1999 2000 Bombardier Traxter Service Manual 2000_Bombardier_Traxter_Service_Manual

User Manual: 1999-2000_Bombardier_Traxter_Service_Manual

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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 and lubrication ....................................................
04 – Storage and 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..........................................................................

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

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 differential ....................................................................... 06-02-1
03 – Rear axle................................................................................... 06-03-1

STEERING/CONTROL
SYSTEM

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

BRAKES

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

TABLE OF CONTENTS

SECTION

SUBSECTION

PAGE

BODY/FRAME

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

TECHNICAL DATA

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

WIRING DIAGRAM

01 – Wiring diagram......................................................................... 12-01-1

INTRODUCTION

INTRODUCTION
This Shop Manual covers the following Bombardier made 1999 ATV:

VEHICLE AND ENGINE SERIAL
NUMBER LOCATION

Models
1

TRAXTER* (Canada) ................................ 7400
TRAXTER* (Canada) ................................ 7413
TRAXTER* (Canada) ................................ 7415
TRAXTER* (Canada) ................................ 7417
TRAXTER* (U.S.)...................................... 7401
TRAXTER* (U.S.)..................................... 7414
TRAXTER* (U.S.)..................................... 7416
TRAXTER* (U.S.)..................................... 7418
*Trademark of Bombardier Inc.

2
V01A16A

1. Engine
2. Vehicle

V01A17A

1. Model number

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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

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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 DIAGRAM
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
VII

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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 Nm
(97 lbfin)
21
22

Therma Lube
grease

5
9

1324 Nm
(17 lbfft)
7

20
20

48 Nm
8 (35 lbfft)
3

3
17

18
20

Tightening torque
nearby fastener. In this
case, nut must be
torqued to
48 Nm or 35 lbfft.

17
9

10 Nm
15 (97 lbfin)

24 Nm
(17 lbfft)
7

Exploded view
assists you in
identifying parts and
related positions.

Therma Lube
grease

Subsection title
indicates
beginning of the
subsection.

31
10
7

48 Nm
(35 lbfft)

10
12

Therma Lube
grease

32 26

30 2
32
29

24 Nm
(17 lbfft)
7

48 Nm
(35 lbfft)
8

Bold face number
indicates special
procedure
concerning this
part.

25
25

25
24

Illustration
number for
publishing
process.

V01C15S

03 02 1

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

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

V01A0QS

VIII

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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 09-02 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 03-02 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
05-02 FRONT DIFFERENTIAL
Unplug the VSS (Vehicle Speed Sensor), located
under engine drive shaft

V01C0EA

1
2
3
4

Shifting valve
GBPS (Gear Box Pos tion Sensor)
Magneto/Trigger plug
Engine coolant hose

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

03 02 2

V01A0RS

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

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.

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).

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.

V01L25A

1. Left
2. Right

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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.
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)
M4
M5

Lbf•in
9
18
27
35
44
53
62
71
80
89
97
106
115
124
133
142
150
159
168

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

FASTENER SIZE (8.8)

M10

Lbf•ft
15
15
16
17
18
18
19
20
21
21
22
23
24
24
25
26
27
27
28
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
XI

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INTRODUCTION

N•m
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
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

FASTENER SIZE (8.8)

M12

Lbf•ft
48
49
49
50
51
52
52
53
54
55
55
56
57
58
58
59
60
60
61
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

N•m
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150

FASTENER SIZE (8.8)

M14

Lbf•ft
80
81
82
83
83
84
85
86
86
87
88
89
89
90
91
91
92
93
94
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

XII

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Section 01

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

TABLE OF CONTENTS
SERVICE TOOLS 01-02-1
ENGINE — MANDATORY SERVICE TOOLS ................................................................... 01-02-2
ENGINE — RECOMMENDED SERVICE TOOLS .............................................................. 01-02-3
ELECTRICAL — MANDATORY SERVICE TOOLS ........................................................... 01-02-5
ELECTRICAL — RECOMMENDED SERVICE TOOLS ...................................................... 01-02-6
SUSPENSION — MANDATORY SERVICE TOOLS ......................................................... 01-02-7
SUSPENSION — RECOMMENDED SERVICE TOOLS .................................................... 01-02-8
DRIVE — MANDATORY SERVICE TOOLS ...................................................................... 01-02-9
DRIVE — RECOMMENDED SERVICE TOOLS ................................................................. 01-02-10
VEHICLE — MANDATORY SERVICE TOOLS .................................................................. 01-02-11
VEHICLE — RECOMMENDED SERVICE TOOLS ............................................................. 01-02-12
SERVICE PRODUCTS ............................................................................................................
MANDATORY SERVICE PRODUCTS ...............................................................................
RECOMMENDED SERVICE PRODUCTS .........................................................................

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

01-01-1

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Section 01

SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)

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

01-02-1

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

ENGINE — MANDATORY SERVICE TOOLS
Lifting bar
(P/N 529 035 610)

Magneto puller
(P/N 529 035 547)

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

NEW

V01B094
V01B0B4

Small hose pincher
(P/N 529 009 900)

F01B294

Fuel and oil system leak tester kit
(P/N 529 033 100)

Crankshaft locking bolt
(P/N 529 035 645)
NEW

A01B2I4

A01B5E4

Large hose pincher
(P/N 529 032 500)

V01B0C4

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

Crankshaft protector
(P/N 290 876 557)
NEW

F01B234
V01B0A4

V01B0D4

01-02-2

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Section 01

SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)

ENGINE — RECOMMENDED SERVICE TOOLS
Sub-transmission positioner
(P/N 529 035 651)

Ring compressor
Not sold by Bombardier

Handle for insertion jig
(P/N 420 877 650)

Snap-on

NEW

RCW60

V01B0E4

Oil pressure gauge (1 to 8 bar)
(P/N 529 035 652)

V01B0H4

NEW

Carburetor tool kit
(P/N 529 035 660)
NEW

A00C3V4

Exhaust spring installer/remover
(P/N 529 035 400)

V01B0K4

Lifting ring
(P/N 529 035 644)
NEW
A00B2F4

Float level gauge
(P/N 529 035 520)

A01B584

Valve spring compressor
Not sold by Bombardier
Snap-on

CF811

Choke nut tool
(P/N 529 035 660)

V01B0F4

A00B4N4

NEW

Digital/induction type tachometer
(P/N 529 014 500)
V01B0I4

V01B0G4

F01B1G4

01-02-3

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

ENGINE — RECOMMENDED SERVICE TOOLS (continued)
Engine stand
(P/N 529 035 646)
NEW

V01B0J4

01-02-4

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Section 01

SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)

ELECTRICAL — MANDATORY SERVICE TOOLS
Six-pin magneto harness
(P/N 529 035 654)
NEW

F01B284

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

V01B0L4

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

V01B0M4

01-02-5

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

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

F00B0E4

Terminal remover
Not sold by Bombardier
Snap-on
TT 600-4

F01B1J4

Multimeter
(P/N 529 022 000)

F01B1O4

01-02-6

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Section 01

SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)

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

V01B0N4

01-02-7

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

SUSPENSION — RECOMMENDED SERVICE TOOLS
Shock spring removal kit
(P/N 529 027 100)
Replacement clevis pin:
(P/N 414 528 400)

A01B4O4

01-02-8

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Section 01

SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)

DRIVE — MANDATORY SERVICE TOOLS
Pliers
(P/N 295 000 069)
Oetiker 1090

F01D184

Pliers
(P/N 295 000 054)
Caillau

F01B1T4

Hub puller
(P/N 529 035 612)
NEW

V01B0O4

01-02-9

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

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

V01B0S4

01-02-10

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Section 01

SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)

VEHICLE — MANDATORY SERVICE TOOLS
41 mm socket for swing arm nut
(P/N 529 035 650)
NEW

V01B0T4

01-02-11

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

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

F04B044

01-02-12

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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)
Loctite 764

Medium strength
threadlocker
(P/N 293 800 060)

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

Loctite 243 (blue)
(10 mL)

A00B3N4

Gasket stripper
(P/N 413 508 500)

A00B324

(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

Dielectric grease
(P/N 293 550 004)

A00B3L4

Dow Corning
(150 g)

A00B2U4
F01B164

01-03-1

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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:

(6 x 1 L)

Gasket eliminator (50 mL)

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)
Loctite 81668

A00B3R4

Form-A-thread 81668

A00A1J4

01-03-2

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F01B0S4

Section 02 MAINTENANCE
Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS
MAINTENANCE CHART ........................................................................................................
NOISE EMISSION CONTROL SYSTEM REGULATION ...................................................
TAMPERING WITH NOISE CONTROL SYSTEM 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
02-03-2
02-03-2
02-03-3
02-03-4
02-03-5

STORAGE/PRE-SEASON PREPARATION ...........................................................................
STORAGE...........................................................................................................................
FUEL STABILIZER ..............................................................................................................
ENGINE LUBRICATION .....................................................................................................
RAGS IN AIR INTAKE AND EXHAUST SYSTEM.............................................................
VEHICLE CLEANING AND PROTECTION.........................................................................
COOLANT DENSITY ..........................................................................................................
PRE-SEASON PREPARATION...........................................................................................

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

02-02-1
02-02-2

02-01-1

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Section 02 MAINTENANCE
Subsection 02 (MAINTENANCE CHART)

MAINTENANCE CHART
NOISE EMISSION CONTROL SYSTEM REGULATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!
U.S. Federal law and Canadian provincial laws may prohibit the following acts or the causing there of:
1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair or
replacement of any device or element of design incorporated into any new vehicle for the purpose of
noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or
2. 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.

02-02-1

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Section 02 MAINTENANCE
Subsection 02 (MAINTENANCE CHART)

ENGINE/
TRANSMISSION

FUEL SYSTEM

ELECTRICAL

DRIVE TRAIN

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

02-02-2

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REFER TO
THE SECTION
02-02

EVERY 200 HOURS
OR 2 YEARS

EVERY 100 HOURS
OR ONCE A YEAR

EVERY 50 HOURS

LUBRICATION AND MAINTENANCE CHART

EVERY 25 HOURS

INITIAL 10 HOURS

MAINTENANCE CHART

03-02
N.A.
02-04

03-03

03-04
05-06
04-04
02-02

04-02
04-03
05-05

05-04

05-07

06-02

06-03

06-02/
06-03

STEERING/
CONTROL
SYSTEMS

SUSPENSION

BRAKE

BODY/FRAME

Throttle condition
Choke condition
Handlebar fastener tightness
Steering system mechanism
Tie rod ends inspection
Steering adjustment
Tire pressure
Wheel mount tightness and stud lubrication
Wear and condition of tires
Front wheel alignment
Swing arm condition
Shock absorber condition
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

REFER TO
THE SECTION

EVERY 200 HOURS
OR 2 YEARS

EVERY 100 HOURS
OR ONCE A YEAR

EVERY 50 HOURS

EVERY 25 HOURS

LUBRICATION AND MAINTENANCE CHART

INITIAL 10 HOURS

Section 02 MAINTENANCE
Subsection 02 (MAINTENANCE CHART)

04-03

07-02

02-02

N.A.

08-02/
08-03

09-02

02-02

10-02

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.

02-02-3

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Section 02 MAINTENANCE
Subsection 03 (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.

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
Remove seat.
Release clamps and remove air filter box cover.
1

V01F05A

1. Release clamps
2. Lift to remove

Remove air baffles, air filter and foam.

2
V01F04A

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.
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.

V01F06A

1. Air baffle

02-03-1

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Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)

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

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

ENGINE OIL AND FILTER
Oil Viscosity
SAE 10W40 is recommended for general use.
Other viscosity should be used if the average temperature is outside the range of the recommended
oil. See chart below.

V01F07A

1. Air filter

°C

°F

140

SAE 5W30

V01F08A

1. Foam

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 dry air
filter and foam thoroughly.
If air filter element or foam is dirty, replace with a
new one.
CAUTION: Never remove or modify any component in the air box. Always use genuine parts
when replacing air filter and foam. The engine
carburation is calibrated to operate specifically
with these components. Otherwise, engine performance degradation or damage can occur.
NOTE: Slight dust may be cleaned using a lowpressure airgun. Blow compressed air backward
of operating air flow.

SAE 20W50

SAE 15W50

SAE 15W40

SAE 10W40

SAE 10W30

120

100

30
80
20
60
10
40
0

-10

-20

-30

-20

V01A0VA

Oil and Oil Filter Change

m 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.

02-03-2

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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. Don’t use synthetic oil, synthetic
blend oil or special additives. 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

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 section 11
for capacity. Do not overfill.

V01C05A

1. Clean out plug

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

02-03-3

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Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)

m WARNING

TIRE PRESSURE

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.

RECOMMENDED

FRONT
48 kPa
(7 PSI)

REAR
38 kPa
(5.5 PSI)

MINIMUM

45 kPa
(6.5 PSI)

35 kPa
(5 PSI)

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.

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

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.

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.

02-03-4

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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.

02-03-5

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Section 02 MAINTENANCE
Subsection 04 (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 02-03.
– Remove air box cover, air filter, foam and baffles
to spray storage oil (P/N 413 711 600) into carburetor bore.
– 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).
– Stop the engine and remove the battery. Store
it in dry and cool place out of the sun, refer to
BATTERY 05-04. Remove the spark plugs and
spray storage oil into cylinder.

– Crank slowly 2 or 3 revolutions to lubricate cylinder.
– Turn the fuel valve to OFF and drain carburetor.
– Reinstall the spark plugs, baffles, foam, air filter
and air box cover.

m WARNING
This procedure must only be performed in a
well-ventilated area. Do not run engine during storage period.

RAGS IN AIR INTAKE AND
EXHAUST SYSTEM
At storage preparation, block air intake inlet and
exhaust system outlet using clean rags.
The air intake hole is located under steering cover.
NOTE: 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.

02-04-1

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

For vinyl and plastic parts, use Vinyl & Plastic
Cleaner (P/N 413 711 200 (6 x 1 L)).
CAUTION: Never clean plastic parts with strong
detergent, degreasing agent, paint thinner, acetone, products containing chlorine, etc.
Inspect the vehicle and repair any damage. Touch
up all metal spots where paint has been scratched
off. Spray all metal parts with BOMBARDIER
LUBE (P/N 293 600 016).
NOTE: Protect the vehicle with a cover to prevent
dust accumulation during storage.
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 manufacturer’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

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

PRE-SEASON PREPARATION
SYSTEM
ENGINE/
TRANSMISSION

PRE-SEASON OPERATIONS
Test Run Vehicle. Check Clutch and Transmission Operation
Engine Oil and Filter Oil Replacement

TO BE PERFORMED BY
CUSTOMER

Coolant Replacement and Pressurization of System
Condition of Seals
Spark Arrester
Exhaust System Condition
Rewind Starter, Rope Condition
Rags Removal (Intake and Exhaust)
FUEL SYSTEM

Fuel Line and Connectors Condition
Carburetor Adjustment
Throttle and Choke Cable Inspection/Adjustment
Air Filter Cleaning/Replacement

ELECTRICAL

Spark Plug Replacement

Battery Condition/Charging and Installation
Starter Connections and Routing
Operation of Lighting System
DRIVE TRAIN

Drive Shaft Boot Inspection
Front Propeller Shaft Lubrication
Front Differential and Rigid Axle Oil Level and Vent Tube
Condition

STEERING/
CONTROL
SYSTEM

Steering System Inspection and Adjustment
Handle Bar Fastener Tightness
Wheel Tightness
Tire Pressure
Tire Condition

SUSPENSION

Suspension System Inspection
Bearing Condition
Swing Arm Condition

BRAKES

Brake Fluid Change
Brake Condition
Brake Cable Adjustment

BODY/FRAME

Frame and Skid Plate Condition
Hitch/Trailer Ball Condition
Front Cover Compartment Cover Latch Condition

REFER TO

DEALER

N.A.
Section 02-02
Section 03-04
N.A.
Section 02-02
Section 03-02
Section 03-05
Section 02-03
Section 04-02
Section 04-03
Section 02-02

Section 05-05
Section 05-04
Section 05-07

Section 06-02
and 06-03

Section 07-02

Section 02-02

Section 08-02
and 08-03

Section 09-02

Section 10-02
and 10-03

Replace oil and filter only if it has not been previously performed at the storage.
Remove rags in intake and exhaust that were installed at the storage.
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.

02-04-3

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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
03-02-6

COOLING SYSTEM ...............................................................................................................
COOLING SYSTEM LEAK TEST .......................................................................................
INSPECTION ......................................................................................................................
DRAINING THE SYSTEM ..................................................................................................
COOLING SYSTEM REFILLING ........................................................................................
PRESSURE CAP .................................................................................................................
RADIATOR .........................................................................................................................
THERMOSTAT ...................................................................................................................
COOLANT TANK ...............................................................................................................
FAN AND OUTLET DEFLECTOR.......................................................................................
TEMPERATURE SENDER..................................................................................................

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

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

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

MAGNETO SYSTEM .............................................................................................................
MAGNETO .........................................................................................................................
ROTOR ...............................................................................................................................
SPARG CLUTCH ................................................................................................................

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

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
03-06-4
03-06-5
03-06-6
03-06-6
03-06-7

03-01-1

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Section 03 ENGINE
Subsection 01 (TABLE OF CONTENTS)

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

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

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

VMR9932_03_01TOC.FM

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Subsection 02

Section 03 ENGINE
(REMOVAL AND INSTALLATION)

REMOVAL AND INSTALLATION
10 Nm
(97 lbfin)
21
22

Therma Lube
grease

5
9

1324 Nm
(17 lbfft)
7

20
20

48 Nm
8 (35 lbfft)
3

3
17

18
20

17
9

24 Nm
(17 lbfft)
7

Therma Lube
grease

10 Nm
15 (97 lbfin)

31
10
7

48 Nm
(35 lbfft)

10
12

30 2
32
29

24 Nm
(17 lbfft)
7

48 Nm
(35 lbfft)
8

11
Therma Lube
grease

32 26

25
25

25
24

V01C15S

03-02-1

VMR9932_03_02.FM

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Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)

ENGINE REMOVAL

1
2
V01C0DA

6
V01A0AC

FRONT VIEW
1. Clutching and clutch modulator solenoids connector
2. STPS (Sub Transmission Position Sensor)
3. VSS (Vehicle Speed Sensor)
4. Shifting engine rod
5. Oil pressure sensor
6. Engine coolant hose

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

Remove seat, front and rear fenders, inner fenders, side panels, shifter guide cover and skid plate.
Refer to BODY 10-02.
Disconnect BLACK negative cable from battery,
then RED positive cable.

 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.

Front Part Preparation

V01C0EA

REAR VIEW
1. Shifting valve
2. GBPS (Gear Box Position Sensor)
3. Magneto/trigger plug
4. Engine coolant hose

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 04-02.
Remove seat pivot bar and unplug clutching and
clutch modulator solenoids connector.
Remove STPS (Sub Transmission Position Sensor).
NOTE: Do not unplug only, remove sensor completely.
Remove shifting rod no. 2. Refer to Shifting Rod
Removal section.
Remove front propeller shaft. Refer to FRONT
DIFFERENTIAL 06-02.
Unplug VSS (Vehicle Speed Sensor), located under
engine drive shaft.

03-02-2

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Subsection 02

Engine Preparation
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 at PCV valve.
Unplug temperature sensor.
3

V01C16A

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

Section 03 ENGINE
(REMOVAL AND INSTALLATION)

Remove fuse box.
Remove shifting valve. Refer to ELECTRIC SHIFT
SYSTEM 05-06.
Disconnect the interlock cable no. 6 from rear
brake pedal.
Remove brake pedal, rear master cylinder and
brake switch. Refer to HYDRAULIC BRAKES 0902.

Rear Part Preparation
Unplug GBPS (Gear Box Position Sensor).
Separate rear propeller shaft from engine. Refer
to REAR SUSPENSION 08-03.
NOTE: Do not separate swing arm from rear axle.
Unplug magneto/trigger wiring harness connector.
Remove radiator outlet hose.
Remove starter.
Remove engine coolant hose (the hose with the
starter clamp).
Separate rear air intake tube from air intake silencer.
Install engine lifting tool (P/N 529 035 610) then
install a hoist.
Remove engine bracket mounting bolts no. 7.
Pull down engine lifting tool arm and lift engine.

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

Remove carburetor no. 5. Refer to FUEL PUMP
AND CARBURETOR 04-03.
Remove engine impulse line.

V01C0FA

V01C0HA

1. Engine impulse line

03-02-3

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Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)

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.
Torque interlock cable lightly.
For the adjustment from interlock, refer to HYDRAULIC BRAKES 09-02.
Reattach cables, hoses, harness wiring, etc.

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. 13 and push support bushing no. 14 and antivibration bushing out the housing.
Use punch to remove the other bushing.

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

V01C0SA
V01C17A

Before to start the engine, remove spark plugs and
ground them on engine or frame. Start vehicle
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 and GBPS. Refer to ELECTRIC SHIFT
SYSTEM 05-06.

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

ANTI-VIBRATION SYSTEM
Anti-Vibration System Removal
Remove flanged bolt no. 8, elastic nut no. 9 and
engine brackets no. 10.
RH Anti-Vibration System
Remove support bushing no. 11, push out with a
punch.
Insert a punch in hole of anti-vibration bushing
no. 12 and push other anti-vibration bushing out
housing.

V01C0TA

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

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Subsection 02

EXHAUST SYSTEM

Section 03 ENGINE
(REMOVAL AND INSTALLATION)

Exhaust Pipe Removal
Remove the exhaust pipe nuts no. 15.

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

Heat Shield Removal
Remove the rear fender. Refer to BODY 10-02.
Remove screws no. 21 retaining heat shield no. 22.

Heat Shield Installation
For installation, reverse the removal procedure.
Paying attention to the following details.
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).

V01C0JA

Remove screw from exhaust pipe bracket no. 16.
Remove springs no. 17 retaining exhaust pipe and
muffler no. 18.
3
2

V01C18A

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

V01C19A

1. Retaining springs

Pull exhaust pipe forward.

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Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)

Exhaust Pipe Installation
For installation, reverse the removal procedure,
paying attention to the following details.
Use a new exhaust pipe gasket no. 19 and make
sure that it is properly installed.

V01C1MA

1. Muffler
2. Retaining rod

Muffler Installation
For the installation, reverse the removal procedure.
NOTE: Check rubber bushings no. 20 for cracks
or other damages, change if necessary.

SHIFTING SYSTEM
V01C0LA

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

1. Exhaust pipe gasket

Shifter Tie-Rod Removal

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.

Remove fuel tank. Refer to FUEL CIRCUIT 04-02.
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. 23, one
on LH ball joint and one on RH ball joint.

Muffler Removal
Remove heat shield no. 22 and exhaust pipe
no. 4.
Pull muffler no. 18 forward, pull out retaining rod
from supports and remove muffler.

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.

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Subsection 02

Section 03 ENGINE
(REMOVAL AND INSTALLATION)

Shifter Column Removal
Remove shifter lever no. 1.
Remove shifter tie-rod no. 23.

A
B

Shifter Column Installation
For installation, reverse the removal procedure.

Shifting Rod Removal

V01I0IA

1.
2.
3.
A.
B.

Remove fuel tank. Refer to FUEL CIRCUIT 04-02.
NOTE: Separate fuel tank from frame, do not remove tank completely.
Separate shifting rod no. 2 from shifting engine
rod. Unscrew bolt no. 30 and pull shifting rod forward.

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
Remove fuel tank. Refer to FUEL CIRCUIT 04-02.
Remove upper and lower retaining clamps no. 24
and half rings no. 25.
Unscrew lever button no. 26.
Remove shifter lever no. 1 from shifter guide.
Unscrew lever retaining bolt no. 27 and pull lever.

Lever Installation
For installation, reverse the removal procedure,
paying attention to the following details.
Place nylon bushing no. 28 in shifter lever.
Place lever spring no. 29 properly.

V01I0KA

1. Shifting rod

Unscrew elastic nuts from RH ball joint.
Remove retaining clamp no. 31 and half rings
no. 32.

Shifting Rod Installation
V01I0JA

For installation, reverse the removal procedure.

LEVER SPRING INSTALLATION

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Section 03 ENGINE
Subsection 03 (COOLING SYSTEM)

COOLING SYSTEM
2

1
10

11 12

3
4

6
7

9
V01C1AS

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Section 03 ENGINE
Subsection 03 (COOLING SYSTEM)

COOLING SYSTEM LEAK TEST
Install special plug (radiator cap) (P/N 529 021 400)
and hose pincher (P/N 529 009 900) on overflow
hose no. 8. Pressurize all system through coolant
reservoir to 103 kPa (15 PSI).
Check all hoses, radiator and cylinder/base for coolant leaks. Spray a soap/water solution and look for
air bubbles.

V01A0AA

1. Cooling plug

COOLING SYSTEM REFILLING

V01C09A

NOTE: The rear fender removal is not necessary.

INSPECTION
Check general condition of hoses and clamp tightness.

DRAINING THE SYSTEM

 WARNING
Never drain or refill cooling system when engine is hot.

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

To drain cooling system, unscrew plug under engine and remove pressure cap.

Refer to TECHNICAL DATA 11-02.

Refilling Procedure
Use hose pincher on coolant hose at thermostat
outlet. Unscrew bleeder on top of thermostat
housing.
With vehicle on a flat surface, engine cold, refill
radiator no. 1 and coolant tank no. 9 up to cold
level mark. Wait a few minutes then refill to mark.
Install pressure cap. Run engine until thermostat
opens then stop engine. Refill up to mark.
Reinstall pressure cap.

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Section 03 ENGINE
Subsection 03 (COOLING SYSTEM)

When engine has completely cooled down, recheck coolant level in radiator no. 1 and coolant
tank no. 9 and top up if necessary.
Check coolant concentration (freezing point) with
proper tester.

PRESSURE CAP
Check if cap pressurizes the system. If not, install
a new 90 kPa (13 PSI) cap (do not exceed this pressure).

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.

THERMOSTAT

RADIATOR

The thermostat is a single action type.

Removal

Drain cooling system.
Remove rear fender. Refer to BODY 10-02.
Remove inlet no. 6 and outlet no. 7 hoses.

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

V01C0BA

1. Remove screws

Remove gasket.

Test
V01C0AA

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

To check thermostat, put in water and heat water.
Thermostat should open when water temperature
reaches 75°C (167°F).

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

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.
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Section 03 ENGINE
Subsection 03 (COOLING SYSTEM)

COOLANT TANK

Overflow Coolant Tank
The coolant expands as the temperature (up to
100 - 110°C (212 - 230°F)) and pressure rise in the
system. If the limiting system working pressure
cap is reached 90 kPa (13 PSI), the pressure relief
valve in the pressure cap is lifted from its seat and
allows coolant to flow through the overflow hose
into the overflow coolant tank.

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

1. Fan connector

Installation

Fan Installation

The installation is the reverse of the removal procedure.

FAN AND OUTLET DEFLECTOR

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

Test

Outlet Deflector Removal

Refer to INSTRUMENTS AND ACCESSORIES 0507.

Remove fan no. 5.
Remove radiator.
Pull outlet deflector upward no. 4.

V01G0BA

Fan Removal
Remove rear fender. Refer to BODY 10-02.
Remove bolts no. 12 and fan supports no. 11. Discard bolts.
1

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

TEMPERATURE SENDER
Test
Refer to INSTRUMENTS AND ACCESSORIES 0507 for proper procedure.

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

Installation
V01G0AA

1. Remove bolts
2. Fan support

Unplug fan connector.

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.

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Section 03 ENGINE
Subsection 04 (REWIND STARTER)

REWIND STARTER

Loctite
242

Silicone
compound
grease
3
4

6
7

8
10
12

5
9

11
13
Loctite
242

V01C1BS

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Section 03 ENGINE
Subsection 04 (REWIND STARTER)

REWIND STARTER
Removal

Remove fuel tank cover and skid plate. Refer to
BODY 10-02.
Remove seat pivot bar and unplug clutching and
clutch modulator valve connector.
Remove rewind mounting bolts no. 15 and pull 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 silicone compound grease (P/N 420 897 061) 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.
1

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.

V01C0XA

TYPICAL
1. Grease inside spring guide

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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

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.

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.

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 242 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 Corning® or
equivalent.

A01C18A

TYPICAL

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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 242 on threads and torque the screw
to 21 N•m (15 lbf•in).

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Section 03 ENGINE
Subsection 05 (MAGNETO SYSTEM)

MAGNETO SYSTEM

13
11

10
Loctite 243

Engine
oil

7 Nm
(62 lbfin)

8
4
9 Nm
(80 lbfin)
5

7
1

Loctite
243

3
2

7 Nm
(62 lbfin)

V01C1NS

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Section 03 ENGINE
Subsection 05 (MAGNETO SYSTEM)

MAGNETO
Removal
Remove engine. Refer to REMOVAL AND INSTALLATION 03-02.
Install engine on engine stand (P/N 529 035 646).
Remove water pump. See the instructions as follow.
Remove:
– radiator outlet hose
– water cooling hose
– bolts
– water pump housing and rubber ring
– circlip on water pump shaft
Unscrew water impeller, use the spaner for water
pump impeller (P/N 529 035 659). Turn counterclockwise.
Water pump removal is completed.
Remove:
– STPS (Sub-Transmission Position Sensor) no. 1
– all bolts retaining ignition cover
– ignition cover no. 2
– gasket no. 3.
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. 4 retaining magneto no. 5 to ignition cover then pull magneto.

Installation
For installation, reverse the removal procedure.
Paying attention to the following details.
At the time of the socket screws installation retaining magneto, apply Loctite 243 on threads.
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 replace
the hydraulic piston.

V01D0JA

1. Hydraulic piston

Slide STPS inside sealing tube.
Align STPS drive with shift drive shaft.

ROTOR
Removal
Lock crankshaft with locking bolt (P/N 529 035
645). Refer to CRANKSHAFT/BALANCER SHAFT
03-07.
Remove:
– ignition cover no. 2
– pawl no. 6 and needle pin no. 7
Unscrew nut no. 8 retaining rotor no. 9.
Remove serrated washer no. 10.
Install magneto puller (P/N 529 035 547) and
crankshaft protector (P/N 290 876 557) then remove rotor.

Installation
For installation, reverse the removal procedure.
Paying attention to the following details.
Insert ring gear in sparg clutch no. 11.
Install nut on crankshaft end. Apply Loctite 243 on
threads. Torque to 140 N•m (103 lbf•ft).

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Section 03 ENGINE
Subsection 05 (MAGNETO SYSTEM)

SPARG CLUTCH
Removal
Remove rotor no. 9.
Unscrew all socket screws no. 12 retaining rotor
and sparg clutch housing no. 13.
Remove sparg clutch from sparg clutch housing.

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

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Subsection 06

Section 03 ENGINE
(CYLINDER AND HEAD)

CYLINDER AND HEAD
10 Nm
(89 lbfin)
11

12
3

Multi-purpose
grease
2
10 Nm
(89 lbfin)

19
4

17
22 Nm
(16 lbfft)
14

Engine oil

50 Nm
(37 lbfft)
13

10 Nm
(89 lbfin)

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.

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Section 03 ENGINE
Subsection 06 (CYLINDER AND HEAD)

1, CYLINDER HEAD

Installation

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 03-02)
– 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

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 (0.008 in)

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

3, ROCKER ARM
Removal

V01C1DA

Remove:
– cylinder head no. 1
– holding strip no. 16
Extract rocker arm shaft no. 17 using a M8 x 53.5
screw.
NOTE: Use a flanged bolt no. 14 retaining cylinder
head to cylinder base.

1. Flanged nuts

Pull up cylinder head.

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

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Subsection 06

Section 03 ENGINE
(CYLINDER AND HEAD)

Any area worn excessively will require part replacement.

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

4, VALVE SPRING
Removal

V01C1EA

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

Remove:
– cylinder head no. 1
– rocker arm no. 3
Compress valve spring with an universal C-clamp
spring compressor such a Snap-on CF811.

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

V01C1GA

V01C1FA

A. 13.76 mm (0.542 in)

ROCKER ARM BORE DIAMETER
SERVICE LIMIT

13.76 mm (0.542 in)

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.

1.
2.
3.
4.

Remove valve cotters no. 18.
Remove spring compressor, valve spring retainer
no. 19 and valve spring.

Inspection
Check valve spring for rust or corrosion, free length
and squareness.

ROCKER ARM SHAFT DIAMETER
SERVICE LIMIT

Valve spring
Valve spring retainer
Valve cotters
C-clamp spring compressor

13.67 mm (0.538 in)

VALVE SPRING FREE LENGTH
SERVICE LIMIT

38 mm (1-1/2 in)

VALVE SPRING MAXIMUM SQUARENESS
SERVICE LIMIT

1.1 mm (0.043 in)
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Section 03 ENGINE
Subsection 06 (CYLINDER AND HEAD)

Installation

Measure valve seat width, using a caliper.

For installation, reverse the removal procedure.

VALVE SEAT CONTACT WIDTH mm (in)

5, VALVE

SERVICE LIMIT

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

Inspection
Valve
Inspect valve surface, check for abnormal stem
wear and bending. If so, replace by a new one.

Exhaust

2 mm (0.078 in)

Intake

1.8 mm (0.07 in)

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

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)
SERVICE LIMIT

V01C1HA

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

Exhaust
6.95 mm (0.274 in)
Intake

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

VALVE GUIDE CLEARANCE mm (in)
SERVICE LIMIT

6, VALVE STEM SEAL

Exhaust
0.13 mm (0.005 in)

Removal

Intake

Change valve if valve stem is out of specification.
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.
Measure valve face contact width.
NOTE: The location of contact area should be in
center of valve face.

Remove valve.
Remove circlip on the bottom of valve stem seal.

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Subsection 06

Section 03 ENGINE
(CYLINDER AND HEAD)

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

1
2
1

1
V01C1IA

1
V01C1JA

1. Circlip
2. Valve stem seal

1. Measure at three points

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.

Difference between measurements should not
exceed 0.10 mm (0.004 in). If so, replace cylinder.
Cylinder Out of Round
Measure cylinder diameter in piston axis direction
from top of cylinder. Take an other measurement
90° from first one and compare. Difference between measurements should not exceed 0.10 mm
(0.004 in). If so, replace cylinder.

7, CYLINDER
Removal
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.

A
B

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

V01C1KA

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

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Section 03 ENGINE
Subsection 06 (CYLINDER AND HEAD)

9, PISTON

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.

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.

8, LIFTER

Inspection

Removal

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.

Removal
Remove cylinder no. 7.
Pull lifter out of crankcase.

Inspection
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
Lifter

22.19 mm (0.874 in)

Lifter bore

22.27 mm (0.876 in)

F01D0NA

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

LIFTER BORE CLEARANCE
SERVICE LIMIT

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

0.08 mm (0.003 in)

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

Installation
For installation, reverse the removal procedure.

PISTON MEASUREMENT
SERVICE LIMIT

88.9 mm (3.5 in)

Piston/Cylinder Clearance
PISTON/CYLINDER CLEARANCE
SERVICE LIMIT

0.13 mm (0.005 in)

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

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Subsection 06

Section 03 ENGINE
(CYLINDER AND HEAD)

Position the dial bore gauge at 16 mm (5/8 in) below cylinder top edge, measuring perpendicularly
(90°) to piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance. 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.

F00B08A

Installation

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).

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.

10, PISTON RINGS

Inspection
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.
F00B09A

RING/PISTON CLEARANCE mm (in)
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge

SERVICE LIMIT

0.15 mm (0.006 in)

1
F00B0AA

TYPICAL
1. Indicator set to 0 (zero)

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Section 03 ENGINE
Subsection 06 (CYLINDER AND HEAD)

A31C2NA

1. Top ring (rectangular, black/gray color)
2. Second ring (scraper, chrome/stainless steel looking ring)
3. Oil ring
V01C1LA

A. Measure here

Ring End Gap
RING END GAP mm (in)
SERVICE LIMIT

1.5 mm (0.06 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.

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

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.

A31C2OA

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

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Subsection 07

Section 03 ENGINE
(CRANKSHAFT/BALANCER SHAFT)

CRANKSHAFT/BALANCER SHAFT

22 Nm
(16 lbfft)
6

240 Nm
(178 lbfft)
4
7

150 Nm
(111 lbfft)
11

Loctite
243

Loctite
243
12

Molykote
G-N

5
Engine
oil

13
3

Loctite
243
14

8
10

Engine
oil

Anti-seize
lubricant
9
2

Molykote
G-N
1

Molykote
G-N

Anti-seize
lubricant

Molykote
G-N

V01C1WS

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Section 03 ENGINE
Subsection 07 (CRANKSHAFT/BALANCER SHAFT)

1, CAMSHAFT
Removal
Remove engine from vehicle (refer to INSTALLATION AND REMOVAL 03-02).
Front Side
Remove:
– rewind starter
(refer to REWIND STARTER 03-04)
– clutch
(refer to CLUTCH 03-09)
– sub-transmission system
(refer to TRANSMISSION 03-10)
– cylinder head, cylinder and piston
(refer to CYLINDER AND HEAD 03-06)
– crankshaft gear nut no. 4, use 46 mm socket
(P/N 529 035 648), then remove crankshaft gear
no. 5
– bolt no. 6, lock washer no. 7 and washer no. 8
retaining cam shaft gear no. 9 with centrifugal
weight no. 10
– nut no. 11 and lock washer no. 12 retaining control gear no. 13 and balancing shaft gear no. 14.
Remove the both gears
– oil pump gear
– holding strip retaining oil pipe

Rear Side
Remove:
– starter, water pump, magneto and ring gear
(refer to MAGNETO SYSTEM 03-05)
– shifting system
(refer to TRANSMISSION 03-10)
Separate crankcase housings.
Remove camshaft.

Inspection
Check each lobe for scoring, scuffing, cracks, or
other sign of wear.
Measure each end of camshaft.
CAMSHAFT ENDS mm (in)
SERVICE LIMIT
Clutch side

31.95 mm (1.258 in)

Magneto side

17.96 mm (0.707 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 (0.71 in)

Subtract the camshaft end diameter from the
proper bore diameter to find clearance.
CAMSHAFT END CLEARANCE mm (in)
V01C1XA

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

SERVICE LIMIT

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

– all bolts and socket screws retaining crankcase

Clutch side

0.086 mm (0.0034 in)

Magneto side

0.075 mm (0.0029 in)

If necessary, change camshaft and/or crankcase.

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Subsection 07

Installation

Section 03 ENGINE
(CRANKSHAFT/BALANCER SHAFT)

For installation reverse the removal procedure.
NOTE: Always install a new crankcase gasket.

2, BALANCER SHAFT
Removal
Refer to CAMSHAFT REMOVAL section above.
Use the same procedure.
Remove balancer shaft.

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

Installation
For installation, reverse the removal procedure.

3, CRANKSHAFT

V01C21A

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)

Removal

SERVICE LIMIT

Use the same removal procedure that camshaft
and balancer shaft.
Remove crankshaft and adjusting washer no. 15.

Inspection
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.

Axial play

1.3 mm (0.05 in)

Connecting Rod/Piston Pin Clearance
Measure piston pin. Compare to inside diameter
of connecting rod.
CONNECTING ROD SMALL END DIAMETER
SERVICE LIMIT

22.05 mm (0.868 in)

PISTON PIN DIAMETER
SERVICE LIMIT

CRANKSHAFT DEFLECTION mm (in)
SERVICE LIMIT

21.99 mm (0.866 in)

PISTON PIN BORE CLEARANCE

Clutch side

0.08 mm (0.003 in)

Magneto side

0.05 mm (0.002 in)

SERVICE LIMIT

0.06 mm (0.002 in)

Installation
For installation, reverse the removal procedure.

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Subsection 08

Section 03 ENGINE
(LUBRICATION SYSTEM)

LUBRICATION SYSTEM

Engine oil

10 Nm
(89 lbfin)

15
16

18 Nm
(159 lbfin)

Engine oil
18

5
4
3
6
2
1
10 Nm 1
(89 lbfin)

Loctite 243

22
21
Engine oil
V01C1SS

23
19
21 Nm
(15 lbfft)

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Section 03 ENGINE
Subsection 08 (LUBRICATION SYSTEM)

TROUBLESHOOTING

When the hydraulic shifter is used, the engine
pressure must increase up to about 810 kPa (118
PSI).
If the engine pressure is out of specifications,
check the points described in LOW OR NO OIL
PRESSURE section above.

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
–
–
–
–
–

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

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

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

Oil Contamination (white appearance)
–
–
–
–

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

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
1

V01A0AB

1. Oil drain plug
V01C1TA

1. Oil pressure gauge
2. Oil filter

The engine pressure should be between 101 kPa
(14.7 PSI) and 608 kPa (88 PSI).

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.

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Subsection 08

Section 03 ENGINE
(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 11-02 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.

ENGINE OIL PRESSURE
REGULATOR

OIL STRAINER

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

Removal

Inspection

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

Inspect piston for scoring or other damages.
Check compression spring for free length, squareness or other damage.

The engine oil pressure regulator is located near
exhaust pipe bracket.

V01C1UA

1. Engine oil pressure regulator

Removal

COMPRESION SPRING FREE LENGTH
SERVICE LIMIT

42 mm (1.65 in)

Installation
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.

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

Installation
For installation, reverse the removal procedure.

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Section 03 ENGINE
Subsection 08 (LUBRICATION SYSTEM)

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

OIL PUMP ROTOR AND INNER ROTOR
CLEARANCE mm (in)
SERVICE LIMIT
A

Removal

Remove engine. Refer to REMOVAL AND INSTALLATION 03-02.
Remove clutch cover and clutch housing. Refer to
CLUTCH 03-09.
Remove:
– 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 rotor no. 17
– inner rotor no. 18

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

0.25 mm (0.009 in)

Measure oil pump rotor thickness and oil pump
rotor bore depth.
Difference between measurements should not
exceed 0.2 mm (0.007 in). If so, replace oil pump
rotor.

Installation
For installation, reverse the removal procedure.

CLUTCH OIL PRESSURE
REGULATOR
Removal
Remove water pump and ignition cover. Refer to
MAGNETO SYSTEM 03-06.
Unscrew plug no. 19.
Remove compression spring no. 20, valve piston
no. 21 and valve seat sleeve no. 22.

Inspection
Inspect piston for scoring or other damages.
Check O-ring no. 23 for damage. Change if necessary.
Check compression spring for free length, squareness or other damage.

B
C

COMPRESION SPRING FREE LENGTH
SERVICE LIMIT

59.5 mm (2.34 in)

V01C1VA

1. Oil pump rotor
2. Inner rotor

Installation
For installation, reverse the removal procedure.

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Section 03 ENGINE
Subsection 09 (CLUTCH)

CLUTCH
150 Nm
(111 lbfft)
1

Loctite
243

21 20

7
150 Nm
(111 lbfft)
10
9

Engine
oil

6
7 Nm
(62 lbfin)

12
Engine
oil

14
11
15

13
18

Engine
oil

Engine
oil 17

V01D01S

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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 have 2.0 mm (5/64 in).

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

1
V01D03A

A. Weight lining

V01D02A

1. Crankshaft locking bolt

Unscrew nut no. 1 retaining clutch weight ass’y
no. 2 to crankshaft.
Pull clutch drum out of housing and remove thrust
washer no. 4.
Separate clutch weight ass’y 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 (0.85 in), change springs.
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.

V01D0EA

A. 21.6 mm (0.85 in)

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

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Section 03 ENGINE
Subsection 09 (CLUTCH)

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

Remove the 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
–
–
–
–
–
–
–
–
–
–
–
–
–

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
circlip
output gear

V01D06A

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

Remove clutch drum no. 3 and thrust washer no. 4.
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.

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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
– clutch basket no. 16
– needle bearings no. 18 and no. 19
– large thrust washer no. 17

STEEL DRIVEN PLATE
MAXIMUM WARPAGE

0.25 mm (0.01 in)

Inspection
Friction Drive Plate
Measure each friction drive plate thickness.
Friction drive plates must be replaced when lining
is 2.7 mm (0.11 in) thick or less.
FRICTION DRIVE PLATE
MINIMUM THICKNESS

2.7 mm (0.11 in)

V01D08A

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

V01D07A
V01D09A

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 (0.01 in) or if they
show signs of discoloration.

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Section 03 ENGINE
Subsection 09 (CLUTCH)

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

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

32.5 mm (1.28 in)

V01D0AA

V01D0CA

Pressure Plate Bearing
Check the pressure plate bearing no. 20. Turn the
bearing with your finger.
The bearing should turn smoothly and don’t have
excessive play. Replace if necessary.

Assembly
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

V01D0DA

V01D0BA

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

1. Retaining plate bearing

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Section 03 ENGINE
Subsection 09 (CLUTCH)

Install 2 clutch springs. Remove clutch hub assembly from clutch basket.

V01D0FA

Install clutch hub. Move the output shaft slowly
and push clutch hub.

V01D0HA

NOTE: Do not remove shift shaft. If the shift shaft
is removed, refer to TRANSMISSION 03-10 for
proper installation.
Install the large thrust washer on main shaft.
Install needle bearings, the large bearing in first,
large thrust washer, clutch basket and then the
small thrust washer on main shaft. Apply engine
oil on needle bearings.
Using the sub-transmission positioner (P/N 529 035

1. Output shaft

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

651), select an other position than PARK.

V01D0IA

V01D0GA

Replace the transmission in PARK position.
At the time of indicator shaft installation, refer to
TRANSMISSION 03-10 for the proper procedure.

1. Sub-transmission positioner

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Section 03 ENGINE
Subsection 10 (TRANSMISSION)

TRANSMISSION
GEAR SHIFT SYSTEM

Engine
oil

10 Nm
(89 lbfin)
4
5

Engine
oil
6

7
22

2
10 Nm
(89 lbfin)

Engine
oil
3

Engine
oil
15

Engine
19 oil

16
Engine
oil

8
12

Engine
oil

18
11

9 10 Nm
(89 lbfin)

13
Engine
oil

10 Nm
(89 lbfin)

V01E0BS

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Section 03 ENGINE
Subsection 10 (TRANSMISSION)

TRANSMISSION
Loctite
243 Anti-seize
lubricant

Anti-seize
lubricant

21
Anti-seize
lubricant
Molykote
GN
Anti-seize
lubricant

Anti-seize
lubricant

10 Nm
(89 lbfin)
Loctite
243

Anti-seize
lubricant
22
Anti-seize
lubricant

15
23
Anti-seize
lubricant

Anti-seize
lubricant

V01E0CS

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Section 03 ENGINE
Subsection 10 (TRANSMISSION)

GEAR SHIFT MECHANISM

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

Disassembly

Front Side
Remove:
– engine from vehicle
(refer to REMOVAL AND INSTALLATION 03-02)
– rewind starter
(refer to REWIND STARTER 03-04)
– clutch (refer to CLUTCH 03-09)
Remove the shift shaft no. 1.
Unscrew socket screw no. 2 retaining index gear
no. 3.
Remove socket screw no. 4, washer no. 5, index
lever no. 6 and index spring no. 7.

V01E0DA

1.
2.
3.
4.

3
2

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.
Remove nut retaining shift drum gear no. 8.
Remove 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.

V01E0EA

1. Index gear
2. Shift shaft

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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.

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

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.

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

V01E0GA

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Section 03 ENGINE
Subsection 10 (TRANSMISSION)

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.

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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
04-02-3
04-02-4
04-02-4

CARBURETOR AND FUEL PUMP.........................................................................................
CARBURETOR ...................................................................................................................
REMOVAL ..........................................................................................................................
CLEANING AND INSPECTION..........................................................................................
CARBURETOR FLOAT LEVEL ADJUSTMENT .................................................................
INSTALLATION..................................................................................................................
CARBURETOR ADJUSTMENTS .......................................................................................
FUEL PUMP .......................................................................................................................
REMOVAL ..........................................................................................................................
VERIFICATION....................................................................................................................
CLEANING AND INSPECTION..........................................................................................
INSTALLATION..................................................................................................................

04-03-1
04-03-1
04-03-1
04-03-2
04-03-2
04-03-3
04-03-4
04-03-7
04-03-7
04-03-7
04-03-7
04-03-7

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

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

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Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)

FUEL CIRCUIT
5
4
6
3

8
9

10
Body

2
7
9
V01N0BS

04-02-1

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Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)

FUEL LINES

m WARNING
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.

m WARNING

V01N02A

Use of improper fuel lines could compromise
fuel system integrity.

USE SCREWDRIVER ONLY IF GROMMET IS TOO TIGHT

Inspection

m WARNING

Ensure that fuel tank strainer no. 8 and fuel line
are clean and not damaged, as per following photo.

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.

FUEL TANK STRAINER
Removal
Close fuel valve no. 1.
Remove fuel tank cover. Refer to BODY10-02.
Disconnect BLACK negative cable from battery.
Drain fuel tank no. 3 by unplugging reserve fuel
hose no. 9 on fuel valve (top hose).
NOTE: To accelerate fuel tank draining and ensure
complete draining, remove cap no. 6.
Manually pull grommet no. 10 out of fuel tank, as
shown in the next photo.
NOTE: In the case that grommet is too tight, use
a flat screwdriver and carefully pull out grommet,
as shown in the next photo.

A31I03A

TYPICAL
1. Fuel tank strainer
2. Fuel line

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.

04-02-2

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Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)

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

V01N03A

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 table.

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

HOSE

VALVE POSITION

Fuel tank top hose

To fuel pump

OUT

Fuel tank bottom hose

RES

FUEL TANK
Removal

V01N04A

UNSCREW VALVE NUT

Unplug all 3 hoses from fuel valve.
Remove valve.

Disconnect BLACK negative cable from battery.
Drain fuel tank no. 3 by unplugging reserve fuel
hose no. 9 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 10-02 for complete detailed procedure:
– steering cover
– shifter guide indicator
– front inner fenders
– seat
– fuel tank cover
– front bumper
– front fender with rack

04-02-3

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Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)

Unplug fuel hoses from tank and disconnect fuel
vent line no. 5.
Remove both fuel tank top screws, as shown in
the next photo.

V01N07A

4 5 6

1. Remove both top fuel tank screws

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

Remove fuel tank bottom nut located beside rewind starter.

Perform fuel system pressurization as described
in the following procedure.

Inspection

FUEL GAUGE

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

Removal

V01N06A

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

Installation
Reverse removal procedure, however pay attention to the following:
Ensure that main fuel tank hose no. 11 and reserve fuel tank hose no. 9 are not inverse. Refer
to FUEL VALVE table.
Position top screws/nuts, washers and spacers as
shown in the next photo.

Nut
Frame bracket
Fuel tank holding tab
Spacer
Washer
Screw head

Remove front fender. Refer to BODY 10-02.
Pull out fuel gauge no. 4 from fuel tank. At the
same time, remove the fuel gauge gasket.

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

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).

04-02-4

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Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)

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
V01N08A

HOSE PINCHER INSTALLED ON FUEL TANK VENT LINE

1. Special cap on tank
2. Air pump

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

04-02-5

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Subsection 03

Section 04 FUEL SYSTEM
(CARBURETOR AND FUEL PUMP)

CARBURETOR AND FUEL PUMP
CARBURETOR
CAUTION: Although some jets be replaced by
other jets from other carburetors, such modifications shouldn’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
Disconnect BLACK negative cable from battery.
Remove seat.
Unplug all fuel hoses from carburetor no. 7.
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.

V01B01A

1. Open key end here

Pull choke cable to remove choke plunger from
carburetor.

Throttle Cable Removal

Choke Cable Removal
Put carburetor on a clean rag.
Unscrew choke plastic nut from carburetor, as
shown in the next photo.

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.

V01F09A

V01F0AA

REMOVE CHOKE PLASTIC NUT

NOTE: To ease choke plastic nut removal use an
open key as shown in the next photo. This tool can
be made with an existing 12 mm key.

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

04-03-1

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

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

Carburetor body and jets should be cleaned in a
carburetor cleaner following manufacturer’s instructions.

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

CARBURETOR FLOAT LEVEL
ADJUSTMENT

V01F0BA

REMOVE CABLE END BUSHING

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

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.
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 without 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.

V01F0TA

1. Gauge tips
2. “L” arm
A. Height H

04-03-2

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Subsection 03

Section 04 FUEL SYSTEM
(CARBURETOR AND FUEL PUMP)

90°

V01F0EA

GAUGE ALIGNED WITH MAIN JET

V01F0FA

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.

CARBURETOR SIDE — RUBBER FLANGE INSTALLATION
1. Flange recess aligned with carburetor notch

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

INSTALLATION
To install carburetor on engine, inverse removal
procedure, as described:
– Inspect throttle and choke cable housing prior
to installation.
– Reinstall and adjust throttle and choke cables,
then side cover. Refer to next section CARBURETOR ADJUSTMENTS.
– 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.
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

04-03-3

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

CARBURETOR ADJUSTMENTS

2
V01F0HA

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

Pilot Screw Preliminary Adjustment
NOTE: The pilot screw is factory pre-set. Adjustment is not necessary unless the carburetor is
overhauled or replaced.
Completely close the pilot screw (until a slight
seating resistance is felt) then back off as specified.
Refer to TECHNICAL DATA 11-02 for specifications.

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.

V01F0WA

1. Bypass hole closes to halfway

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 11-02 for idle speed
specifications.

04-03-4

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Subsection 03

Section 04 FUEL SYSTEM
(CARBURETOR AND FUEL PUMP)

Choke

Pilot Screw Adjustment

Remove top cover from carburetor.
Detach diaphragm from carburetor body, then pull
out throttle slide.
With choke lever at fully closed position, choke
plunger must be fully closed. With lever halfway,
plunger must be opened to specification and with
lever completely opened, plunger must be
opened.
See next photos for proper choke lever and plunger positioning.

NOTE: The pilot screw is factory pre-set. Adjustment is not necessary unless the carburetor is
overhauled or replaced. Warm the engine to operating temperature.
Turn the pilot screw clockwise until you hear the
engine misses or decreases air speed, then turn
counterclockwise until the engine again misses or
decreases air speed.
Center the pilot screw exactly between these too
extreme positions.
If idle speed changes after adjustment of the pilot
screw, readjust the idle speed screw.

V01F0JS

FULLY CLOSED POSITION
1. Plunger end must be here

1
A

V01F0KT

HALFWAY POSITION
1. Plunger end must be here
A. Opening to specification value

04-03-5

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

V01F0LS

FULLY OPENED POSITION
1. Plunger end must be here

Plunger Adjustment

Throttle

If plunger needs to be adjusted use cable adjuster,
as shown in the next photo.

m WARNING
Ensure the key is turned OFF, prior to performing the throttle cable adjustment.
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,
doesn’t lean against carburetor body.

V01F0MA

USE CABLE ADJUSTER TO ADJUST PLUNGER POSITION
1. Choke plunger

NOTE: For the proper adjustment at halfway position, use a bit with diameter to opening specification.

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.

V01F0RA

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

Retorque lock nut.
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Subsection 03

Section 04 FUEL SYSTEM
(CARBURETOR AND FUEL PUMP)

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 no. 12.
1

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.

m WARNING
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.
V01F0NA

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

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

Remove fuel pump no. 2.

VERIFICATION
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.

04-03-7

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Section 04 FUEL SYSTEM
Subsection 04 (AIR INTAKE SILENCER)

AIR INTAKE SILENCER
1
2

6
14
13
15
16

Engine
Valve Cover

Engine
7

11
V01C13S

04-04-1

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Section 04 FUEL SYSTEM
Subsection 04 (AIR INTAKE SILENCER)

AIR FILTER BOX

Inspection

Removal

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

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
Unfasten bolts no. 5 and remove drain tubes no. 9
under air filter box no. 10.
Pull out the air filter box.

Installation
For installation, reverse the removal procedure.

REAR AIR INTAKE TUBE

Installation
For installation, reverse the removal procedure.

FRONT AIR INTAKE TUBE
Removal
Remove:
– front fender
– LH inner fender
Refer to BODY 10-02
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.

Inspection

Removal
Remove:
– front fender
– LH inner fender
– LH side panel
NOTE: For all body parts removal, refer to BODY
10-02.
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.

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

Installation
For installation, reverse the removal procedure.

PCV VALVE
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.

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 vaccum
should be felt immediately. If not, replace the PCV
valve.

04-04-2

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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.

04-04-3

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Section 05 ELECTRICAL
Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS
OVERVIEW............................................................................................................................. 05-02-1
GENERAL OPERATION INFORMATION........................................................................... 05-02-1
MPEM (MULTI-PURPOSE ELECTRONIC MODULE)............................................................ 05-02-1
CHARGING SYSTEM......................................................................................................... 05-02-1
STARTING SYSTEM .......................................................................................................... 05-02-2
IGNITION SYSTEM............................................................................................................ 05-02-2
ELECTRIC SHIFT SYSTEM ................................................................................................ 05-02-3
GAUGES/ACCESSORIES .................................................................................................. 05-02-3
GENERAL TESTING/TROUBLESHOOTING INFORMATION .......................................... 05-02-4
SERVICING PACKARD CONNECTORS ............................................................................ 05-02-4
SERVICING DEUTSCH CONNECTORS ............................................................................ 05-02-5
SERVICING AMP CONNECTORS (26 PINS)..................................................................... 05-02-5
IDENTIFICATION OF FUSE BLOCK ON VEHICLE ............................................................ 05-02-9
IDENTIFICATION OF MAJOR CONNECTOR PINS .......................................................... 05-02-9
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 .............................................................................................
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
05-04-9
05-04-9
05-04-9

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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 .........................................................................................
SENSOR REMOVAL/INSTALLATION...............................................................................
STPS (SUB-TRANSMISSION POSITION SENSOR) .........................................................
GBPS (GEAR BOX POSITION SENSOR)...........................................................................
VSS (VEHICLE SPEED SENSOR) .......................................................................................
VALVES/SOLENOIDS TESTS............................................................................................
CLUTCHING VALVE AND CLUTCH MODULATOR VALVE TESTS .................................
UPSHIFT/DOWNSHIFT SOLENOIDS TESTS ....................................................................
SENSOR TESTS .................................................................................................................
STPS (SUB-TRANSMISSION POSITION SENSOR)
AND GBPS (GEAR BOX 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
05-06-9
05-06-9
05-06-9
05-06-10
05-06-11
05-06-11
05-06-11
05-06-11
05-06-13
05-06-13
05-06-13
05-06-15

05-01-2

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05-06-15
05-06-15
05-06-16
05-06-16

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 .................................................................................................................
TESTS.................................................................................................................................
12-VOLT AUXILIARY POWER OUTLET............................................................................
12-VOLT POWER OUTLET ................................................................................................
COOLING FAN OPERATION TEST ...................................................................................
HEADLIGHT .......................................................................................................................
HI-LO SWITCH ...................................................................................................................
INDICATOR LIGHTS ..........................................................................................................
SPEEDOMETER .................................................................................................................

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
05-07-5
05-07-5
05-07-5
05-07-5
05-07-5
05-07-5
05-07-6
05-07-6

05-01-3

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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 onand 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.

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.
The MPEM also controls the accessories such as
the speedometer, 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
4

VO1G0IA

1.
2.
3.
4.

Magneto flywheel
Stator
Voltage regulator/rectifier
Battery
05-02-1

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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)

Voltage Regulator/Rectifier

IGNITION SYSTEM

A 3-phase full-wave shunt-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).

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

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

V01G0KA

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

Battery/Ignition Switch

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

Start/Stop Switch
Besides enabling the starting system, the start/stop
switch enables/disables the ignition system through
the MPEM.

6
V01G0JA

MPEM
(Multi-Purpose Electronic Module)

TYPICAL
1. Battery
2. Ignition switch
3. Start/stop switch
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.

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.

05-02-2

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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)

Magneto Flywheel/Trigger Coil

Upshift/Downshift Switch

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.

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

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.

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

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.
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 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.

MPEM
3

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.

4
5
2

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 opened
and released (modulation). The hydraulic system
is enclosed in the engine/transmission case and
the same oil as the engine is used for the hydraulic
valves.

6
V01G0LA

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

Solenoid/Valve

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.

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.
05-02-3

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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.

m 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.

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

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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)

SERVICING DEUTSCH
CONNECTORS

– 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.

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

V01G0QA

FEMALE CONNECTOR HOUSING
1. Retaining tab

V01G0OA

FEMALE HOUSING
1. Female lock

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.

SERVICING AMP CONNECTORS
(26 PINS)
When servicing electrical system, special care
must be taken when working with AMP plug connectors in order to prevent any malfunction of the
system.
V01G0PA

MALE HOUSING
1. Male lock

NOTE: Before extraction, push wire forward to relieve pressure on retaining tab.
05-02-5

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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)

Identification

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

Parts
5
9
1
2

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.
2
1

V0IG0MA

TYPICAL
1. AMP connectors
2. Identification numbers

F00H12A

TYPICAL
1. Mechanically keyed

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

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.

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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)

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.

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
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.
1

F00B0EA

CRIMPING TOOL (P/N 295 100 164)

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.
1

F00H0OB

1. Wedge lock
2. Locking tab

F00H10A

1. Seal plug
2. Wire seal

F00H0PA

1. Wedge lock in open position

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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)

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.

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.

Contact Installation

F00H0RA

1. Pull locking tab (both sides)

Before extraction, push wire forward to relieve
pressure on retaining tab.

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.

05-02-8

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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)

Apply a thin coat of DEOXIT contact lubricant to
the pins of the header on the MPEM only.
1
4

2
5

3
6

V01G02A

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

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.

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

IDENTIFICATION OF MAJOR
CONNECTOR PINS
AMP Connectors of MPEM

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

F04H6FA

V01G04A

1. Battery
2. Fuse holder

Fuses are identified by a number located beside the
fuses.

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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)

AMP Connectors of Wiring Harness

F04H6GA

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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

A
C
D

V01G0ES

B
FE

C
B A

4
3
4
3

1
2

1
2
3

B
C

A
B

A
C

85
87
87a
86 30

A
D

A
CB

A
B

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

05-02-11

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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

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.

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.

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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 con-nector.
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 Ω ± 0.1.

F01H4WA

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

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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)

STARTING SYSTEM
BATTERY
TROUBLESHOOTING
SYMPTOM: DISCHARGED OR WEAK BATTERY
CAUSE
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).

REMEDY

A17E0JA

Replace.

TYPICAL
1. Specific gravity 1.265

4. Charging system fuse
burnt or faulty voltage
regulator/rectifier.*

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

5. Faulty charging system
generator coil.*

Replace.

* To test charging system, refer to CHARGING SYSTEM 05-03.

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.

BATTERY TESTING

ELECTROLYTE
TEMPERATURE

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.

OPERATION TO PERFORM

°C

°F

100

.004

Unload Test

correct reading

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.

.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

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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.

m WARNING

m 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.

m 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.

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

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.

m 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

m 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.

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.

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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)

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).

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.

ACTIVATION OF A NEW BATTERY

m 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.

m WARNING

A17E0HA

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

m WARNING

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

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.

A17E0FA

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.

1. Battery electrolyte

05-04-3

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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)

A17E0LA

1. Baking soda

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

m 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.

m 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.

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.

05-04-4

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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)

– 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.

CHARGING 2 OR MORE
BATTERIES AT A TIME

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

m 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.

Connect all positive battery posts together and
use a charger with a capacity (rated) equal to number of battery to be charged.
1

V01G05A

A17E0PA

1. Cable between battery and strap

TYPICAL
1. Two batteries connected in parallel

05-04-5

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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 button 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.

STPS
(Sub-Transmission Position Sensor)
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,
section 05-06. If it tests good, continue the other
tests.

Start/Stop Switch
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.

m 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

V01G0TA

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

1. Unplug connector
2. RED wiring harness

Ignition Switch

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

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, section 05-05 for testing procedure. If it tests good, continue the other
tests.

POSITION

WIRE

Switch released
Switch depressed
and held

RESISTANCE
Infinite (0.L)

BLACK and
YELLOW

0.4 Ω max.

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

05-04-7

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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)

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

Electrical Cables or Connections
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.

Electric Starter
12 Vdc

BLACK

If solenoid test good, check the electric starter. If
starter test good, the MPEM can be suspected.
See MPEM below.

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.

NOTE: Starter is located behind LH side panel.
Remove LH side panel to give access to the starter. Refer to BODY/FRAME, section 10-02.
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.

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.

05-04-8

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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)

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

m 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
10-02.
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.

m 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.

05-04-9

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Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)

IGNITION SYSTEM
IGNITION SYSTEM TESTING PROCEDURE
GENERAL

IGNITION SYSTEM TEST

Ignition Problems

Safety Precautions

When dealing with ignition problems, the 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.

m 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 isn’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.

05-05-1

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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.

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.

V01G0XA

Multimeter
6-pin magneto harness adapter
WHITE wire
BLACK wire

IGNITION COIL
1. Primary side
2. Secondary side

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.

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.
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.

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Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)

Measure resistance between ignition coil outlet
caps and spark plug caps. The obtained value
should be between 5.4 and 5.7 Ω. If resistance is
good, continue check. If not, change spark plug
wires.
DYNAMIC TEST
An ignition coil tester available from after-market
tool/equipment suppliers can be used.
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 05-04 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 05-07.

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

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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.

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
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

2
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

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

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).

05-05-5

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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

Projected
Insulator Type

Taper
Seat Type

V-Type

Surface
Discharge Type

05-05-7

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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)

ELECTRIC SHIFT SYSTEM
GENERAL
The electric shift system controls several valves/solenoids that control the shifting and also allow an 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 is slippery or is too hard.
If a new sensor or valve/solenoid is installed, the GBPS (Gear Box Position Sensor) and STPS (SubTransmission Position Sensor) calibration is necessary. The MPEM (Multi-Purpose Electronic Module)
adjust values with the new specifications of new components installed.
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.

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

DIAGNOSTIC/CALIBRATION MODE
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 pressure and clutch modulation
– calibrate sensors when replacing components

05-06-1

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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:
– Place a diagnostic jumper in the diagnostic connector.

V01A0WA

1. Diagnostic jumper
2. 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.
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.
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.

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

05-06-3

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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)

Task 2: Clutch Modulator Calibration
The LED “Check Engine” blinks for a maximum time of 5 seconds or until the user begins the calibration
process or removes the jumper.

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

2+3

SMOOTHNESS
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.

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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)

Task 3: Sensors and Solenoids Verification
The MPEM reads all sensors and solenoids and displays the information with the LED “Hi-Lo beam”. The
LED “Reverse” is ON during all the time the MPEM is verifying the components.
Each abnormal components is represented by a coded number (see table below) and each code number
correspond to the number of blinks that the LED “Hi-Lo bean” 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

1
2

Starter solenoid
Clutching valve

LED ON
LED ON

LED blinks 1 time
LED blinks 2 times

Clutch modulator valve

LED ON

LED blinks 3 times

4
5

Downshift solenoid
Upshift solenoid

LED ON
LED ON

LED blinks 4 times
LED blinks 5 times

MPEM Memory

LED ON

LED blinks 6 times

7
8

Headlight supply
Accessory supply

LED ON
LED ON

LED blinks 7 times
LED blinks 8 times

Reference supply output

LED ON

LED blinks 9 times

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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)

Table 3: Abnormality Conditions
CODE
ABNORMALITY CONDITION
NO.

ACTION

– Short circuit to battery is detected.
– Operating current on the starter output has
exceeded 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.

5
6

– Short circuit to battery is detected.
– Operating current on the clutch modulator valve
output has exceeded the overload threshold.
– Short circuit to battery is detected.
– Operating current on the downshift solenoid
output has exceeded the overload threshold.
– Short circuit to battery is detected.
– Operating current on the upshift solenoid
output has exceeded the overload threshold.
– Programmable parameters are corrupted.

Refer to STARTING SYSTEM 05-04.

Change clutch modulator valve. Refer to VALVE
REMOVAL/INSTALLATION section.
Change shifting valve. Refer to VALVE
REMOVAL/INSTALLATION section.
Change shifting valve. Refer to VALVE
REMOVAL/INSTALLATION section.
Install a new MPEM. Refer to INSTRUMENTS AND
ACCESSORIES 05-07.

Check:
– Short circuit to ground is detected .
– Wiring condition.
– Operating current on the headlight supply
output has exceeded the overload threshold. – Headlight. Refer to INSTRUMENTS AND
ACCESSORIES 05-07.
Check:
– Short circuit to ground is detected.
– Wiring condition.
– Operating current on the accessory supply
output has exceeded the overload threshold. – Speedometer. Refer to INSTRUMENTS AND
ACCESSORIES 05-07.
Check:
– Wiring condition.
– Short circuit to ground is detected.
– STPS and GBPS sensors. Refer to SENSOR TESTS
section.

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

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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

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.

05-06-7

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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

LED

OPERATION

1. INDICATOR LIGHTS
TEST

“5” blinks first, through “1”
and after “Check Engine”
through “Neutral”.

This validates all indicator lights are good.

2. CLUTCH
MODULATOR
CALIBRATION

“Check Engine” blinks.

Press

3. SENSORS AND
SOLENOIDS TEST

“Reverse” is ON
“Hi-Lo Beam” blinks.

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

4. GBPS CALIBRATION

“1” and “Hi-Lo Beam” are
ON.

Simultaneously, press

and

buttons.

5. STPS CALIBRATION

“Neutral” and “Hi-Lo Beam”
are ON.

Simultaneously, press

and

buttons.

button.

Remove the jumper on the diagnostic connector and
RESET REGISTERS

N.A.

press the

05-06-8

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button simultaneously.

Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)

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

Installation

SHIFTING VALVE
The upshift/downshift solenoids are installed on
shifting valve. This valve is located on the rear part
of engine.
2

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

For the installation, reverse the removal procedure, paying attention to the following details:
– Install a new gasket.
– Apply Loctite 242 on threads and torque to 5
N•m (44 lbf•in).
– Calibrate GBPS (Gear Box Position Sensor) and
STPS (Sub-Transmission Position Sensor). Refer to DIAGNOSTIC/CALIBRATION MODE section, tasks 4 and 5.

CLUTCHING VALVE
The clutching valve is located on front of engine.

3
2

V01C0EB

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

Test
Refer to VALVES/SOLENOIDS TESTS section.

Removal
Remove seat.
Unplug connector.

V01C0DB

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

Test
Refer to TEST section.

V01J03C

1. Upshift/downshift solenoid connector
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)

Removal

CLUTCH MODULATOR VALVE

Remove fuel tank cover. Refer to BODY 10-02.
Unplug connector on seat pivot bar.

The clutch modulator valve is located in front of engine.

V01C0DC
V01G0RA

1. Clutch modulator valve

1. Unplug this connector

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 242 on threads and torque screws
to 3 N•m (27 lbf•in).
– Calibrate GBPS (Gear Box Position Sensor) and
STPS (Sub-Transmission Position Sensor). Refer
to DIAGNOSTIC/CALIBRATION MODE section,
tasks 4 and 5.

Test
Refer to VALVES/SOLENOIDS TESTS section.

Removal
Remove fuel tank cover. Refer to BODY 10-02.
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.
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.
– Tap clutch modulator valve gently with rubber
hammer.
– Apply Loctite 242 on threads and torque screws
to 3 N•m (27 lbf•in).
– Calibrate GBPS (Gear Box Position Sensor) and
STPS (Sub-Transmission Position Sensor). Refer to DIAGNOSTIC/CALIBRATION MODE section, tasks 4 and 5.

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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)

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

STPS
(Sub-Transmission Position Sensor)
The STPS is located on front of engine.

Test
Refer to SENSORS TESTS section.

Removal
Remove fuel tank cover. Refer to BODY 10-02.
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 GBPS and engine shaft.
– Place connector on top. Secure with screws and
lock washers. Apply Loctite 242 on threads.
– Torque screws to 3 N•m (27 lbf•in).
– Calibrate GBPS.
Refer to DIAGNOSTIC/CALIBRATION MODE section, task 4.

VSS (Vehicle Speed Sensor)
The VSS is located on front of engine.

Test
Refer to SENSORS TESTS section.

Removal

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 242 on threads.
– Torque screws to 3 N•m (27 lbf•in).
– Calibrate STPS.
Refer to DIAGNOSTIC/CALIBRATION MODE
section, task 5.

Remove skid plate under vehicle. Refer to BODY
10-02.
Remove engine oil. Refer to MAINTENANCE 02-02.
Unplug VSS.
Remove engine bolt under VSS.

GBPS (Gear Box Position Sensor)
The GBPS is located on rear of engine.

Test
Refer to SENSORS TESTS section.

Removal
Unplug GBPS.
Remove screws and lock washers.
Pull GBPS.

V01C0DD

1. Remove this bolt in first

Remove bolt retaining VSS.
Pull VSS out of engine.

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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)

Installation
For installation, reverse the removal procedure.
Pay attention to the following detail:
– Check O-ring and change if necessary.
– Install VSS and secure with screw. Torque to 9
N•m (80 lbf•in).
NOTE: Don’t apply Loctite on threads.
– Install engine bolt. Torque to 9 N•m (80 lbf•in).
– Refill engine with oil.
Refer to MAINTENANCE/LUBRICATION 02-03.

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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)

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.

m 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.
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 RED and BLUE indicator lights blink when button
is pushed, clutching valve and clutch modulator
valve are operational.
If RED 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 05-02.
– Install a new MPEM. Refer to INSTRUMENTS
AND ACCESSORIES 05-07.
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 05-02.
– Install a new MPEM. Refer to INSTRUMENTS
AND ACCESSORIES 05-07.
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 05-02.
– Install a new MPEM. Refer to INSTRUMENTS
AND ACCESSORIES 05-07.

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 RED and BLUE indicator light blink when button
is pushed, the solenoids are good.
If RED 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 05-02.
– Install a new MPEM. Refer to INSTRUMENTS
AND ACCESSORIES 05-07.
If no indicator light blinks when button is pushed
on upshift or downshift position:
– Check fuse.
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)

– Check wiring condition.
– Check upshift/downshift switch, refer to UPSHIFT/
DOWNSHIFT BUTTON TESTS section.
– Install a new shifting valve, refer to VALVES
REMOVAL/INSTALLATION section.
– Check AMP connectors on MPEM. Refer to
OVERVIEW 05-02.
– Install a new MPEM. Refer to INSTRUMENTS
AND ACCESSORIES 05-07.

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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)

SENSOR TESTS
STPS
(Sub-Transmission Position Sensor)
AND GBPS
(Gear Box Position Sensor) TESTS
NOTE: The reverse vehicle speed limiter doesn’t
work when STPS is faulty.
If STPS or GBPS sensor blink code is indicated.
The sensor can be defective. Check the following
details:
SENSOR

LED

STPS

R and N

Blinks

GBPS

1 to 5
(simultaneously)

Blinks

– 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 or 5.
– Check AMP connectors on MPEM. Refer to
OVERVIEW 05-02.
– Install a new MPEM. Refer to INSTRUMENTS
AND ACCESSORIES 05-07.
– If the problem persists, mechanical problem is
probable. Call SERVICE REPRESENTATIVE.

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 05-02.
– Install a new MPEM. Refer to INSTRUMENTS
AND ACCESSORIES 05-07.

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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)

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

WIRE

RESISTANCE

UPSHIFT
Switch released
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.

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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 connectors are protected by heat shrink tubing.
The 12-volt auxiliary power outlet allows the installation of additional accessories.

Test
Refer to TESTS section.
V01A02A

12-VOLT POWER OUTLET

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

Test

Installation

Refer to TESTS section.

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

Removal
Remove the steering cover. Refer to BODY 10-02.
Unplug the connectors of the power outlet.
Unscrew the retaining nut.

Installation

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

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
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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

1. Lens
2. Screws

90°

IGNITION SWITCH
1

Test
Refer to IGNITION SYSTEM 05-05.

Removal

90°

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

V01I0VA

1. Headlights center lines
2. Light beam center

90°
A

B
1

V01I0UA

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.

V01G0CA

1. Switch connector

Installation
For the installation, reverse the removal procedure.

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Subsection 07

Section 05 ELECTRICAL
(INSTRUMENTS AND ACCESSORIES)

INDICATOR LIGHTS

Installation

Test

For the installation, reverse the removal procedure.

Refer to TESTS section.

SPEEDOMETER

Removal
Remove the steering cover. Refer to BODY 10-02.
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.

Installation

Test
Refer to TESTS section.

Removal
Remove the steering cover. Refer to BODY 10-02.
Remove the two nuts under speedometer and unplug the connector.
1

For the installation, reverse the removal procedure.

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

Removal
Remove fuel tank.
NOTE: It’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

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Section 05 ELECTRICAL
Subsection 07 (INSTRUMENTS AND ACCESSORIES)

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

V01I0EA

1. Speedometer
2.

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.

V01I0DA

1. Pull bulb out

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

Installation
For the installation, reverse the removal procedure.
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Subsection 07

Section 05 ELECTRICAL
(INSTRUMENTS AND ACCESSORIES)

TESTS
12-VOLT AUXILIARY POWER
OUTLET
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.

COOLING FAN OPERATION TEST
Unplug the temperature sender connectors.
Install a jumper wire end in each connector. Replace the fan if it does not work.

12-VOLT POWER OUTLET
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

V01G0DA

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 diming 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.
V01G0GB

HI-LO SWITCH

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

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

Open multi-function switch box.
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.
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Section 05 ELECTRICAL
Subsection 07 (INSTRUMENTS AND ACCESSORIES)

INDICATOR LIGHTS

SPEEDOMETER

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

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.

V01G0GA

V01G0HA

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.

– No voltage on speedometer:
• Check VSS (Vehicle Speed Sensor), refer to
ELECTRIC SHIFT SYSTEM 05-06. If VSS voltage is good, check fuse no. 3 and wiring condition.
– No voltage on speedometer and VSS:
• Check MPEM wiring condition and/or change
MPEM.
– Voltage on speedometer:
• If VSS voltage is good, change speedometer.
• No voltage on VSS. Check VSS.

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Section 06 DRIVE TRAIN
Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS
FRONT DIFFERENTIAL..........................................................................................................
FRONT DRIVE SHAFT .......................................................................................................
FRONT DIFFERENTIAL......................................................................................................
FRONT PROPELLER SHAFT ..............................................................................................

06-02-1
06-02-2
06-02-3
06-02-4

REAR AXLE ............................................................................................................................
RIGID AXLE ........................................................................................................................
REAR PROPELLER SHAFT.................................................................................................

06-03-1
06-03-2
06-03-4

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Section 06 DRIVE TRAIN
Subsection 02 (FRONT DIFFERENTIAL)

FRONT DIFFERENTIAL

10
21

9
8

11
140 Nm
(103 lbfft)
(MINIMUM)

15
7
6

20
5

17 18

42 Nm
(31 lbfft)

14
22

3
45 Nm
(33 lbfft)

21 12
13
10
11
140 Nm
(103 lbfft)
(MINIMUM)

V01H0VS

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Section 06 DRIVE TRAIN
Subsection 02 (FRONT DIFFERENTIAL)

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 disk brake
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

3
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).

V01H0EA

1.
2.
3.
4.

Castellated nut
Cotter pin
Lower suspension arm
Upper suspension arm

06-02-2

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Section 06 DRIVE TRAIN
Subsection 02 (FRONT DIFFERENTIAL)

FRONT DIFFERENTIAL

Drive Shaft Boot
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 10-02 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
– 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.

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

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Section 06 DRIVE TRAIN
Subsection 02 (FRONT DIFFERENTIAL)

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

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.

V01H0WA
V01H0IA

1. Drain plug
2. Filler plug

Remove front differential by the RH side.
Separate 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.

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 11-02.
Reinstall filler plug.

FRONT PROPELLER SHAFT

Installation
For installation, reverse the removal procedure.
NOTE: Do not forget flat washer when rear
mounting bolt no. 5 installation.

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 be reach the
lower edge.
Add oil if necessary. Refer to TECHNICAL DATA
11-02 for capacity and recommended oil.

Removal
Remove:
– skid plate
– winch protector
– front bumper
– inner fender
Refer to BODY 10-02 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 vent tube no. 15 on the top from the front
differential.

06-02-4

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Section 06 DRIVE TRAIN
Subsection 02 (FRONT DIFFERENTIAL)

Pull differential forward then separate propeller
shaft from differential and engine.

Inspection
Check propeller shaft for wear or damage, replace
if necessary.

Installation
Installation is the reverse of removal procedure.

V01H0YA

1. Snap ring

V01H0JA

Support inner yoke in vice and drive other yoke
down with a soft hammer.

1. Engine side
2. Differential side

NOTE: Secure propeller shaft with new self-locking
screws.

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.
Reinstall inner fender.

Front Propeller Shaft U-joint
Removal
Remove internal snap ring from bearing caps.

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.

06-02-5

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Section 06 DRIVE TRAIN
Subsection 02 (FRONT DIFFERENTIAL)

V01H10A

Tighten vise to force bearing caps in.

V01H11A

Using a suitable arbor, fully seat bearing cap in one
side. Continually, check for free movement of
bearing cross as bearing caps are assembled.

V01H12A

Install snap ring.
Repeat procedure for other sides.
Grease U-joint, using a grease gun with SHELL,
Alvania EP-2 grease only.

06-02-6

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Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)

REAR AXLE
8
11
1
6
33 Nm
(24 lbfft)
7

43 Nm
(32 lbfft)

50 Nm
(37
lbfft)
5

27 Nm
4 (20 lbfft)

38 Nm
(28 lbfft)

140 Nm
(103 lbfft)
minimum

17
15

19
14
12
21

V01H0US

140 Nm 13
(103 lbfft)
minimum

06-03-1

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Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)

RIGID AXLE

Remove the M10 x 25 socket screws no. 7 retaining rigid axle center section to swing arm.

Removal
Lift rear of the vehicle until rear shock absorbers
are fully extended. Install jack stands under frame
to support vehicle.
Remove the rear wheels.
Remove lower shock absorber bolts and elastic
flanged nuts.

V01J05A

1. Remove M10 x 25 socket screws

Remove the M10 x 25 flanged bolts no. 5 and
elastic flanged nuts no. 6 retaining swing arm to
rigid axle.

V01J03B

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.
Disconnect vent tube no. 8 on rigid axle.
2

V01J06A

1. Remove flanged bolts and elastic flanged nuts

Detach rigid axle from swing arm.

Installation

V01J04A

1. Brake hose
2. Vent tube

Remove the M8 x 10 flanged bolts no. 4 retaining
protector no. 2 under rear rigid axle center section.

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 rigid axle center section to swing arm
with socket screws. Apply sealant Right Stuff (P/N
293 800 053) between both parts. Do not tighten
yet.

06-03-2

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Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)

Secure rear axle tube to swing arm with bolts. Do
not tighten yet.
When all bolts are installed, torque in a criss-cross
sequence.

V01J05B

RIGID AXLE CENTER SECTION

Inspection
Check axle for wear or other damage, 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.
LH SIDE AXLE
Remove:
– wheel and wheel cap
– cotter pin no. 12
– castellated nut no.13
– flat washer no. 14 and O-ring
– rigid axle from vehicle
Unfasten TORX head screws no. 20 retaining axle
tube from rear rigid axle center section no. 17.
Remove axle tube then pull out axle no. 21.

Unfasten TORX head screws no. 16 retaining axle
housing from rear rigid axle center section no. 17.
Remove axle housing then pull out axle no. 18.

Inspection
Check axle for wear or other damage, 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.

V01J06B

REAR AXLE TUBE

Rear Axle
Removal
RH SIDE AXLE
Remove:
– wheel and wheel cap
– cotter pin no. 12
– castellated nut no.13
– flat washer no. 14 and O-ring
– caliper
– rigid axle center section protector no. 2
– lower bolt retaining shock from axle housing
no. 15

06-03-3

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Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)

Rear Rigid Axle Center Section Oil Level
Lift back of vehicle. Place swing arm to the horizontal position.
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

V01H0RB

Clean drain plug area then reinstall drain plug.
Use a funnel and refill rear rigid axle center section
at the proper level with recommended oil. Refer
to TECHNICAL DATA 11-02.
Reinstall filler plug.

1. Filler plug

Add oil if necessary. Refer to TECHNICAL DATA
11-02 for capacity and recommended oil.

Rear Rigid Axle Center Section Oil Change
Ensure vehicle is on a level surface.
Clean drain plug area.
Place a drain pan under rigid axle center section
drain plug area.
Unscrew filler plug.
Remove drain plug.

REAR PROPELLER SHAFT
Removal
Remove swing arm with rigid axle assembly. Refer
to REAR SUSPENSION 08-03.
Remove the M8 x 16 propeller shaft bolt no. 9 and
flat washer no. 10.
Separate rear propeller shaft no. 3 from engine.

Inspection
Check yoke U-joint no. 11 for wear, backlash or
axial play, replace if necessary.

06-03-4

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Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)

Installation
Installation is essentially the reverse of removal
procedure.
Apply grease (P/N 293 550 019) to spring and
splines before insert the end of the propeller shaft
into swing arm.
Apply grease to splines from engine.
Grease U-joint from rear propeller shaft. Use a
grease gun with SHELL, Alvania EP-2 grease only.

Rear Propeller Shaft U-Joint
Refer to FRONT PROPELLER SHAFT U-JOINT 0602.

06-03-5

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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 ..........................................................................................................

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

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Section 07 STEERING/CONTROL SYSTEMS
Subsection 02 (STEERING/CONTROL SYSTEMS)

STEERING/CONTROL SYSTEMS
1
3
26

24 Nm
(18 lbfft)
5

17 16 15

22
21

14 24 Nm
(18 lbfft)

20 19
21 75 Nm
(55 lbfft)
22
19 Nm
23
(168
lbfin)
25
13

11
10
75 Nm
(55 lbfft)

24
20
75 Nm 19
(55 lbfft) 18

75 Nm 19 18
(55 lbfft)
20
13
21

20
18

V01I0XS

19 75 Nm
(55 lbfft)

07-02-1

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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 10-02)
– handle bar grips no. 1 (discard screws)
– brake handles no. 2. (refer to HYDRAULIC BRAKES
09-02)
– 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

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.

Installation
For the installation, reverse the removal procedure.

TIE-ROD
Removal
Place the vehicle on jack stands and remove front
wheel(s).
Remove front fender. Refer to BODY 10-02.
Remove fuel tank. Refer to FUEL CIRCUIT 04-02.
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

STEERING COLUMN
Removal
Remove:
– steering cover (refer to BODY 10-02)
– steering clamp mounting bolts no. 5, steering
clamp no. 6 and steering cover support no. 8
– fuel tank (refer to FUEL CIRCUIT 04-02)
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.

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
A

V01I0YA

MODEL
mm
TRAXTER

20 ± 5

311 ± 1

25/32 ± 0.197 12 1/4 ± 0.039

NOTE: Torque the ball joint lock nut no. 22 to 36
N•m (27 lbf•in).

07-02-2

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Section 07 STEERING/CONTROL SYSTEMS
Subsection 02 (STEERING/CONTROL SYSTEMS)

Toe Adjustment
Place vehicle on level surface.
Check that handlebar is straight.
Use a long rule and check if the rear and front wheels
are aligned.
Adjust alignment with tie-rod.
Adjust toe to 0º ± 0.3º.

STEERING COLUMN BEARING
Removal
Place vehicle on jack stands and remove front
wheels.
Remove front fender. Refer to BODY 10-02.
Remove fuel tank. Refer to FUEL CIRCUIT 04-02.
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 05-06 for the
START/STOP button and UPSHIFT/DOWNSHIFT
button. Refer to INSTRUMENTS AND ACCESSORIES 05-07 for Hi-Lo Beam button.

Removal
Remove bolts.

Installation
For installation, reverse the removal procedure.
Pay attention to the following detail.
Place flanged collar toward outside.
Install carriage bolts no. 23, apply Loctite 277 on
threads.

V01I0OA

1. Remove the bolts

07-02-3

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Section 07 STEERING/CONTROL SYSTEMS
Subsection 02 (STEERING/CONTROL SYSTEMS)

Separate multi-function switch no. 5 from handle
bar no. 7.
Remove steering cover. Refer to BODY 10-02.
Unplug multi-function switch connector. The connector is located under steering cover.

V01I10A

1. Throttle handle housing
2. Throttle cable

V01I0PA

UNDER STEERING COVER
1. Unplug this connector

Slide cable in clip slot and remove the end of the
cable from clip.

Installation

For installation, reverse the removal procedure.
If replaced, the calibration is required. Refer to ELECTRIC SHIFT SYSTEM 05-06.

For installation, reverse the removal procedure.
Refer to CARBURATOR AND FUEL PUMP 04-03 for
adjustment procedure.

THROTTLE HANDLE

LH HANDLE BRAKE

Removal

Remove screws no. 26.

Remove screws.

V01I0ZA

V01I0SA

1. Remove screws

1. Remove the screws

Separate throttle handle no. 3 from handle bar no. 7.
Remove throttle cable from housing.

Separate handle brake no. 2 from handle bar no. 7.
If necessary, cut locking tie.

07-02-4

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Section 07 STEERING/CONTROL SYSTEMS
Subsection 02 (STEERING/CONTROL SYSTEMS)

Cable Removal
Refer to HYDRAULIC BRAKES 09-02 for specifics
instructions.

Installation
For installation, reverse the removal procedure.

RH HANDLE BRAKE
Removal
Remove screws.

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 09-02 for specifics
instructions.

Installation
For installation, reverse the removal procedure.

07-02-5

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Section 08 SUSPENSION
Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS
FRONT SUSPENSION ..........................................................................................................
SHOCKS ASSEMBLY ........................................................................................................
UPPER A-ARM ...................................................................................................................
LOWER A-ARM..................................................................................................................
KNUCKLE ...........................................................................................................................
WHEEL BEARING CONDITION .........................................................................................

08-02-1
08-02-2
08-02-3
08-02-4
08-02-5
08-02-6

REAR SUSPENSION.............................................................................................................
REAR SHOCK.....................................................................................................................
SWING ARM ......................................................................................................................

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

08-01-1

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Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION )

FRONT SUSPENSION

48 Nm
(35 lbfft)

1
6

2
7

75 Nm
(55 lbfft)

67 Nm
(49 lbfft)

1
6

7
3

8
67 Nm
(49 lbfft)

67 Nm
(49 lbfft)

7
5
7

4
2

67 Nm
(49 lbfft)
8
3

75 Nm
(55 lbfft)
V01J0BT

08-02-1

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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

Inspection

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.

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.

08-02-2

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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 N•m (55 lbf•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

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
08-02-3

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Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION )

Inspection
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 upper A-arm as an assembly if ball joint is damaged.

Torque nuts to 67 N•m (49 lbf•ft).
Attach upper A-arm to knuckle. Install castellated
nut and torque to 75 N•m (55 lbf•ft).
Install a new cotter pin.
Secure brake hose to upper A-arm.
NOTE: Do not interchange left and right tires.
Check direction of rotation mark on tires.

V01J0JA

RH UPPER A-ARM ASSEMBLY

Check upper A-arm for distortion or damage. Replace as required.
Inspect pivot bushings for wear or damages.
Replace A-arms if necessary.
V01J0KA

Installation

DIRECTION OF ROTATION

Position upper A-arm and install bolts and nuts.
Do not torque yet.
Install bolt and nut retaining shock absorber to upper A-arm.
NOTE: Position the upper A-arm in order to have
a distance of 311 mm (12 in) between shock absorber retaining bolts (center to center). Use special A-arm tool (P/N 529 035 611).

Torque wheel nuts to 75 N•m (55 lbf•ft) in a crisscross sequence.

LOWER A-ARM
Removal
Remove cotter pin and castellated nut retaining
lower A-arm no. 3 to ball joint on the knuckle.

V01J0FA
V01J0HA

1. Torque nuts to 65 N•m (48 lbf•ft)
A. 311 mm (12 in)

1.
2.
3.
4.

Lower A-arm
Castellated nut
Lower ball joint
Knuckle

08-02-4

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Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION )

Use a suitable ball joint remover and detach knuckle
from the lower A-arm.
Remove nuts and bolts no. 8 retaining lower A-arm
to frame.

V01J0KA

DIRECTION OF ROTATION

V01J0GA

1. Lower A-arm
2. Remove nuts and bolts

Torque wheel nuts to 75 N•m (55 lbf•ft) in a crisscross sequence.

KNUCKLE

Remove lower A-arm from vehicle.

Removal
Inspection
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 lower Aarm assembly if ball joint is damaged.
Check lower A-arm for distortion or damage.
Inspect pivot bushings for wear or damages.
Replace A-arms if necessary.

Installation
For assembly, reverse the disassembly procedure. However, pay attention to the following.
Install lower A-arm to frame and torque nuts to 67
N•m (49 lbf•ft).
Attach lower A-arm no. 2 to knuckle. Install castellated nut and new cotter pin.
NOTE: Do not interchange left and right tires.
Check direction of rotation mark on tires.

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 0902.
Remove cotter pin and castellated nut from upper
and lower suspension A-arm.
Detach upper and lower suspension A-arm from
knuckle.
Remove cotter pin and castellated nut from tie-rod
and separate tie-rod from knuckle.
Separate knuckle from drive shaft.

Inspection
Inspect knuckle for damage.
If any damage is detected, change the knuckle.

08-02-5

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Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION )

Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
For hub installation, refer to HYDRAULIC BRAKE
09-02.
Reinstall front wheel(s) and torque nuts to 75 N•m
(55 lbf•ft) in a criss-cross sequence.
NOTE: Do not interchange left and right tires.
Check direction of rotation mark on tires.

WHEEL BEARING CONDITION
Raise front of vehicle.
Take tire by the top and the bottom. Check lateral
play.
If there is any play, change knuckle and hub assembly.
NOTE: Be careful not to misjudge play in the suspension ball joint. Refer to STEERING/CONTROLS
SYSTEMS 07-02 for inspection.

08-02-6

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Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)

REAR SUSPENSION
8
7

4
6

1
6

10
11

16
15

12
13

V01J01S

08-03-1

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Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)

REAR SHOCK

Push down on handle until it locks. Remove spring
stopper and cap then release handle.

Removal
Lift rear of vehicle until rear shock absorbers no. 1
are fully extended.
Install a jack or a block under the frame to support
the vehicle.
Remove upper no. 4 and lower no. 5 bolts and
nuts no. 6 retaining shock absorbers each side.

1
2

A01B4LA

TYPICAL
1. Clevis pin
2. Bar
3. Handle horizontal

At installation, cap opening no. 8 must be 180°
from spring stopper opening no. 7.

3
2

V01J02A

RIGHT SIDE SHOWN
1. Upper bolt and nut
2. Lower bolt and nut
3. Rear shock absorber RH

1
2

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.

A03F12A

TYPICAL
1. Cap opening
2. Spring stopper opening

08-03-2

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Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)

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.
– Oil leakage.
– A gurgling noise, after completing one full compression and extension stroke.
Renew if any faults are present.

V01J03A

1.
2.
3.
4.
5.

Rear brake caliper
Remove bolts
Brake hose
Swing arm
Vent tube

Detach brake hose from brackets on rear axle tube
and on swing arm.
Disconnect vent tube.
2

SWING ARM
Removal
Lift rear of vehicle until rear shock absorbers no. 1
are fully extended.
Install a jack or a block under the frame to support
the vehicle.
Remove lower nuts no. 6 and bolts no. 5 retaining
shock to rear drive train each side.

V01J04A

1. Brake hose
2. Vent tube

08-03-3

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Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)

Remove M8 flanged screws retaining master cylinder.
CAUTION: Don’t let caliper hang by the hose
and don’t stretch or twist brake hose.

Unscrew and remove RH pivot bolt no. 14.
2

3
1
2

V01J07A

1. Swing arm bellows
2. Pivot bolt RH

Pull back rear train assembly to detach swing arm
assembly from the frame and disengage the propeller shaft.
Remove the M10 x 25 socket screws retaining
rear rigid axle center section to swing arm.

V01K05A

1.
2.
3.
4.

Remove bolts
Master cylinder
Remove spring
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.

V01J05A

1. Remove M10 x 25 socket screws

V01J08A

1. Swing arm
2. Pivot bolt LH
3. Jam nut

08-03-4

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Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)

Remove M10 nuts and bolts retaining swing arm
to rear axle tube.

Installation
Installation is essentially the reverse of removal
procedure. However, pay attention to the following details.
Secure rear rigid axle center section 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 tube to swing arm with bolts. Do
not tighten yet.
When all bolts are installed, tighten in a criss-cross
sequence.

V01J06A

1. Remove nuts and bolts

Detach swing arm no. 9 from rear drive system
assembly.

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 swing arm if necessary.
Ensure outer race of bearing fits tightly inside
swing arm pivot.

V01J05B

RIGID AXLE CENTER SECTION

V01J06B

REAR AXLE TUBE

Install cone bearings into cavity. Pack bearing cavities with Therma Lube grease (P/N 293 550 018).
V01J09A

1. Swing arm bellows
2. Oil seal
3. Cone bearing

08-03-5

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Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)

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
12 N•m (9 lbf•ft).
Install jam nut and torque to 147 N•m (108 lbf•ft)
while holding pivot bolt.

m WARNING

The LH pivot bolt must have more than 2
threads out of jam nut.

V01H09A

1. Propeller shaft
2. Apply grease

Push rear drive train 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.
Torque to 147 N•m (108 lbf•ft).
1

Attach swing arm bellows to engine and install
clamp. Torque to 5 N•m (4 lbf•ft).
Reinstall master cylinder. Check brake pedal adjustment. Refer to HYDRAULIC BRAKES 09-02 for
complete adjustment procedure.
Route brake hose and secure to the brackets.
Connect vent hose.
Reinstall shock absorbers.

V01J0AA

1. RH pivot bolt
2. Pivot bearing

08-03-6

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Section 09 BRAKES
Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS
HYDRAULIC BRAKES............................................................................................................ 09-02-1
FRONT BRAKES ................................................................................................................ 09-02-1
REAR BRAKE ..................................................................................................................... 09-02-2
GENERAL ........................................................................................................................... 09-02-3
MASTER CYLINDER .......................................................................................................... 09-02-3
CALIPER ............................................................................................................................. 09-02-4
BRAKE PADS ..................................................................................................................... 09-02-5
BRAKE DISC....................................................................................................................... 09-02-6
BRAKE PEDAL ................................................................................................................... 09-02-7
BRAKE CABLE ................................................................................................................... 09-02-8
INTERLOCK CABLE ........................................................................................................... 09-02-8
BRAKE HOSES AND BRAKE TUBES................................................................................ 09-02-9
BRAKE SYSTEM BLEEDING ............................................................................................. 09-02-11
BRAKE LIGHT SWITCH ..................................................................................................... 09-02-12

09-01-1

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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)

HYDRAULIC BRAKES
FRONT BRAKES

24 Nm
(18 lbfft)
12
11

10
34 Nm
(25 lbfft)

6
10

24 Nm
(18 lbfft)
25

10
8
9

34 Nm
(25 lbfft)
14

24 Nm 12 11
(18 lbfft)

24 Nm
(18 lbfft)

11
1

12
3

13
V01K06T

09-02-1

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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)

REAR BRAKE

24 Nm
(18 lbfft)
12

15
16

11
25
24 Nm
(18 lbfft)

24 Nm
12(18 lbfft)
11

34 Nm
(25 lbfft)

19
14
22
13
21

17
20

V01K07T

09-02-2

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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

1.
2.
3.
4.

Oil level mark
Bolt
Sealing washers
Remove screws

Rear Brake
Remove seat to have access to master cylinder
reservoir no. 15.
Unscrew reservoir cover.
2

V01K0KA

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.

V01K0HA

1. Brake fluid reservoir
2. Reservoir cover
3. Flexible hose

Raise rear of vehicle and support it securely.
Remove RH wheel 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

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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

V01K0JA

1.
2.
3.
4.
5.

Installation
For the installation, reverse the removal procedure, paying attention to the following details.
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.

1
V01K13A

Master cylinder
Flexible hose
Rear brake hose
Push rod
Remove bolts

Connect brake hose to master cylinder with bolt
and new sealing washers.

Inspection and Lubrication
Discard any remaining fluid inside reservoir.
Clean reservoir thoroughly with clean brake fluid.
If master cylinder is damaged or leaking, replace
as an assembly.
Before rear master cylinder installation, remove
the pusher and boot. Apply grease (P/N 293 550
007), about 2 g, inside the boot then reinstall boot
and pusher. Wipe out any grease spillage on boot.

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
V01K16A

1. Rear master cylinder
2. Pusher
3. Boot

Loosen wheel nuts.
Raise vehicle and support it securely.
Remove wheels.

09-02-4

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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)

Disassembly

Only brake pads are available as spare parts. If caliper is damaged, replace as an assembly.

Installation
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.

V01K14A

RH FRONT BRAKE
1. Caliper
2. Brake hose

BRAKE PADS

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.
3

V01K15A

Removal
Raise vehicle and support it securely.
Remove wheels.
Remove caliper from knuckle.
Remove retaining clip.
While holding spring, pull out pin retaining brake
pads.

1. Remove bolt and washers
2. Unscrew bolts
3. Brake hose

V01K0CA

09-02-5

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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)

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.

Inspection

BRAKE DISC
Inspection

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 (0.18 in).
Replace disc if not within specifications.
CAUTION: Brake discs should never be machined.
Turn the disc by hand and check run out.

V01K0FA

1.
2.
3.
4.

Check for leaks and make sure the brakes operate
normally before driving.

Clip
Pin
Retaining spring
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 brake pad thickness.
Brake pads must be replaced when lining is 1 mm
(1/32 in) thick or less.
BRAKE PAD MINIMUM
THICKNESS

1 mm (1/32 in)

CAUTION: Brake pads must always be replaced in pairs.

DISC MINIMUM
THICKNESS

4.7 mm (0.18 in)

DISC RUN OUT (MAX.)

0.25 mm (0.01 in)

Removal
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.

m WARNING
Avoid getting oil or grease on brake pads.
Contaminated brake pads can affect stopping
capacities.

Installation
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.

V01H0BA

1. Remove O-ring
09-02-6

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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)

Using a suitable puller, pull out wheel hub with
disc.
1

BRAKE PEDAL
Removal
Remove RH side panel with foot peg.
Refer to section 10-02 BODY for removal procedure.
Unhook the return spring no. 21.
Unhook the brake cable no. 17, interlock cable and
push rod from brake pedal.
3

V01K0AA

1. Knuckle
2. Wheel hub

Remove screws no. 14 retaining brake disc
no. 13 to wheel hub. Discard screws
NOTE: Heat up disc around screws to facilitate removal.
V01K0IA

Installation
Install brake disc on wheel hub and tighten in a
criss-cross sequence.

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

Brake light switch
Interlock cable
Master cylinder
Return spring
Brake cable
Brake pedal

Remove cotter pin and washer then remove pedal
no. 20 from pivot.

Installation and Adjustment

3
4
2

V01K0BA

Place a shim between brake pedal lever and
switch nut. The tightness of the shim must be 2 mm
(5/64 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 N•m (39 lbf•in).
Remove the shim and press the brake pedal lever.
Check for the light play in the system.

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).

09-02-7

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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)

Brake Handle
Unscrew the bolt retaining the parking lever lock
from brake lever no. 18 and remove the lever.
Release the tension on brake lever. Rotate cable
end bushing so that cable aligns with the brake
lever recess, then lift cable end.

Inspection
Inspect cable ends for wear or deterioration. Replace if necessary.

Installation and Adjustment
V01K0YA

1. Push rod jam nut
2. Brake pedal return spring

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

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.
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

V01K0ZA

1. Adjustment nut
2. Stopper
3. Max. 1 mm (1/32 in) gap
V01K0MA

INTERLOCK CABLE

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.

Removal
NOTE: Before removing interlock cable from vehicle, note cable routing for reinstallation.
Remove the fuel tank. Refer to FUEL CIRCUIT 0402.

09-02-8

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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)

Remove the LH and RH side panels. Refer to
BODY 10-02.
Disconnect the interlock cable under shift lever.
Unscrew the nut from interlock adjustment.
Remove the interlock cable from interlock bracket.

Adjust cable so that the pin end from interlock cable is flush with the shifter lever plate. Use the
interlock cable adjustment.

2 3 1

V01E04A

1. Interlock pin end
2. Sifter lever plate

Torque nut and jam nut.
V01K10A

BRAKE HOSES AND BRAKE
TUBES

1. Interlock adjustment
2. Interlock bracket
3. Unscrew this nut completely

Rotate cable end bushing so that cable align with
the interlock fastener recess, then lift cable end.

Inspection
Inspect cable ends for wear or deterioration. Replace if necessary.

Installation and Adjustment
Installation is the reverse of the removal procedure.
NOTE: Under shifter lever, torque interlock cable
lightly.

Removal
Front Flexible Brake Hoses
Remove front luggage rack and front fender assembly.
Remove fuel tank cover.
Refer to BODY 10-02 for complete procedure.
Unscrew the brake tube no. 6 from the hose fitting no. 7.

09-02-9

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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)

V01K0SA

LEFT HAND SIDE
1. Flexible hose
2. Tube clip

V01K0NA

Rear Flexible Brake Hose
Remove bolt no. 12 retaining flexible hose no. 23
on top of rear master cylinder no. 19.

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.

V01K0JA

1. Disconnect brake hose

V01K0RA

RIGHT HAND SIDE
1. Flexible hose
2. Tube clip

09-02-10

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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)

Remove bolt no. 12 and washers no 11 retaining
hose to rear caliper.

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.

Brake Tubes
Connect the brake tubes to the hose fitting but
don’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.

V01K0WA

1. Rear brake caliper
2. Flexible brake hose

Detach hose no. 23 from swing arm and remove
from vehicle.

BRAKE SYSTEM BLEEDING

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.

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.

V01K0TA

1.
2.
3.
4.
5.

Vertical tube
Horizontal tube
Left flexible hose
Right flexible hose
Unscrew tube fitting

09-02-11

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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)

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 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.

MAX

MIN
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 10-02 for removal procedure.
Disconnect wire harness.
Unscrew jam nut and remove switch from bracket.

V01K0UA

REAR BRAKE MASTER CYLINDER

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.
The rear brake light switch cannot be adjusted.

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.

09-02-12

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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 FENDER/REAR FENDER COVER ............................................................................
REAR MUDGUARD/FACIA ................................................................................................
SKID PLATE .......................................................................................................................
ARM PROTECTOR .............................................................................................................
LATCH LEVER/LATCH BASE/SPRING ..............................................................................
SEAT ADJUSTMENT ........................................................................................................
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
10-02-12
10-02-13
10-02-13
10-02-13
10-02-14
10-02-14
10-02-14
10-02-15
10-02-15
10-02-16
10-02-16

FRAME ...................................................................................................................................
1, FOOTREST .....................................................................................................................
2, REMOVABLE BRACE.....................................................................................................
3, REAR EXTENSION FRAME ...........................................................................................
4, WINCH PLATE ...............................................................................................................
5, FRAME ...........................................................................................................................

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

10-01-1

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Section 10 BODY/FRAME
Subsection 02 (BODY)

BODY
BODY PARTS
13

17
45
44

18
48

5
47

41
12

36
39
20

6
51

28
V01L2FS

52
15 Nm
(133 lbfin)

10
34

10-02-1

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Section 10 BODY/FRAME
Subsection 02 (BODY)

15 Nm
(133 lbfin)
32

8
31

15
24 Nm
(17 lbfft)
30
15 Nm
(133 lbfin)

43
15 Nm
(133 lbfin)

7
24 Nm
29 (17 lbfft)
3

V01L2GS

10-02-2

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Section 10 BODY/FRAME
Subsection 02 (BODY)

SEAT

21
53

54
23

24 Nm
(17 lbfft)

56
57

V01L2HS

10-02-3

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Section 10 BODY/FRAME
Subsection 02 (BODY)

SEAT/ENGINE COVER

2, Engine Cover
Remove seat and screws no. 24.

Removal
1, Seat
Pull latch upward while gently lifting rear of seat.
Continue lifting movement until you can release
the front retaining devices, then, completely remove seat.

V01L0GA

On the inside, remove bolts no. 25.

V01L0AA

V01L1QA

Installation
Installation is the reverse order of removal.

10-02-4

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Section 10 BODY/FRAME
Subsection 02 (BODY)

STORAGE/STEERING/SHIFTER
GUIDE COVER
Removal

Inspection
Check latches no. 27 from storage cover for
cracks or other damages. Change if necessary.

3, Storage Cover
Unlatch cover, lift then remove cover.

Installation

4, Steering Cover
Remove screws under handle bar.

FRONT SKID PLATE/BUMPER/
LUGGAGE RACK

Installation is the reverse order of removal.

Removal
6, Front Skid Plate
Remove bolts no. 28.

V01L0WA

Remove ignition switch and choke lever.
NOTE: For the choke lever removal, remove the
roll pin retaining the lever then unscrew the large
plastic nut.
Unplug all connectors.
5, Shifter Guide Cover
Remove steering cover.
Unfasten plastic screws no. 26.

V01L0YA

7, Front Bumper
Remove front skid plate.
Remove bolts no. 29 and no. 30.

V01L0XA

10-02-5

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Section 10 BODY/FRAME
Subsection 02 (BODY)

Cut locking tie holding the cable of the sealed
beam.
NOTE: Install a new locking tie at the time of luggage rack installation.
Pull upside.

Installation
Installation is in the reverse order of removal.

FRONT FENDER/MUDGUARD/
FACIA
Removal
V01L0ZA

8, Front Luggage Rack
Remove bolts no. 30, no. 31 and no. 32.
NOTE: Remove sealed beam to reach nut. Refer
to INSTRUMENTS AND ACCESSORIES 05-07.

9, Front Fender
Remove front luggage rack and shifter guide cover.
Remove screws no. 33 and no. 34 on each side.

V01L13A

Remove fuel cap.

V01L12A

10-02-6

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Section 10 BODY/FRAME
Subsection 02 (BODY)

10, Front Mudguard
Remove screws no. 34 and no. 35.
Remove screw no. 36 near the front facia.

V01L16A

Remove bolts no. 28, no. 29 and no. 30.

V01L1PA

11, Front Facia
Remove sealed beams.
Remove the screws no. 37 under facia.

V01L0YB

Pull front bumper forward.

Installation
Installation is the reverse order of removal.

V01L15A

Remove the screws no. 38 on the top of facia.

10-02-7

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Section 10 BODY/FRAME
Subsection 02 (BODY)

INNER FENDER
Removal
12, Inner Fender
Remove front wheel.
Remove screws no. 39, two on bottom side and
one behind shock.

V01L17A

Installation
Install in first, the upper screw; secondly, the lower front screw and then the lower rear screw.
NOTE: Install all screws before torque.

FUEL TANK COVER/SIDE PANEL

V01L1AA

Remove screw on the LH side and separate from
dart on the RH side.

Removal

13, Fuel Tank Cover
Remove seat.
Turn steering to the right side and remove screw
retaining shifter guide cover and fuel tank cover.
Turn steering to the left side and remove the other
screw.

V01L2KA

1. Screw
2. Dart

10-02-8

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Section 10 BODY/FRAME
Subsection 02 (BODY)

Remove latches no. 40. Three by side.

V01L1DA
V01L14A

14, Side Panel
Remove seat.
Remove footpeg.
Remove plastic pin and screws retaining the side
panel with front and rear fender.

Installation
Installation is the reverse order of removal.

REAR LUGGAGE RACK
Removal
15, Rear Luggage Rack
Remove bolts no. 42 under rear facia.

V01L1CA

On front and rear mudguards, remove the three
first screws no. 35 and screws no. 34 retaining
side panel with mudguards.

V01L1EA

10-02-9

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Section 10 BODY/FRAME
Subsection 02 (BODY)

Under rear fender, remove bolts no. 43. One on
each side.

REAR FENDER/REAR FENDER
COVER
Removal
16, Rear Fender
Remove seat and rear luggage rack.
Remove screws no. 44 under rear facia and
screws no. 45 on the top.

V01L1FA

Pivot the bottom of rear luggage rack toward inside of ATV.
Pull the rear luggage rack toward back.
2
V01L1HA

Remove plastic pin of rear fender.
Remove screws no. 33 and no. 34.

V01L1GA

Step 1 : Pivot botton of rear rack toward inside
Step 2 : Pull rear rack toward back

Installation
Installation is the reverse order of removal.
NOTE: Install all bolts before torque.

V01L1IA

Disconnect brake light.

10-02-10

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Section 10 BODY/FRAME
Subsection 02 (BODY)

Rear Fender Cover
Remove rear luggage rack.
Remove screws no. 44 under rear facia.

REAR MUDGUARD/FACIA
Removal
18, Rear Mudguard
Remove screws no. 47 retaining mudguard 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.
19, Rear Facia
Remove rear luggage rack.
Unfasten screws no. 44 and no. 49.

V01L1MA

V01L1LA

Installation
Installation is the reverse order of removal.

10-02-11

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Section 10 BODY/FRAME
Subsection 02 (BODY)

Installation

ARM PROTECTOR

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.

Removal
Remove the bolts.

V01L1NA

Instalation

V01L1OA

Installation is the reverse order of removal.

SKID PLATE

LATCH LEVER/LATCH BASE/
SPRING

Inspection
The skid plate protected the engine. Check for
damage, crack or looseness.
Change if skid plate is damaged or cracked.
Torque all bolts at the regular interval.

Removal

Removal
21, Latch Lever
Remove push nut no. 53 and rivet no. 54.
Separate latch lever from spring no. 23.
22, Latch Base
Remove bolts no. 55 and separate latch base from
spring.

20, Skid Plate
Under vehicle, remove bolts no. 50 and no. 51.

Installation
CAUTION: Be sure to install rubber spacer no. 52
between skid plate and engine.
Installation is the reverse order of removal.
NOTE: Install all bolts before torque.

23, Spring
Remove latch base.
Separate spring from latch base and latch lever.

10-02-12

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Section 10 BODY/FRAME
Subsection 02 (BODY)

SEAT ADJUSTMENT
For latch stud no. 56 adjustment, unscrew the
latch stud nut no. 57 and screw or unscrew the
latch stud to the best height. See the following
illustration.
1

V01L1SA

1. Lock pin
2. Adjustment nut (apply Loctite 271)
A. 38 ± 1 mm (1-1/2 ± 3/64 in)

F01L3YA

TYPICAL
1. Piece of wood
2. ETN-50 (electric) or T-50 (manual)

Torque the latch stud nut.

SEAT COVER REPLACEMENT
Remove the old seat cover no. 58. Check the
foam and replace if necessary.
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, it’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.

After cover installation cut all around the excess
of material.

STORAGE COVER LATCH
Inspection
Inspect for crack or damage. Change if a any crack
or damage are detected.

Removal
Under front fender, pull the storage cover latch.

Installation
Under front fender, insert the storage cover latch
in the slot. Pull the latch by the top.

10-02-13

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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 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.

Installation
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.
INSTALLATION ON PLASTIC
Clean surface with isopropyl alcohol.
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.

HITCH/TRAILER BALL
Inspection
The hitch/trailer ball is optional. If the vehicle is
equipped with this option, often check the solidity
of the installation.

10-02-14

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Section 10 BODY/FRAME
Subsection 02 (BODY)

PLASTIC MAINTENANCE
MAINTENANCE
Clean the vehicle thoroughly, removing all dirt and
grease accumulation.
To clean use a soft clean cloth and either soapy
water or isopropyl alcohol.
To remove grease, oil or glue use isopropyl 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

10-02-15

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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 MOLECULAR
WEIGHT
POLYETHYLENE

HIGH DENSITY
POLYETHYLENE

Fuel tank cover
Front and rear facia
Front and rear fender
Rear fender cover
Side panel
Steering cover
Storage cover
Front and rear mudguard
Inner fender
Front skid plate

10-02-16

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LOW DENSITY
POLYETHYLENE

Section 10 BODY/FRAME
Subsection 03 (FRAME)

FRAME

3
48 Nm 11
(35 lbfft)

10
11

5
1

8 24 Nm
(17 lbfft)

24 Nm
(17 lbfft)
12
13

9 24 Nm
(17 lbfft)
2
7

4
13

6
24 Nm
(17 lbfft)

V01L2IS

10-03-1

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Section 10 BODY/FRAME
Subsection 03 (FRAME)

1, FOOTREST

3, REAR EXTENSION FRAME

Removal

Remove footpeg and side panel. Refer to BODY
10-02.
Remove M8 x 20 mounting flanged bolts no. 6 and
flanged nuts no. 7.

Remove rear fender. Refer to BODY 10-02.
Remove:
– radiator, (refer to COOLING SYSTEM 03-03)
– muffler, (refer to REMOVAL AND INSTALLATION
03-02)
– voltage regulator, (refer to CHARGING SYSTEM
05-03)
– ignition coil retaining bolt

1
2
3
V01L20A

1. M8 x 20 mounting flanged bolts

Inspection
Check for cracks or bent tube. Change or repair if
necessary.

Installation
Installation is essentially the reverse of removal
procedure.

2, REMOVABLE BRACE
Removal
Remove footpegs and side panel. Refer to BODY
10-02.
Unscrew bolts no. 8 and no. 9.

Inspection
Check for crack or bent tube. Change if necessary.

4
V01L23A

1.
2.
3.
4.

Radiator with ventilator
Muffler
Voltage regulator
Ignition coil retaining bolt

Installation
For the installation, reverse the removal procedure.

10-03-2

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Section 10 BODY/FRAME
Subsection 03 (FRAME)

Remove M10 x 55 mounting flanged bolts no. 10
and the flanged nuts no. 11.

1
1
V01L0YC

1. Remove M8 x 20 flanged bolts

Inspection
Check for crack or other damage. Change if necessary.

Installation
Installation is the reverse of removal procedure.

5, FRAME

V01L2JA

1. Remove the M10 x 55 mounting flanged bolts

Cleaning

Inspection
Check for crack, bent tube or other damage. Repair or change if necessary.

Installation
Installation is the reverse of removal procedure.

4, WINCH PLATE
Removal
Remove front skid plate and front bumper. Refer to
BODY 10-02.
Remove M8 x 20 flanged bolts no. 12 and flanged
nut no. 13.

Clean frame and 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
Steel Frame:
– electric welding
– amperage: 70 - 110 A
– voltage: 20 - 24 V
– rod: E-7014 (3/32 in)

10-03-3

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Section 10 BODY/FRAME
Subsection 03 (FRAME)

CAUTION: Before performing electrical welding anywhere on the vehicle, unplug the multiple connector at the MPEM. Also unplug the
negative cable and the voltage regulator. This
will protect the MPEM and battery against
damage caused by flowing current when 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.

10-03-4

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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 ...................................................
kilopascal ................................................
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 × 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.

11-01-1

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Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)

ENGINE AND VEHICLE
VEHICLE MODEL

7400/7401

Engine type

Electric and manual

Number of cylinder(s)

Number of valves

2 valves with hydraulic lifters (no adjustment)

ENGINE

Decompressor type

Automatic
Standard

Stroke
Displacement

mm (in)

89 (3.5)

mm (in)

80 (3.15)

cm3 (in3)

498 (30.4)

Compression ratio

9:1

Maximum HP RPM

± 100 RPM

6000

Lubrication

Wet sump with replaceable oil filter

Oil filter

BOMBARDIER-ROTAX

Air filter type
Exhaust system

Cleanable synthetic panelette
Type

Nelson, stainless steel

Spark arrester

USDA approved

Magneto/generator

400 W @ 6000 RPM

Ignition system type

ELECTRICAL

Spark plug

I.D.I. (Inductive Discharge Ignition)
Make and type
Gap

NGK BR8EA
mm (in)

0.65 (.026)

Trigger coil

Ω

190 – 300

Battery charging coil

Ω

0.4 ± 01

Ω

0.4 to 0.9 @ 20°C (68°F)

kΩ

Not measurable

Ignition coil

Primary
Secondary

Engine RPM limiter

7500
Type

Battery

Electrolyte battery type

Voltage

12 volts

Nominal rating

19 A•h (21 optional)

Power starter output

Fuses

0.6 KW

Ignition

15 A

Accessories

15 A

Solenoids

15 A

Fan

15 A

MPEM

20 A

Charging system
Carburetor

30 A
Mikuni constant depressurant type with manual choke and ECS
(Enricher Coating System)

Type
Model

CARBURETION

Fuel pump

BST34-232

Type

Mikuni

Model

External (vacuum-operated)

Idle engine speed

RPM

1050 ± 50

1100 ± 100

Needle jet

0-7M (850)

Jet needle

5GBF61-2

Clip position number
Choke plunger position

± 0.5 mm

2.5

± .039 in

0.098

Variable choke

0.5 mm (0.02 in)

Preliminary pilot screw turn
Float level

Fuel

1100 ± 100

Middle
Opening
Halfway
Throttle cable

Adjustment

7415/7416/7417/7418

BOMBARDIER-ROTAX 511, longitudinal mount, liquid cooled

Starting system

Bore

7413/7414

2.25 turn (see section 04-03 for setting procedure)

± 0.5 mm

10.6

± 0.020 in

0.417

Type
Octane no.

Regular unleaded gasoline
87 (Ron + Mon)/2

11-02-1

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Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

7400/7401

COOLING

Fan
Fan thermostat
Engine thermostat

96°C (205°F)

Closing temperature

102°C (221°F)

Opening temperature

85°C (185°F)

Closing temperature

75°C (167°F)
90 kPa (13 PSI)

Type

DRIVE TRAIN

Normal oil operating pressure of engine

Dual range (HI-LO) with park, neutral and reverse

Speeds

Model

Electronically controlled hydraulic shift

Minimum

101 kPa (14.7 PSi)

Maximum

608 kPa (88 PSi)

Operating pressure for shifting and clutching

810 kPa (118 PSi)

Clutch type

1 centrifugal and 1 multi-disk hydraulically controlled

Engagement RPM

± 100 RPM

Front differential

1300

1600

Shaft driven/single Auto-Lock differential (pump driven)

Front differential ratio

3.6:1

Rear axle

STEERING/
CONTROL

7415/7416/7417/7418

Thermostatic
Opening temperature

Radiator cap opening pressure
Transmission

7413/7414

Shaft driven/solid axle

Rear axle ratio

3.6:1

Turning radius

3.3 m (11 ft)

Total toe (vehicle on ground)

± 0.3°

0°

Camber angle

0°
± 5 mm

Tie-rod maximum length unengaged

± 0.197 in

0.787

FRONT
Suspension type

Independent suspension — double A-arm

Suspension travel

SUSPENSION

Shock absorber

178 mm (7 in)
Qty

Type

oil

Spring free length

270 mm (11 in)

Spring color code

Silver/Blue/Black

Front preload adjustment

N.A.

REAR
Suspension type

Rigid swing arm

Suspension travel
Shock absorber

191 mm (8 in)
Qty

Type

Oil

Spring free length

355 mm (14 in)

Spring color code

Blue/Black/Black

Rear preload adjustment

BRAKES

Front brake
Rear brake
Parking brake

N.A.
Qty

Type

Brembo hydraulic

Qty

Type

Brembo hydraulic
Transmission brake and brake lever lock on LH brake lever

Lining material

Metallic

Minimum pad thickness

1 mm (0.04 in)

Minimum brake disk thighness

4.7 mm (0.18 in)

Maximum brake disk warpage

0.25 mm (0.01 in)
Fixed

Caliper

11-02-2

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Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

7400/7401

7413/7414

7415/7416/7417/7418

TIRES AND WHEELS

TIRE
Front
Pressure
Rear

Minimum

Size

48 kPa (7 PSi)
45 kPa (6.5 PSi)

Recommended

38 kPa (5.5 PSi)

Minimum

34.5 kPa (5 PSi)

Minimum tire thread depth

4 mm (0.16 in)
Front

635 x 203 x 305 mm (25 x 8 x 12 in)

Rear

635 x 254 x 305 mm (25 x 10 x 12 in)

Front

305 x 165 mm (12 x 6.5 in)

Rear

305 x 203 mm (12 x 8 in)

WHEELS
Size

DIMENSION

Recommended

Overall length

2071 mm (81.5 in)

Overall width

1194 mm (47 in)

Overall height

1143 mm (45 in)

Dry weight

340 kg (755 lb)

Wheel base

1296 mm (51 in)

Wheel track

Front

992 mm (39 in)

Rear

940 mm (37 in)

Front and under engine ground clearance

244 mm (9.6 in)

Rear rigid axle ground clearance

188 mm (7.4 in)

LIQUID
Fuel tank

20 L (5.7 U.S. gal)

Fuel tank reserve
Engine/transmission oil

Differential oil

6 L (1.6 U.S. gal)
Capacity

3 L (0.8 U.S. gal)

Recommended
Capacity

SAE 10W40, a 4 stroke mineral based oil SH or SJ
Front
Rear

Recommended

CAPACITIES

CV joint grease

300 mL (10 U.S. oz)
Synthetic polyolester oil 75W90 (API GL5)
TEXACO, HTBJ grease (M3014), ONLY

Propeller shaft grease
Hydraulics brakes

650 mL (22 U.S. oz)

SHELL, Alvania EP-2, ONLY
Capacity
Recommended

Cooling system

250 mL (8.5 U.S. oz)
Brake fluid DOT 4, ONLY
2.5 L (0.7 U.S. gal)

Ethylene-glycol concentration

60%

BODY AND FRAME
Weight distribution

Front/rear

Front storage tray
Rack

49/51
10 kg (22 lb)

Front

40 kg (90 lb)

Rear (including tongue weight)

80 kg (175 lb)

Total vehicle load allowed

220 kg (485 lb)

Gross vehicle weight rating

540 kg (1200 lb)

Towing

500 kg (1100 lb)
14 kg (30 lb)

Tongue (included with rear rack weight)

11-02-3

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Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL
Frame
Front/rear rack
Front bumper

MATERIAL

Front/rear fender
Fuel tank cover
Steering cover
Storage compartment cover
Front/rear facia
Side panel
Mudguard
Seat cover

7400/7401

7413/7414

7415/7416

Material

Steel

Color

Black

Material
Color

Steel
Red

Black

Material

Steel

Color
Material
Color
Material
Color
Material
Color
Material
Color
Material
Color
Material
Color
Material
Color
Material
Color

Silver
High density polyethylene
Red

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

ENGINE
Engine support

24 N•m (17 lbf•ft)

Engine mount

48 N•m (35 lbf•ft)

Spark plug

22 N•m (16 lbf•ft)

Rewind starter

10 N•m (89 lbf•in)

Rear solenoid block

5 N•m (44 lbf•in)

Magneto

9 N•m (80 lbf•in)

Starter

10 N•m (89 lbf•in)

Starter RED (+) cable

6 N•m (53 lbf•in)

STPS (Sub-Transmission Position Sensor)

3 N•m (27 lbf•in)

GBPS (Gear Box Position Sensor)

3 N•m (27 lbf•in)

TORQUE

COOLING
Radiator mount screw/nut

10 N•m (89 lbf•in)

Temperature sensor

17 N•m (151 lbf•in)

Water pump

10 N•m (89 lbf•in)

Fan mount screw/nut

4 N•m (35 lbf•in)

Temperature sender

3 N•m (27 lbf•in)

EXHAUST
Exhaust nut

11 N•m (97 lbf•in)

Heat shield screws

10 N•m (89 lbf•in)

FUEL
Carburetor mounting clamp

0.6 N•m (5.4 lbf•in)

DRIVE TRAIN
Front wheel hub nut

140 N•m (103 lbf•ft) (MINIMUM)

Rear wheel hub nut
Front differential

140 N•m (103 lbf•ft) (MINIMUM)
Front

48 N•m (35 lbf•ft)

Rear

48 N•m (35 lbf•ft)

Rear differential socket screws
Propeller shaft screw

48 N•m (35 lbf•ft)
Engine side

32 N•m (24 lbf•ft)

Differential side

42 N•m (31 lbf•ft)

11-02-4

http://ReadManuals.com

7417/7418

Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)

VEHICLE MODEL

7400/7401

7413/7414

7415/7416

7417/7418

WHEEL
Wheel nuts

75 N•m (55 lbf•ft)

STEERING/CONTROL
Upper/lower A-arm lock nut

75 N•m (55 lbf•ft)

Tie rod ends

75 N•m (55 lbf•ft)

Steering arm (castellated nut)

75 N•m (55 lbf•ft)

Steering column support screws

24 N•m (17 lbf•ft)

Handlebar screws

24 N•m (17 lbf•ft)

Flanged bearing bolts

24 N•m (17 lbf•ft)

SUSPENSION
Shock absorber bolt

48 N•m (35 lbf•ft)

Front upper swing arm

67 N•m (49 lbf•ft)

Front lower swing arm

67 N•m (49 lbf•ft)

TORQUE

Rear swing arm RH pivot

147 N•m (108 lbf•ft)

Rear swing arm LH pivot

11 N•m (97 lbf•in)

Rear swing arm LH nut

147 N•m (108 lbf•ft)

Rear swing arm hexagonal screws

48 N•m (35 lbf•ft)

BRAKE
Caliper brake screws

24 N•m (17 lbf•ft)

Brake disk screws

34 N•m (25 lbf•ft)

BODY/FRAME
Front bumper
Front rack
Rear rack

24 N•m (17 lbf•ft)
Front

24 N•m (17 lbf•ft)

Rear

15 N•m (133 lbf•in)

Upper

15 N•m (133 lbf•in)

Lower

15 N•m (133 lbf•in)

Rear extension frame

48 N•m (35 lbf•ft)

Front differential support

24 N•m (17 lbf•ft)

Seat pivot bar

24 N•m (17 lbf•ft)

Winch plate support

24 N•m (17 lbf•ft)

Footrest

24 N•m (17 lbf•ft)

Removable brace

24 N•m (17 lbf•ft)

Skid plate

15 N•m (133 lbf•in)

Headlight adjustment

0.6 N•m (5.4 lbf•in)

11-02-5

http://ReadManuals.com

Section 12 WIRING DIAGRAM
Subsection 01 (WIRING DIAGRAM)

WIRING DIAGRAM
WIRING CONNECTORS CODING
CONNECTOR HOUSING AREA

m WARNING
Ensure all terminals are properly crimped on
the wires and all connector housings are
properly fastened.

XX/XX

XX/XX
1-02D
A00I04C

1
2 3 4

THE SHADED PART INDICATES THE CONNECTOR HOUSING
AREA

A00I04A

1.
2.
3.
4.

1 -02D

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.

AREA

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
BK
BL
BR
GN
GY
OR

—
—
—
—
—
—

BLACK
BLUE
BROWN
GREEN
GREY
ORANGE

PK
RD
TA
VI
WH
YL

—
—
—
—
—
—

PINK
RED
TAN
VIOLET
WHITE
YELLOW

3
8

V01L25B

XX/XX

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

http://ReadManuals.com

Section 12 WIRING DIAGRAM
Subsection 01 (WIRING DIAGRAM)

CONNECTOR LOCATION IN
HOUSING
This is the wire position in the connector. The number
or letter given refers to the physical identification
stamped on the connector.

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 0502.

12-01-2

ANNEX 1

Problem with the shifting system
(Electric Components)
REFER TO
Prob em w th the
sh ft ng system
(Hydraulic/Mechanical
Components)

YES

Is emergency sh fter shaft mov ng wh e
press ng upsh ft/downsh ft button ?

NO
Check fuse(s)

Is fuse burned ?
Refer to
DIAGNOSTIC/
CALIBRATION MODE
sect on

Task 1:
Ind cator ghts test

YES

Task 3:
Sensors and
so eno ds test

YES
Is adjustment
performed g ve
sat sfactory resu ts ?

Change nd cator
ght(s)

Change fuse

Start the d agnost c/
ca brat on mode
(see task 1 to 5 be ow)

Task 2:
C utch modu ator
ca brat on

Task 4 and 5:
GBPS (Gear Box
Pos t on Sensor) and
STPS (Sub Transm ss on
Pos t on Sensor)
ca brat on

NO
Abnorma t (s)
detected ?

YES

Try another
sett ng

Change
component(s)

Recheck e ectr c
sh ft system
Is the prob em
pers st ng ?

The e ectr c
sh ft system s
now good

If a pos t ons
are bad

YES

Refer to
VALVES/SOLENOIDS
TESTS sect on

Recheck e ectr c
sh ft system
Is the prob em
pers st ng ?

YES
Are ghts good ?

YES

Check va ve/
so eno d w th
test ng too

Are va ves/
so eno ds good ?

NO
NO

Change va ves/
so eno ds

Recheck e ectr c
sh ft system
Is the prob em
pers st ng ?

YES
Check
upsh ft/downsh ft
sw tch

Is sw tch good ?

YES

NO
Change sw tch

Recheck e ectr c
sh ft system
Is the prob em
pers st ng ?

YES
Check AMP
connectors and
w r ng

Are connectors
and w r ng good ?

YES
Change MPEM

Ca brate GBPS
and STPS

YES

V01A15S

Recheck e ectr c
sh ft system
Is the prob em
pers st ng ?

YES

Repa r or
change connector
or w r ng

YES

Recheck e ectr c
sh ft system
Is the prob em
pers st ng ?

ANNEX 2
Problem with the shifting system
(Hydraulic/Mechanical Components)
REFER TO:
Problem with the
shifting system
(Electric Components)

Is emergency shifter shaft moving when
pressing upshift/dowshift button ?

YES
Check the engine/transmision oil level.

Is engine oil
level good ?

Refill engine
with oil.

Recheck electric
shift system. Is the
problem persisting ?

YES
The engine/transmission oil
and filter oil replacement
may be a solution. Change if
necessary. Refer to the
MAINTENANCE CHART.

YES

Check the
engine/transmission
oil pressure.

Is engine/transmission
oil pressure good ?

YES
Check for engine leakage.
Call
SERVICE
REPRESENTATIVE.

V01A14S

YES

Leakage ?

The problem
is resolved !

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1999 2000 Bombardier Traxter Service Manual 2000_Bombardier_Traxter_Service_Manual

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