probe on engine and the positive probe in the charging system fuse location where the value is 0 Vdc. The obtained value in the other location should be 12 Vdc. Place shifter lever on NEUTRAL position and start engine. The obtained value should be between 4 and 7 Vdc.

Current Test Proceed as follows: – Start engine. – Lay an inductive ammeter on positive cable of battery. – Bring engine to approximately 3500 RPM. Depending on battery charge, current reading should be approximately 5 amperes. If not, check magneto output prior to concluding that voltage regulator/rectifier is faulty. Voltage Test Proceed as follows: – Start engine. – Connect a multimeter to battery posts. Set multimeter to Vdc scale. – Bring engine to approximately 5500 RPM. If multimeter reads over 15 volts, voltage regulator/ rectifier is defective. Replace it. NOTE: Whatever the voltmeter type used (peak voltage or RMS), the voltage must not exceed 15 V. A faulty voltage regulator/rectifier will allow voltage to exceed 15 V as engine speed is increased. VMR2001_050_05_03A.FM

V01G0SA

NOTE: If the voltage regulator/rectifier is within the specification, the wiring harness between the voltage regulator/rectifier and battery is defective. If the voltage regulator/rectifier is out of specification and the stator test good, the voltage regulator/ rectifier is defective.

05-03-1

Section 05 ELECTRICAL Subsection 03 (CHARGING SYSTEM)

Stator STATIC TEST: CONTINUITY 1. Disconnect the magneto wiring harness connector. Connect the 6-pin magneto test harness (P/N 295 000 136) on the engine connector. With a good multimeter (preferably a digital one), place the 2 meter test probes onto the stator wire leads AC-1 and AC-2 of the stator. The resistance should be 0.4 â&#x201E;Ś Âą 0.1.

F01H4WA

YL YL YL BK BK-YL YL-WH

STATIC TEST: INSULATION With the stator leads disconnected, insert either meter test probe onto AC-1 and ground the other meter test probe to the engine or the stator iron core and note the reading. There should be no continuity (infinity) between the stator insulated coils and ground. If there is a reading, the stator coils and/or the wiring from the coils is grounded and needs to be replaced/repaired respectively.

YL YL YL BK BK-YL YL-WH F01H4YA

TYPICAL

2. Place either meter test probe into the remaining stator lead (AC-3) and note the resistance (same as step no. 1). If the readings are out of specification, the stator will need to be replaced.

DYNAMIC TEST 1. Unplug magneto connector at engine. 2. Connect the 6-pin magneto test harness (P/N 295 000 136) between the unplugged connectors. 3. Connect test probes of the multimeter to two of the YELLOW wires of the 6-pin magneto harness adapter. 4. Set multimeter to Vac scale. 5. Start and rev engine. The obtained value should be between 10 and 12 Vac. 6. If the stator is out of specification, replace it.

YL YL YL BK BK-YL YL-WH F01H4XA

TYPICAL

05-03-2

VMR2001_050_05_03A.FM

Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM)

STARTING SYSTEM

BATTERY TROUBLESHOOTING 1 SYMPTOM: DISCHARGED OR WEAK BATTERY CAUSE

REMEDY

1. Battery posts and/or cable terminal oxidized.

Clean and coat with dielectric grease.

2. Loose or bad connections.

Check wiring and connector cleanliness, damaged or short circuit.

3. Faulty battery (sulfated, doesn’t keep a full charge, damaged casing, loose rectifier). 4. Charging system fuse burnt or faulty voltage regulator/rectifier.* 5. Faulty charging system generator coil.*

Replace.

First check charging system generator coil. If it is in good condition replace fuse or rectifier. Replace.

* To test charging system, refer to CHARGING SYSTEM.

BATTERY TESTING There are 2 types of battery tests: unloaded and loaded. An unloaded test is made on a battery without discharging current. It is the simplest and commonly used. However, be aware that the voltage test can be good while the battery has not enough power to start the engine. A load test gives more accuracy of the battery condition.

Unload Test Check charge condition using either a hydrometer or a multimeter. With a multimeter, voltage readings appear instantly to show the state of charge. Always respect polarity. A fully charged battery will have a reading of 12.6 Vdc. A hydrometer more accurately measures the charge of a battery in terms of specific gravity of the electrolyte. A fully charged battery will have a specific gravity between 1.265 to 1.280.

VMR2001_051_05_04A.FM

A17E0JA

TYPICAL 1. Specific gravity 1.265

A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte. Most hydrometers give a true reading at 21°C (70°F). In order to obtain correct readings, adjust the initial reading by adding .004 points to the hydrometer readings for each 5.5°C (10°F) above 21°C (70°F) and by subtracting .004 point for every 5.5°C (10°F) below 21°C (70°F). This chart will be useful to find the correct reading. ELECTROLYTE TEMPERATURE

OPERATION TO PERFORM

°C

°F

100

.004

correct reading

.004

.012 add

.008

.008 subtract

.012

-1

.016

to the reading

from the reading

EXAMPLE NO. 1

EXAMPLE NO. 2

Temperature below 21°C (70°F): Hydrometer reading: 1.250 Electrolyte temperature: - 1°C (30°F) Subtract .016 Sp. Gr. Corrected Sp. Gr. is 1.234

Temperature above 21°C (70°F): Hydrometer reading: 1.235 Electrolyte temperature: 38°C (100°F) Add .012 Sp. Gr. Corrected Sp. Gr. is 1.247

05-04-1

Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM)

Load Test

INSPECTION

This is the best test of battery condition under a starting load. Use a load testing device that has an adjustable load. Apply a load of 3 times the ampere-hour rating of the battery. At 14 seconds into the test, check battery voltage; if battery is in good condition, it will have at least 10.5 Vdc.

Visually inspect battery casing for cracks or other possible damage. If casing is damaged, replace battery and thoroughly clean battery rack with water and baking soda.

REMOVAL Remove seat. Disconnect negative BLACK cable first then positive cable.

 WARNING Always respect this order for disassembly; disconnect BLACK negative cable first. Electrolyte or fuel vapors can be present in engine compartment and a spark may ignite them and possibly cause personal injuries. Remove the holding straps. Pull out vent tube from frame. Remove battery from vehicle being careful not to tilt it so that electrolyte flows out of vent tube.

 WARNING Electrolyte is poisonous and dangerous. Avoid contact with eyes, skin and clothing. Wear protective eyeglasses and a suitable pair of nonabsorbent gloves when removing the battery by hand. CAUTION: Should any electrolyte spillage occur, immediately wash off with a solution of baking soda and water.

CLEANING

 WARNING Electrolyte is poisonous, dangerous and explosive. It contains sulfuric acid and can cause severe burns. Avoid contact with eyes, skin and clothing. Clean the battery casing, caps, cables and battery posts using a solution of baking soda and water. Remove corrosion (if so) from battery cable terminals and battery posts using a firm wire brush. Rinse with clear water and dry well. 05-04-2

 WARNING Should the battery casing be damaged, wear a suitable pair of non-absorbent gloves when removing the battery by hand. Inspect battery rack mounting. Inspect battery posts for security of mounting. Inspect for cracked or damaged battery caps, replace defective caps.

 WARNING Battery caps do not have vent holes. Make sure that vent tube is not obstructed.

BATTERY STORAGE Disconnect and remove battery from the vehicle (see above). Check electrolyte level in each cell, add distilled water up to upper level line. CAUTION: Do not overfill. The battery must always be stored in fully charged condition. If required, charge until specific gravity of 1.260 is obtained. CAUTION: Battery electrolyte temperature must not exceed 50°C (122°F). The casing should not feel hot. Clean battery terminals and cable connections using a wire brush. Apply a light coat of dielectric grease (P/N 413 701 700) or petroleum jelly on terminals. Clean battery casing and caps using a solution of baking soda and water. Do not allow cleaning solution to enter battery, otherwise it will destroy the electrolyte. Rinse battery with clear water and dry well using a clean cloth. Store battery on a wooden shelf in a cool dry place. Such conditions reduce self-discharging and keep fluid evaporation to a minimum. During the storage period, recheck electrolyte level and specific gravity readings at least every 40 days. As necessary, keep the battery at its upper level line and near full charge as possible (trickle charge). VMR2001_051_05_04A.FM

Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM)

ACTIVATION OF A NEW BATTERY

 WARNING Never charge or boost battery while installed on vehicle. CAUTION: Prior to charging the battery, always remove it from the vehicle to prevent electrolyte spillage. A new battery is factory fresh dry charged. For storage purposes, it is fitted with a temporary sealing tube. Do not remove the sealing tube or loosen battery caps unless activation is desired. In case of accidental premature removal of caps or sealing tube, battery should be given a full charge. Perform the following operations anytime a new battery is to be installed. 1. Remove the sealing tube from the vent elbow. Install vent tube, included in the battery kit, to battery elbow.

 WARNING Failure to remove the sealing tube could result in an explosion.

A17E0HA

5. Readjust the electrolyte level to the UPPER LEVEL line. 6. Connect a 2 A battery charger for 10 to 20 hours.

 WARNING Gases given off by a battery being charged are highly explosive. Always charge in a well ventilated area. Keep battery away from cigarettes or open flames. Always turn battery charger off prior to disconnecting cables. Otherwise a spark will occur and battery might explode. CAUTION: If charging rate raises higher than 2.4 A reduce it immediately. If cell temperature rises higher than 50°C (122°F) (if the casing feels hot) discontinue charging temporarily or reduce the charging rate. 7. Disconnect battery charger. 8. Test battery state of charge. Use a hydrometer. 9. Let battery settle for 1 hour. 10. Allow gas bubbles to escape by lightly shaking battery. 11. Readjust electrolyte level. 12. Reinstall caps and clean any electrolyte spillage using a solution of baking soda and water.

A17E0FA

1. Battery electrolyte

2. Remove caps and fill battery to UPPER LEVEL line with electrolyte (specific gravity: 1.260 at 20°C (68°F)). 3. Allow the battery to stand for 30 minutes MINIMUM so that electrolyte soaks through battery cells. 4. Allow gas bubbles to escape by lightly shaking battery by hand. VMR2001_051_05_04A.FM

A17E0LA

1. Baking soda 05-04-3

Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM)

CAUTION: Do not allow cleaning solution to enter battery interior since it will destroy the electrolyte. NOTE: It is recommended to verify the battery charge once a month. If necessary, fully charge battery.

TIPS FOR CHARGING A USED BATTERY

 WARNING Prior to charging the battery, always remove it from vehicle. For best results, battery should be charged when the electrolyte and the plates are at room temperature. A battery that is cold may not accept current for several hours after charging has begun. Do not charge a frozen battery. If the battery charge is very low, the battery may freeze. If it is suspected to be frozen, keep it in a heated area for about 2 hours before charging.

 WARNING Do not place battery near open flame. The time required to charge a battery will vary depending on some factors such as: – Battery temperature: The charging time is increased as the temperature goes down. The current accepted by a cold battery will remain low. As the battery warms up, it will accept a higher rate of charge. – State of charge: Because the electrolyte is nearly pure water in a completely discharged battery, it cannot accept current as well as electrolyte. This is the reason the battery will not accept current when the charging cycle first begins. As the battery remains on the charger, the current from the charger causes the electrolytic acid content to rise which makes the electrolyte a better conductor and then, the battery will accept a higher charging rate. – Type of charger: Battery chargers vary in the amount of voltage and current that they can supply. Therefore, the time required for the battery to begin accepting measurable current will also vary.

05-04-4

Charging a Very Flat or Completely Discharged Battery Unless this procedure is properly followed, a good battery may be needlessly replaced. – Measure the voltage at the battery posts with an accurate voltmeter. If it is below 10 volts, the battery will accept current at very low rate, in term of milliamperes, because electrolyte is nearly pure water as explained above. It could be some time before the charging rate increases. Such low current flow may not be detectable on some charger ammeters and the battery will seem not to accept any charge. – Exceptionally for this particular case, set the charger to a high rate. NOTE: Some chargers have a polarity protection feature which prevents charging unless the charger leads are connected to the correct battery terminals. A completely discharged battery may not have enough voltage to activate this circuitry, even though the leads are connected properly. This will make it appear that the battery will not accept a charge. Follow the charger manufacturer’s instruction on how to bypass or override this circuitry so that the charger will turn on and charge a low-voltage battery. – Since the battery chargers vary in the amount of voltage and current they provide, the time required for the battery to accept measurable charger current might be up to approximately 10 hours or more. – If the charging current is not up to a measurable amount at the end of about 10 hours, the battery should be replaced. – If the charging current is measurable before the end or at the end of about 10 hours, the battery is good and charging should be completed in the normal manner. – It is recommended that any battery recharged by this procedure be load tested prior to returning it to service.

VMR2001_051_05_04A.FM

Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM)

CHARGING 2 OR MORE BATTERIES AT A TIME Connect all positive battery posts together and use a charger with a capacity (rated) equal to number of battery to be charged.

A17E0PA

TYPICAL 1. Two batteries connected in parallel

INSTALLATION Reinstall battery and fasten making sure to reinstall the vent tube.

î°? WARNING Connect positive RED cable first then negative cable. Always connect RED positive cable first. NOTE: Place the positive RED cable between holding straps and battery.

V01G05A

1. Cable between battery and strap

VMR2001_051_05_04A.FM

05-04-5

Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM)

STARTING SYSTEM TROUBLESHOOTING SYMPTOM

CAUSE

REMEDY

Starter does not turn.

Ignition switch is in the OFF position.

Turn switch in the ON position.

Burnt fuse.

Check solenoid fuse, MPEM fuse and wiring condition.

Transmission is not set on the Park or Neutral.

Set transmission either in Park or Neutral or use the override mode.

Poor contact of battery terminal(s) or ground cable connections.

Clean and tighten terminal(s).

Weak battery.

Recharge battery.

Poor contact or open circuit of: start/stop switch or start button and engine stop switch, ignition switch or starting solenoid.

Check and replace defective part.

STPS (Sub Transmission Position Sensor) is defective.

Check STPS and wiring condition.

MPEM is defective.

Check wiring. Change MPEM.

Engine mechanical problem (ensure that other electric components are good).

Communicate with the Service Representative.

Poor contact of battery terminal(s).

Clean and tighten terminal(s).

Poor battery ground cable connection.

Clean and tighten.

Burnt or poor contact of solenoid switch contact disc.

Replace starting solenoid.

Poor contact of brush.

Straighten commutator and brush or replace electric starter.

Burnt commutator.

Turn commutator in a lathe or replace electric starter.

Worn commutator segments.

Undercut mica or replace electric starter.

Shorted armature.

Replace electric starter.

Weak brush spring tension.

Replace electric starter.

Weak magnet.

Replace electric starter.

Worn bushings.

Replace electric starter.

Weak battery.

Recharge or replace battery.

Worn clutch pinion gear.

Replace electric starter.

Defective clutch.

Replace electric starter.

Poor movement of clutch on splines.

Replace electric starter.

Worn clutch bushing.

Replace electric starter.

Worn ring gear.

Recharge ring gear.

Shorted starting solenoid switch winding.

Replace starter solenoid.

Melted solenoid contacts.

Replace starter solenoid.

Sticking or defective starter clutch.

Lubricate or replace electric starter.

Starter turns; but does not crank the engine.

Starter turns, but overrunning clutch pinion does not mesh with ring gear.

Starter motor keeps running.

05-04-6

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Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM)

STARTING SYSTEM TESTS GENERAL First ensure the problem is not related to engine mechanical components. Try cranking the engine with the rewind starter. If it does not turn, perform the necessary repair. Otherwise, test the starting system. Causes of troubles are not necessarily related to starter but may be due to a burnt fuse (solenoids or MPEM) faulty battery, start/stop switch, ignition switch, start/stop switch, STPS (Sub-Transmission Position Sensor), starting solenoid, electrical cables or connections or the MPEM. Check these components before removing starter. Consult also the Starting System Troubleshooting table above for a general view of possible problems.

Start/Stop Switch All Models except FOOTSHIFT If engine does not turn when pressing the start/ stop button, test the switch as follows. Remove steering cover and unplug the multifunction switch connector. 1

î°? WARNING Short circuiting electric starter is always a danger, therefore disconnect the battery ground cable before carrying out any kind of maintenance on starting system. Do not place tools on battery.

Fuses Make sure the solenoids fuse no. 3 (includes the starting system) and the MPEM fuse no. 5, in the fuse block, are in good condition. If they test good, continue the other tests.

Battery To check battery condition, refer to Battery above. If it tests good, continue the other tests.

V01G0TA

1. Unplug connector 2. RED wiring harness

Using a multimeter, measure the resistance between the following wires. POSITION

WIRE

Switch released Switch depressed and held

RESISTANCE Infinite (0.L)

BLACK and YELLOW

0.4 â&#x201E;Ś max.

Replace switch if defective. If switch tests good, check wiring going to MPEM. If it tests good, continue the other tests.

Ignition Switch A quick test to validate it is working. If the lights turn on in the cluster display just after turning on the key, the ignition switch is good. Otherwise, refer to IGNITION SYSTEM, for testing procedure. If it tests good, continue the other tests.

STPS (Sub-Transmission Position Sensor)

Engine Stop Switch FOOTSHIFT Model If engine does not turn when placing engine stop switch to RUN and pressing the start button, test the engine stop switch as follows. Remove the front facia and unplug the multi-function switch connector.

Ensure the transmission lever is either in PARK or in NEUTRAL. To quickly check the STPS, temporarily bypass it by pressing any brake lever and try to start engine. If engine turned, the STPS can be suspected. Refer to ELECTRIC SHIFT SYSTEM. If it tests good, continue the other tests. VMR2001_051_05_04A.FM

05-04-7

Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM)

Using a multimeter, measure the resistance between the following wires. POSITION

WIRE

Switch to OFF

BLACK and BLACK/WHITE

Switch to RUN

RESISTANCE 1 Ω max. Infinite (0.L)

Replace multi-function switch if defective. If switch tests good, check wiring. If it tests good, continue the other tests.

Start Button FOOTSHIFT Model If engine does not turn when pressing the start button, test the switch as follows. Remove the front facia and unplug the multi-function switch connector. Using a multimeter, measure the resistance between the following wires.

If solenoid does not properly receive current, the MPEM can be suspected. See MPEM below. If voltage is adequate, test the MPEM as follows. Using a 12 V test light, connect its positive wire to the positive post of the battery. Connect the negative wire of the test light to the YELLOW/RED wire connecting to the solenoid. When pressing the start/stop button with the ignition key turned on, the test light must turn on. Otherwise, it indicates a defective MPEM or wiring going to the MPEM. If solenoid receives current, test the solenoid as follows. Disconnect large cables from solenoid. Inspect connections and clean as necessary. Solenoid condition can be checked with an ohmmeter. Install test probes on large connectors of solenoid. Measure resistance when current is applied to small connectors; if it is more than a few ohms, replace solenoid. If solenoid test good, check the electric starter. If starter test good, the MPEM can be suspected. See MPEM below.

POSITION

WIRE

RESISTANCE

Switch released

RED/VIOLET and YELLOW/RED

Infinite (0.L)

Electrical Cables or Connections

0.6 Ω max.

Check all connections, cables and wires. Tighten any loose cables. Replace any chafe wires/cables. If wiring and connectors are good, check the electric starter. See below.

Switch depressed and held

Replace multi-function switch if defective. If switch tests good, check wiring going to electronic module. If it tests good, continue the other tests.

Starting Solenoid NOTE: Solenoid is located on frame, behind fuse block. Ensure the solenoid receives electric current as follows. Using a multimeter, measure the voltage between the following wires when pressing the start/stop button with the ignition key turned on. WIRE COLOR WHITE/RED

CONNECTOR

Position B

On wiring connecting to solenoid

—

Battery ground post (-)

VOLTAGE

Electric Starter NOTE: Starter is located behind LH side panel. Remove LH side panel to give access to the starter. Refer to BODY/FRAME. Using boosting cables, carefully supply current from the battery directly to the starter. Connect the BLACK negative cable first. Then connect the remaining jump cable from the battery then to the starter. If starter now turns ensure the cables/connections from battery to solenoid and to starter are in good condition. If they test good, the MPEM can be suspected. See MPEM below. If starter does not turn, check for mechanical problems in the starter.

12 Vdc BLACK

05-04-8

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Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM)

MPEM When other components have been tested above and are good, the MPEM can be suspected. Ensure wiring and connectors are in good condition prior to replacing the MPEM.

ELECTRIC STARTER REMOVAL Turn OFF ignition switch. Disconnect BLACK cable ground connection from battery.

 WARNING Always disconnect ground cable first and reconnect last. Disconnect RED cable connection from battery. Clean starter area. Remove LH side panel. Refer to BODY/FRAME. Remove starter mount screws. Pull starter out.

INSTALLATION Installation is essentially the reverse of removal procedure. However, pay particular attention to the following. Make sure that starter and engine mating surfaces are free of debris. Serious trouble may arise if starter is not properly aligned. Properly torque starter screws. Connect the RED battery cable to the starter and torque nut to 6 N•m (53 lbf•in). Apply dielectric grease on terminal and nut. First connect RED cable to battery then connect the BLACK cable.

 WARNING Always connect RED positive cable first then BLACK negative cable last. Whenever connecting the RED positive cable to the starter motor make sure the battery cables are disconnected to prevent electric shock. Test starter operation.

VMR2001_051_05_04A.FM

05-04-9

Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM)

IGNITION SYSTEM IGNITION SYSTEM TESTING PROCEDURE GENERAL Ignition Problems When dealing with ignition problems, the following items should be checked in this order. After one item has been checked and it is found not to be the problem, continue with the next item. 1. Ignition and MPEM (Multi-Purpose Electronic Module) fuses condition. 2. Spark occurrence. 3. Battery condition. 4. Ignition switch. 5. Trigger coil. 6. Ignition coil. 7. MPEM.

Intermittent Ignition Problems In dealing with intermittent problems there is no easy diagnosis. For example, problems that occur only at normal engine operating temperature have to be tested under similar conditions. In most cases of temperature and/or vibration failure, only parts replacement might solve the problem as most of these failures return to normal when engine is not running.

Multiple Problems There is always the possibility of more than one faulty part. If after a component has been replaced, the problem still persists, carefully repeat the complete test procedure to find the other faulty part.

0 IGNITION SYSTEM TEST Safety Precautions

î°? WARNING To prevent powerful electric shocks while cranking engine, neither touch any electronic ignition components (ignition coil, high tension wire, wire harness, etc.) nor tester lead clips. Also make sure that tester leads do not touch any metallic object.

Ignition and MPEM Fuse Condition Check ignition fuse no. 1 and MPEM fuse no. 5 condition. Replace burnt fuse as necessary.

Spark Occurrence Remove one spark plug and connect to its cable. While holding the spark plug against a metallic part of the engine, start the engine. Look for a spark at the spark plug tip. Proceed the same with the other spark plug. Replace defective spark plug. NOTE: If a spark plug is found defective, replace both spark plugs at the same time. Both spark plugs must be checked individually. If one works and the other isnâ&#x20AC;&#x2122;t, try another spark plug. Keep in mind that a spark plug might test good this way while not being able to work properly under combustion chamber mixture and pressure. If known good spark plug(s) do(does) not work, continue the other tests. NOTE: Spark occurrence can be checked with a tester such as Superex Canada Ltd P/N 15-785 or the equivalent.

Battery Condition A battery must be present in the vehicle to allow the ignition system to work. Also, at least 8 V is required at the MPEM for proper operation. Check battery voltage.

VMR2001_052_05_05A.FM

05-05-1

Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM)

Ignition Switch A quick test to validate it is working. If the lights turn on in the cluster display just after turning on the key, the ignition switch is good. Test Ensure the MPEM fuse no. 5 is in good condition. Disconnect ignition switch. Measure voltage between RED/GREEN supply wire and the battery ground. If voltage is lower than battery voltage, test the wiring. If voltage is good, test switch.

V01G0VA

Replace switch if defective. If switch is good, test wiring going to MPEM. If it tests good continue the other tests.

Trigger Coil IMPORTANT: If wires of trigger coil are inverted, no spark will take place. Ensure BLACK / YELLOW wire is in cavity E of connector. The trigger coil is not adjustable. V01G0UA

Use a multimeter and measure the resistance between the following wires. POSITION

WIRE

RESISTANCE

OFF

RED/GREEN and RED/YELLOW

Infinite (0.L)

OFF

RED/GREEN and RED/VIOLET

Infinite (0.L)

ON (w/lights)

RED/GREEN and RED/VIOLET

0.1 Ω max.

ON (w/o lights)

RED/GREEN and RED/YELLOW

0.1 Ω max.

05-05-2

STATIC TEST: CONTINUITY Check resistance with a high-sensitivity ohmmeter. 1. Disconnect the Deutsch 6-pin connector at engine. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136).

F01B28A

3. Connect one of the multimeter leads to the WHITE/YELLOW wire of the 6-pin magneto harness adapter. 4. Connect the other multimeter lead to the BLACK wire of the 6-pin magneto harness adapter. 5. Measure resistance; it should be between 190 - 300 ohms.

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Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM)

Ignition Coil 2 2 4

V01G0WA

1. 2. 3. 4.

Multimeter 6-pin magneto harness adapter WHITE wire BLACK wire

DYNAMIC TEST 1. Disconnect magneto wiring harness connector. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136). 3. Connect one of the multimeter leads to the WHITE/YELLOW wire of the 6-pin magneto harness adapter. 4. Connect the other multimeter lead to the BLACK/ YELLOW wire of the 6-pin magneto harness adapter. 5. Remove the ignition fuse and press START/STOP button, note result. The obtained value should be between 0.4 and 0.7 Vac. 6. If the trigger coil is out of specification, replace it. If it tests good continue the other tests.

Ignition Coil NOTE: An ignition coil with good resistance measurement can still be faulty. Voltage leak can occur at high voltage level which is not detectable with an ohmmeter. Replacing the ignition coil may be necessary as a test.

VMR2001_052_05_05A.FM

V01G0XA

IGNITION COIL 1. Primary side 2. Secondary side

Primary Winding Disconnect the wire connector on the primary side of the ignition coil. Using a multimeter, check the resistance between the terminals 1 and 2. Repeat a resistance test between terminals 2 and 3. The resistance should be between 0.4 and 0.9 Ω at 20°C (68°F). If not within specification, replace the ignition coil. If the ignition coil test good, check the power supply on the primary side. There should be 12 Vdc between the RED/YELLOW and BLACK/GREEN wires or between the RED/ YELLOW and GREEN wires while starting the engine. If there is no voltage, either the MPEM or the wiring harness is defective. Secondary Winding Due to the integrated diode, it is not possible to take any resistance measurement.

05-05-3

Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM)

The output voltage should not be less than 12 kV (12 000 V). The ignition coil outlet caps and the spark plug caps include a resistance. They should be checked prior to replacing a suspected ignition coil. Measure resistance between ignition coil outlet caps and spark plug caps. The obtained value should be between 5.4 and 5.7 Kâ&#x201E;Ś. If resistance is good, continue check. If not, change spark plug wires. DYNAMIC TEST An ignition coil tester available from after-market tool/equipment suppliers can be used. CAUTION: Do NOT use coil tester on metal work bench. Follow manufacturer instructions. If the ignition coil is out of specification, replace it. If it tests good ensure the wiring and connectors are in good condition then continue the other tests.

MPEM When every other components above have been tested and are good, the MPEM can be suspected. Ensure wiring and connectors are in good condition prior to replacing the MPEM.

OTHER IGNITION SYSTEM PROBLEMS If engine does not stop when pressing the start/ stop button, refer to STARTING SYSTEM for testing procedure. If switch is good, test wiring going to MPEM. If it tests good the MPEM may be suspected. Try another one. Refer to INSTRUMENTS AND ACCESSORIES.

IGNITION TIMING It is impossible to check the ignition timing with a timing lamp because there is no access window or mark. The MPEM adjust the timing automatically and the mechanics can not verify and adjust the ignition timing.

05-05-4

VMR2001_052_05_05A.FM

Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM)

SPARK PLUG DISASSEMBLY First unscrew the spark plug one turn. Clean the spark plug and cylinder head with pressurized air then completely unscrew.

FOULING

HEAT RANGE The proper heat range of the spark plugs is determined by the spark plugs ability to dissipate the heat generated by combustion. The longer the heat path between the electrode tip to the plug shell, the hotter the spark plug operating temperature will be and inversely, the shorter the heat path, the colder the operating temperature will be. A “cold” type plug has a relatively short insulator nose and transfers heat very rapidly into the cylinder head. Such a plug is used in heavy duty or continuous high speed operation to avoid overheating. The “hot” type plug has a longer insulator nose and transfers heat more slowly away from its firing end. It runs hotter and burns off combustion deposits which might tend to foul the plug during prolonged idle or low speed operation.

A too “hot” plug will result in overheating preignition, etc. A too “cold” plug will result in fouling (shorting the spark plug) or may create carbon build up which can heat up red-hot and cause pre-ignition or detonation.

Fouling of the spark plug is indicated by irregular running of the engine, decreased engine speed due to misfiring, reduced performance, and increased fuel consumption. This is due to a loss of compression. Other possible causes are: prolonged idling or low-speed riding, or running on a too rich mixture due to abuse of choke, a clogged air filter, a faulty carburetor adjustment, incorrect fuel, defective ignition system, incorrect ignition timing, incorrect spark plug gap, lubricating oil entering the combustion chamber, or too cold spark plug. The plug face of a fouled spark plug has either a wet black deposit or a black carbon fouling. Such coatings form a conductive connection between the center electrode and ground.

SPARK PLUG ANALYSIS

A00E0AA

TYPICAL 1. Overheated (light grey, white) 2. Normal (light brown, brown) 3. Fouled (black, wet or dry, dark deposits, grey, melted coating)

A00E09A

TYPICAL 1. Cold 2. Hot

The plug face reveals the condition of the engine, operating condition, method of driving and fuel mixture. For this reason it is advisable to inspect the spark plug at regular intervals, examining the plug face (i.e. the part of the plug projecting into the combustion chamber).

CAUTION: Severe engine damage might occur or major plastic parts might melt if a wrong heat range plug is used.

VMR2001_052_05_05A.FM

05-05-5

Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM)

SPARK PLUG INSTALLATION Prior to installation make sure that contact surfaces of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap according to the following chart. 2. Apply anti-seize lubricant over the spark plug threads to prevent possible seizure. 3. Hand screw spark plug into cylinder head and tighten with a torque wrench and a proper socket.

A00E0BA

1. Proper socket 2. Improper socket

4. Torque spark plug to 22 N•m (16 lbf•ft).

05-05-6

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Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM)

NGK SPARK PLUG SYMBOL EXPLANATION WIDE GAP

SUFFIX

PREFIX

B P 5 E S Thread diameter

A: B: C: D: E: J:

18 mm

10 mm

12 mm x 19 mm Reach

Compact Type

Projected Insulator Type

Hot

12 mm 8 mm

Resistor Type

5 6

19 mm (3/4")

Special Design

Taper Seat

Single Ground Special Alloy

12.7 mm (1/2")

Dual Ground Special Alloy

11.2 mm (7/16")

Racing Type

21 mm (53/54")

GV:

Blank 8

18 mm ø 12 mm (31/64")

14 mm ø 9.5 mm (3/8")

Surface Discharge Inductive Suppressor Type

Firing end construction

Reach

14 mm

Construction

R: U:

Heat rating numbers 2

10: 1.0 mm (.040") 11: 1.1 mm (.044") 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080")

Racing Version of V-Type

Half Heat Range

Standard Center Electrode

Fine Wire Center Electrode

Booster Gap

V-Grooved Center Electrode

Cold

F02H08S

CROSSCUTS AND GAP STYLES OF SPARK PLUGS

A01E1PS

Standard Type

VMR2001_052_05_05A.FM

Projected Insulator Type

Taper Seat Type

V-Type

Surface Discharge Type

05-05-7

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

ELECTRIC SHIFT SYSTEM

GENERAL All Models except FOOTSHIFT The electric shift system controls several valves/solenoids that control the shifting and also allow an adjustment to the clutch pressure to modify the gear change. It is possible to calibrate the clutch for the hardness or smoothness of shifting action. This calibration is to be used when the clutch engagement is slippery or is too hard. If a new GBPS (Gear Box Position Sensor) and STPS (Sub-Transmission Position Sensor) is installed, calibration is necessary. The MPEM (Multi-Purpose Electronic Module) adjust values with the new specifications of new components installed. NOTE: On AUTOMATIC model, there is a TPS (Throttle Position Sensor) and this calibration is necessary if it is changed. The diagnostic/calibration mode preserves in memory the previous problems. The reset option erases the codes registered in memory. Refer to the following text for specific procedures. FOOTSHIFT Model The FOOTSHIFT model uses an electric and mechanical shift system. The electric shift system controls the clutching valve that controls the clutch disengagement. A clutch activation switch sends a signal to active the clutch valve when the mechanical shift system is activated. Note that the diagnostic/calibration mode is not used with the FOOTSHIFT model.

TROUBLESHOOTING Problem with the shifting system, refer to the annexes 1 and 2.

DIAGNOSTIC/CALIBRATION MODE All Models except FOOTSHIFT The diagnostic/calibration mode of the MPEM is used to display light-coded signals to indicate problems mainly in the shifting system and in the MPEM. When in operation, the MPEM continuously monitors the system. When needed, we can enable the diagnostic/calibration mode to check the system condition. The MPEM can detect the following problems: – short circuits of external components – internal MPEM problems – electric current overload. The diagnostic/calibration mode is also used to: – calibrate clutch modulation – calibrate sensors when replacing them.

VMR2001_053_05_06A.FM

05-06-1

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

PREPARATION Before going into the diagnostic/calibration mode, the ignition switch needs to be on position OFF, the transmission in FIRST gear and shifter lever on NEUTRAL position.

V01A12S

To set the MPEM into the diagnostic/calibration mode, the following sequence needs to be done: â&#x20AC;&#x201C; Place a diagnostic jumper (P/N 529 035 605) in the diagnostic connector.

NOTE: On the XL model, the diagnostic connector is located under rear cargo box on the LH side of rear frame extension. For the other models, the diagnostic connector is located on the LH side of rear extension frame. On the FOOTSHIFT model, the diagnostic connector is installed but it is used only at the factory. 1

V01B0MA

DIAGNOSTIC JUMPER (P/N 529 035 605)

V03G01A

XL MODEL 1. Diagnostic connector

05-06-2

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Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

TESTING The following tasks are performed in this order by the MPEM in the diagnostic/calibration mode: – Task 1: Indicator lights test. – Task 2: Clutch modulator calibration. – Task 3: Sensors and solenoids verification. – Task 4: GBPS (Gear Box Position Sensor) calibration. – Task 5: STPS (Sub-Transmission Position Sensor) calibration. – Task 6: TPS (Throttle Position Sensor) calibration (AUTOMATIC model only). See below for detailed steps. Once each task has been completed, the MPEM goes to the next task if the proper button(s) is(are) not activated after 3 seconds.

1 V01A2VA

ALL OTHER MODELS 1. Diagnostic connector

– Turn ignition switch to ON. Once the MPEM detects the diagnostic jumper in diagnostic connector, it sets itself into the diagnostic/ calibration mode. During the diagnostic/calibration mode, the engine is off, all the solenoids are not working, and the accessory output is off. NOTE: At any time, if the jumper is removed during the diagnostic/calibration mode, the MPEM is powered off automatically.

VMR2001_053_05_06A.FM

05-06-3

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

Task 1: Indicator Lights Test This validates all indicator lights are good to allow proper display of the diagnostic codes. All LEDS turn ON. The LED “5” blinks first, through “1” and after the LED “Check Engine” through the LED “Neutral”. If a LED is found defective, replace it prior to continuing the other tests.

V01A0XS

NOTE: On the AUTOSHIFT model, the LED “Auto” should appear between the LED “Hi-Lo beam” and LED “Reverse”.

05-06-4

VMR2001_053_05_06A.FM

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

Task 2: Clutch Modulator Calibration NOTE: When the number 3 of the clutch modulator calibration is selected, an automatic calibration mode is activated. It is possible to change the calibration manually in performing the following instructions but the MPEM looses the feature of automatic calibration mode then. The LED “Check Engine” blinks for a maximum time of 5 seconds or until the user begins the calibration process or removes the jumper.

V01A0YS

The upshift/downshift button is used to change the calibration of the clutch modulator valve. When one of these buttons is activated, the LED “Check Engine” stops to blink and goes ON. The corresponding LEDS are turned ON according to the calibration (See table below). Table 1: Corresponding Clutch Modulation Calibration GEAR LED HARDNESS 1

1+2

SMOOTHNESS 2+3

3+4

4+5

If the upshift/downshift button is not activated during the time the LED “Check Engine” blinks, the MPEM goes to the next task. Run vehicle to verify if the calibration is OK. The jumper needs to be removed and the key turned OFF and back ON before running the vehicle with the new calibration. NOTE: Each time you press the button, it gives a 0.5% change in modulation; this gives a total of 20 possible settings. There are ten (10) settings on each side of the no. 3 LED light. (Indicator lights are used as a point of reference).

VMR2001_053_05_06A.FM

05-06-5

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

Task 3: Sensors and Solenoids Verification The MPEM reads all main power supply outputs during operation of the vehicle. If any abnormality occurs, the MPEM will record the information in a register. The diagnostic components register is displayed with the LED “Hi-Lo beam”. The LED “Reverse” is ON during all the time the MPEM is verifying the diagnostic memory. Each abnormal components is represented by a coded number (see table below) and each code number correspond to the number of blinks that the LED “Hi-Lo bean” is doing. When there are two or more abnormal items, the lowest coded numbered item is first indicated and a delay of 2 seconds separates each following code. When a problem happens, all leds blink in the dashboard to show that there is a problem and will do so until the key switch is turned off. The corresponding register is increased when a problem happen. BLINK

ON V01A13S

Table 2: Abnormality-Diagnosis Components CODE NO.

DIAGNOSIS COMPONENT

LED “REVERSE”

LED “HI-LO BEAM”

LED ON for 3 seconds only

LED OFF

No abnormal components found

Starter solenoid

LED ON

LED blinks 1 time

Clutching valve

LED ON

LED blinks 2 times

Clutch modulator valve

LED ON

LED blinks 3 times

Downshift solenoid

LED ON

LED blinks 4 times

Upshift solenoid

LED ON

LED blinks 5 times

MPEM Memory

LED ON

LED blinks 6 times

Headlight supply

LED ON

LED blinks 7 times

Accessory/speedometer supply

LED ON

LED blinks 8 times

Reference supply output (GBPS, STPS and TPS (on AUTOMATIC model))

LED ON

LED blinks 9 times

05-06-6

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Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

Table 3: Abnormality Conditions CODE NO.

ABNORMALITY CONDITION

ACTION

– Short circuit to battery is detected. – Operating current on the starter output has ex- Refer to STARTING SYSTEM. ceeded the overload threshold.

– Short circuit to battery is detected. Change clutching valve. Refer to VALVE – Operating current on the clutch solenoid output REMOVAL/INSTALLATION section. has exceeded the overload threshold.

– Short circuit to battery is detected. Check clutch modulator valve. Refer to VALVE – Operating current on the clutch modulator valve REMOVAL/INSTALLATION section. output has exceeded the overload threshold.

– Short circuit to battery is detected. Check shifting valve. Refer to VALVE – Operating current on the downshift solenoid REMOVAL/INSTALLATION section. output has exceeded the overload threshold.

– Short circuit to battery is detected. Check shifting valve. Refer to VALVE – Operating current on the upshift solenoid out- REMOVAL/INSTALLATION section. put has exceeded the overload threshold.

– Programmable parameters are corrupted.

Check: – Short circuit to ground is detected ➀. – Wiring condition. – Operating current on the headlight supply out– Headlight. Refer to INSTRUMENTS AND ACput has exceeded ➀ the overload threshold.

Install a new MPEM. Refer to INSTRUMENTS AND ACCESSORIES.

CESSORIES.

Check: – Short circuit to ground is detected. – Wiring condition. – Operating current on the accessory supply out– Speedometer. Refer to INSTRUMENTS AND put has exceeded the overload threshold.

ACCESSORIES. Check: 9

– Short circuit to ground is detected.

– Wiring condition. – STPS, GBPS and TPS (on AUTOMATIC model) sensors. Refer to SENSOR TESTS section.

➀ These abnormality conditions are not detected when the headlight supply output is in dimming mode.

VMR2001_053_05_06A.FM

05-06-7

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

Task 4: GBPS (Gear Box Position Sensor) Calibration The LEDS “1” and “Hi-Lo beam” are ON during a maximum of 5 seconds or until the user sets the calibration. This calibration mode sets the nominal position of sensor. The GBPS calibration is automatically set when the Start/Stop button and the Hi/Lo beam button are activated at the same time.

V01A10S

Task 5: STPS (Sub-Transmission Position Sensor) Calibration The LEDS “Neutral” and “Hi-Lo beam” are ON during a maximum of 5 seconds or until the user sets the calibration. This calibration mode sets the nominal position of sensor. The STPS calibration is automatically set when the Start/Stop button and the Hi/Lo beam button are activated at the same time.

V01A11S

05-06-8

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Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

Task 6: TPS (Throttle Position Sensor) Calibration The LEDS “AUTO” and “Hi-Lo beam” are ON during a maximum of 5 seconds or until the user sets the calibration. This calibration mode sets the nominal position of sensor. The TPS calibration is automatically set when the Start/Stop button and the Hi/Lo beam button are activated at the same time.

V01A2XS

The MPEM waits 3 seconds before exiting the diagnostic/calibration mode and switch off. The jumper needs to be removed and the ignition switch turned OFF and back ON before running the vehicle with the new calibration. NOTE: If after resetting a sensor, the 2 appropriate lights start to flash, this indicates that the reading received by the MPEM is out of the preset range. Be sure you are in the 1st gear and NEUTRAL and the throttle is set at the idle position. If those items are correct, check the wiring and connections. If those are good replace the sender.

VMR2001_053_05_06A.FM

05-06-9

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

Resetting the Diagnostic Components Register Before resetting the diagnostic components registers, the MPEM needs to be in the diagnostic/calibration mode. The register is automatically reset when the following sequence is performed: – The jumper on the diagnostic connector is removed while the START/STOP button is activated. The MPEM will reset the register (see table ABNORMALITY-DIAGNOSIS COMPONENTS and table ABNORMALITY CONDITIONS) and after it will turn off itself. Table 4: Summary of all Tasks TASK 1. INDICATOR LIGHTS TEST 2. CLUTCH MODULATOR CALIBRATION 3. SENSORS AND SOLENOIDS TEST 4. GBPS CALIBRATION

LED “5” blinks first, through “1” and after “Check Engine” through “Neutral” “Check Engine” blinks “Reverse” is ON “Hi-Lo Beam” blinks “1” and “Hi-Lo Beam” are ON

OPERATION This validates all indicator lights are good.

Press

button.

Do not press any button. Each code number correspond to the number of blinks that the “Hi-Lo Beam” is doing. Simultaneously, press

and

buttons.

5. STPS CALIBRATION

“Neutral” and “Hi-Lo Beam” Simultaneously, press are ON

and

buttons.

6. TPS CALIBRATION

“AUTO” and “Hi-Lo Beam” are ON

and

buttons.

RESET REGISTERS

N.A.

Simultaneously, press Press and hold the

button while removing the

diagnostic jumper. This must be performed before the diagnostic mode shuts down.

N.A.: Not Applicable.

05-06-10

VMR2001_053_05_06A.FM

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

VALVE REMOVAL/ INSTALLATION

Test

CAUTION: It is recommended to always disconnect the battery when replacing any electric or electronic part(s).

Removal

Refer to VALVES/SOLENOIDS TESTS section.

SHIFTING VALVE

Remove seat. Unplug connector. 1

All Models except FOOTSHIFT The upshift/downshift solenoids are installed on shifting valve. This valve is located on the rear part of engine. 2

V01J03C

1. Upshift/downshift solenoid connector

Remove screws on top of shifting valve. Pull shifting valve.

Installation For the installation, reverse the removal procedure, paying attention to the following details: – Install a new gasket. – Apply Loctite 243 on threads and torque to 5 N•m (44 lbf•in). V01C2KA

TYPICAL 1. Shifting valve 2. Upshift solenoid 3. Downshift solenoid

VMR2001_053_05_06A.FM

05-06-11

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

CLUTCHING VALVE

All Models The clutching valve is located on front of engine. 1

V01G0RA

TYPICAL 1. Unplug this connector

V01C2LA

TYPICAL — ALL MODELS 1. Clutching valve 2. STPS (Sub-Transmission Position Sensor) 3. Cable clip

Test Refer to VALVES/SOLENOIDS TEST section.

Removal Remove fuel tank cover. Refer to BODY. Unplug connector on seat pivot bar.

05-06-12

Remove seat pivot bar. Remove cable clip from oil duct cover. Separate wires from Deutsch connector. Unplug STPS (Sub-Transmission Position Sensor). Remove screw retaining clutching valve. Pull clutching valve. Use a pair of pliers and a flat screwdriver.

Installation For the installation, reverse the removal procedure, paying attention to the following details: – Apply engine oil on O-rings. – Insert clutching valve in place. – Tap clutching valve gently with a rubber hammer. – Apply Loctite 243 on threads and torque screws to 3 N•m (27 lbf•in).

VMR2001_053_05_06A.FM

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

CLUTCH MODULATOR VALVE All Models except FOOTSHIFT The clutch modulator valve is located in front of engine.

– Tap clutch modulator valve gently with rubber hammer. – Apply Loctite 243 on threads and torque screws to 3 N•m (27 lbf•in).

CLUTCH ACTIVATION SWITCH FOOTSHIFT Model

V01C2LB

TYPICAL 1. Clutch modulator valve

Test Refer to VALVES/SOLENOIDS TESTS section.

Removal Remove fuel tank cover. Refer to BODY. Unplug connector on seat pivot bar. Remove seat pivot bar. Remove cable clip from engine. Separate wires from Deutsch connector. Remove screw retaining clutch modulator valve. Pull clutch modulator valve. Use a pair of pliers and flat screwdriver.

Installation For the installation, reverse the removal procedure, paying attention to the following details: – Apply engine oil on O-rings. – Insert clutch modulator valve in place.

VMR2001_053_05_06A.FM

V01C2MA

1. Clutch activation switch

Test Unplug and remove the clutch activation switch. Using an multimeter, measure the resistance between both wire. CLUTCH ACTIVATION SWITCH RESISTANCE Switch depressed

O.L.

Switch pressed

0.1 to 0.5 Ω

If the resistance is out of specification, change the switch.

Removal Unplug the connector. Unscrew the clutch activation switch.

Installation For the installation, reverse the removal procedure.

05-06-13

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

SENSOR REMOVAL/ INSTALLATION

Installation

All Models The STPS is located on front of engine.

For installation, reverse the removal procedure. Pay attention to the following details: – Check O-ring and change if necessary. – Align interior of GBPS and engine shaft. – Place connector on top. Secure with screws and lock washers. Apply Loctite 243 on threads. – Torque screws to 3 N•m (27 lbf•in). – Calibrate GBPS. Refer to DIAGNOSTIC/ CALIBRATION MODE section, task 4.

Test

VSS (Vehicle Speed Sensor)

Refer to SENSORS TESTS section.

All Models The VSS is located on front of engine.

CAUTION: It is recommended to always disconnect the battery when replacing any electric or electronic part(s).

STPS (Sub-Transmission Position Sensor)

Removal Remove fuel tank cover. Refer to BODY. Remove seat pivot bar. Unplug STPS. Remove screws and lock washers retaining STPS on engine. Pull STPS.

Installation For installation, reverse the removal procedure. Pay attention to the following details: – Check O-ring and change if necessary. – Align interior of the STPS and engine shaft. – Place connector on top. Secure with screws and lock washers. Apply Loctite 243 on threads. – Torque screws to 3 N•m (27 lbf•in). – Calibrate STPS. Refer to DIAGNOSTIC/ CALIBRATION MODE section, task 5.

Test Refer to SENSORS TESTS section.

Removal Remove skid plate under vehicle. Refer to BODY. Remove engine oil. Refer to MAINTENANCE/ LUBRICATION. Unplug VSS. Remove engine bolt under VSS.

GBPS (Gear Box Position Sensor) All Models except FOOTSHIFT The GBPS is located on rear of engine.

Test Refer to SENSORS TESTS section.

Removal Unplug GBPS. Remove screws and reinforcements. Pull GBPS. 05-06-14

V01C2LC

TYPICAL 1. Remove this bolt in first

VMR2001_053_05_06A.FM

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

Remove bolt retaining VSS. Pull VSS out of engine.

Installation For installation, reverse the removal procedure. Pay attention to the following detail: – Check O-ring and change if necessary. – Install VSS and secure with screw. Torque to 9 N•m (80 lbf•in). NOTE: Don’t apply Loctite on threads. – Install engine bolt. Torque to 9 N•m (80 lbf•in). – Refill engine with oil. Refer to MAINTENANCE/ LUBRICATION.

TPS (THROTTLE POSITION SENSOR) AUTOMATIC Model Only

Removal Unplug the TPS connector. Remove the screws retaining the TPS to the carburetor.

Installation For the installation, reverse the removal procedure. NOTE: Align the TPS recess with the notch in the carburetor.

VALVES/SOLENOIDS TESTS CLUTCHING VALVE AND CLUTCH MODULATOR VALVE TESTS CAUTION: It is recommended to always disconnect the battery when replacing any electric or electronic part(s). Always place the transmission on NEUTRAL position and select FIRST gear.

 WARNING Apply parking device. Place vehicle on level surface. Install vehicle on jack stands to raise all four tires off the ground. Unplug clutching and clutch modulator valve connector. VMR2001_053_05_06A.FM

Plug tester (P/N 529 035 653). Start engine. Place transmission on HI or LO position and select SECOND or THIRD gear to permit upshift and downshift selection. Rev engine (about 2500 RPM) and push upshift button. If GREEN and BLUE indicator lights blink when button is pushed, clutching valve and clutch modulator valve are operational. If GREEN indicator light blinks when button is pushed, clutching valve is operational and clutch modulator valve can be defective. Check the following details: – Check wiring condition of clutch modulator valve. – Check upshift/downshift switch, refer to UPSHIFT/ DOWNSHIFT BUTTON TESTS section. – Install a new clutch modulator valve. Refer to VALVES REMOVAL/INSTALLATION section. – Check AMP connectors on MPEM. Refer to OVERVIEW. – Install a new MPEM. Refer to INSTRUMENTS AND ACCESSORIES. If BLUE indicator light blinks when button is pushed, clutch modulator valve is operational and clutching valve can be defective. Check the following details: – Check wiring condition from clutching valve. – Check upshift/downshift switch, refer to UPSHIFT/ DOWNSHIFT BUTTON TESTS section. – Install a new clutching valve. Refer to VALVES REMOVAL/INSTALLATION section. – Check AMP connectors on MPEM. Refer to OVERVIEW. – Install a new MPEM. Refer to INSTRUMENTS AND ACCESSORIES. If no indicator light blinks when button is pushed: – Check fuse. – Check wiring condition. – Check upshift/downshift switch, refer to UPSHIFT/ DOWNSHIFT BUTTON TESTS section. – Install a new clutching valve and a new clutch modulator valve. Refer to VALVES REMOVAL/ INSTALLATION section. – Check AMP connectors on MPEM. Refer to OVERVIEW.

05-06-15

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

– Install a new MPEM. Refer to INSTRUMENTS AND ACCESSORIES.

UPSHIFT/DOWNSHIFT SOLENOIDS TESTS Unplug shifting valve connector. Connect tester. Start engine. Place transmission on NEUTRAL position and select SECOND or THIRD gear. Push upshift/downshift button. If GREEN and BLUE indicator light blink when button is pushed, the solenoids are good. If GREEN or BLUE indicator light doesn’t blink when button is pushed: – Check wiring condition. – Check upshift/downshift switch, refer to UPSHIFT/ DOWNSHIFT BUTTON TESTS section. – Install a new shifting valve, refer to VALVES REMOVAL/INSTALLATION section. – Check AMP connectors on MPEM. Refer to OVERVIEW. – Install a new MPEM. Refer to INSTRUMENTS AND ACCESSORIES. If no indicator light blinks when button is pushed on upshift or downshift position: – Check fuse. – Check wiring condition. – Check upshift/downshift switch, refer to UPSHIFT/ DOWNSHIFT BUTTON TESTS section. – Install a new shifting valve, refer to VALVES REMOVAL/INSTALLATION section. – Check AMP connectors on MPEM. Refer to OVERVIEW. – Install a new MPEM. Refer to INSTRUMENTS AND ACCESSORIES.

05-06-16

SENSORS TESTS STPS (Sub-Transmission Position Sensor), GBPS (Gear Box Position Sensor) AND TPS (Throttle Position Sensor) TESTS

 WARNING The reverse speed limiter doesn’t work when STPS is faulty. If STPS, GBPS or TPS sensor blink code is indicated, t he sensor can be defective. Check the following details: SENSOR

LED

STPS

R and N

Blinks

GBPS

1 to 5 (simultaneously)

Blinks

TPS

AUTO

Blink

– Check wiring condition. – Remove sensor and turn inner parts with a finger: • If LEDS work properly, sensor is good. Continue check. • If LEDS don’t work when inner parts are turned, change sensor and calibrate the new sensor, see DIAGNOSTIC/CALIBRATION MODE section, task 4, 5 or 6. – Check AMP connectors on MPEM. Refer to OVERVIEW. – Install a new MPEM. Refer to INSTRUMENTS AND ACCESSORIES. – If the problem persists, mechanical problem is probable. Refer to TRANSMISSION.

VMR2001_053_05_06A.FM

Section 05 ELECTRICAL Subsection 06 (ELECTRIC SHIFT SYSTEM)

VSS (Vehicle Speed Sensor) TESTS If VSS is not working properly, the speedometer will not indicate vehicle speed. Check the following details: – Measure voltage between BLACK/BROWN and PINK wires on speedometer connector under steering cover. Place vehicle on NEUTRAL position, turn ignition switch ON and move vehicle very slowly. The obtained value vary between 0.5 and 8 Vdc. If voltage is good, continue check. If not, change VSS. – Check wiring condition. – Check AMP connectors from MPEM. Refer to OVERVIEW. – Install a new MPEM. Refer to INSTRUMENTS AND ACCESSORIES.

UPSHIFT/DOWNSHIFT SWITCH TESTS UPSHIFT/DOWNSHIFT SWITCH Open multi-function switch box. Using a multimeter, measure resistance between the following wires. POSITION

WIRE

RESISTANCE

UPSHIFT Switch released Switch depressed and held

Infinite (0.L) BLACK and RED

0.4 Ω max.

DOWNSHIFT Switch released Switch depressed and held

Infinite (0.L) BLACK and GREEN

0.4 Ω max.

Replace switch if defective.

VMR2001_053_05_06A.FM

05-06-17

Subsection 07

Section 05 ELECTRICAL (INSTRUMENTS AND ACCESSORIES)

INSTRUMENTS AND ACCESSORIES

REMOVAL AND INSTALLATION CAUTION: It is recommended to always disconnect the battery when replacing any electric or electronic parts.

12-VOLT AUXILIARY POWER OUTLET The 12-volt auxiliary power outlet is located on the LH rear part of the rear extension frame. The wires are hidden inside harness and are protected by heat shrink tubing. The 12-volt auxiliary power outlet allows the installation of additional accessories. NOTE: This is a direct connection, no key is necessary to get the 12 volts.

Test Refer to TESTS section.

12-VOLT POWER OUTLET

V01A02A

1. Remove screws 2. Lift up the sealed beam cover

Installation Properly reinstall removed parts in the reverse order of their removal.

Test

Adjustment

Refer to TESTS section.

Adjust beam aiming as follows: Turn knobs to adjust beam height and side orientation as explained below. Adjust both headlights evenly.

Removal Remove the steering cover. Refer to BODY. Unplug the connectors of the power outlet. Unscrew the retaining nut.

Installation Reverse the removal procedure.

HEADLIGHT Removal Remove screw and lift up the sealed beam cover.

V01A02B

1. Headlight 2. Beam height adjustment 3. Beam side adjustment

VMR2001_054_05_07A.FM

05-07-1

Section 05 ELECTRICAL Subsection 07 (INSTRUMENTS AND ACCESSORIES)

HEADLIGHT BEAM AIMING

Select high intensity. Beam aiming is correct when center of high beam is 131 mm (5 in) below the headlight horizontal center line, scribed on a test surface, 5 m (17 ft) away. NOTE: Sit down the driver or place the same weight on the vehicle. Measure headlight center distance from ground. Scribe a line at this height on test surface (wall or screen). Light beam center should be 131 mm (5 in) below scribed line.

V01L0HA

90°

TYPICAL 1. Lens 2. Screws

IGNITION SWITCH

Test Refer to IGNITION SYSTEM. 90°

Removal

V01I0VA

Lift the steering cover and unscrew the ignition switch nut. NOTE: Do not unplug connectors when steering cover is lifted. Unplug the switch connector.

TYPICAL 1. Headlights center lines 2. Light beam center

90° A

B 1

V01I0UA

TYPICAL 1. Light beam center A. 5 m (17 ft) B. 131 mm (5 in)

Taillight Bulb Replacement Unscrew lens screws to expose bulb. Push bulb in and hold while turning courterclockwise to release. Install the new bulb by first pushing in while turning clockwise.

05-07-2

V01G0CA

1. Switch connector

Installation For the installation, reverse the removal procedure.

VMR2001_054_05_07A.FM

Subsection 07

Section 05 ELECTRICAL (INSTRUMENTS AND ACCESSORIES)

INDICATOR LIGHTS

Installation

Test

For the installation, reverse the removal procedure.

Refer to TESTS section.

SPEEDOMETER (if so equipped)

Removal

Test

Remove the steering cover. Refer to BODY. NOTE: Do not unplugged all connectors. Lift up the steering cover and unplug the indicator lights connector(s) only. Press locking tabs on each side of the indicator lights and push the indicator lights outside.

Refer to TESTS section.

Removal Remove the steering cover. Refer to BODY. Remove the two nuts under speedometer and unplug the connector. 1

Installation For the installation, reverse the removal procedure.

MPEM Test Refer to specific system (ignition system, etc.) for testing procedures.

Removal Remove fuel tank. NOTE: Itâ&#x20AC;&#x2122;s not necessary to remove fuel tank completely, lean toward engine only. Unplug AMP connectors. Remove the screws on the top of MPEM. Slide MPEM to right side.

V01G06A

1. Remove the two nuts 2. Unplug the connector

V01G0FA

VMR2001_054_05_07A.FM

05-07-3

Section 05 ELECTRICAL Subsection 07 (INSTRUMENTS AND ACCESSORIES)

Speedometer Bulbs Replacement

WINCH

Each bulb can be replaced individually. Proceed as follows: Using a small screwdriver, pry cap out to expose bulb socket.

XT Model

Removal Disconnect, at the battery, the negative BLACK cable first then positive cable.

V01I0EA

1. Speedometer 2. Pry cap out

Insert a small screwdriver in socket slot and turn counterclockwise until stopped. Use small long nose pliers to pull bulb out or carefully pry out using a small screwdriver.

Disconnect the winch power cables. NOTE: Identify the position of the power cables for the installation. Remove: – fairlead – front skid plate – lower bolts retaining the front bumper – upper frame bolts. Loose the top bolts that are attached to the rack. Swing out the whole bumper. Remove the lower winch bolts. Remove winch.

Installation For the installation, reverse the removal procedure. 1

WINCH CONTROL SWITCH XT Model

Test Refer to TESTS section.

Removal

V01I0DA

1. Pull bulb out

Reinstall new bulb using long nose pliers. Turn bulb socket clockwise to lock.

Installation

Remove screws retaining winch control switch to fender. Disconnect the cables under switch. NOTE: Identify the position of cables for the installation.

Installation For the installation, reverse the removal procedure.

For the installation, reverse the removal procedure.

05-07-4

VMR2001_054_05_07A.FM

Subsection 07

Section 05 ELECTRICAL (INSTRUMENTS AND ACCESSORIES)

TESTS

COOLING FAN OPERATION TEST

12-VOLT AUXILIARY POWER OUTLET

NOTE: No key required. Unplug the temperature sender connectors. Install a jumper wire end in connector. Replace the fan if it does not work.

NOTE: No key required. Using a multimeter, measure the voltage between RED/BLACK and BLACK wires. The obtained value should be between 12 and 14.5 Vdc. – No voltage: • Check fuse no. 2 and wiring condition. – Voltage is good: • Check outer accessory.

12-VOLT POWER OUTLET NOTE: No key required. Remove the steering cover. Unplug the power outlet connectors. Using a multimeter, measure the voltage between RED/BLACK and BLACK wires. The obtained value should be between 12 and 14.5 Vdc. 1

HEADLIGHT Using a multimeter, measure the voltage between GREEN/ORANGE and BLACK wires. Start the engine. The obtained value should be between 12 and 14.5 Vdc. NOTE: In dimming mode, the obtained value should be between 7 and 10 Vdc. – No voltage: • Check wiring condition and HI-LO switch. – Voltage is good: • Change headlights.

HI-LO SWITCH All Models except FOOTSHIFT Using a multimeter, measure the resistance between the following wires. POSITION

WIRE

Switch released Switch depressed and held

RESISTANCE Infinite (0.L)

BLACK and BLUE

0.4 Ω max.

Replace switch if defective.

MULTI-FUNCTION SWITCH

V01G0GB

1. 12-volts power outlet 2. Power outlet connectors

– No voltage: • Check fuse no. 2 and wiring condition. – Voltage is good: • Change power outlet.

FOOTSHIFT Model Using a multimeter, measure the resistance between the following wires. POSITION

WIRE

RESISTANCE

Switch to LO

RED/YELLOW and GREEN

0.6 Ω max.

Switch to HI

RED/YELLOW and BLUE

0.5 Ω max.

Replace switch if defective.

VMR2001_054_05_07A.FM

05-07-5

Section 05 ELECTRICAL Subsection 07 (INSTRUMENTS AND ACCESSORIES)

INDICATOR LIGHTS Remove steering cover. If switch tests good, check wiring condition and MPEM. Unplug indicator light connector.

V01G0HA

V01G0GA

1. Indicator lights connectors

Test each LEDS with two 1.5 V battery (AA), connected in series. – LEDS are good • Check wiring condition. • Check AMP connectors. • Change MPEM. – LEDS are burned • Change indicator lights.

SPEEDOMETER (if so equipped) Using a multimeter, measure the voltage between RED/GREY and BLACK/BROWN wires. Turn ignition switch to ON. The obtained value should be between 12 and 14.5 Vdc.

05-07-6

– No voltage on speedometer: • Check wiring condition and MPEM connector. If good, change MPEM. – Voltage on speedometer: • If VSS voltage is good, change speedometer. • No voltage on VSS. Check VSS and wiring condition from VSS to MPEM.

WINCH CONTROL SWITCH (if so equipped) Remove power cables under winch control switch. NOTE: Identify the position of the power cables for the installation. Use a multimeter on beeper position to check the following items: – Check the continuity between terminal no. 2 and positive (+) terminal when the switch is turned on IN position. – Check the continuity between terminal no. 1 and positive (+) terminal when the switch is turned on OUT position. – Check the continuity between terminal no. 2 and negative (-) terminal when the switch is turned on OUT position. – Check the continuity between terminal no. 1 and negative (-) terminal when the switch is turned on IN position. – Check the continuity between terminal no. 1 and terminal no. 2 when the switch is not turned on any position.

VMR2001_054_05_07A.FM

Subsection 07

Section 05 ELECTRICAL (INSTRUMENTS AND ACCESSORIES)

V01D0QA

Replace switch if defective.

VMR2001_054_05_07A.FM

05-07-7

Section 06 DRIVE TRAIN Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

FRONT DRIVE ........................................................................................................................ 06-02-1 FRONT DRIVE SHAFT ....................................................................................................... 06-02-2 FRONT DIFFERENTIAL ...................................................................................................... 06-02-3 FRONT PROPELLER SHAFT .............................................................................................. 06-02-10 KNUCKLE ........................................................................................................................... 06-02-12 WHEEL BEARING .............................................................................................................. 06-02-12 REAR AXLE ............................................................................................................................ RIGID AXLE AND PROPELLER SHAFT............................................................................. RIGID AXLE ........................................................................................................................ RH AXLE.......................................................................................................................................... LH AXLE ............................................................................................................................. REAR PROPELLER SHAFT................................................................................................. REAR HUB.......................................................................................................................... REAR DIFFERENTIAL ........................................................................................................ REAR DIFFERENTIAL OIL LEVEL ...................................................................................... REAR DIFFERENTIAL OIL REPLACEMENT ................................................................................ REAR DIFFERENTIAL ........................................................................................................

VMR2001_065_06_01ATOC.FM

06-03-1 06-03-1 06-03-2 06-03-3 06-03-3 06-03-4 06-03-4 06-03-5 06-03-6 06-03-6 06-03-6

06-01-1

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE)

FRONT DRIVE

13 12 10

140 N m (103 lbf ft) 11 21 MINIMUM

Synthetic grease 9 4 23 N m (17 lbf ft)

6 67 N m (49 lbf ft)

42 N m (31 lbf ft)

19 20 Synthetic grease

18 17 35 N m (26 lbf ft)

67 N m (49 lbf ft)

3 29 33

30 32 24

23 22 27 26

V01H13S

VMR2001_055_06_02A.FM

PARTS

FLAT RATE

06-02-1

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE)

FRONT DRIVE SHAFT Removal Raise the front of vehicle, support it securely on jack stands and remove front wheel(s). Remove wheel cap no. 13, cotter pin no. 12, castellated nut no. 11, flat washer no. 10 and O-ring no. 21.

Separate knuckle no. 8, with hub and brake disc no. 9, from lower and upper suspension arms. Separate knuckle from the drive shaft no. 7 or no. 14. Pull drive shaft out of differential no. 1. NOTE: Pull drive shaft strongly.

Inspection Inspect the condition of boots. If there is any damage or evidence of leaking lubricant, replace them. Refer to Drive Shaft Boot section.

Installation Apply grease (P/N 293 550 019) to the splines and insert the end of drive shaft in differential and pull joint a little to make sure that the stop ring is locked in differential side gear groove.

V01H0DA

CHECK THE O-RING FOR DAMAGE, REPLACE IF NECESSARY

Remove cotter pin and castellated nut from upper and lower suspension arms.

V01H0FA

1. Stop ring

4 1 2

Insert the other end of drive shaft in the knuckle and install the knuckle, with hub and disk brake, to the lower and upper suspension arm. Torque the castellated nuts to 75 N•m (55 lbf•ft) and install a new cotter pin. Install the flat washer and torque the castellated nut on the drive shaft end to 140 N•m (103 lbf•ft) minimum. Install a new cotter pin and the wheel cap. Reinstall the front wheel(s) and torque the four nuts to 75 N•m (55 lbf•ft).

3 1 2 V01H0EA

1. 2. 3. 4.

Castellated nut Cotter pin Lower suspension arm Upper suspension arm

06-02-2

VMR2001_055_06_02A.FM

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE)

Drive Shaft Boot

FRONT DIFFERENTIAL

Removal Remove: – clamps from rubber boot using boot clamp pliers (P/N 295 000 069 and 295 000 054) – large end of the boot from plunging joint or CV joint. Move apart circlip and pull out the shaft from bearing. Do not remove circlip.

V01H0XA

Removal Raise front of vehicle, support it securely on jack stands and remove front wheels. Remove: – skid plate – winch protector – front bumper – inner fender. Refer to BODY for the proper instructions. On LH side, remove: – wheel cap no. 13 – cotter pin no. 12 – castellated nut no. 11 – flat washer no. 10 – O-ring no. 21. On front side, remove: – differential mounting bracket bolt no. 4 – front mounting bolt no. 3 – rear mounting bolt no. 5 – differential bracket no. 22 – mounting bracket no. 2. 3

1. Circlip 2. Shaft

Remove boot from drive shaft. Inspection Check bearing in plunging joint or CV joint. If bearing is hard to move, change plunging joint or CV joint. Check circlip for damage, change as necessary. Installation For installation, reverse the removal procedure. Paying attention to the following details. Insert boot, do not forget the small clamp. Insert shaft and push firmly. Pack bearing area with grease (including with the new boot kit). NOTE: Do not use an other grease.

V01H0GA

1. 2. 3. 4. VMR2001_055_06_02A.FM

Front mounting bolt M10 x 200 Differential mounting bracket bolts Bracket Rear mounting bolt M10 x 60 06-02-3

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE)

On RH side, remove drive shaft. Unscrew propeller shaft bolt no. 19. Differential side only. Remove rubber bellows no. 15 on the top from the front differential. Pull differential forward then separate RH propeller shaft no. 7 from differential.

V01H16A

Place the other end of measuring attachment tool in vise. Install the measuring attachment lever (P/N 529 035 665) onto the end of pinion gear and secure it with the â&#x20AC;&#x153;Tâ&#x20AC;? bar fastener. Install an dial gauge. The indicator probe touching the lever of measuring attachment lever. V01H0IA

Remove front differential by the RH side. Separate LH drive shaft no. 14 from differential.

Inspection Turn front differential gear with a finger; it should turn smoothly. Replace if necessary. With drive shafts installed, check backlash and axial play.

Backlash Procedure NOTE: The backlash is the last procedure when the differential is rebuilt. Insert the measuring attachment tool into the differential and secure it with a screw. NOTE: The measuring attachment tool could be not available immediately. In such a case, use a drive shaft to replace the measuring attachment tool.

06-02-4

V01H17A

Gently lift the lever attachment until some resistance is felt. Note the indicator reading. An acceptable backlash is in the range from 0.102 to 0.356 mm inclusive (.004 to .014 in). If backlash is out of specifications, disassemble the differential and change ring gear carrier shims. See PINION GEAR AND RING GEAR CARRIER RECENTERING below.

VMR2001_055_06_02A.FM

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE)

Disassembly Ring Gear Carrier/Ring Gear Removal To change ring gear carrier no. 22 or ring gear no. 23: – Unscrew the drain plug no. 24 and empty differential. – Unscrew the TORX screws no. 25, then separate half housings. – Extract ring gear carrier with ring gear out of half housing. – Unscrew Allen socket screws no. 26 then separate ring gear from ring gear carrier. To assembly, reverse the removal procedure. Paying attention to the following details. NOTE: If ring gear carrier, pinion gear, ring gear, housing or bearing is (are) changed, recenter the ring gear carrier in the housing before final assembly. See PINION GEAR AND RING GEAR CARRIER RECENTERING below. Verify condition of half housing seal no. 27. Change seal if necessary. Check all bearings and all oil seals. Change them if necessary. Pinion Gear Removal Remove oil seal no. 28. Unscrew the pinion nut no. 29. Use the differential spanner socket (P/N 529 035 649).

V01H18A

VMR2001_055_06_02A.FM

Remove the bearing no. 30 at the same time as the pinion gear no. 31. NOTE: The pinion gear and bearing can be easily removed using the following suggested tool: – pipe 3-1/2” dia. x 5” (1) – screwed rod M10 x 1.25, 7” in length (1) – nut M10 x 1.25 (3) – flat bar (1). To install, reverse the removal procedure. Paying attention to the following details. Check O-ring no. 32 for damage. If so, change it. Install the shim no. 33 then the ball bearing. NOTE: If ring gear carrier, pinion gear, ring gear, housing or bearing is (are) changed, recenter the ring gear carrier in the housing before final assembly. See below. Install the nut and a new oil seal.

Pinion Gear and Ring Gear Carrier Recentering NOTE: All measurements require great care and absolute cleanliness if accurate results are to be obtained. First; center pinion gear. Install pinion gear into housing. Measure distance between mount surface and the top of pinion gear. This is measure “A”.

V01H19A

06-02-5

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE)

Remove pinion and install ring gear carrier with ring gear installed. Measure distance between mount surface and the top of ring gear. This is measure “B”.

V01H1CA

V01H1AA

Subtract measure “B” from measure “A”. Note this result “C”. A-B=C Remove ring gear carrier then install pinion gear into housing. Measure distance between mounting surface and the pinion shim surface. This is measure “D”.

V01H1BA

Subtract measure “E” from measure “D”. Note this result “F”. D - E =F The difference between result “F” and result “C” is the pinion shims thickness. F - C = Pinion shims thickness. Determine the appropriate pinion shim using the following pinion gear shims kit (P/N 703 500 049). THICKNESS

NOTCHES

0.25 mm (.010 in)

0.38 mm (.015 in)

0.51 mm (.020 in)

0.56 mm (.022 in)

Install pinion, shims, bearing and pinion nut. Apply Loctite 243 to nut and torque to 98 N•m (72 lbf•ft). Check if pinion gear teeth and ring gear teeth are equal. After pinion installation, center ring gear carrier. Take the half housing with pinion gear. Measure distance between housing edge and the inner ring of bearing. This is measure “G”.

Remove pinion gear then measure the distance between mount surface and bearing surface. This is measure “E”.

06-02-6

VMR2001_055_06_02A.FM

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE)

Subtract the measure “J” from measure “H” then add this result to “G”. Note this result “K”. G + (H - J) = K (housing inside length) Measure ring gear carrier length. This is measure “L”.

V01H1DA

Measure the other half housing between housing edge and the inner ring of bearing. This is measure “H”.

V01H1GA

Measure the distance between the end of ring gear carrier and the bearing shoulder. Note this measure “M”.

V01H1EA

Measure the edge of half housing. This is measure “J”.

V01H1HA

V01H1FA

VMR2001_055_06_02A.FM

06-02-7

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE)

Take the same distance to the other end. This is measure “N”.

V01H1IA

Add measure “M” from measure “N”. Subtract this result from measure “L”. Note this result “P”. The result “P” is the length of ring gear carrier between bearings. L - (M + N) = P Subtract result “P” from “K”. At this measure subtract the clearance 0.127 mm (.005 in). This is the shim thickness. K - P = X - 0.127 mm (.005 in) = shim thickness. Determine the appropriate shim using the following ring gear carrier shims kit (P/N 703 500 050). THICKNESS

NOTCHES

0.25 mm (.010 in)

0.38 mm (.015 in)

0.51 mm (.020 in)

0.64 mm (.025 in)

0.56 mm (.022 in)

Distribute total shim thickness between both end of ring gear carrier to obtain specified backlash between ring gear and pinion gear.

06-02-8

VMR2001_055_06_02A.FM

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE)

J H

V01H1JS

VMR2001_055_06_02A.FM

06-02-9

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE)

Assembly and Installation The rear differential assembly is essentially the reverse of the disassembly procedure. Paying attention to the following detail. Install the rear differential on the vehicle before filling oil. Use specified oil, refer to TECHNICAL DATA.

Front Differential Oil Level Clean filler plug prior to check oil level. With vehicle on a level surface, check oil level by removing filler plug. Oil level must reach the lower edge. Add oil if necessary. Refer to TECHNICAL DATA for capacity and recommended oil.

Front Differential Oil Change Place vehicle on a level surface. Set transmission in park position. Lift LH side of vehicle. Clean drain plug area. Place a drain pan under differential drain plug area. Remove drain plug. Unscrew filler plug.

FRONT PROPELLER SHAFT Removal Remove: – skid plate – winch protector – front bumper – inner fender. Refer to BODY for the proper instructions. Remove propeller shaft bolts and flat washers. One on engine side no. 17 and 18, one on differential side no. 19 and 20. Discard bolts. Remove rubber bellows no. 15 on the top from the front differential. Pull differential forward then separate propeller shaft no. 16 from differential and engine.

Inspection Check propeller shaft for wear or damage, replace if necessary.

Installation Installation is the reverse of removal procedure.

V01H0JA

1. Engine side 2. Differential side

NOTE: Secure propeller shaft with new self-locking screws. V01H0WA

1. Drain plug 2. Filler plug

Clean drain plug area then reinstall plug. Lower vehicle. Use a funnel and refill front differential at the proper level with the recommended oil. Refer to TECHNICAL DATA. Reinstall filler plug.

06-02-10

Front Propeller Shaft Lubrication Place vehicle on a level surface. Set transmission in park position. Remove inner fender on front right side. Set transmission on neutral position and move vehicle back and forth to place grease fittings toward opening. Re-set transmission in park position. Grease rear and front U-joint. Use a grease gun with SHELL, Alvania EP-2 grease only. VMR2001_055_06_02A.FM

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE)

Reinstall inner fender.

Front Propeller Shaft U-Joint Removal Remove internal snap ring from bearing caps.

V01H10A

Tighten vise to force bearing caps in.

V01H0YA

1. Snap ring

Support inner yoke in vice and drive other yoke down with a soft hammer.

V01H11A

Using a suitable tappet, fully seat bearing cap in one side. Continually, check for free movement of bearing cross as bearing caps are assembled.

V01H0ZA

Support U-joint in vice and drive inner yoke down to remove remaining bearing caps. Remove U-joint cross. Installation Install new U-joint cross in inner yoke. Install new bearing cap by hand. NOTE: Carefully install U-joint cross with grease fitting properly positioned.

VMR2001_055_06_02A.FM

V01H12A

Install snap ring. Repeat procedure for other sides. Grease U-joint, using a grease gun with SHELL, Alvania EP-2 grease only.

06-02-11

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE)

KNUCKLE

WHEEL BEARING

Removal

Inspection

Raise front of vehicle, support it securely on jack stands and remove front wheel(s). Remove wheel cap, cotter pin, castellated nut, flat washer and O-ring. NOTE: Check O-ring for damage, replace if necessary. Remove hub. Refer to HYDRAULIC BRAKES. Remove cotter pin and castellated nut from upper and lower A-arm. Detach upper and lower A-arm from knuckle. Remove cotter pin and castellated nut from tie-rod and separate tie-rod from knuckle. Separate knuckle from drive shaft.

Raise front of vehicle. Take tire by the top and the bottom. Check lateral play. If there is any play, change wheel bearing. NOTE: Verify the ball joints play in first. Perform all repairs before check the wheel bearing condition. Be careful not to misjudge play in the ball joint.

Inspection Inspect knuckle for damage. If any damage is detected, change the knuckle.

Removal Separate wheel hub from knuckle. Refer to HYDRAULIC BRAKES. Remove: – knuckle – seals and circlip. Place knuckle in vise. Remove and discard bearing.

Installation Installation For installation, reverse the removal procedure. Pay attention to the following details. For hub installation, refer to HYDRAULIC BRAKES. Reinstall front wheel(s) and torque nuts to 75 N•m (55 lbf•ft) in a criss-cross sequence. NOTE: Do not interchange left and right tires. Check direction of rotation mark on tires.

06-02-12

Place new bearing in a freezer for 10 minutes before installation. Place the knuckle in oven to 100°C (212°F) for a half hour maximum to ease bearing installation. Apply synthetic grease on bearing then install the new seals. Install the other parts in the reverse order of removal procedure.

VMR2001_055_06_02A.FM

Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE)

REAR AXLE

RIGID AXLE AND PROPELLER SHAFT 12

140 N m (103 lbf ft) 13 MINIMUM 14

38 N m (28 lbf ft)

18 16 24 N m (18 lbf ft)

17 21

19 20 24 N m (18 lbf ft) 14

11 33 N m (24 lbf ft) 7

43 N m (32 lbf ft)

13 12

140 N m (103 lbf ft) MINIMUM

43 N m (32 lbf ft) 9

50 N m 5 (37 lbf ft)

27 N m 4 (20 lbf ft)

V01H15S

VMR2001_056_06_03A.FM

PARTS

FLAT RATE

06-03-1

Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE)

RIGID AXLE

Remove flanged bolts no. 5 and elastic flanged nuts no. 6 retaining swing arm to rigid axle.

Removal Lift rear of the vehicle until rear shock absorbers are fully extended. Install jack stands under frame to support vehicle. Remove the rear wheels. Remove lower shock absorber bolts and elastic flanged nuts.

V01J06A

1. Remove flanged bolts and elastic flanged nuts

Detach rigid axle from swing arm.

Installation V01J03B

TYPICAL 1. Lower shock absorber bolts

Remove rear brake caliper and detach brake hose from bracket on rigid axle no. 1. CAUTION: Don’t let caliper hang by the hose and don’t stretch or twist brake hose. Remove flanged bolts no. 4 retaining protector no. 2 under rear differential. Remove socket screws no. 7 retaining rear differential to swing arm.

Installation is essentially the reverse of removal procedure. Paying attention to the following details. Apply grease (P/N 293 550 019) on the spring to the end of the propeller shaft. Secure rear differential to swing arm with socket screws. Apply sealant Right Stuff (P/N 293 800 053) between both parts. Do not tighten yet. Secure rear axle to swing arm with bolts no. 5. Do not tighten yet. When all bolts are installed, torque in a criss-cross sequence. See the following illustrations. 1

2 V01J05A

1. Remove socket screws

06-03-2

V01J06C

TORQUE TO 48 N•m (35 lbf•ft)

VMR2001_056_06_03A.FM

Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE)

Installation For installation, reverse the removal procedure. paying attention to the following details. Apply grease (P/N 293 550 019) on splines. Torque castellated nut no.13 to 140 N•m (103 lbf•ft) minimum.

V01J05C

TORQUE TO 48 N•m (35 lbf•ft)

RH AXLE RH Axle Housing Removal Lift rear of the vehicle. Install jack stands under swing arm. Remove: – wheel and wheel cap – cotter pin no. 12 – castellated nut no.13 – flat washer no. 14 and O-ring no. 8 – caliper CAUTION: Don’t let caliper hang by the hose and don’t stretch or twist brake hose. – rear differential protector no. 2 – lower bolt retaining RH shock from axle housing no. 15. Unfasten TORX head screws no. 16 retaining axle housing from rear differential no. 17. Remove axle housing then pull out axle no. 18. Inspection Check axle housing for wear or other damage, replace if necessary. Check axle for wear, cracks, bend, spots of rust, or other damage. Change the axle if any problem is detected. Check all axle housing ball bearings for excessive play and smooth operation. Replace if necessary.

VMR2001_056_06_03A.FM

LH AXLE LH Axle Housing Removal Lift rear of the vehicle. Install a jack stand under swing arm and an other under rear differential. Remove: – wheel and wheel cap – cotter pin no. 12 – castellated nut no.13 – flat washer no. 14 and O-ring no. 8 – rear differential protector no. 2 – lower bolt retaining LH shock from axle housing no. 19. Unfasten TORX head screws no. 20 retaining axle housing from rear differential no. 17. Remove axle tube then pull out axle no. 21. Inspection Check axle housing for wear or other damage, replace if necessary. Check axle for wear, cracks, bend, spots of rust, or other damage. Change the axle if any problem is detected. Check all axle housing ball bearings for excessive play and smooth operation. Replace if necessary. Installation For installation, reverse the removal procedure. paying attention to the following details. Apply grease (P/N 293 550 019) on splines. Torque castellated nut no. 13 to 140 N•m (103 lbf•ft) minimum.

06-03-3

Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE)

REAR PROPELLER SHAFT

REAR HUB

Removal

Remove swing arm with rigid axle assembly. Refer to REAR SUSPENSION. Remove the propeller shaft bolt no. 9 and flat washer no. 10. Separate rear propeller shaft no. 3 from engine.

CAUTION: Replace bearing when brake disc is changed. Lift rear of the vehicle until rear shock absorbers are fully extended. Install jack stands under frame to support vehicle. Remove: – rear wheel(s) – caliper (RH side only) CAUTION: Don’t let caliper hang by the hose and don’t stretch or twist hose. – cotter pin no. 12 – castellated nut no. 13 – flat washer no. 14 – O-ring no. 8. Using the hub puller (P/N 529 035 612), pull out hub (with brake disc on RH side).

Inspection Check yoke U-joint no. 11 for wear, backlash or axial play, replace if necessary.

Installation Installation is essentially the reverse of removal procedure. Apply grease (P/N 293 550 019) to spring and splines before insert the end of the propeller shaft into swing arm. Apply grease to splines from engine. Grease U-joint from rear propeller shaft. Use a grease gun with SHELL, Alvania EP-2 grease only.

Rear Propeller Shaft U-Joint

Installation Installation is essentially the reverse of the removal procedure.

Use the same procedure that front propeller shaft U-joint. Refer to FRONT DRIVE subsection.

06-03-4

VMR2001_056_06_03A.FM

Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE)

REAR DIFFERENTIAL

27 23 22 Loctite 243

29 98 N m 28 (72 lbf ft)

V01J0US

VMR2001_056_06_03A.FM

PARTS

FLAT RATE

06-03-5

Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE)

REAR DIFFERENTIAL OIL LEVEL Lift back of vehicle. Place swing arm horizontally. Clean filler plug prior to check oil level. Check oil level by removing filler plug. Oil level must reach lower edge.

V01H0RA

1. Drain plug 2. Filler plug

Clean drain plug area then reinstall drain plug. Use a funnel and refill rear differential at the proper level with recommended oil.

V01H0RB

1. Filler plug

MODEL

CAPACITY

RECOMMENDED OIL

All models

200 mL (6.76 U.S. oz)

REDLINE pump oil 75W90 (API GL5)

Add oil if necessary. MODEL

CAPACITY

RECOMMENDED OIL

All models

200 mL (6.76 U.S. oz)

REDLINE pump oil 75W90 (API GL5)

REAR DIFFERENTIAL OIL REPLACEMENT Ensure vehicle is on a level surface. Clean drain plug area. Place a drain pan under rear differential drain plug area. Unscrew filler plug. Remove drain plug.

06-03-6

Reinstall filler plug.

REAR DIFFERENTIAL Removal Remove the rigid axle from swing arm. Remove the rear differential protector no. 2. Unscrew all TORX screws retaining axle housings to differential.

VMR2001_056_06_03A.FM

Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE)

V01H16A

Place the other end of measuring attachment tool in vise. Install the measuring attachment lever (P/N 529 035 665) onto the end of pinion gear and secure it with the “T” bar fastener. Install an dial gauge. The indicator probe touching the lever of measuring attachment lever.

V01H17A

VMR2001_056_06_03A.FM

06-03-7

Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE)

Pinion Gear Removal Remove oil seal no. 28. Unscrew the pinion nut no. 29. Use the differential spanner socket (P/N 529 035 649).

V01H18A

V01H19A

Remove pinion and install ring gear carrier with ring gear installed. Measure distance between mount surface and the top of ring gear. This is measure “B”.

V01H1AA

06-03-8

VMR2001_056_06_03A.FM

Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE)

THICKNESS

NOTCHES

0.25 mm (.010 in)

0.38 mm (.015 in)

0.51 mm (.020 in)

0.56 mm (.022 in)

V01H1BA

Remove pinion gear then measure the distance between mount surface and bearing surface. This is measure “E”.

V01H1DA

Measure the other half housing between housing edge and the inner ring of bearing. This is measure “H”.

V01H1CA

Subtract measure “E” from measure “D”. Note this result “F”. D-E=F The difference between result “F” and result “C” is the pinion shims thickness. F - C = Pinion shims thickness. Determine the appropriate pinion shim using the following pinion gear shim kit (P/N 703 500 049).

VMR2001_056_06_03A.FM

V01H1EA

06-03-9

Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE)

Measure the edge of half housing. This is measure “J”.

V01H1HA

Take the same distance to the other end. This is measure “N”. V01H1FA

V01H1IA

V01H1GA

Measure the distance between the end of ring gear carrier and the bearing shoulder. Note this measure “M”.

06-03-10

Add measure “M” from measure “N”. Subtract this result from measure “L”. Note this result “P”. The result “P” is the length of ring gear carrier between bearings. L - (M + N) = P Subtract result “P” from result “K”. At this measure subtract the clearance 0.127 mm (.005 in). This is the shim thickness. K - P = X - 0.127mm (.005 in) = shim thickness.

VMR2001_056_06_03A.FM

Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE)

Determine the appropriate shim using the following ring gear carrier shim kit (P/N 703 500 050). THICKNESS

NOTCHES

0.25 mm (.010 in)

0.38 mm (.015 in)

0.51 mm (.020 in)

0.64 mm (.025 in)

0.56 mm (.022 in)

Distribute total shim thickness between both end of ring gear carrier to obtain specified backlash between ring gear and pinion gear.

VMR2001_056_06_03A.FM

06-03-11

Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE)

J H

V01H1JS

06-03-12

VMR2001_056_06_03A.FM

Section 07 STEERING/CONTROL SYSTEMS Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS STEERING/CONTROL SYSTEMS......................................................................................... HANDLE BAR ..................................................................................................................... STEERING COLUMN ......................................................................................................... TIE-ROD.............................................................................................................................. STEERING COLUMN BEARING........................................................................................ MULTI-FUNCTION SWITCH ............................................................................................. THROTTLE HANDLE.......................................................................................................... LH HANDLE BRAKE........................................................................................................... RH HANDLE BRAKE ..........................................................................................................

VMR2001_065_07_01ATOC.FM

0 07-02-1 07-02-2 07-02-2 07-02-2 07-02-3 07-02-3 07-02-4 07-02-4 07-02-5

07-01-1

Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS)

STEERING/CONTROL SYSTEMS

3 26

7 4 N m (35 lbf in)

5 4 N m (35 lbf in)

6 4

20 18

75 N m (55 lbf ft) MINIMUM 13

24 N m (17 lbf ft) 14 15

16 19 20 21 22

18 21 22

20 N m 23 (15 lbf ft) 24 25

Loctite 243 13

19 10 75 N m 75 N m (55 lbf ft) (55 lbf ft) MINIMUM MINIMUM

20 V01I1AS

VMR2001_057_07_02A.FM

PARTS

75 N m 19 (55 lbf ft) MINIMUM

FLAT RATE

07-02-1

Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS)

HANDLE BAR

Inspection

Removal

Inspect steering column for damage, cracks or bending, replace if any problems is detected.

Remove: – steering cover (refer to BODY) – handle bar grips no. 1 (discard screws) – brake handles no. 2. (refer to HYDRAULIC BRAKES) – throttle handle no. 3 and multi-function switch no. 4 (refer to the specific section) – steering clamp mounting bolts no. 5 and steering clamp no. 6 – handle bar no. 7. NOTE: On the XT model, remove the hand protector. Refer to BODY.

Inspection Inspect the handle bar for damage, cracks or bending, replace if any problems is detected.

Installation For the installation, reverse the removal procedure. NOTE: Replace screws retaining handle bar grip by a new self-locking screws.

STEERING COLUMN Removal Remove: – steering cover (refer to BODY) – steering clamp mounting bolts no. 5, steering clamp no. 6 and steering cover support no. 8 – fuel tank (refer to FUEL CIRCUIT) NOTE: Do not remove fuel tank completely, separate fuel tank from frame only. Do not remove fuel lines. – cotter pin no. 9, castellated nut no. 10 and flat washer no. 11 to bottom end of steering column no. 12. Separate steering column and tie-rods no. 13. Refer to TIE-ROD section. Remove half housing bolts no. 14, stopper plates no. 15, half housings no. 16 and housing bushings no. 17. Pull steering column.

07-02-2

Installation For the installation, reverse the removal procedure. Install a new cotter pins. Both ends of cotter pin must be folded.

TIE-ROD Removal Place the vehicle on jack stands and remove front wheel(s). Remove front fender. Refer to BODY. Remove fuel tank. Refer to FUEL CIRCUIT. NOTE: Do not remove tank completely, separate fuel tank from frame. Do not remove fuel lines. Remove cotter pin no. 18, castellated nut no. 19, hardened washer no. 20 and flat washer no. 21.

Inspection Inspect ball joint ends for wear or looseness, if excessive, replace.

Installation For the installation, reverse the removal procedure. Pay attention to the following details. At the time of the reinstallation or the new tierod(s) installation, screw threaded end of tie-rod into ball joint. The maximum length for tie-rod groove to ball joint end must be the value A in the following chart: B

V01I0YA

MODEL

A A

20 ± 5

311 ± 1

25/32 ± 0.197

12-1/4 ± 0.039

TRAXTER

VMR2001_057_07_02A.FM

Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS)

NOTE: Torque the ball joint lock nut no. 22 to 36 N•m (27 lbf•in). Install a new cotter pin. Both ends of cotter pin must be folded.

Toe Adjustment Place vehicle on level surface. Check that handlebar is straight. Use a long rule and check if the rear and front wheels are aligned. Adjust alignment with tie-rod. Adjust toe-out to 17 mm ± 4 mm (.669 in ± .157 in).

STEERING COLUMN BEARING Removal Place vehicle on jack stands and remove front wheels. Remove front fender. Refer to BODY. Remove fuel tank. Refer to FUEL CIRCUIT. NOTE: Do not remove tank completely, separate fuel tank from frame. Do not remove fuel lines. Separate tie-rods no. 13 from steering column no. 12. Refer to TIE-ROD section. Remove cotter pin no. 9, castellated nut no. 10 and flat washer no. 11 to bottom end of steering column no. 12. Pull up steering column. Remove carriage bolts no. 23 and first bearing flange no. 24. Remove bearing no. 25.

V01I0NA

1. Flanged collar 2. Bearing

MULTI-FUNCTION SWITCH Test Refer to ELECTRIC SHIFT SYSTEM for the START/ STOP button and UPSHIFT/DOWNSHIFT button. Refer to INSTRUMENTS AND ACCESSORIES for Hi-Lo Beam button.

Removal Remove bolts.

Installation For installation, reverse the removal procedure. Pay attention to the following details. Place flanged collar toward outside. NOTE: Install both bearing flanges on top of frame support. Install carriage bolts no. 23, apply Loctite 243 on threads. Install a new cotter pin. Both ends of cotter pin must be folded.

V01I0OA

1. Remove the bolts

VMR2001_057_07_02A.FM

07-02-3

Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS)

Separate multi-function switch no. 5 from handle bar no. 7. Remove steering cover. Refer to BODY. Unplug multi-function switch connector. The connector is located under steering cover.

Separate throttle handle no. 3 from handle bar no. 7. Remove throttle cable from housing. 2

V01I0PA V01I10A

UNDER STEERING COVER 1. Unplug this connector

1. Throttle handle housing 2. Throttle cable

Installation For installation, reverse the removal procedure.

THROTTLE HANDLE Removal Remove screws no. 26. 1

Slide cable in clip slot and remove the end of the cable from clip.

Installation For installation, reverse the removal procedure. Refer to CARBURATOR AND FUEL PUMP for adjustment procedure.

LH HANDLE BRAKE Removal Remove screws. 1

V01I0ZA

1. Remove screws

V01I0SA

TYPICAL 1. Remove the screws 07-02-4

VMR2001_057_07_02A.FM

Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS)

Separate handle brake no. 2 from handle bar no. 7. If necessary, cut locking tie.

Cable Removal Refer to HYDRAULIC BRAKES for specifics instructions.

Installation For installation, reverse the removal procedure.

RH HANDLE BRAKE Removal Remove screws.

V01I11A

1. Remove the screws

Separate handle brake no. 2 from handle bar no. 7. If necessary, unplug connectors under steering cover and cut locking tie.

Hose Removal Refer to HYDRAULIC BRAKES for specifics instructions.

Installation For installation, reverse the removal procedure.

VMR2001_057_07_02A.FM

07-02-5

Section 08 SUSPENSION Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

FRONT SUSPENSION .......................................................................................................... SHOCKS ASSEMBLY ........................................................................................................ UPPER A-ARM ................................................................................................................... LOWER A-ARM .................................................................................................................. BALL JOINT ....................................................................................................................... A-ARM BUSHINGS............................................................................................................

08-02-1 08-02-2 08-02-3 08-02-4 08-02-5 08-02-5

REAR SUSPENSION............................................................................................................. REAR SHOCK ..................................................................................................................... SWING ARM ......................................................................................................................

08-03-1 08-03-2 08-03-3

VMR2001_065_08_01ATOC.FM

08-01-1

Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION )

FRONT SUSPENSION

1 6

48 N m (35 lbf ft)

5 63 N m (46 lbf ft) 7 9 4

63 N m (46 lbf ft)

8 63 N m (46 lbf ft)

8 3

V01J0RS

VMR2001_058_08_02A.FM

75 N m (55 lbf ft)

2.5 N m (22 lbf in)

PARTS

FLAT RATE

08-02-1

Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION )

SHOCKS ASSEMBLY Removal Loosen wheel nuts. Lift front of vehicle and install a jack stand under the frame to support the vehicle off the ground. NOTE: Lift up vehicle high enough to have the wheel off the ground and shock absorber no. 1 fully extended. Remove wheels. Remove lower bolt no. 5 then upper bolt no. 6 of shock.

1 2

A01B4LA

TYPICAL 1. Clevis pin 2. Bar 3. Handle horizontal

Push down on the handle until it locks. Remove spring stopper then release handle. 2

V01J0IA

1. Remove bolts 2. Front shock assembly

Disassembly For shock spring disassembly use shock spring remover (P/N 529 027 100) in a vise. Mount shock in it and turn shock so that spring coils matched spring compressor. Close and lock the bar. Adjust the handle horizontal position by changing the position of the clevis pin.

08-02-2

Inspection Inspect the spring for damage. Replace if necessary. Inspect shock for oil leakage. Extend and compress the piston several times over its entire stroke. Check that it moves smoothly and with uniform resistance with its rod upwards. Any of the following conditions will denote a defective shock: – A skip or hang back when reversing stroke at mid travel. – Seizing or binding condition except at extreme end of either stroke. – A gurgling noise after completing one full compression and extension stroke. Replace shock if any of these conditions are found.

VMR2001_058_08_02A.FM

Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION )

Installation For assembly, reverse the disassembly and removal procedures. NOTE: Do not interchange left and right tires. Check direction of rotation mark on tires.

Remove cotter pin and castellated nut from upper ball joint no. 4.

V01J0DA

1. Remove cotter pin 2. Castellated nut 3. Upper ball joint V01J0KA

DIRECTION OF ROTATION

Torque wheel nuts to 75 Nâ&#x20AC;˘m (55 lbfâ&#x20AC;˘ft) in a crisscross sequence.

Use a suitable ball joint remover and detach upper A-arm from knuckle. Remove bolts no. 7 and nuts retaining upper Aarm to frame.

UPPER A-ARM Removal NOTE: Both upper no. 2 and lower no. 3 A-arms can be removed without removing the tie rods. Remove bolt no. 5 retaining the shock absorber no. 1 to upper A-arm. Detach brake hose from upper A-arm. 2

V01J0EA

TYPICAL 1. Upper A-arm 2. Remove nuts and bolts

Remove upper A-arm from vehicle.

V01J0CA

1. 2. 3. 4.

Upper A-arm Detach brake hose from tubing Brake hose Remove nut and bolt

VMR2001_058_08_02A.FM

08-02-3

Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION )

Inspection Check upper A-arm for distortion or damage. Replace as required. Move A-arm from side to side. There should be no noticeable side play. Replace bushings if necessary. Move A-arm up and down. There should be no noticeable play. Replace bushings if necessary. Inspect pivot bushings for wear or damages. Check ball joint rubber on upper A-arm for crack or any other damage. Inspect ball joint end for damages. Ensure it is moving freely. Replace ball joint as required, see below for procedure.

LOWER A-ARM Removal Remove cotter pin and castellated nut retaining lower A-arm no. 3 to ball joint on the knuckle.

Installation Position upper A-arm and install bolts and nuts. Do not torque yet. Install bolt and nut retaining shock absorber to upper A-arm. Torque to 63 N•m (46 lbf•ft). Attach upper A-arm to knuckle. Install castellated nut and torque to 56 N•m (41 lbf•ft). NOTE: Make sure the conic sections are clean (without grease or oil). Install a new cotter pin. Both ends of cotter pin must be folded. Secure brake hose to upper A-arm. NOTE: Do not interchange left and right tires. Check direction of rotation mark on tires.

V01J0FA

1. 2. 3. 4.

Lower A-arm Castellated nut Lower ball joint Knuckle

Use a suitable ball joint remover and detach knuckle from the lower A-arm. Remove nuts and bolts no. 8 retaining lower A-arm to frame.

V01J0GA

1. Lower A-arm 2. Remove nuts and bolts

Remove lower A-arm from vehicle. V01J0KA

DIRECTION OF ROTATION

Torque wheel nuts to 75 N•m (55 lbf•ft) in a crisscross sequence. 08-02-4

VMR2001_058_08_02A.FM

Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION )

Inspection Check lower A-arm for distortion or damage. Replace A-arms if necessary. Move A-arm from side to side. There should be no noticeable side play. Replace bushings if necessary. Move A-arm up and down. There should be no noticeable play. Replace bushings if necessary. Inspect pivot bushings for wear or damages. Replace bushings if necessary. Check ball joint rubber on lower A-arm for crack or any other damage. Inspect ball joint end for damages. Ensure it’s moving freely. Replace ball joint as required, see below for procedure.

BALL JOINT Inspection Check ball joint for damage, pitting, free play and if it turns roughly. If so, replace ball joint. Check ball joint rubber for crack. Change if necessary.

Removal Remove upper or lower A-arms. Withdraw the circlip no. 9. Extract the ball joint no. 4.

Installation

The installation is the reverse of removal procedure.

For assembly, reverse the disassembly procedure. However, pay attention to the following. Install lower A-arm to frame and torque nuts to 63 N•m (46 lbf•ft). Attach lower A-arm no. 2 to knuckle. Install castellated nut and new cotter pin. Both ends of cotter pin must be folded. NOTE: Do not interchange left and right tires. Check direction of rotation mark on tires.

A-ARM BUSHINGS Removal Remove: – A-arm (see above) – inner bushing – both cushions.

Installation The installation is the reverse of the removal procedure. Paying attention to the following details. Apply synthetic grease (P/N 293 550 010) on inner bushing before installation. Lubricate front A-arms with synthetic grease (P/N 293 550 010).

V01J0KA

DIRECTION OF ROTATION

Torque wheel nuts to 75 N•m (55 lbf•ft) in a crisscross sequence.

VMR2001_058_08_02A.FM

08-02-5

Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION)

REAR SUSPENSION

8 7

48 N m (35 lbf ft) 4 6

48 N m 5 (35 lbf ft) 1 5 48 N m (35 lbf ft) 147 N m (108 lbf ft) 14

18 5 N m (44 lbf in)

6 1

Synthetic grease 17 5 N m 16 (44 lbf in) 15

10 11 147 N m 12 (108 lbf ft)

Synthetic grease

13 11 N m (97 lbf in)

V01J0SS

VMR2001_059_08_03A.FM

PARTS

FLAT RATE

08-03-1

Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION)

REAR SHOCK Removal Lift rear of vehicle until rear shock absorbers no. 1 are fully extended. Install jack stands or blocks under the frame to support the vehicle. Remove upper no. 4 and lower no. 5 bolts and nuts no. 6 retaining shock absorbers each side.

Disassembly Use shock spring remover (P/N 529 027 100) and put it in a vise. Mount shock in it and turn shock so that spring coils no. 3 match spring compressor. Close and lock bar. Adjust handle horizontal by changing position of clevis pin. Push down on handle until it locks. Remove spring stopper and cap then release handle.

1 2

V03J01A

XL MODEL ONLY

A01B4LA

TYPICAL 1. Clevis pin 2. Bar 3. Handle horizontal

V01J0TA

ALL OTHER MODELS

08-03-2

VMR2001_059_08_03A.FM

Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION)

At installation, cap opening no. 8 must be 180° from spring stopper opening no. 7.

– Oil leakage. – A gurgling noise, after completing one full compression and extension stroke. Renew if any faults are present.

Installation Assembly and installation are essentially the reverse of disassembly and removal procedures.

SWING ARM

1 2

A03F12A

TYPICAL 1. Cap opening 2. Spring stopper opening

Removal Lift rear of vehicle until rear shock absorbers no. 1 are fully extended. Install a jack stands or a blocks under the frame to support the vehicle. Remove both side panels. On the XL model, remove the both rear fenders too. Refer to BODY. Remove lower nuts no. 6 and bolts no. 5 retaining shock to rear drive train each side.

Inspection

Secure the shock body end no. 2 in a vise with its rod upward. 1

A14F0BA

TYPICAL 1. Clamp here

CAUTION: Do not clamp directly on shock body. Examine each shock for leaks. Extend and compress the piston several times over its entire stroke. Check that it moves smoothly and with uniform resistance with its rod upward. Pay attention to the following conditions that will denote a defective shock: – A skip or a hang back when reversing stroke at mid travel. – Seizing or binding condition except at extreme end of either stroke.

VMR2001_059_08_03A.FM

V01J03D

TYPICAL 1. Rear brake caliper 2. Remove bolts 3. Brake hose 4. Swing arm

Unfasten rear brake caliper. Detach brake hose from brackets on rear axle tube and on swing arm. CAUTION: Don’t let caliper hang by the hose and don’t stretch or twist brake hose.

08-03-3

Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION)

Remove M8 flanged screws retaining master cylinder.

Unscrew and remove RH pivot bolt no. 14. 2

2 1 1

V01J07A

TYPICAL 1. Swing arm bellows 2. Pivot bolt RH

V01K05B

TYPICAL 1. Remove bolts 2. Master cylinder 3. Loosen clamp

Loosen clamp no. 16 retaining swing arm bellows no. 15 to engine. Loosen jam nut no. 12. Unscrew and remove LH pivot bolt no. 13.

Pull back rear drive train assembly to detach swing arm assembly from the frame and disengage the propeller shaft. Separate the swing arm from rear axle. Refer to REAR AXLE.

Inspection Check condition of swing arm. Inspect for distortion or damage. Check swing arm bellows for cracks or damage. Check oil seals no. 11 for wear or damage. Replace swing arm if necessary. Check condition of bearings no. 10. Make sure they turn smoothly. Replace if necessary.

V01J08A

TYPICAL 1. Swing arm 2. Pivot bolt LH 3. Jam nut

08-03-4

VMR2001_059_08_03A.FM

Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION)

Ensure outer race of bearing fits tightly inside swing arm pivot. 1

Push rear axle assembly toward the engine to engage propeller shaft splines and position the swing arm in the frame. Line up cone bearing and install RH pivot bolt. 1

V01J09A

1. Swing arm bellows 2. Oil seal 3. Cone bearing

V01J0AA

Installation

1. RH pivot bolt 2. Pivot bearing

Installation is essentially the reverse of removal procedure. However, pay attention to the following details. Join the rear axle and the swing arm together. See the REAR AXLE section for the proper procedure. Pack cone bearing cavities with synthetic grease (P/N 293 550 010). Apply grease (P/N 293 550 019) to spring and splines before insert the end of the propeller shaft into swing arm.

Install LH pivot bolt. Move the swing arm up and down several times and tighten LH pivot bolt. Torque LH pivot bolt to 11 N•m (97 lbf•in). Torque RH pivot bolt to 147 N•m (108 lbf•ft). Install jam nut and torque to 147 N•m (108 lbf•ft) while holding pivot bolt.

 WARNING The LH pivot bolt must have more than 2 threads out of jam nut. Attach swing arm bellows to engine and install clamp. Torque to 5 N•m (44 lbf•in). Reinstall master cylinder. Check brake pedal adjustment. Refer to HYDRAULIC BRAKES for complete adjustment procedure. Fasten rear brake caliper. Route brake hose and secure to the brackets. Reinstall shock absorbers.

V01H09A

1. Propeller shaft 2. Apply grease

VMR2001_059_08_03A.FM

08-03-5

Section 09 BRAKES Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

HYDRAULIC BRAKES............................................................................................................ 09-02-1 FRONT BRAKES ................................................................................................................ 09-02-1 REAR BRAKE ..................................................................................................................... 09-02-2 GENERAL ........................................................................................................................... 09-02-3 MASTER CYLINDER .......................................................................................................... 09-02-3 CALIPER ............................................................................................................................. 09-02-5 BRAKE PADS ..................................................................................................................... 09-02-5 BRAKE DISC....................................................................................................................... 09-02-6 BRAKE PEDAL ................................................................................................................... 09-02-7 BRAKE CABLE ................................................................................................................... 09-02-8 BRAKE HOSES AND BRAKE TUBES................................................................................ 09-02-9 BRAKE SYSTEM BLEEDING ............................................................................................. 09-02-11 BRAKE LIGHT SWITCH ..................................................................................................... 09-02-12

VMR2001_065_09_01ATOC.FM

09-01-1

Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)

HYDRAULIC BRAKES

FRONT BRAKES

11 12 24 N m (18 lbf ft) 5 10 14 N m (124 lbf in)

6 N m (53 lbf in)

20 N m (15 lbf ft)

10 24 N m (18 lbf ft) 14

24 N m (18 lbf ft) 14

20 N m (15 lbf ft)

24 N m (18 lbf ft) 25

6 N m (53 lbf in) 9

24 N m 10 (18 lbf ft)

11 12 24 N m (18 lbf ft)

2 14 N m (124 lbf in)

24 N m 12 (18 lbf ft) 11

14 N m (124 lbf in)

V01K1AS

VMR2001_060_09_02A.FM

PARTS

FLAT RATE

09-02-1

Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)

REAR BRAKE

4 N m (35 lbf in) 18 24 N m (18 lbf ft) 12

15 16

24 N m 25 (18 lbf ft) 11

12 24 N m (18 lbf ft)

14 N m (124 lbf in) 10 N m (89 lbf in)

14 34 N m (25 lbf ft)

V01K19S

09-02-2

PARTS

FLAT RATE

VMR2001_060_09_02A.FM

Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)

GENERAL

Hydraulic Brakes System The brake system consists of two separate circuits. Each system has its own master cylinder and reservoir. Both front and rear brakes are disc type.

Parking Device The parking device operates the rear brake only. It is activated by a locking mechanism on LH brake lever. 2

V01K12A

TYPICAL 1. Oil level mark 2. Bolt 3. Sealing washers 4. Remove screws

Rear Brake Remove seat to have access to master cylinder reservoir no. 15. Unscrew reservoir cover. 2

V01K0KA

TYPICAL 1. LH Brake lever 2. Locking mechanism

MASTER CYLINDER Removal Front Brakes Remove reservoir cover with diaphragm and drain brake fluid from master cylinder no. 4. CAUTION: Avoid spilling brake fluid on plastic, rubber or painted parts. Protect these parts with a rag when servicing brake system. Remove bolt no. 12 and sealing washers no. 11 retaining brake hose no. 5 to master cylinder. Remove screws from master cylinder holder and remove master cylinder from handlebar.

VMR2001_060_09_02A.FM

V01K0HA

TYPICAL 1. Brake fluid reservoir 2. Reservoir cover 3. Flexible hose

Raise rear of vehicle and support it securely. Remove RH wheel and RH side panel to have access to rear brake master cylinder no. 19. Disconnect flexible hose no. 16 from reservoir and plug the end to avoid brake fluid spillage.

09-02-3

Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)

Remove bolt no. 12 and sealing washers no. 11 retaining brake hose no. 23 to master cylinder no. 19. Discard sealing washers. Unhook push rod from brake pedal no. 20. Remove bolt retaining master cylinder no. 19 to frame. 2

V01K16A

TYPICAL 1. Rear master cylinder 2. Pusher 3. Boot

Installation For the installation, reverse the removal procedure, paying attention to the following details.

V01K0JA

TYPICAL 1. Master cylinder 2. Flexible hose 3. Rear brake hose 4. Push rod 5. Remove bolts

Front Brakes Place the master cylinder no. 4 on the handlebar. Position cylinder holding bracket with the UP mark upward. Install bolts and tighten loosely. With the handlebar in straight ahead position, position cylinder reservoir parallel to the ground. Tighten upper bolt in first.

Inspection and Lubrication Discard any remaining fluid inside reservoir. Clean reservoir thoroughly with clean brake fluid. If master cylinder is damaged or leaking, change the defective part(s) or replace as an assembly. Before rear master cylinder installation, remove the pusher and boot. Apply synthetic grease (P/N 293 550 010), about 0.07 oz. (2 g) inside the boot then reinstall boot and pusher. Wipe out any grease spillage on boot.

V01K13A

TYPICAL

Connect brake hose to master cylinder with bolt and new sealing washers.

09-02-4

VMR2001_060_09_02A.FM

Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)

Rear Brake Install master cylinder to frame. Install rear brake hose to master cylinder using new sealing washers. Connect flexible hose from reservoir and secure with new locking tie. Fill up reservoir with clean brake fluid. CAUTION: Do not mix different types of brake fluid. Use only DOT 4 brake fluid. Bleed both front and rear brake systems. Check for leaks and make sure the brakes operate normally before driving.

CALIPER Removal Loosen wheel nuts. Raise vehicle and support it securely. Remove wheels. 2

V01K15A

TYPICAL 1. Remove bolt and washers 2. Unscrew bolts 3. Brake hose

Disassembly Only brake pads are available as spare parts. If caliper is damaged, replace as an assembly.

Installation

V01K14A

TYPICAL â&#x20AC;&#x201D; RH FRONT BRAKE 1. Caliper 2. Brake hose

Remove bolt no. 12 with sealing washers no. 11 and detach brake hose from caliper. Catch spilled fluid with a rag. Attach the brake hose in a position to prevent the fluid from flowing out. Unscrew bolts no. 25 retaining caliper to knuckle and remove caliper. Discard bolts.

VMR2001_060_09_02A.FM

For the installation, reverse the removal procedure, paying attention to the following details. Use new sealing washers when installing bolt retaining brake hose to caliper. Install caliper to knuckle with the new self-locking bolts. If hose was disconnected, bleed the brakes. Check for leaks and make sure the brakes operate normally before driving.

BRAKE PADS Removal Raise vehicle and support it securely. Remove wheels. Remove caliper from knuckle. Remove retaining clip.

09-02-5

Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)

While holding spring, pull out pin retaining brake pads.

CAUTION: Do not clean brake pads in petroleum based solvent. Use brake system cleaner or clean brake fluid only. Soiled brake pads must be replaced by new ones. Measure lining brake pad thickness. Brake pads must be replaced when lining is 1 mm (1/32 in) thick or less. BRAKE PAD MINIMUM THICKNESS

Callout

1 mm (1/32 in)

CAUTION: Brake pads must always be replaced in pairs.

 WARNING Avoid getting oil or grease on brake pads. Contaminated brake pads can affect stopping capacities.

Installation

V01K0CA

Remove brake pads no. 3 from caliper. CAUTION: Don’t let the caliper hang by the hose and don’t stretch or twist the hose.

1. 2. 3. 4.

BRAKE DISC Inspection

Inspection

V01K0FA

Push caliper pistons inward before installing brake pads. After the job is completed, firmly depress the brake lever a few times to bring the pads in contact with the disc. Check for leaks and make sure the brakes operate normally before driving.

Brake discs no. 13 can be inspected without removing from the vehicle. Raise vehicle and support it securely. Remove wheels and visually inspect disc surfaces for scratches or grooves. Make sure to check both sides of disc. Measure thickness of the disc. Minimum thickness is 4.7 mm (.18 in). Replace disc if not within specifications. CAUTION: Brake discs should never be machined. Turn the disc by hand and check run out. DISC MINIMUM THICKNESS

4.7 mm (.18 in)

DISC RUN OUT (MAX.)

0.25 mm (.01 in)

Clip Pin Retaining spring Brake pads

09-02-6

VMR2001_060_09_02A.FM

Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)

Removal CAUTION: Replace the bearing when the brake disc is changed. Remove caliper as described previously. After removing the caliper, suspend it out of the way. CAUTION: Don’t let the caliper hang by the hose and don’t stretch or twist the hose. NOTE: Wheel hub has to be removed from vehicle to replace brake disc no. 13. Remove cotter pin and unscrew castellated nut. Remove O-ring.

Remove screws no. 14 retaining brake disc no. 13 to wheel hub. Discard screws. NOTE: Heat up disc around screws to facilitate removal.

Installation Install brake disc on wheel hub and tighten in a criss-cross sequence.

1 3 4 2

V01K0BA

TORQUE TO 34 N•m (25 lbf•ft)

Install new self-locking screws and torque screws no. 14 to 34 N•m (25 lbf•ft).

V01H0BA

TYPICAL 1. Remove O-ring

BRAKE PEDAL

Using a suitable puller, pull out wheel hub with disc. 1

Removal Remove RH side panel with foot peg. Refer to BODY for removal procedure. Unhook the return spring no. 21. Unhook the brake cable no. 17 and push rod from brake pedal.

V01K0AA

TYPICAL 1. Knuckle 2. Wheel hub

VMR2001_060_09_02A.FM

09-02-7

Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)

BRAKE CABLE Removal NOTE: Before removing brake cable from vehicle, note cable routing for reinstallation. Brake Pedal Remove adjusting nut no. 24 and disconnect brake cable no. 17 from brake pedal. 1

V01K0IA

TYPICAL 1. Brake light switch 2. Interlock cable 3. Master cylinder 4. Return spring 5. Brake cable 6. Brake pedal

Remove cotter pin and washer then remove pedal no. 20 from pivot.

Installation and Adjustment Place a shim between brake pedal lever and switch nut. The tightness of the shim must be 3 mm (1/8 in). Adjust push rod to eliminate free play between brake pedal lever and master cylinder. When the light pressure is feeling, torque push rod nut to 4.5 Nâ&#x20AC;˘m (39 lbfâ&#x20AC;˘in). Remove the shim and press the brake pedal lever. Check for the light play in the system.

V01K0MA

TYPICAL 1. Adjusting nut 2. Brake cable

It may be necessary to hold the rod with locking pliers to prevent it from turning. Release cable housing from frame bracket. Brake Handle Unscrew the bolt retaining the parking lever lock from brake lever no. 18 and remove the lever. Release the tension on brake lever. Rotate cable end bushing so that cable aligns with the brake lever recess, then lift cable end.

Inspection Inspect cable ends for wear or deterioration. Replace if necessary.

Installation and Adjustment

V01K0YA

TYPICAL 1. Push rod jam nut 2. Brake pedal return spring

09-02-8

Installation is the reverse of the removal procedure. NOTE: Adjust brake pedal prior to adjusting brake cable. If brake pedal is not correctly adjusted, the parking device will not function properly.

VMR2001_060_09_02A.FM

Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)

While holding rod with locking pliers, turn the adjustment nut until stopper comes in contact with the brake pedal lever. Unscrew adjustment nut approximately 1/4 turn to make sure there is no tension on brake cable. 1

1 V01K0NA V01K0ZA

TYPICAL 1. Adjustment nut 2. Stopper 3. Max. 1 mm (1/32 in) gap

BRAKE HOSES AND BRAKE TUBES Removal

TYPICAL 1. Vertical brake tube 2. Brake hose 3. Tube clip

Be careful not to bend the brake tubes. Remove screw holding tube clip no. 10 and detach hoses from the frame or upper swing arm. Remove bolt no. 12 from caliper or master cylinder and discard sealing washers no. 11.

Front Flexible Brake Hoses Remove front luggage rack and front fender assembly. Remove fuel tank cover. Refer to BODY for complete procedure. Unscrew the brake tube no. 6 from the hose fitting no. 7.

V01K0RA

TYPICAL â&#x20AC;&#x201D; RIGHT HAND SIDE 1. Flexible hose 2. Tube clip

VMR2001_060_09_02A.FM

09-02-9

Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)

V01K0SA

TYPICAL â&#x20AC;&#x201D; LEFT HAND SIDE 1. Flexible hose 2. Tube clip

Rear Flexible Brake Hose Remove bolt no. 12 retaining flexible hose no. 23 on top of rear master cylinder no. 19. 1

V01K0WA

TYPICAL 1. Rear brake caliper 2. Flexible brake hose

Detach hose no. 23 from swing arm and remove from vehicle. Brake Tubes Disconnect the brake tubes no. 6 and no. 8 from fitting on flexible hoses no. 9. Remove tube clip no. 10 retaining left flexible hose to frame. 5

V01K0JA

TYPICAL 1. Disconnect brake hose

Remove bolt no. 12 and washers no 11 retaining hose to rear caliper.

V01K0TA

TYPICAL 1. Vertical tube 2. Horizontal tube 3. Left flexible hose 4. Right flexible hose 5. Unscrew tube fitting

09-02-10

VMR2001_060_09_02A.FM

Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)

Inspection Periodically inspect flexible brake hoses for cracks, leaks, blisters and any other damage. If any sign of deterioration is found, replace the defective part with a new one.

Installation Flexible Hoses To install hoses, attach it to the caliper first. Always use new washers on both sides of the fitting. Make sure brake hoses are properly secured and that they do not come in contact with moving parts.

NOTE: Check the fluid level often in the reservoir. Add brake fluid when level is low. Repeat procedure until no air appears in hose. Proceed the same way with the left side front caliper. NOTE: Front and rear brakes must be bled separately as they are separate systems. Refill the master cylinder to proper level at the end of the operation.

Brake Tubes Connect the brake tubes to the hose fitting but donâ&#x20AC;&#x2122;t tighten yet. Install the tube clips no. 10 retaining the brake hose to the frame. Tighten the brake tube fitting, paying attention not to twist tubes.

MAX

MIN

BRAKE SYSTEM BLEEDING If the brake hoses have been disconnected at the master cylinder, or if air has entered the system due to low fluid level, it will be necessary to bleed complete system. If a brake hose has been disconnected only at one wheel, only that caliper must be bled. Remove cover and fill reservoir with DOT 4 brake fluid. Check the fluid level often during the bleeding operation. Keep sufficient brake fluid in reservoir at all times. CAUTION: Do not mix different types of brake fluid. Use only DOT 4 brake fluid. Place caliper on the top of the disk brake. The bleeder must be as high as possible. Install a hose on left side bleeder. Route this hose to a container. Connect the plastic hose of the brake bleeder tool to the bleeder valve of the right side front caliper. NOTE: Use the air pump (P/N 529 021 800) and bottle included in engine leak tester (P/N 861 749 100). Use the pump in vacuum mode. Pump gauge lever and open bleeder valve. And check for air to escape.

VMR2001_060_09_02A.FM

V01K0UA

REAR BRAKE MASTER CYLINDER

V01K12B

FRONT BRAKE MASTER CYLINDER 1. Indicator level

Install cover on master cylinder. Check for leaks and make sure the brakes operate normally before driving.

09-02-11

Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)

BRAKE LIGHT SWITCH Removal Front Brake Light Switch The front brakes switch is located on the master cylinder and cannot be adjusted. Check that switch is securely installed.

V01K0XA

1. Front brake light switch

Rear Brake Light Switch The rear brake switch is located above brake pedal. Remove RH side panel with foot peg. Refer to BODY for removal procedure. Disconnect wire harness. Unscrew jam nut and remove switch from bracket.

Inspection and Installation Check switch for dirt or corrosion. Make sure it is operating properly. Depress brake pedal and check for brake light to turn on. For installation, reverse the removal procedure. NOTE: The rear brake light switch cannot be adjusted.

09-02-12

VMR2001_060_09_02A.FM

Section 10 BODY/FRAME Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

BODY ...................................................................................................................................... BODY PARTS ..................................................................................................................... SEAT................................................................................................................................... SEAT/ENGINE COVER....................................................................................................... STORAGE/STEERING/SHIFTER GUIDE COVER .............................................................. FRONT SKID PLATE/BUMPER/ LUGGAGE RACK ........................................................... FRONT FENDER/MUDGUARD/ FACIA ............................................................................. INNER FENDER.................................................................................................................. FUEL TANK COVER/SIDE PANEL ..................................................................................... REAR LUGGAGE RACK/REAR BUMPER.......................................................................... REAR FENDER/REAR FENDER COVER ............................................................................ REAR MUDGUARD/FACIA ................................................................................................ SKID PLATE ....................................................................................................................... ARM PROTECTOR ............................................................................................................. LATCH LEVER/LATCH BASE/ SPRING ............................................................................. SEAT ADJUSTMENT ........................................................................................................ REAR CARGO BOX LATCHES ADJUSTMENT ................................................................ REAR CARGO BOX............................................................................................................ REAR CARGO BOX GATE ................................................................................................. SEAT COVER REPLACEMENT .......................................................................................... STORAGE COVER LATCH................................................................................................. SEAT CLEANING ............................................................................................................... DECALS REPLACEMENT .................................................................................................. HITCH/TRAILER BALL ....................................................................................................... PLASTIC MAINTENANCE ................................................................................................. MAINTENANCE ................................................................................................................. PLASTIC REPAIR................................................................................................................ REPAIR................................................................................................................................

10-02-1 10-02-1 10-02-3 10-02-4 10-02-5 10-02-5 10-02-6 10-02-8 10-02-8 10-02-9 10-02-10 10-02-11 10-02-12 10-02-12 10-02-13 10-02-13 10-02-13 10-02-14 10-02-14 10-02-14 10-02-14 10-02-15 10-02-15 10-02-15 10-02-15 10-02-15 10-02-16 10-02-16

FRAME ................................................................................................................................... FOOTREST ......................................................................................................................... REMOVABLE BRACE......................................................................................................... REAR FRAME EXTENSION ............................................................................................... WINCH LATCH ................................................................................................................... FRAME ...............................................................................................................................

10-03-1 10-03-3 10-03-3 10-03-4 10-03-5 10-03-5

VMR2001_065_10_01ATOC.FM

10-01-1

Section 10 BODY/FRAME Subsection 02 (BODY)

BODY

BODY PARTS 1.5 N m (13 lbf in) 49

17 40 2.5 N m (22 lbf in) 45 44 2.5 N m (22 lbf in)

3 N m (27 lbf in) 49

4 26

48 1.5 N m (13 lbf in)

18 47

37 11

2.5 N m (22 lbf in)

4.5 N m (40 lbf in)

52 16 N m (142 lbf in) 28 V01L3HS

VMR2001_061_10_02A.FM

39 5 N m (44 lbf in)

15 51

7 N m (62 lbf in)

15 N m (133 lbf in) 50

PARTS

FLAT RATE

10-02-1

Section 10 BODY/FRAME Subsection 02 (BODY)

8 15 N m (133 lbf in)

XT Model

25 N m (18 lbf ft)

2.5 N m (22 lbf in)

15 N m (133 lbf in)

7 29 25 N m 3

(18 lbf ft)

60 59

43 15 N m (133 lbf in)

15 N m (133 lbf in)

V01L3IS

10-02-2

PARTS

FLAT RATE

VMR2001_061_10_02A.FM

Section 10 BODY/FRAME Subsection 02 (BODY)

SEAT All Models except XL

21 53

54 23

24 N m (17 lbf ft)

56 57

V01L2HS

VMR2001_061_10_02A.FM

PARTS

FLAT RATE

10-02-3

Section 10 BODY/FRAME Subsection 02 (BODY)

SEAT/ENGINE COVER Removal Seat All Models except XL To remove seat no. 1, pull latch upward while gently lifting rear of seat. Continue lifting movement until you can release the front retaining devices, then, completely remove seat.

XL Model Push latch backwards while gently lifting rear of seat. Continue lifting movement until you can release the front retaining devices then completely remove seat.

V01L02A

1. Seat latch

Engine Cover All Models The engine cover no. 2 is located in front of seat. Remove seat and screws no. 24.

V01L0AA

V01L0GA

10-02-4

VMR2001_061_10_02A.FM

Section 10 BODY/FRAME Subsection 02 (BODY)

On the inside, remove bolts no. 25.

Remove ignition switch and choke lever. Unplug all connectors. Shifter Guide Cover Lift steering cover. Unfasten plastic screws no. 26 then remove shifter guide cover no. 5.

V01L1QA

Installation Installation is the reverse order of removal.

STORAGE/STEERING/ SHIFTER GUIDE COVER

V01L0XA

All Models

Inspection

Removal

Check latches no. 27 from storage cover for cracks or other damages. Change if necessary.

Storage Cover The storage cover no. 3 is retained by two rubber latches no. 27. Unlatch cover, lift then remove cover. Steering Cover Remove screws under handlebar then lift the steering cover no. 4.

Installation Installation is the reverse order of removal.

FRONT SKID PLATE/BUMPER/ LUGGAGE RACK Removal Front Skid Plate All Models except XT To remove front skid plate no. 6, unscrew bolts no. 28 and screws no. 15.

V01L0WA

VMR2001_061_10_02A.FM

10-02-5

Section 10 BODY/FRAME Subsection 02 (BODY)

Front Luggage Rack Remove bolts no. 30, no. 31 and no. 32. NOTE: Remove sealed beam to reach nut. Refer to INSTRUMENTS AND ACCESSORIES.

V01L0YA

XT Model Remove: – hitch hook no. 41 – fairlead no. 52 – screws no. 15. Withdraw front skid plate no. 6. Front Bumper NOTE: The attachments of front bumper no. 7 are located at the same place for all models even if the bumper shape is different. Remove front skid plate. Remove bolts no. 29 and no. 30.

V01L12A

Detach the cable of the sealed beam. Pull front luggage rack no. 8 upside.

Installation Installation is in the reverse order of removal.

FRONT FENDER/MUDGUARD/ FACIA Removal Front Fender Remove front luggage rack and shifter guide cover. Remove screws no. 33 and no. 34 on each side. V01L0ZA

TYPICAL

10-02-6

VMR2001_061_10_02A.FM

Section 10 BODY/FRAME Subsection 02 (BODY)

V01L15A

V01L13A

Remove the screws no. 38 on the top of facia.

Remove fuel cap. Lift front fender no. 9. Front Mudguard Remove screws no. 34 and no. 35. Remove screw no. 36 near the front facia then separate front mudguard no. 10 from fender.

V01L16A

Remove bolts no. 28, no. 29 and no. 30.

V01L1PA

Front Facia Remove sealed beams. Remove the screws no. 37 under facia.

V01L0YB

VMR2001_061_10_02A.FM

10-02-7

Section 10 BODY/FRAME Subsection 02 (BODY)

Pull front bumper forward and remove front facia no. 11.

Installation Installation is the reverse order of removal.

INNER FENDER Removal Inner Fender Remove front wheel to access inner fender no. 12. Remove screws no. 39.

Installation Install in first, the upper clip; secondly, the lower front screw and then the lower rear screw. NOTE: Install all screws before torquing.

FUEL TANK COVER/SIDE PANEL Removal Fuel Tank Cover Remove seat. Turn steering to the right side and remove screw retaining shifter guide cover and fuel tank cover no. 13. Turn steering to the left side and remove the other screw.

V01A30A

Remove screw on the LH side and separate from dart on the RH side. 1

V01L2KA

1. Screw 2. Dart

10-02-8

VMR2001_061_10_02A.FM

Section 10 BODY/FRAME Subsection 02 (BODY)

Remove latches no. 40. Three by side.

V01L1DA V01L14A

Side Panel Remove seat. Remove footpeg. Remove plastic pin and screws retaining the side panel no. 14 with front and rear fender.

Installation Installation is the reverse order of removal.

REAR LUGGAGE RACK/ REAR BUMPER Removal All Models except XL Under rear fender, remove bolts no. 43. One on each side.

V01L1CA

TYPICAL â&#x20AC;&#x201D; TRAXTER SHOWN

On front and rear mudguards, remove the three first screws no. 35 and screws no. 34 retaining side panel with mudguards.

V01L1FA

Remove bolts no. 59 retaining rear luggage rack to rear bumper. Withdraw rear luggage rack.

VMR2001_061_10_02A.FM

10-02-9

Section 10 BODY/FRAME Subsection 02 (BODY)

Rear Bumper Remove bolts no. 59 retaining rear luggage rack to rear bumper no. 60. Remove bolts no. 42 under rear facia. Pull the rear bumper.

Installation Installation is the reverse order of removal. NOTE: Install all bolts before torque.

REAR FENDER/ REAR FENDER COVER Removal Rear Fender All Models except XL Remove seat, rear luggage rack. Remove screws no. 44 under rear facia, screws no. 45 near tail light and screws no. 49 on the top.

V01L1IA

Disconnect brake light. XL Model On the XL model, there are 2 rear fenders. Lift the rear cargo box and remove the three screws on the top of fender. Remove the screws located in the compartment, and the other screws on the side. Remove the screws retaining side panel and rear fender.

V01L1HA

Remove plastic pin of rear fender no. 16. Remove screws no. 33 and no. 34.

V03L0BA

10-02-10

VMR2001_061_10_02A.FM

Section 10 BODY/FRAME Subsection 02 (BODY)

Rear Fender Cover

Installation

All Models except XL Remove rear luggage rack. Remove screws no. 44 under rear facia.

Installation is the reverse order of removal.

REAR MUDGUARD/FACIA Removal Rear Mudguard All Models except XL Remove screws no. 47 retaining mudguard no. 18 and rear fender. Remove screws retaining mudguard and side panel.

V01L1HB

Lift the rearward of the rear fender and remove the ten latches no. 46.

V01L1IB

Remove screw no. 48 near rear facia. XL Model Remove the five screws on the side. Lift the rear cargo box and remove the screw retaining mudguard to fender.

V01L1LA

Remove rear fender cover no. 17.

VMR2001_061_10_02A.FM

10-02-11

Section 10 BODY/FRAME Subsection 02 (BODY)

V01L1OA

SKID PLATE Inspection

V03L0BB

The skid plate no. 20 protected the engine. Check for damage, crack or looseness. Change if skid plate is damaged or cracked. Torque all bolts at the regular interval.

Rear Facia

Removal

All Models except XL Remove rear luggage rack. Unfasten screws no. 44 and no. 49 retaining rear facia no. 19 to rear fender.

Skid Plate Under vehicle, remove bolts no. 50 and no. 51.

Installation Installation is the reverse order of removal. NOTE: Install all bolts before torque.

ARM PROTECTOR Removal Remove the bolts.

V01L1MA

Installation Installation is the reverse order of removal. However, pay attention to the following details. For the rear facia installation, install the flat washers between rear fender and rear facia with a needle nose pliers.

V01L1NA

10-02-12

VMR2001_061_10_02A.FM

Section 10 BODY/FRAME Subsection 02 (BODY)

Installation

Installation is the reverse order of removal.

LATCH LEVER/LATCH BASE/ SPRING

Removal Latch Lever All Models except XL Remove push nut no. 53 and rivet no. 54. Separate latch lever no. 21 from spring no. 23. XL Model Detach lever spring from lever. Unscrew pivot bolt. Remove latch springs from lever rod. Remove lever rod cap then pull the lever rod and the lever.

V01L1SA

1. Lock pin 2. Adjustment nut (apply Loctite 271) A. 38 ± 1 mm (1-1/2 ± 3/64 in)

XL Model 1

Latch Base Remove bolts no. 55 and separate latch base no. 22 from spring. Spring Remove latch base. Separate spring from latch base and latch lever.

Installation Installation is the reverse order of removal.

SEAT ADJUSTMENT All Models except XL For latch stud no. 56 adjustment, unscrew the latch stud nut no. 57 and screw or unscrew the latch stud to the best height. See the following illustration.

VMR2001_061_10_02A.FM

V03L0CA

1. Lock pin 2. Adjustment nut (apply Loctite 271) A. 17 ± 1 mm (11/16 ± 3/64 in)

Torque the latch stud nut.

REAR CARGO BOX LATCHES ADJUSTMENT XL Model NOTE: A good maintenance and adjustment of the rear cargo box latches will improve the life expectancy of the closing mechanism. A poorly maintained mechanism and a bad adjustment will result in premature deterioration.

10-02-13

Section 10 BODY/FRAME Subsection 02 (BODY)

To adjust the latch studs: Make sure the box is closed properly (latched on each side). If one side is hard to latch it means the stud is adjusted too short; note which side it is and proceed with step 1. If the box is too loose or too tight proceed with step 2. Otherwise, leave the vehicle as is. 1. Check if there is a lot of slack in the box latch by lifting one side at a time while the mechanism is still closed. Do not force it. If it is very loose, note how much it travels. 2. Open the rear cargo box and remove the rubber cap on the studs by pulling them downwards. 3. Use a 13 mm key to tighten or untighten the studs on each side depending on the adjustment needed. Note that the space between the large washer and the box frame should remain between 11 mm (.433 in) and 19 mm (.748 in). 4. Install the rubber cap and close the box. Repeat the procedure until the box is well adjusted and until it locks on each side whenever it is closed.

Install staples with an electric tacker such as Arrow tacker no. ETN-50 or with a manual tacker such as Arrow tacker no. T-50. NOTE: For an easier installation, itâ&#x20AC;&#x2122;s highly recommended to use an electric tacker. Ensure that the seat rest firmly against a hard surface such as a piece of wood. This is done to get the staples completely pushed in place.

REAR CARGO BOX XL Model

Removal Detach the shock under box. Unscrew all bolts in the bottom of box.

Installation Installation is the reverse order of removal.

1 F01L3YA

TYPICAL 1. Piece of wood 2. ETN-50 (electric) or T-50 (manual)

After cover installation cut all around the excess of material.

REAR CARGO BOX GATE

STORAGE COVER LATCH

Removal

Inspection

Under gate, remove a cap nut at the end of gate rod then pull the gate rod by the other side. Detach the cables door.

Inspect for crack or damage. Change if a any crack or damage are detected.

Installation

Under front fender, pull the storage cover latch.

Installation is the reverse order of removal.

Installation

SEAT COVER REPLACEMENT

Under front fender, insert the storage cover latch in the slot. Pull the latch by the top.

Removal

Remove the old seat cover no. 58. Check the foam and replace if necessary.

10-02-14

VMR2001_061_10_02A.FM

Section 10 BODY/FRAME Subsection 02 (BODY)

SEAT CLEANING It is recommended to clean the seat with a solution 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. that may cause damage to the seat cover.

DECALS REPLACEMENT Removal

Using a pencil and the decal as a template, mark the area where decal will be located. Apply an activator (P/N 293 530 036) to prepare the surface using a clean cloth. After a few seconds, when the activator evaporates, the surface is ready. CAUTION: Do not use soapy water to locate decal on plastic parts. Remove back protective film from decal and carefully align decal with marks. When well aligned squeegee decal beginning at center and working outward using firm, short, overlapping strokes.

Using a heat gun warm up one end of decal for a few seconds until decal can roll off when rubbing with your finger. Pull decal slowly and when necessary apply more heat to ease removal on the area that has to be peeled off. If decal tears while pulling off, it has to be heated for a few seconds longer. If decal tends to stretch while pulling off, stop heating and wait a few seconds to let it cool, then peel it off.

HITCH/TRAILER BALL

Installation

Clean the vehicle thoroughly, removing all dirt and grease accumulation. To clean use a soft clean cloth and either soapy water or isopropyl alcohol. To remove grease, oil or glue use isopropyl alcohol. CAUTION: Do not apply isopropyl alcohol or acetone directly on decals. CAUTION: The following products must not be used to clean or wax any of the plastic components used on the vehicles: – gasoline – brake fluid – kerosene – diesel fuel – lighter fluid – varsol – naphtha – acetone – strong detergents – abrasive cleaners – waxes containing an abrasive or a cleaning agent in their formula.

There are 2 types of decals used on ATV. One has a protective film on back side and the other has a protective film on both sides. They are used on 2 types of materials; plastic and metal. DECALS HAVING A PROTECTIVE FILM ON BACK SIDE ONLY These decals usually contain written information (ex.: warning) and are used on metal. Clean surface with a good solvent such as ACRYLICLEAN DX 330 from PPG or equivalent (refer to manufacturer instructions). Using a pencil and the decal as a template, mark the area where decal will be located. Remove half of the decal back protective film and align decal with marks. Start sticking it from center and remove the other half of the film to stick it completely. Carefully squeegee decal beginning at center and working outward using, firm, short, overlapping strokes. DECALS HAVING A PROTECTIVE FILM ON BOTH SIDES These decals usually contain graphics and are used on plastic.

Inspection The hitch/trailer ball is optional. If the vehicle is equipped with this option, often check the solidity of the installation.

PLASTIC MAINTENANCE MAINTENANCE

INSTALLATION ON PLASTIC Clean surface with isopropyl alcohol. VMR2001_061_10_02A.FM

10-02-15

Section 10 BODY/FRAME Subsection 02 (BODY)

PLASTIC REPAIR REPAIR The very first step before repairing plastic materials is to find out exactly which type of material is involved. Refer to following chart. CAUTION: Consult the plastic maintenance chart carefully, some maintenance products are not compatible with certain plastics. IRREPARABLE PART

HIGH DENSITY POLYETHYLENE

LOW DENSITY POLYETHYLENE

Fuel tank cover Front and rear facia Front and rear fender Rear fender cover Side panel Steering cover Storage cover Inner fender Front skid plate Front and rear mudguard Rear cargo box and gate

10-02-16

VMR2001_061_10_02A.FM

Section 10 BODY/FRAME Subsection 03 (FRAME)

FRAME

All Models except XL 3

24 N m (17 lbf ft) 10 9 48 N m (35 lbf ft) 4

48 N m (35 lbf ft) 9

1 5

24 N m (17 lbf ft)

2 6 FOOTSHIFT Model

24 N m (17 lbf ft) 8

V01L3ES

24 N m (17 lbf ft) 8

VMR2001-062_10_03A.FM

6 24 N m (17 lbf ft)

PARTS

FLAT RATE

10-03-1

Section 10 BODY/FRAME Subsection 03 (FRAME)

XL Model

3 48 N m (35 lbf ft) 9

9 48 N m (35 lbf ft)

8 24 N m (17 lbf ft)

48 N m 7 (35 lbf ft)

6 24 N m (17 lbf ft)

8 24 N m (17 lbf ft)

V03L09S

10-03-2

PARTS

FLAT RATE

VMR2001-062_10_03A.FM

Section 10 BODY/FRAME Subsection 03 (FRAME)

FOOTREST Removal All Models except XL Remove: – side panel (refer to BODY) – mounting flanged bolts no. 6.

XL Model NOTE: Empty the rear cargo box. Remove: – side panel (refer to BODY) – screws retaining rear fender to footrest – mounting flanged bolts no. 6. Unscrew the bolt no. 7 then remove the footrest.

V03L0DA

Inspection V01L3GA

Check for cracks or bent tube. Change or repair if necessary.

TRAXTER, XT AND AUTOSHIFT MODELS

Installation Installation is essentially the reverse of removal procedure.

REMOVABLE BRACE Removal Remove side panel. Refer to BODY. Unscrew bolts no. 8. Remove the removable brace no. 2. V01L3FA

FOOTSHIFT MODEL — LH SIDE

Withdraw the footrest no. 1.

Inspection Check for crack or bent tube. Change if necessary.

Installation For the installation, reverse the removal procedure.

VMR2001-062_10_03A.FM

10-03-3

Section 10 BODY/FRAME Subsection 03 (FRAME)

REAR FRAME EXTENSION Removal All Models except XL Remove: – rear fender (refer to BODY) – battery (refer to STARTING SYSTEM) – radiator with fan, (refer to COOLING SYSTEM) – muffler and heat shield (refer to REMOVAL AND INSTALLATION) – voltage regulator, (refer to CHARGING SYSTEM) – taillight – winch solenoid (XT model). Remove mounting flanged bolts no. 9 then withdraw the rear frame extension no. 3.

XL Model Remove: – rear cargo box, rear fenders and release lever (refer to BODY) – battery (refer to STARTING SYSTEM) – radiator with fan, (refer to COOLING SYSTEM) – muffler and heat shield (refer to REMOVAL AND INSTALLATION) – voltage regulator, (refer to CHARGING SYSTEM) – winch solenoid – shock absorbers. Remove mounting flanged bolts no. 7 and no. 9 then withdraw the rear frame extension no. 3.

V03L0AA

XL MODEL 1. Remove the mounting flanged bolts

Inspection Check for crack, bent tube or other damage. Repair or change if necessary. V01L2JA

ALL MODELS EXCEPT XL 1. Remove the mounting flanged bolts

10-03-4

Installation Installation is the reverse of removal procedure.

VMR2001-062_10_03A.FM

Section 10 BODY/FRAME Subsection 03 (FRAME)

WINCH LATCH

FRAME

Removal

Cleaning

Remove front skid plate and front bumper. Refer to BODY. Remove flanged bolts no. 10.

Clean frame no. 5 and rear frame extension with appropriate cleaners and rinse with high pressure hose. Touch up all metal spots where paint has been scratched off. Spray all bare metal parts of vehicle with metal protector.

Welding

V01L0YC

1. Remove flanged bolts

Withdraw the winch latch no. 4 from the frame.

Inspection Check for crack or other damage. Change if necessary.

Installation

Steel Frame: – electric welding – amperage: 70 - 110 A – voltage: 20 - 24 V – rod: E-7014 (3/32 in). CAUTION: Before performing electrical welding anywhere on the vehicle, unplug the multiple connector at the MPEM or the electronic module connector (FOOTSHIFT model only). Also unplug the negative cable and the voltage regulator. This will protect the MPEM or the electronic module and battery against damage caused by flowing current when welding. NOTE: Install the ground as close as possible from the reparation area. CAUTION: If welding is to be done near plastic material, it is recommended to either remove the part from the area or to protect it with aluminum foil to prevent damage.

Installation is the reverse of removal procedure.

VMR2001-062_10_03A.FM

10-03-5

Subsection 01

Section 11 TECHNICAL DATA (SI METRIC INFORMATION GUIDE)

TECHNICAL DATA

SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION

UNIT

SYMBOL

length .................................................................. mass .................................................................... force .................................................................... liquid .................................................................... temperature ........................................................ pressure .............................................................. torque .................................................................. speed ..................................................................

meter ..................................................... kilogram ................................................. newton ................................................... liter ......................................................... Celsius ................................................... kilo pascal ............................................... newton•meter ....................................... kilometer per hour ..................................

m kg N L °C kPa N•m km/h

PREFIXES PREFIX

SYMBOL

MEANING

VALUE

kilo ................................ centi ............................. milli ............................... micro ............................

k ............................... c ............................... m .............................. µ ...............................

one thousand ......................................... one hundredth ........................................ one thousandth ...................................... one millionth ..........................................

1 000 0.01 0.001 0.000001

CONVERSION FACTORS TO CONVERT

TO †

MULTIPLY BY

in ......................................................................... in ......................................................................... in2 ........................................................................ in3 ........................................................................ ft .......................................................................... oz ......................................................................... lb ......................................................................... lbf ........................................................................ lbf•in ................................................................... lbf•ft .................................................................... lbf•ft .................................................................... PSI (lbf/in2) .......................................................... imp. oz ................................................................. imp. oz ................................................................. imp. gal ................................................................ imp. gal ................................................................ U.S. oz ................................................................. U.S. gal ................................................................ MPH .................................................................... Fahrenheit ........................................................... Celsius .................................................................

mm ......................................................... cm .......................................................... cm2 ......................................................... cm3 ......................................................... m ............................................................ g ............................................................. kg ........................................................... N ............................................................ N•m ....................................................... N•m ....................................................... lbf•in ...................................................... kPa ......................................................... U.S. oz .................................................... mL .......................................................... U.S. gal ................................................... L ............................................................. mL .......................................................... L ............................................................. km/h ...................................................... Celsius ................................................... Fahrenheit ..............................................

25.4 2.54 6.45 16.39 0.3 28.35 0.45 4.4 0.11 1.36 12 6.89 0.96 28.41 1.2 4.55 29.57 3.79 1.61 (°F - 32) ÷ 1.8 (°C x 1.8) + 32

* The international system of units abbreviates SI in all languages. † To obtain the inverse sequence, divide by the given factor. To convert ’’mm’’ to ’’in’’, divide by 25.4. NOTE: Conversion factors are rounded off to 2 decimals for easier use.

VMR2001_063_11_01A.FM

11-01-1

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

ENGINE AND VEHICLE VEHICLE MODEL

TRAXTER

Engine type Starting system Number of cylinder(s) Number of valves Decompressor type Bore Stroke Displacement Compression ratio Maximum HP RPM Lubrication Oil filter Intake valve opening Intake valve closing Exhaust valve opening Exhaust valve closing Valve stem diameter

Standard

± 100 RPM

Intake Exhaust

Valve shaft clearance

ENGINE

Valve spring free length Valve spring squareness Intake Valve seat contact width Exhaust Piston measurement Piston/cylinder clearance

Piston ring end gap

mm (in)

6.95 (.274)

New (minimum) New (maximum) Wear limit

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) 1st 2nd 3rd mm (in) 1st 2nd 3rd mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

0.026 (.001) 0.052 (.002) 0.13 (.005) 39 (1.54) 1.1 (.043) 1.8 (.071) 2 (.079) 88.9 (3.5) 0.09 (.0035) Rectangular Taper-face Oil scrapper ring 1.5 (.06) 1.2 (.047) 1.2 (.047) 2.45 (.0967) 0.15 (.006) 0.2 (.008) 13.76 (.542) 13.67 (.538) 89.00 (3.5) 89.03 (3.505) 0.035 (.0014) 0.09 (.0035) 0.005 (.0002) 0.015 (.0006) 31.95 (1.258) 17.96 (.707) 32.036 (1.261) 18.035 (.71) 32.418 (1.276) 32.25 (1.269) 0.08 (.003) 0.05 (.002) 1.3 (.05) 22.05 (.868) 21.99 (.866) 0.08 (.003) 140.4 (5.53)

Maximum Wear limit Wear limit Wear limit Wear limit

Wear limit

Ring height Piston groove clearance Push rod bend Rocker arm bore diameter Rocker arm shaft diameter Cylinder bore Cylinder taper Cylinder out of round Clutch Magneto Clutch Camshaft bore Magneto Intake Cam height Exhaust Clutch Crankshaft deflection Magneto Connecting rod big end axial play Connecting rod small end diameter Piston pin diameter Piston pin bore clearance Clutch drum I.D. VMR2001_063_11_02A.FM

BOMBARDIER-ROTAX 511, longitudinal mount, liquid cooled Electric and manual 1 2 valves with hydraulic lifters (no adjustment) Automatic 89 (3.5) 80 (3.15) 498 (30.4) 9:1 6000 Wet sump with replaceable oil filter BOMBARDIER-ROTAX 21.52° BTDC 53.68° ABDC 40.00° BBDC 25.20° ATDC

Wear limit

Piston ring type

Camshaft ends

mm (in) mm (in) cm3 (in3)

AUTOSHIFT

Wear limit Wear limit Wear limit Wear limit New (maximum) Wear limit New (maximum) Wear limit New (maximum) Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit

11-02-1

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL Weight lining thickness Weight spring length ENGINE

Friction drive plate Steel driven plate

TRAXTER Wear limit Wear limit Minimum thickness Maximum warpage

Clutch spring free length Air filter type Exhaust system

mm (in) mm (in)

2 (.078) 21.6 (.85)

mm (in)

2.7 (.11)

mm (in)

0.25 (.01)

mm (in)

38 (1.5) 2 stage foam filter Nelson, stainless steel USDA approved 400 W @ 6000 RPM I.D.I. (Inductive Discharge Ignition) Not adjustable 2 NGK DR8EA 0.6 to 0.7 (.024 to .027) 190 – 300 0.4 ± 01 0.4 to 0.9 @ 20°C (68°F) Not measurable 7600 Electrolyte battery type 12 volts 19 A•h (20 optional) 0.7 or 0.9 KW 2 x 55 W, H4703 8/27 W, 1157 LEDS, 0.7 V approximately (each) 15 A 15 A (power outlet and auxiliary supply) 15 A 15 A 20 A 30 A Mikuni constant depression type with manual choke and ECS (Enricher Coasting System) BSR33 Mikuni External (vacuum-operated) 1100 ± 100 130 145 32.5 37.5 0-8 (826) 5FEY1-3 3 Variable choke 0.5 mm (.02 in) 2 10.6 .417 Regular unleaded gasoline 87 (Ron + Mon)/2

Type Spark arrester

Magneto/generator Ignition system type Ignition timing Spark plug

Quantity Make and type Gap

Trigger coil Battery charging coil

ELECTRICAL

Ignition coil

Primary Secondary

mm (in) W W W kW

Engine RPM limiter

Battery

Type Voltage Nominal rating Power starter output

Headlight Taillight Pilot lamp cluster

Fuses

Carburetor

CARBURETION

Fuel pump Idle engine speed Main jet Pilot jet Needle jet Jet needle Clip position number Choke plunger position

Adjustment

Fuel

11-02-2

AUTOSHIFT

Ignition Accessories Solenoids Fan MPEM Charging system Type Model Type Model RPM

Throttle cable Preliminary pilot screw turn ± 0.5 mm Float level ± 0.020 in Type Octane no.

VMR2001_063_11_02A.FM

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

TRAXTER

Ethyl glycol/water mix (60% coolant, 40% water). Use coolant specifically designed for aluminum engines Thermostatic 102°C (221°F) 96°C (205°F) 75°C (167°F) 85°C (185°F) 110 kPa (16 PSI)

COOLING

Coolant Fan Fan thermostat Engine thermostat

Switch ON Switch OFF Opening temperature Closing temperature

Radiator cap opening pressure Type

STEERING/ CONTROL

DRIVE TRAIN

Transmission

Normal oil operating pressure of engine

Dual range (HI-LO) with park, neutral and reverse

Speeds Model Minimum Maximum

Operating pressure for shifting and clutching Clutch type Engagement RPM Front differential Front differential ratio Rear axle Rear axle ratio Turning radius

± 100 RPM

Total toe (vehicle on ground)

AUTOSHIFT

5 Electronically controlled hydraulic shift 101 kPa (14.7 PSI) 608 kPa (88 PSI) 810 kPa (118 PSI) 1 centrifugal and 1 multi-disk hydraulically controlled 1600 Shaft driven/single Auto-Lock differential (pump driven) 3.6:1 Shaft driven/solid axle 3.6:1 2.13 m (7 ft)

mm (in)

17 ± 4 ( .669 ± .157)

mm (in)

20 ± 5 (.787 ± 0.197)

Camber angle

0°

Tie-rod maximum length unengaged FRONT Suspension type Suspension travel

SUSPENSION

Shock absorber

Qty Type

Spring free length Spring color code Front preload adjustment REAR Suspension type Suspension travel

Parking brake Lining material Minimum pad thickness Minimum brake disk thighness

Rigid swing arm 190.5 mm (7.5 in) 2 Oil 355 mm (14 in) Green/White/Black 3 settings 2 Hydraulic 1 Hydraulic Transmission brake and brake lever lock on LH brake lever Metallic 1 mm (.04 in) 4.7 mm (.18 in)

Maximum brake disk warpage

0.25 mm (.01 in)

Shock absorber

Qty Type

Spring free length Spring color code Rear preload adjustment Front brake Rear brake BRAKES

Independent suspension — double A-arm 178 mm (7 in) 2 oil 270 mm (11 in) Orange/Black/Black N.A.

VMR2001_063_11_02A.FM

Qty Type Qty Type

11-02-3

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

TRAXTER

AUTOSHIFT

TIRE

TIRES AND WHEELS

Front Pressure Rear Minimum tire thread depth Size

Front Rear

38 kPa (5.5 PSI) 35 kPa (5 PSI) 35 kPa (5 PSI) 31 kPa (4.5 PSI) 4 mm (0.16 in) 635 x 203 x 305 mm (25 x 8 x 12 in) 635 x 254 x 305 mm (25 x 10 x 12 in)

WHEELS Size

DIMENSION

Recommended Minimum Recommended Minimum

Front Rear

305 x 165 mm (12 x 6.5 in) 305 x 203 mm (12 x 8 in) 2071 mm (81.5 in) 1194 mm (47 in) 1143 mm (45 in) 340 kg (755 lb) 1296 mm (51 in) 992 mm (39 in) 940 mm (37 in) 244 mm (9.6 in) 188 mm (7.4 in)

Overall length Overall width Overall height Dry weight Wheel base Wheel track

Front Rear

Front and under engine ground clearance Rear rigid axle ground clearance LIQUID Fuel tank Fuel tank reserve

20 L (5.7 U.S. gal) 6 L (1.6 U.S. gal) 3 L ( 3.17 quarts) SAE, 4 stroke mineral based oil SH or SJ or Bombardier synthetic oil for wet clutch type. Donâ&#x20AC;&#x2122;t use synthetic oil, other than Bombardier brand name, synthetic blend oil or special oil additives. Refer to the oil viscosity chart in the MAINTENANCE/LUBRICATION section 650 mL (22 U.S. oz) 200 mL (6.76 U.S. oz) Synthetic polyolester oil 75W90 (API GL5) TEXACO, HTBJ grease (M3014), ONLY SHELL, Alvania EP-2, ONLY 250 mL (8.5 U.S. oz) Brake fluid DOT 4, ONLY 2.5 L (2.65 quarts)

Capacity Engine/transmission oil

Differential oil

Recommended

Capacity

Front Rear

CAPACITIES

Recommended CV joint grease Propeller shaft grease Hydraulics brakes

Capacity Recommended

Cooling system BODY AND FRAME Weight distribution Front storage tray Rack

Front/rear Front (including front storage tray) Rear (including tongue weight)

Total vehicle load allowed (including driver, all other loads and added accessories) Gross vehicle weight rating Towing Tongue (included with rear rack weight)

11-02-4

49/51 10 kg (22 lb) 40 kg (90 lb) 80 kg (175 lb) 220 kg (485 lb) 540 kg (1200 lb) 500 kg (1100 lb) 14 kg (30 lb)

VMR2001_063_11_02A.FM

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL Frame Front/rear rack Front bumper Front/rear fender

MATERIAL

Fuel tank cover Steering cover Storage compartment cover Front/rear facia Side panel Mudguard Seat cover

VMR2001_063_11_02A.FM

TRAXTER Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color

AUTOSHIFT Steel Black Steel Black Steel Silver High density polyethylene Red or Green High density polyethylene Black High density polyethylene Black High density polyethylene Black High density polyethylene Black High density polyethylene Black Low density polyethylene Black Thermoformed vinyl Black

11-02-5

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

TRAXTER

AUTOSHIFT

ENGINE

SERVICE PRODUCT

Engine support Engine mount Spark plug Rewind starter housing Rear solenoid block Magneto cover bolts Starter bolts Starter RED (+) cable STPS (Sub-Transmission Position Sensor) GBPS (Gear Box Position Sensor)

M8 M10

24 N•m (17 lbf•ft) 48 N•m (35 lbf•ft) 22 N•m (16 lbf•ft) 4.5 N•m (40 lbf•in) 5 N•m (44 lbf•in) 10 N•m (89 lbf•in) 10 N•m (89 lbf•in) 6 N•m (53 lbf•in) 3 N•m (27 lbf•in) 3 N•m (27 lbf•in)

None None Anti-seize Loctite 243 Loctite 243 None None Dielectric grease Loctite 243 Loctite 243

10 N•m (89 lbf•in) 17 N•m (151 lbf•in) 10 N•m (89 lbf•in) 4 N•m (35 lbf•in) 11 N•m (97 lbf•in)

None None None None None

11 N•m (97 lbf•in) 10 N•m (89 lbf•in)

None None

0.6 N•m (5.4 lbf•in)

None

140 N•m (103 lbf•ft) (MINIMUM) 140 N•m (103 lbf•ft) (MINIMUM) 67 N•m (49 lbf•ft) 75 N•m (55 lbf•ft) 48 N•m (35 lbf•ft) 34 N•m (26 lbf•ft) 42 N•m (31 lbf•ft)

None None None None None None None

75 N•m (55 lbf•ft)

Anti-seize

56 N•m (41 lbf•ft) 75 N•m (55 lbf•ft) 75 N•m (55 lbf•ft) 24 N•m (17 lbf•ft) 63 N•m (46 lbf•ft) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) 19 N•m (168 lbf•in) 4 N•m (35 lbf•in)

None None None None None None None Loctite 243 None

COOLING Radiator mount screw/nut Temperature sensor Water pump Fan mount screw/nut Temperature sender on radiator EXHAUST

TORQUE

Exhaust nut Heat shield screws FUEL Carburetor mounting clamp DRIVE TRAIN Front wheel hub nut Rear wheel hub nut Front differential

Front Rear

Rear differential socket screws Propeller shaft screw

Engine side Differential side

11-02-6

VMR2001_063_11_02A.FM

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

TRAXTER

AUTOSHIFT

SUSPENSION

SERVICE PRODUCT

Shock absorber bolt Rear swing arm RH pivot Rear swing arm LH pivot Rear swing arm LH nut Rear swing arm hexagonal screws

48 N•m (35 lbf•ft) 147 N•m (108 lbf•ft) 11 N•m (97 lbf•in) 147 N•m (108 lbf•ft) 48 N•m (35 lbf•ft)

None None None None None

24 N•m (17 lbf•ft) 34 N•m (25 lbf•ft) 10 N•m (89 lbf•in) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) 14 N•m (124 lbf•in) 4.5 N•m (39 lbf•in)

None None None None None None None None

24 N•m (17 lbf•ft) 2.5 N•m (22 lbf•in) 15 N•m (133 lbf•in) 15 N•m (133 lbf•in) 48 N•m (35 lbf•ft) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) 29 N•m (21 lbf•ft) 4 N•m (35 lbf•in) 5 N•m (44 lbf•in) 2.5 N•m (22 lbf•in) 24 N•m (17 lbf•ft) 4.5 N•m (39 lbf•in) 24 N•m (17 lbf•ft) 7 N•m (62 lbf•in) 15 N•m (133 lbf•in) 0.6 N•m (5.4 lbf•in)

None None None None None None None None None None None None None None None None None None

BRAKE

TORQUE

Caliper brake screws Brake disk screws Rear master cylinder bolts Rear master cylinder BANJO bolt Front master cylinder BANJO bolt Caliper BANJO bolt Caliper bleeder valve Rear master cylinder rod nut BODY/FRAME Front bumper Front rack Rear rack Rear extension frame Front differential support Seat pivot bar Winch plate support Seat latch stud Seat latch base Inner fender A-arm protector Footrest Footpeg Removable brace Engine skid plate Headlight housing

VMR2001_063_11_02A.FM

M6 M8 M8

M6 M8

11-02-7

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

FOOTSHIFT

Standard

± 100 RPM

Intake Exhaust

Valve shaft clearance Valve spring free length Valve spring squareness

ENGINE

Valve seat contact width

Intake Exhaust

Piston measurement Piston/cylinder clearance

Piston ring end gap

mm (in)

6.95 (.274)

New (minimum) New (maximum) Wear limit

Maximum Wear limit Wear limit Wear limit Wear limit

Wear limit

Ring height Piston groove clearance Push rod bend Rocker arm bore diameter Rocker arm shaft diameter Cylinder bore Cylinder taper Cylinder out of round

Camshaft bore Cam height Crankshaft deflection

11-02-8

Clutch Magneto Clutch Magneto Intake Exhaust Clutch Magneto

Wear limit

Piston ring type

Camshaft ends

mm (in) mm (in) cm 3 (in3)

VMR2001_063_11_02A.FM

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

ENGINE

VEHICLE MODEL Connecting rod big end axial play Connecting rod small end diameter Piston pin diameter Piston pin bore clearance Clutch drum I.D. Weight lining thickness Weight spring length Friction drive plate Steel driven plate Clutch spring free length Air filter type Exhaust system

FOOTSHIFT Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit Minimum thickness Maximum warpage

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

Type Spark arrester

Magneto/generator Ignition system type Ignition timing Spark plug

Quantity Make and type Gap

Trigger coil Battery charging coil

ELECTRICAL

Ignition coil

Primary Secondary

mm (in) W W W kW

Engine RPM limiter Battery

Type Voltage Nominal rating Power starter output

Headlight Taillight Pilot lamp cluster

Fuses

Carburetor

CARBURETION

Fuel pump

Ignition Accessories Solenoids Fan MPEM Charging system Type Model Type Model

Idle engine speed Main jet Pilot jet Needle jet Jet needle Clip position number Choke plunger position Adjustment Fuel

VMR2001_063_11_02A.FM

RPM

Throttle cable Preliminary pilot screw turn Float level Type Octane no.

mm (in)

1.3 (.05) 22.05 (.868) 21.99 (.866) 0.08 (.003) 140.4 (5.53) 2 (.078) 21.6 (.85) 2.7 (.11) 0.25 (.01) 38 (1.5) 2 stage foam filter Nelson, stainless steel USDA approved 400 W @ 6000 RPM I.D.I. (Inductive Discharge Ignition) Not adjustable 2 NGK DR8EA 0.6 to 0.7 (.024 to .027) 190 – 300 0.4 ± 01 0.4 to 0.9 @ 20°C (68°F) Not measurable 7600 Electrolyte battery type 12 volts 19 A•h (20 optional) 0.7 or 0.9 KW 2 x 55 W, H4703 8/27 W, 1157 LEDS, 0.7 V approximately (each) 15 A 15 A (power outlet and auxiliary supply) 15 A 15 A 20 A 30 A Mikuni constant depression type with manual choke and ECS (Enricher Coasting System) BSR33 Mikuni External (vacuum-operated) 1100 ± 100 145 130 37.5 32.5 0-8 (826) 5FEY1-3 3 Variable 0.5 mm (.02 in) 2 10.6 ± 0.5 (.417 ± 0.02) Regular unleaded gasoline 87 (Ron + Mon)/2

11-02-9

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

FOOTSHIFT

Ethyl glycol/water mix (60% coolant, 40% water). Use coolant specifically designed for aluminum engines Thermostatic 102°C (221°F) 96°C (205°F) 75°C (167°F) 85°C (185°F) 110 kPa (16 PSI)

COOLING

Coolant Fan Fan thermostat Engine thermostat

Switch ON Switch OFF Opening temperature Closing temperature

Radiator cap opening pressure

Transmission

Type Speeds

STEERING/ CONTROL

DRIVE TRAIN

Model Normal oil operating pressure of engine

Minimum Maximum

Operating pressure for shifting and clutching Clutch type Engagement RPM Front differential Front differential ratio Rear axle Rear axle ratio Turning radius

kPa (PSI) kPa (PSI) kPa (PSI) ± 100 RPM

mm (in) mm (in)

Total toe (vehicle on ground)

Camber angle

Dual range (HI-LO) with park, neutral and reverse 5 Mechanically controlled Electronically controlled hydraulic shift hydraulic shift 101 (14.7) 608 (88) 810 (118) 1 centrifugal and 1 multi-disk hydraulically controlled 1600 Shaft driven/single Auto-Lock differential (pump driven) 3.6:1 Shaft driven/solid axle 3.6:1 2130 (84) 2209.8 (87) 17 ± 4 (.669 ± .157) 0°

Tie-rod maximum length unengaged

mm (in)

20 ± 5 (.787 ± 0.197)

FRONT Suspension type Suspension travel

SUSPENSION

Shock absorber

mm (in) Qty Type

Spring free length Spring color code Front preload adjustment

mm (in)

REAR Suspension type Suspension travel Shock absorber

mm (in) Qty Type

Spring free length Spring color code Rear preload adjustment

BRAKES

Front brake

11-02-10

Independent suspension — double A-arm 178 (7) 2 oil 270 (11) Orange/Black/Black N.A.

Rear brake Parking brake Lining material Minimum pad thickness Minimum brake disk thighness Maximum brake disk warpage

mm (in)

Qty Type Qty Type

mm (in) mm (in) mm (in)

Rigid swing arm 190.5 (7.5) 2 Oil 355 (14) Green/White/Black 3 settings 2 Hydraulic 1 Hydraulic Transmission brake and brake lever lock on LH brake lever Metallic 1 (.04) 4.7 (.18) 0.25 (.01)

VMR2001_063_11_02A.FM

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

FOOTSHIFT

38 kPa (5.5 PSI) 35 kPa (5 PSI) 35 kPa (5 PSI) 31 kPa (4.5 PSI)

35 kPa (5 PSI) 31 kPa (4.5 PSI) 38 kPa (5.5 PSI) 35 kPa (5 PSI)

TIRE

Front Rear

Recommended Minimum Recommended Minimum mm (in) mm (in) mm (in)

Front Rear

mm (in) mm (in)

TIRES AND WHEELS

Front Pressure Rear Minimum tire thread depth Size WHEELS Size

DIMENSION

4 (0.16) 635 x 203 x 305 (25 x 8 x 12) 635 x 254 x 305 (25 x 10 x 12) 660 x 305 x 305 (26 x 12 x 12)

Overall length Overall width Overall height Dry weight Wheel base Wheel track

mm (in) mm (in) mm (in) kg (lb) mm (in) mm (in) mm (in) mm (in) mm (in)

Front Rear

Front and under engine ground clearance Rear rigid axle ground clearance

305 x 165 (12 x 6.5) 305 x 203 (12 x 8) 2071 (81.5) 1194 (47)

2116 (83.3) 1270 (50) 1143 (45)

340 (755)

361 (795) 1296 (51) 992 (39) 940 (37) 244 (9.6) 188 (7.4)

LIQUID Fuel tank (including fuel tank reserve) Fuel tank reserve

20 L (5.7 U.S. gal) 6 L (1.6 U.S. gal) 3 L (3.17 quarts) SAE, 4 stroke mineral based oil SH or SJ or Bombardier synthetic oil for wet clutch type. Donâ&#x20AC;&#x2122;t use synthetic oil, other than Bombardier brand name, synthetic blend oil or special oil additives. Refer to the oil viscosity chart in the MAINTENANCE/LUBRICATION section. 650 mL (22 U.S. oz) 200 mL (6.76 U.S. oz) Synthetic polyolester oil 75W90 (API GL5) TEXACO, HTBJ grease (M3014), ONLY SHELL, Alvania EP-2, ONLY 250 mL (8.5 U.S. oz) Brake fluid DOT 4, ONLY 2.5 L (2.65 quarts)

Capacity Engine/transmission oil

CAPACITIES

Differential oil

Recommended

Capacity

Front Rear

Recommended CV joint grease Propeller shaft grease Hydraulics brakes

Capacity Recommended

Cooling system BODY AND FRAME Weight distribution Front storage tray Rack

Front/rear

Front (including front storage tray) Rear (including tongue weight)

Total vehicle load allowed (including driver, all other loads and added accessories) Gross vehicle weight rating Towing Tongue (included with rear rack weight)

VMR2001_063_11_02A.FM

49/51 10 kg (22 lb) 40 kg (90 lb) 80 kg (175 lb) 220 kg (485 lb) 540 kg (1200 lb) 500 kg (1100 lb) 14 kg (30 lb)

11-02-11

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL Frame Front/rear rack Front bumper Front/rear fender

MATERIAL

Fuel tank cover Steering cover Storage compartment cover Front/rear facia Side panel Mudguard Seat cover

11-02-12

FOOTSHIFT Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color

Steel Black Steel Black Steel Silver High density polyethylene Red or Green Yellow High density polyethylene Black High density polyethylene Black High density polyethylene Black High density polyethylene Black High density polyethylene Black Low density polyethylene Black Thermoformed vinyl Black

VMR2001_063_11_02A.FM

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

FOOTSHIFT

ENGINE

SERVICE PRODUCT

M8 M10

24 N•m (17 lbf•ft) 48 N•m (35 lbf•ft) 22 N•m (16 lbf•ft) 4.5 N•m (40 lbf•in) 5 N•m (44 lbf•in) 10 N•m (89 lbf•in) 10 N•m (89 lbf•in) 6 N•m (53 lbf•in) 3 N•m (27 lbf•in) N.A. 3 N•m (27 lbf•in) 42 N•m (31 lbf•ft) N.A. 10 N•m (89 lbf•in) N.A. 20 N•m (15 lbf•ft) N.A. 10 N•m (89 lbf•in) N.A.

None None Anti-seize Loctite 243 Loctite 243 None None Dielectric grease Loctite 243 Loctite 243 None None None None

10 N•m (89 lbf•in) 17 N•m (151 lbf•in) 10 N•m (89 lbf•in) 4 N•m (35 lbf•in) 11 N•m (97 lbf•in)

None None None None None

11 N•m (97 lbf•in) 10 N•m (89 lbf•in)

None None

0.6 N•m (5.4 lbf•in)

None

140 N•m (103 lbf•ft) (MINIMUM) 140 N•m (103 lbf•ft) (MINIMUM) 67 N•m (49 lbf•ft) 75 N•m (55 lbf•ft) 48 N•m (35 lbf•ft) 34 N•m (26 lbf•ft) 42 N•m (31 lbf•ft)

None None None None None None None

TORQUE

COOLING Radiator mount screw/nut Temperature sensor Water pump Fan mount screw/nut Temperature sender on radiator EXHAUST Exhaust nut Heat shield screws FUEL Carburetor mounting clamp DRIVE TRAIN Front wheel hub nut Rear wheel hub nut Front differential

Front Rear

Rear differential socket screws Propeller shaft screw

VMR2001_063_11_02A.FM

Engine side Differential side

11-02-13

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

FOOTSHIFT

WHEEL

SERVICE PRODUCT

Wheel nuts

75 N•m (55 lbf•ft)

Anti-seize

None None None None None None None Loctite 243 None

48 N•m (35 lbf•ft) 147 N•m (108 lbf•ft) 11 N•m (97 lbf•in) 147 N•m (108 lbf•ft) 48 N•m (35 lbf•ft)

None None None None None

24 N•m (17 lbf•ft) 34 N•m (25 lbf•ft) 10 N•m (89 lbf•in) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) 14 N•m (124 lbf•in) 4.5 N•m (39 lbf•in)

None None None None None None None None

STEERING/CONTROL Upper/lower A-arm Tie rod ends Steering arm (castellated nut) Steering column support screws Ball joint end Handlebar screws Steering column half housing bolts Flanged bearing bolts Handle grip screw SUSPENSION Shock absorber bolt Rear swing arm RH pivot Rear swing arm LH pivot Rear swing arm LH nut Rear swing arm hexagonal screws

TORQUE

BRAKE Caliper brake screws Brake disk screws Rear master cylinder bolts Rear master cylinder BANJO bolts Front master cylinder BANJO bolts Caliper BANJO bolts Caliper bleeder valve Rear master cylinder rod nut BODY/FRAME Front bumper Front rack Rear rack Rear extension frame Front differential support Seat pivot bar Winch plate support Winch bolts Fairlead Seat latch stud Seat latch base Inner fender A-arm protector Footrest Footpeg Removable brace Engine skid plate Headlight housing

11-02-14

M6 M8 M8

M6 M8

24 N•m (17 lbf•ft) 2.5 N•m (22 lbf•in) 15 N•m (133 lbf•in) 15 N•m (133 lbf•in) 48 N•m (35 lbf•ft) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) N.A. 15 N•m (133 lbf•in) N.A. 15 N•m (133 lbf•in) 29 N•m (21 lbf•ft) 4 N•m (35 lbf•in) 5 N•m (44 lbf•in) 2.5 N•m (22 lbf•in) 24 N•m (17 lbf•ft) 4.5 N•m (39 lbf•in) 24 N•m (17 lbf•ft) 7 N•m (62 lbf•in) 15 N•m (133 lbf•in) 0.6 N•m (5.4 lbf•in)

None None None None None None None None None None None None None None None None None None None None

VMR2001_063_11_02A.FM

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

Standard

± 100 RPM

Intake Exhaust

Valve shaft clearance Valve spring free length Valve spring squareness

ENGINE

Valve seat contact width

Intake Exhaust

Piston measurement Piston/cylinder clearance

Wear limit

mm (in)

6.95 (.274)

New (minimum) New (maximum) Wear limit

Maximum Wear limit Wear limit Wear limit Wear limit

Piston ring type Piston ring end gap

Wear limit

Ring height Piston groove clearance Push rod bend Rocker arm bore diameter Rocker arm shaft diameter Cylinder bore Cylinder taper Cylinder out of round Camshaft ends Camshaft bore Cam height Crankshaft deflection

VMR2001_063_11_02A.FM

mm (in) mm (in) cm 3 (in3)

Clutch Magneto Clutch Magneto Intake Exhaust Clutch Magneto

11-02-15

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

ENGINE

XL Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit Wear limit Minimum thickness Maximum warpage

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

1.3 (.05) 22.05 (.868) 21.99 (.866) 0.08 (.003) 140.4 (5.53) 2 (.078) 21.6 (.85)

mm (in)

2.7 (.11)

mm (in) mm (in)

0.25 (.01) 38 (1.5) 2 stage foam filter Nelson, stainless steel USDA approved 400 W @ 6000 RPM I.D.I. (Inductive Discharge Ignition) Not adjustable 2 NGK DR8EA 0.6 to 0.7 (.024 to .027) 190 – 300 0.4 ± 01 0.4 to 0.9 @ 20°C (68°F) Not measurable 7600 Electrolyte battery type 12 volts 19 A•h (20 optional) 0.7 or 0.9 KW 2 x 55 W, H4703 8/27 W, 1157 LEDS, 0.7 V approximately (each) 15 A 15 A (power outlet and auxiliary supply) 15 A 15 A 20 A 30 A Mikuni constant depression type with manual choke and ECS (Enricher Coasting System) BSR33 Mikuni External (vacuum-operated) 1100 ± 100 130 32.5 0-8 (826) 5FEY1-3 3 Variable 0.5 mm (.02 in) 2 10.6 ± 0.5 (.417 ± 0.02) Regular unleaded gasoline 87 (Ron + Mon)/2

Type Spark arrester

Magneto/generator Ignition system type Ignition timing Spark plug

Quantity Make and type Gap

Trigger coil Battery charging coil

ELECTRICAL

Ignition coil

Primary Secondary

mm (in) W W W kW

Engine RPM limiter

Battery

Type Voltage Nominal rating Power starter output

Headlight Taillight Pilot lamp cluster

Fuses

Carburetor

CARBURETION

Fuel pump Idle engine speed Main jet Pilot jet Needle jet Jet needle Clip position number Choke plunger position Adjustment

Fuel

11-02-16

Ignition Accessories Solenoids Fan MPEM Charging system Type Model Type Model RPM

Throttle cable Preliminary pilot screw turn Float level mm (in) Type Octane no.

VMR2001_063_11_02A.FM

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

COOLING

Coolant Fan Fan thermostat Engine thermostat

Switch ON Switch OFF Opening temperature Closing temperature

Radiator cap opening pressure

STEERING/ CONTROL

DRIVE TRAIN

Transmission

Normal oil operating pressure of engine

Type Speeds Model Minimum Maximum

Operating pressure for shifting and clutching Clutch type Engagement RPM Front differential Front differential ratio Rear axle Rear axle ratio Turning radius

kPa (PSI) kPa (PSI) kPa (PSI) ± 100 RPM

mm (in) mm (in)

Total toe (vehicle on ground) Camber angle

Ethyl glycol/water mix (60% coolant, 40% water). Use coolant specifically designed for aluminum engines Thermostatic 102°C (221°F) 96°C (205°F) 75°C (167°F) 85°C (185°F) 90 kPa (13 PSI) Dual range (HI-LO) with park, neutral and reverse 5 Electronically controlled hydraulic shift 101 (14.7) 608 (88) 810 (118) 1 centrifugal and 1 multi-disk hydraulically controlled 1600 Shaft driven/single Auto-Lock differential (pump driven) 3.6:1 Shaft driven/solid axle 3.6:1 2514.6 (99) 17 ± 4 ( .669 ± .157) 0°

Tie-rod maximum length unengaged

mm (in)

20 ± 5 (.787 ± 0.197)

FRONT Suspension type Suspension travel

SUSPENSION

Shock absorber

mm (in) Qty Type

Spring free length Spring color code Front preload adjustment

mm (in)

REAR Suspension type Suspension travel Shock absorber

mm (in) Qty Type

Spring free length Spring color code Rear preload adjustment Front brake

BRAKES

Independent suspension — double A-arm 178 (7) 2 oil 270 (11) Orange/Black/Black N.A.

Rear brake Parking brake Lining material Minimum pad thickness Minimum brake disk thighness Maximum brake disk warpage

VMR2001_063_11_02A.FM

mm (in)

Qty Type Qty Type

mm (in) mm (in) mm (in)

Rigid swing arm 101.6 (4.0) 2 Oil 361 (14) Green/White/Black 5 settings 2 Hydraulic 1 Hydraulic Transmission brake and brake lever lock on LH brake lever Metallic 1 (.04) 4.7 (.18) 0.25 (.01)

11-02-17

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

TIRE

TIRES AND WHEELS

Front Pressure Rear Minimum tire thread depth Size

48 kPa (7 PSI) 45 kPa (6.5 PSI) 48 kPa (7 PSI) 45 kPa (6.5 PSI) 4 (0.16) 635 x 203 x 305 (25 x 8 x 12) 635 x 254 x 305 (25 x 10 x 12)

WHEELS Size

DIMENSION

Front Rear

Recommended Minimum Recommended Minimum mm (in) mm (in) mm (in)

Front Rear

mm (in) mm (in) mm (in) mm (in) mm (in) kg (lb) mm (in) mm (in) mm (in) mm (in) mm (in)

Overall length Overall width Overall height Dry weight Wheel base Wheel track

Front Rear

Front and under engine ground clearance Rear rigid axle ground clearance

305 x 165 (12 x 6.5) 305 x 203 (12 x 8) 2490 (98) 1194 (47) 1168 (465) 386 (850) 1553 (61) 992 (39) 940 (37) 244 (9.6) 188 (7.4)

LIQUID Fuel tank (including fuel tank reserve) Fuel tank reserve Capacity Engine/transmission oil

Differential oil

Recommended

Capacity

Front Rear

CAPACITIES

Recommended CV joint grease Propeller shaft grease Hydraulics brakes

Capacity Recommended

Cooling system

20 L (5.7 U.S. gal) 6 L (1.6 U.S. gal) 3 L (3.17 quarts) SAE, 4 stroke mineral based oil SH or SJ or Bombardier synthetic oil for wet clutch type. Donâ&#x20AC;&#x2122;t use synthetic oil, other than Bombardier brand name, synthetic blend oil or special oil additives. Refer to the oil viscosity chart in the MAINTENANCE/LUBRICATION section. 650 mL (22 U.S. oz) 200 mL (6.76 U.S. oz) Synthetic polyolester oil 75W90 (API GL5) TEXACO, HTBJ grease (M3014), ONLY SHELL, Alvania EP-2, ONLY 250 mL (8.5 U.S. oz) Brake fluid DOT 4, ONLY 2.5 L (2.65 quarts)

BODY AND FRAME Weight distribution Front/rear % Front storage tray Rack Front (including front storage tray) Rear cargo box (including tongue load) Lateral compartment Total vehicle load allowed (including driver, all other loads and added accessories) Gross vehicle weight rating Towing Tongue (included with rear cargo box weight)

11-02-18

50/50 10 kg (22 lb) 40 kg (90 lb) 273 kg (600 lb) 6.8 kg (15 lb), each compartment 364 kg (800 lb) 750 kg (1650 lb) 500 kg (1100 lb) 14 kg (30 lb)

VMR2001_063_11_02A.FM

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL Frame Front/rear rack Front bumper Front/rear fender

MATERIAL

Fuel tank cover Steering cover Storage compartment cover Front/rear facia Side panel Mudguard Seat cover Rear cargo box

VMR2001_063_11_02A.FM

XL Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color Material Color

Steel Black Steel Black Steel Silver High density polyethylene Green High density polyethylene Black High density polyethylene Black High density polyethylene Black High density polyethylene Black High density polyethylene Black Low density polyethylene Black Thermoformed vinyl Black Low linear density polyethylene Black

11-02-19

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

ENGINE

SERVICE PRODUCT M8

M10

None None Anti-seize Loctite 243 Loctite 243 None None Dielectric grease Loctite 243 Loctite 243

10 N•m (89 lbf•in) 17 N•m (151 lbf•in) 10 N•m (89 lbf•in) 4 N•m (35 lbf•in) 11 N•m (97 lbf•in)

None None None None None

11 N•m (97 lbf•in) 10 N•m (89 lbf•in)

None None

0.6 N•m (5.4 lbf•in)

None

140 N•m (103 lbf•ft) (MINIMUM) 140 N•m (103 lbf•ft) (MINIMUM) 67 N•m (49 lbf•ft) 75 N•m (55 lbf•ft) 48 N•m (35 lbf•ft) 34 N•m (26 lbf•ft) 42 N•m (31 lbf•ft)

None None None None None None None

75 N•m (55 lbf•ft)

Anti-seize

None None None None None None None Loctite 243 None

48 N•m (35 lbf•ft) 147 N•m (108 lbf•ft) 11 N•m (97 lbf•in) 147 N•m (108 lbf•ft) 48 N•m (35 lbf•ft)

None None None None None

COOLING Radiator mount screw/nut Temperature sensor Water pump Fan mount screw/nut Temperature sender on radiator EXHAUST Exhaust nut Heat shield screws FUEL

TORQUE

Carburetor mounting clamp DRIVE TRAIN Front wheel hub nut Rear wheel hub nut Front differential

Front Rear

Rear differential socket screws Propeller shaft screw

Engine side Differential side

WHEEL Wheel nuts STEERING/CONTROL Upper/lower A-arm Tie rod ends Steering arm (castellated nut) Steering column support screws Ball joint end Handlebar screws Steering column half housing bolts Flanged bearing bolts Handle grip screw SUSPENSION Shock absorber bolt Rear swing arm RH pivot Rear swing arm LH pivot Rear swing arm LH nut Rear swing arm hexagonal screws

11-02-20

VMR2001_063_11_02A.FM

Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

BRAKE

SERVICE PRODUCT

Caliper brake screws Brake disk screws Rear master cylinder bolts Rear master cylinder BANJO bolts Front master cylinder BANJO bolts Caliper BANJO bolts Caliper bleeder valve Rear master cylinder rod nut

24 N•m (17 lbf•ft) 34 N•m (25 lbf•ft) 10 N•m (89 lbf•in) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) 14 N•m (124 lbf•in) 4.5 N•m (39 lbf•in)

None None None None None None None None

24 N•m (17 lbf•ft) 2.5 N•m (22 lbf•in) 15 N•m (133 lbf•in) 48 N•m (35 lbf•ft) 16 N•m (142 lbf•in) 13 N•m (115 lbf•in) 13 N•m (115 lbf•in) 15 N•m (133 lbf•in) 4 N•m (35 lbf•in) 29 N•m (21 lbf•ft) 4 N•m (35 lbf•in) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) 24 N•m (17 lbf•ft) 5 N•m (44 lbf•in) 2.5 N•m (22 lbf•in) 24 N•m (17 lbf•ft) 4.5 N•m (39 lbf•in) 24 N•m (17 lbf•ft) 7 N•m (62 lbf•in) 15 N•m (133 lbf•in) 0.6 N•m (5.4 lbf•in)

None None None None None None None None None None None None None None None None None None None None None None

BODY/FRAME Front bumper

TORQUE

Front rack

M6 M8

Rear extension frame Rear cargo box pivot bolt Rear cargo box latch stud Rear cargo box latch base Rear cargo box retaining bolt Rear cargo box shock absorber Seat latch stud Seat latch base Front differential support Seat pivot bar Winch plate support Inner fender A-arm protector Footrest Footpeg Removable brace Engine skid plate Headlight housing

VMR2001_063_11_02A.FM

M6 M8

11-02-21

Section 12 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS)

WIRING DIAGRAMS

WIRING CONNECTORS CODING CONNECTOR HOUSING AREA

 WARNING Ensure all terminals are properly crimped on the wires and all connector housings are properly fastened. XX/XX

A00I04C

1-02D

1 -02D

THE SHADED PART INDICATES THE CONNECTOR HOUSING AREA

2 3 4

A00I04A

1. 2. 3. 4.

XX/XX

Wire colors Connector housing area Housing number per area Wire connector location in housing

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.

XX/XX 1-02D

A00I04B

THE SHADED PART INDICATES THE WIRE COLOR

Example: YL/ BK is a YELLOW wire with a BLACK stripe. COLOR CODE — — — — — —

BLACK BLUE BROWN GREEN GREY ORANGE

VMR2001_064_12_01A.FM

PK RD TA VI WH YL

— — — — — —

PINK RED TAN VIOLET WHITE YELLOW

3 8

V01L25B

XX/XX

BK BL BR GN GY OR

AREA

4 LOCATION

Front of engine compartment

RH side of engine compartment

LH side of engine compartment

Behind fuel tank

Under steering cover

Front of vehicle

Rear of vehicle

Near radiator hoses

12-01-1

Section 12 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS)

CONNECTOR LOCATION IN HOUSING This is the wire position in the connector. The number or letter given refers to the physical identification stamped on the connector. XX/XX

1-02 D

A00I04D

THE SHADED PART INDICATES THE CONNECTOR LOCATION IN HOUSING

B A B A

B A

B C

D A

D A A00E4WB

C B

TYPICAL

See connector housing illustration to OVERVIEW.

12-01-2

VMR2001_064_12_01A.FM

FOOTSHIFT MODEL

TRAXTER FOOTSHIFT

MPEM

COLOR CODE

V01Z02

TAN

BLACK

BLUE

BROWN

GREEN

GREY

ORANGE

RED

VIOLET

WHITE

YELLOW

PINK

TRAXTER, XT, AUTO MODELS

TRAXTER, XT, AUTO

MPEM

COLOR CODE

V01Z03

TAN

BLACK

BLUE

BROWN

GREEN

GREY

ORANGE

RED

VIOLET

WHITE

YELLOW

PINK

XL MODEL

TRAXTER XL

MPEM

COLOR CODE

V01Z04

TAN

BLACK

BLUE

BROWN

GREEN

GREY

ORANGE

RED

VIOLET

WHITE

YELLOW

PINK

ANNEX 1 VMR2001_053_05_06_ANNEXES_A.FM

Repaired.

Check fuses. Are fuses burned? No

Is the shift shaft moving while depressing the shift button? No

Yes

Reset the GBPS and STPS sensors.

Replace MPEM.

Are connections and wire condition OK. Yes

Check all connections and wire condition.

Yes

Was switch good?

Check Multi-function switch.

Was there continuity on all wires. No

Check for signal from MPEM. Procedure BB

Yes

Was there battery No voltage?

Repair and retry shift.

Electrical shif system is good.

Retry shift, is the problem persisting?

V01A318

Procedure BB: With an Ohm Meter go from GREEN/RED for the upshift solenoid to ground. Press upshift button, should have continuity. Perform same test for ORANGE/RED, downshift. Press downshift and should have continuity. To test the clutch solenoids, go from the BLUE/RED to ground, press up or down shift and should have continuity. For the clutch re-engagement or modulation solenoid, go from BLUE/ORANGE to ground, rev engine to 2000 RPM, press shift button up or down, should have continuity. (this is a duty cycle solenoid, the duty cycle comes from the MPEM). ..................

Procedure AA: Connect the T-harness P/N 529 035 653 into the Duetsch 4 pin connector for the valve body solenoids. With engine at idle press the shift button up then down. You should see one light for down shift and one for up shift. Connect next into the 4 pin Duetsch connector for the clutch solenoids. At idle while pressing the shift button you should see one light. Now raise RPM to 2000 and press button the other light should come on.

Yes Retry shift, is the problem persisting?

Replace the failed solenoid or solenoids.

Yes Was the resistance value for each solenoid OK?

Did test lights light for up and down shift for all four solenoids?

fuse.

Replace

Check for 12 volts going to the solenoids. Solenoids should have 12 volts at all times. Check both the WHITE/RED wires in the both 4 pin connectors.

Is shift problem persisting. Yes

Retry shift.

Yes

Perform T-harness test. Verify that lights come on for both shift and clutch solenoids. Procedure AA

Task 4-5-6; GBPS, STPS and TPS (AUTO model) recalibration.

Mode. Tasks 3-5.

Start Diagnostic/Calibration

Yes

Using emergency shift lever, are you able to shift through all gears? Leave in first gear when test complete. (May have to move vehicle to obtain shift).

Check the resistance value of each solenoid. Value for shift solenoid = 2.2-3 Ohms Value for clutch solenoid = 2.2-3 Ohms Value of modulation solenoid = .8-1.5 Ohms

Is problem persisting.

Before proceeding to the Hydraulic/Mechanical troubleshooting Procedure AA and ohm test on each solenoid must be performed. The T-harness test must be good. Re-perform test.

Yes

Repair failed part & Clear codes. Retry shift.

Are there any Fault codes. Yes

Task 3; Fault codes.

Refer to Shop Manual for diagnostic procedure.

Refer to: Annex 2, Problem with hydraulic mechanical shift system.

PROBLEM WITH SHIFT SYSTEM. DIAGNOSING ELECTRICAL COMPONENTS

ANNEX 1

VMR2001_053_05_06_ANNEXES_A.FM

ANNEX 2 VMR2001_053_05_06_ANNEXES_A.FM

V01A328

Replace the clutch activation solenoid.

Was the oil pressure within the specification?

Check the oil pressure of the shift system. Refer to Procedure CC.

Is there any external oil leakage? No

All O-rings and gaskets for internal leakage.

Oil pump.

Main oil pressure regulator located under the magneto cover.

Yes

Call the Service Department

Retry shift, is the problem persisting?

Solved.

Retry shift, is the problem persisting?

Replace the valve body.

Yes

Bring to correct level.

No Repair, Yes Retry shift, is problem persisting?

Solved.

Retry shift, is problem persisting? No Yes

Yes

Problem is internal. Check the following items for leakage, blockage or failure.

Is problem persisting?

Engine oil and filter replacement maybe a solution. Refer to maintenance chart, for recommended intervals and the proper oil viscosity.

Yes

Is oil level good?

Check engine oil level.

Yes

Is the shift shaft moving when pressing the shift button?

Yes

Problem is internal, first inspect the shift linkage under the stator cover. If nothing is found proceed into transmission and check shift drum, shift forks and gears.

Procedure CC: Oil pressure test must be performed with warm engine and the recommended viscosity oil. Remove the oil pressure switch. Be sure all connections are tight. Vehicle in neutral and emergency brake applied, start engine, press the shift button with engine at idle, (may require multiple shift selections to achieve dog on dog, to be able to see the pressure on the gauge you will need to create a miss shift, or dog on dog. Otherwise the gauge will not re-act fast enough to show the quick spike in pressure) should see 60 PSI to 120 PSI. Now rev engine to 3000 RPM, again press shift button, should see from 100 PSI to 130 PSI (same multiple shift selection procedure applies).

Problem solved.

Yes

Repair leak and retry shift.

Proceed to electrical flow chart.

T-harness test was good?

Perform T-harness test from the electrical flow chart.

Using emergency shift lever , are you able to shift through all gears? Engine not running. (May have to move vehicle to obtain shift).

PROBLEM WITH SHIFT SYSTEM. HYDRAULIC/MECHANICAL

ANNEX 2

VMR2001_053_05_06_ANNEXES_A.FM