1999 2000 Bombardier Traxter Service Manual 2000_Bombardier_Traxter_Service_Manual

User Manual: 1999-2000_Bombardier_Traxter_Service_Manual

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I
SECTION SUBSECTION PAGE
SAFETY NOTICE ................................................................................................................................... III
WHAT’S NEW ....................................................................................................................................... IV
INTRODUCTION .................................................................................................................................. V
01 SERVICE TOOLS AND
SERVICE PRODUCTS
01 – Table of contents...................................................................... 01-01-1
02 – Service tools............................................................................. 01-02-1
03 – Service products....................................................................... 01-03-1
02 MAINTENANCE 01 – Table of contents...................................................................... 02-01-1
02 – Maintenance chart.................................................................... 02-02-1
03 – Maintenance and lubrication .................................................... 02-03-1
04 – Storage and pre-season preparation......................................... 02-04-1
03 ENGINE 01 – Table of contents...................................................................... 03-01-1
02 – Removal and installation........................................................... 03-02-1
03 – Cooling system......................................................................... 03-03-1
04 – Rewind starter.......................................................................... 03-04-1
04 FUEL SYSTEM 01 – Table of contents...................................................................... 04-01-1
02 – Fuel circuit ................................................................................ 04-02-1
03 – Carburetor and fuel pump ........................................................ 04-03-1
04 – Air intake silencer..................................................................... 04-04-1
05 ELECTRICAL 01 – Table of contents...................................................................... 05-01-1
02 – Overview.................................................................................. 05-02-1
03 – Charging system ...................................................................... 05-03-1
04 – Starting system ........................................................................ 05-04-1
05 – Ignition system......................................................................... 05-05-1
06 – Electric shift system................................................................. 05-06-1
07 – Instruments and accessories ................................................... 05-07-1
06 DRIVE TRAIN 01 – Table of contents...................................................................... 06-01-1
02 – Front differential ....................................................................... 06-02-1
03 – Rear axle................................................................................... 06-03-1
07 STEERING/CONTROL
SYSTEM
01 – Table of contents...................................................................... 07-01-1
02 – Steering/control systems ......................................................... 07-02-1
08 SUSPENSION 01 – Table of contents...................................................................... 08-01-1
02 – Front suspension...................................................................... 08-02-1
03 – Rear suspension....................................................................... 08-03-1
09 BRAKES 01 – Table of contents...................................................................... 09-01-1
02 – Hydraulic brakes ....................................................................... 09-02-1
TABLE OF CONTENTS
II
10 BODY/FRAME 01 – Table of contents ..................................................................... 10-01-1
02 – Body......................................................................................... 10-02-1
03 – Frame....................................................................................... 10-03-1
11 TECHNICAL DATA 01 – SI metric information guide...................................................... 11-01-1
02 – Engine and vehicle ................................................................... 11-02-1
12 WIRING DIAGRAM 01 – Wiring diagram......................................................................... 12-01-1
SECTION SUBSECTION PAGE
TABLE OF CONTENTS
V
INTRODUCTION
This
Shop Manual
covers the following Bombar-
dier made 1999 ATV:
Models
1. Model number
VEHICLE AND ENGINE SERIAL
NUMBER LOCATION
1. Engine
2. Vehicle
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.
V01A17A
1
V01A16A
1
2
INTRODUCTION
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VI
Serial Number Meaning
10 11 12 13 14 15 16 17987654321
SECTION 1 SECTION 2 SECTION 3 SECTION 4
321
SECTION 1
Class
Make
Manufacturer
87654
SECTION 2
Factory use
Engine type II
Engine type I
Product line
Type of drive
9
SECTION 3
Check digit
10 11 12 13 14 15 16 17
SECTION 4
Number sequentially assigned by the manufacturer
in the production process
Plant of manufacture
Model year
V01A0PS
INTRODUCTION
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VII
ARRANGEMENT OF THE
MANUAL
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.
LIST OF ABBREVIATIONS USED
IN THIS MANUAL
A ampere
amp ampere
A•h ampere-hour
AC alternate current
BDC bottom dead center
BTDC before top dead center
°C degree Celsius
cm centimeter
cm² square centimeter
cm³ cubic centimeter
DC direct current
°F degree Fahrenheit
fl. oz fluid ounce
ft foot
GRD ground
hal. halogen
I.D. inside diameter
IDI induction discharge ignition
imp. oz imperial ounce
in inch
in² square inch
in³ cubic inch
k kilo (thousand)
kg kilogram
km/h kilometer per hour
kPa kilo pascal
L liter
lb pound
lbf pound (force)
lbf/in² pound per square inch
LH left hand
m meter
MAG magneto
Max. maximum
Min. minimum
mL milliliter
mm millimeter
MPEM multi-purpose electronic module
MPH mile per hour
N newton
N.A. not applicable
no. number
00.0 continuity
0.L overload (open circuit)
O.D. outside diameter
OPT optional
oz 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)
V volt
Vac volt (alternative current)
INTRODUCTION
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VIII
V01C15S
10
8
7
10
9
7
11
10
8
9
7
914
78
10
19
15
30 2
32
4
31
32 26
1
28
27
25
25
24
25
25
24
23 6
33
17
13
12
29
11
16
21
21
21
20
20
20
22
18
17
5Therma Lube
grease
Therma Lube
grease
Therma Lube
grease
12
48 Nm
(35 lbfft)
48 Nm
(35 lbfft)
24 Nm
(17 lbfft)
24 Nm
(17 lbfft)
10 Nm
(97 lbfin)
24 Nm
(17 lbfft) 48 Nm
(35 lbfft)
10 Nm
(97 lbfin)
03 02 1
Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)
REMOVAL AND INSTALLATION
Page heading
indicates section
and subsection
detailed.
Bold face number
indicates special
procedure
concerning this
part.
Tightening torque
nearby fastener. In this
case, nut must be
torqued to
48 Nm or 35 lbfft.
This Shop Manual uses technical terms wich may be
slightly different from the ones in the parts catalog.
Exploded view
assists you in
identifying parts and
related positions.
TYPICAL PAGE
V01A0QS
Illustration
number for
publishing
process.
Subsection title
indicates
beginning of the
subsection.
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
CAUTION: Pay attention to
torque specifi
cations. Some
of these are in
lbfin instead
of lbfft. Use appro
priate torque
wrench.
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Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)
03 02 2
1 Shifting valve
2 GBPS (Gear Box Pos tion Sensor)
3 Magneto/Trigger plug
4 Engine coolant hose
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 fend-
ers, side panels, steering cover, shifter guide cov-
er and skid plate Refer to the section 09-02 BODY
Disconnect BLACK negative cable from battery,
then RED positive cable
Front Part Preparation
Remove fuel tank and fuel valve Refer to the sec-
tion 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 Sen-
sor)
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
Engine Preparation
Unplug spark plug cables
Unplug oil pressure sensor
Remove radiator inlet hose
Remove breather` hose
Unplug the temperature sensor
WARNING
Always disconnect battery or starter cables
exactly in the specified order, BLACK nega-
tive cable first. It is recommended to discon-
nect electrical connections prior to discon-
necting fuel lines.
2
V01C0DA 431 6
5
1
3
V01C0EA 24
Vehicle Preparation
2 STPS (Sub Transmission Position Sensor)
3 VSS (Vehicle Speed Sensor)
4 Shifting engine rod
5 Oil pressure sensor
6 Engine coolant hose
1 Clutching and clutch modulator valves connector
Remove exhaust pipe no. 5 Refer to the EXHAUST
SYSTEM section
Remove shifting rod no. 3 Refer to the SHIFTING
ENGINE REMOVAL
m
TYPICAL PAGE
Title indicates
main procedure
to be carried out.
Reference to look
up a certain section
and subsection.
In this case it
concerns
exhaust system.
Bold face number
following part
name refers to
exploded view
at beginning of
subsection.
Call outs for
above illustration.
V01A0RS
INTRODUCTION
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X
GENERAL INFORMATION
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. Bombardier Inc. however, main-
tains a policy of continuous improvement of its
products without imposing upon itself any obliga-
tion to install them on products previously manu-
factured.
Due to late changes, it may have some differences
between the manufactured product and the descrip-
tion and/or specifications in this document.
Bombardier Inc. reserves the right at any time to
discontinue or change specifications, designs,
features, models or equipment without incurring
obligation.
ILLUSTRATIONS AND
PROCEDURES
Illustrations and photos show the typical construc-
tion 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 vice-
versa. Mismatched or incorrect fasteners could
cause damage to the vehicle or possible per-
sonal injury.
As many of the procedures in this manual are in-
terrelated, we suggest, that before undertaking
any task, you read and thoroughly understand the
entire section or subsection in which the proce-
dure is contained.
A number of procedures throughout the book re-
quire 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).
1. Left
2. Right
12
V01L25A
INTRODUCTION
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XI
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in explod-
ed views and text. When they are not specified
refer to following table.The table also gives the
metric conversion.
N•m FASTENER SIZE (8.8) Lbf•in
19
2M418
327
4M535
544
653
762
871
980
10 M6 89
11 97
12 106
13 115
14 124
15 133
16 142
17 150
18 159
19 168
N•m FASTENER SIZE (8.8) Lbf•ft
20 15
21 15
22 16
23 M8 17
24 18
25 18
26 19
27 20
28 21
29 21
30 22
31 23
32 24
33 24
34 25
35 26
36 27
37 27
38 28
39 29
40 30
41 30
42 31
43 32
44 32
45 33
46 34
47 35
48 M10 35
49 36
50 37
51 38
52 38
53 39
54 40
55 41
56 41
57 42
58 43
59 44
60 44
61 45
62 46
63 46
64 47
INTRODUCTION
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XII
TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS
N•m FASTENER SIZE (8.8) Lbf•ft
65 48
66 49
67 49
68 50
69 51
70 52
71 52
72 53
73 54
74 55
75 55
76 56
77 57
78 58
79 58
80 M12 59
81 60
82 60
83 61
84 62
85 63
86 63
87 64
88 65
89 66
90 66
91 67
92 68
93 69
94 69
95 70
96 71
97 72
98 72
99 73
100 74
101 74
102 75
103 76
104 77
105 77
106 78
107 79
108 80
N•m FASTENER SIZE (8.8) Lbf•ft
109 80
110 81
111 82
112 83
113 83
114 84
115 85
116 86
117 86
118 87
119 88
120 89
121 89
122 90
123 91
124 91
125 92
126 93
127 94
128 94
129 95
130 96
131 97
132 97
133 98
134 99
135 M14 100
136 100
137 101
138 102
139 103
140 103
141 104
142 105
143 105
144 106
145 107
146 108
147 108
148 109
149 110
150 111
INTRODUCTION
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01-01-1
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 ............................................................................................................ 01-03-1
MANDATORY SERVICE PRODUCTS ............................................................................... 01-03-1
RECOMMENDED SERVICE PRODUCTS ......................................................................... 01-03-2
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-1
SERVICE TOOLS
This is a list of tools to properly service ATV vehicle. If you need to replace or add to your tool inventory
these items can be ordered through the regular parts channel.
Following mention points out new tool:
NEW
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-2
ENGINE — MANDATORY SERVICE TOOLS
Lifting bar
(P/N 529 035 610)
V01B094
Small hose pincher
(P/N 529 009 900)
A01B2I4
Large hose pincher
(P/N 529 032 500)
F01B234
NEW
Magneto puller
(P/N 529 035 547)
F01B294
Fuel and oil system leak tester kit
(P/N 529 033 100)
A01B5E4
46 mm socket for crankshaft
(P/N 529 035 648)
V01B0A4
NEW
Spanner tool for clutch basket
(P/N 529 035 647)
V01B0B4
Crankshaft locking bolt
(P/N 529 035 645)
V01B0C4
Crankshaft protector
(P/N 290 876 557)
V01B0D4
NEW
NEW
NEW
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-3
ENGINE — RECOMMENDED SERVICE TOOLS
Sub-transmission positioner
(P/N 529 035 651)
V01B0E4
Oil pressure gauge (1 to 8 bar)
(P/N 529 035 652)
V01B0K4
Lifting ring
(P/N 529 035 644)
V01B0F4
Choke nut tool
(P/N 529 035 660)
V01B0G4
NEW
NEW
NEW
NEW
Ring compressor
Not sold by Bombardier
Snap-on
RCW60
V01B0H4
Carburetor tool kit
(P/N 529 035 660)
A00B2F4
Float level gauge
(P/N 529 035 520)
A00B4N4
Digital/induction type tachometer
(P/N 529 014 500)
F01B1G4
NEW
1234
Handle for insertion jig
(P/N 420 877 650)
A00C3V4
Exhaust spring installer/remover
(P/N 529 035 400)
A01B584
Valve spring compressor
Not sold by Bombardier
Snap-on
CF811
V01B0I4
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-4
ENGINE — RECOMMENDED SERVICE TOOLS (continued)
Engine stand
(P/N 529 035 646)
V01B0J4
NEW
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-5
ELECTRICAL — MANDATORY SERVICE TOOLS
Six-pin magneto harness
(P/N 529 035 654)
F01B284
T-Harness for diagnoses of
solenoids
(P/N 529 035 653)
V01B0L4
Jumper for self-diagnoses
(P/N 529 035 605)
V01B0M4
NEW
NEW
NEW
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-6
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
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-7
SUSPENSION — MANDATORY SERVICE TOOLS
Front suspension space bar
(P/N 529 035 611)
V01B0N4
NEW
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-8
SUSPENSION — RECOMMENDED SERVICE TOOLS
Shock spring removal kit
(P/N 529 027 100)
Replacement clevis pin:
(P/N 414 528 400)
A01B4O4
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-9
DRIVE — MANDATORY SERVICE TOOLS
Pliers
(P/N 295 000 069)
Oetiker 1090
F01D184
Pliers
(P/N 295 000 054)
Caillau
F01B1T4
Hub puller
(P/N 529 035 612)
V01B0O4
NEW
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-10
DRIVE — RECOMMENDED SERVICE TOOLS
Differential spanner socket
(P/N 529 035 649)
V01B0S4
NEW
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-11
VEHICLE — MANDATORY SERVICE TOOLS
41 mm socket for swing arm nut
(P/N 529 035 650)
V01B0T4
NEW
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-12
VEHICLE — RECOMMENDED SERVICE TOOLS
Flexible spout for oil container
(P/N 414 837 300)
F04B044
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
01-03-1
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
A00B3N4
Gasket stripper
(P/N 413 508 500)
(500 mL)
F01B1W4
Dielectric grease
(P/N 293 550 004)
Dow Corning
(150 g)
F01B164
Medium strength
threadlocker
(P/N 293 800 060)
Loctite 243 (blue)
(10 mL)
A00B324
Gasket/paint remover
(P/N 413 708 500)
Loctite® 79040 Chisel
510 g (18 oz)
A00B3L4
The Right Stuff (sealant)
(P/N 293 800 053)
Permatex®
(198 g)
F00B0V4
High strength
threadlocker
(P/N 293 800 005)
Loctite 271 (red)
(10 mL)
A00B2U4
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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
01-03-2
RECOMMENDED SERVICE PRODUCTS
Anti-seize lubricant
(P/N 413 701 000)
Loctite anti-seize
lubricant 454 g (16 oz)
F01B174
Bombardier storage oil
(P/N 413 711 600)
(12 x 350 g)
A02B054
Silicone compound
(P/N 420 897 061)
Dow Corning® MS4
A00B3R4
Degreaser
(P/N 413 708 400)
Permatex® 48 TA
433 g (15 oz)
A00B3K4
Plastic & vinyl cleaner
(P/N 413 711 200)
(6 x 1 L)
A00B4V4
Stripped threads repair kit
(P/N 413 708 600)
Loctite 81668
Form-A-thread 81668
A00A1J4
Fuel stabilizer
(P/N 413 408 600)
236 mL (8 oz)
A00B3V4
Paste gasket
(P/N 413 702 700)
Loctite® 515:
Gasket eliminator (50 mL)
A00B2T4
BOMBARDIER LUBE
(P/N 293 600 016)
(12 x 14 oz)
F01B0S4
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02-01-1
Section 02 MAINTENANCE
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
MAINTENANCE CHART........................................................................................................ 02-02-1
NOISE EMISSION CONTROL SYSTEM REGULATION ................................................... 02-02-1
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! ...................................... 02-02-1
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE
THE ACTS LISTED BELOW: .............................................................................................. 02-02-1
MAINTENANCE CHART .................................................................................................... 02-02-2
MAINTENANCE/LUBRICATION ........................................................................................... 02-03-1
AIR FILTER CLEANING/DRAINING................................................................................... 02-03-1
BOLTS, FASTENERS AND NUTS..................................................................................... 02-03-2
ENGINE OIL AND FILTER.................................................................................................. 02-03-2
SPARK ARRESTER ............................................................................................................ 02-03-3
TIRES AND WHEELS ......................................................................................................... 02-03-4
ENGINE COMPARTMENT................................................................................................. 02-03-5
STORAGE/PRE-SEASON PREPARATION ........................................................................... 02-04-1
STORAGE........................................................................................................................... 02-04-1
FUEL STABILIZER .............................................................................................................. 02-04-1
ENGINE LUBRICATION ..................................................................................................... 02-04-1
RAGS IN AIR INTAKE AND EXHAUST SYSTEM............................................................. 02-04-1
VEHICLE CLEANING AND PROTECTION......................................................................... 02-04-1
COOLANT DENSITY.......................................................................................................... 02-04-2
PRE-SEASON PREPARATION........................................................................................... 02-04-3
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Section 02 MAINTENANCE
Subsection 02 (MAINTENANCE CHART)
02-02-1
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 re-
moval 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.
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Section 02 MAINTENANCE
Subsection 02 (MAINTENANCE CHART)
02-02-2
MAINTENANCE CHART
LUBRICATION AND MAINTENANCE CHART
INITIAL 10 HOURS
EVERY 25 HOURS
EVERY 50 HOURS
EVERY 100 HOURS
OR ONCE A YEAR
EVERY 200 HOURS
OR 2 YEARS
REFER TO
THE SECTION
ENGINE/
TRANSMISSION
Engine/transmission oil level
02-02Engine/transmission oil and filter replacement
Spark arrester (cleaning)
Engine mount fasteners 03-02
Exhaust system (leak)
Condition of seals N.A.
Coolant density 02-04
Coolant level
03-03
Coolant replacement
Cooling system condition
Radiator cap pressure test
Radiator condition/cleanliness (air ducts)
Rewind starter rope condition 03-04
Clutch and transmission operation 05-06
PCV valve (inspection) 04-04
FUEL SYSTEM
Air filter cleaning/draining 02-02
Air filter and foam replacement
Fuel lines and connections 04-02
Fuel tank strainer replacement
Carburetor adjustment 04-03
ELECTRICAL
Spark plug inspection/replacement 05-05
Battery electrolyte level and vent condition 05-04
Battery connections
Wiring harness, cables and lines
05-07
Condition of ignition switch and start/stop button
Condition of lighting system
(hi/lo intensity, brake light, etc.)
Headlight beam aiming
DRIVE TRAIN
Drive shaft boot inspection and protector
condition
06-02
Front propeller shaft joint lubrication
(grease fitting)
Drive shaft joint inspection
Wheel bearing condition
Rear propeller shaft joint lubrication (grease fitting) 06-03
Front differential and rear rigid axle oil level,
seals and vent condition 06-02/
06-03
Front differential and rear rigid axle oil
replacement
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Section 02 MAINTENANCE
Subsection 02 (MAINTENANCE CHART)
02-02-3
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.
LUBRICATION AND MAINTENANCE CHART
INITIAL 10 HOURS
EVERY 25 HOURS
EVERY 50 HOURS
EVERY 100 HOURS
OR ONCE A YEAR
EVERY 200 HOURS
OR 2 YEARS
REFER TO
THE SECTION
STEERING/
CONTROL
SYSTEMS
Throttle condition 04-03
Choke condition
Handlebar fastener tightness
07-02
Steering system mechanism
Tie rod ends inspection
Steering adjustment
Tire pressure
02-02Wheel mount tightness and stud lubrication
Wear and condition of tires
Front wheel alignment N.A.
SUSPENSION Swing arm condition 08-02/
08-03
Shock absorber condition
BRAKE
Brake fluid level front/rear
09-02
Brake fluid replacement front/rear
Brake cable condition
Brake cable adjustment
Brake system condition (discs, hoses, etc.)
Brake pads condition
BODY/FRAME
Engine compartment 02-02
Fastener condition/tightness
Skid plate condition
10-02
Hitch/trailer ball condition (if installed)
Seat latch
Frame inspection
Vehicle cleaning and protection
Storage cover latchs
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Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)
02-03-1
MAINTENANCE/LUBRICATION
AIR FILTER CLEANING/DRAINING
Air Filter Box Draining
Periodically inspect air filter box drain plugs for wa-
ter or deposits. Refer to the maintenance chart.
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.
When water/deposits are found, air filter must be
inspected/dried/replaced depending on its condi-
tion.
Remove air filter as explained below.
Air Filter Removal
Remove seat.
Release clamps and remove air filter box cover.
1. Release clamps
2. Lift to remove
Remove air baffles, air filter and foam.
1. Air baffle
V01F04A
1
2
3
1
V01F05A
2
V01F06A
1
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Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)
02-03-2
1. Air filter
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 com-
ponent 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 per-
formance degradation or damage can occur.
NOTE: Slight dust may be cleaned using a low-
pressure airgun. Blow compressed air backward
of operating air flow.
Properly reinstall removed parts in the reverse or-
der of their removal.
BOLTS, FASTENERS AND NUTS
Check that all fasteners, bolts and nuts are tight-
ened to the proper torque.
ENGINE OIL AND FILTER
Oil Viscosity
SAE 10W40 is recommended for general use.
Other viscosity should be used if the average tem-
perature is outside the range of the recommended
oil. See chart below.
Oil and Oil Filter Change
NOTE: Oil and filter are to be replaced at the same
time. Oil change should be done with a warmed
up engine.
V01F07A
1
V01F08A
1
m WARNING
The engine oil can be very hot. Wait until en-
gine oil is warm.
SAE 5W30
SAE 10W30
SAE 10W40
SAE 15W40
SAE 15W50
SAE 20W50
°C °F
60
50
40
30
20
10
-10
-20
-30
0
140
120
100
80
60
40
20
0
-20
V01A0VA
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Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)
02-03-3
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.
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 de-
signed for this engine. This filter does not op-
erate at the same pressure than other brands.
Using a non-recommended filter may cause se-
rious 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 nec-
essary. Clean gasket area on engine and drain plug
then reinstall plug.
Refill engine at the proper level with the recom-
mended oil. Refer to TECHNICAL DATA section 11
for capacity. Do not overfill.
NOTE: The same oil lubricates both engine and
transmission. Don’t use synthetic oil, synthetic
blend oil or special additives. As they could af-
fect 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 neces-
sary.
Dispose oil as per your local environmental regu-
lations.
SPARK ARRESTER
The muffler must be periodically purged of accu-
mulated carbon.
Select a well-ventilated area and make sure the
muffler is cool.
Place transmission on park position.
Remove the clean out plug.
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.
V01A0AB
1
V01C05A 12
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Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)
02-03-4
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 de-
flate 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 con-
ditions has changed.
For your convenience, a pressure gauge is sup-
plied in tool box.
Tire/Wheel Condition
Check tire for damage and wear. Measure thread
height. It should be 4 mm (5/32 in) minimum. Re-
place if damaged or worn.
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.
m WARNING
Never run engine in an enclosed area.
Never perform this operation immediately af-
ter the engine has been run because exhaust
system is very hot.
Make sure that there are no combustible ma-
terials in the area.
Wear eye protector and gloves.
Never stand behind the vehicle while purging
exhaust system.
Respect all applicable laws and regulations.
TIRE PRESSURE
RECOMMENDED
FRONT
48 kPa
(7 PSI)
REAR
38 kPa
(5.5 PSI)
MINIMUM 45 kPa
(6.5 PSI)
35 kPa
(5 PSI)
V01A05A
A
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Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)
02-03-5
Wheel Removal
Untighten nuts then lift vehicle where needed.
Place a support under vehicle. Remove nuts then
withdraw wheel.
At installation, it is recommended to apply anti-
seize lubricant on threads. Gently tighten nuts in a
criss-cross sequence then apply a final torque of
75 N•m (55 lbf•ft).
1. Taper side of nut
ENGINE COMPARTMENT
Check in the engine compartment, for leak or oth-
er damage. Clean mud, leafs, etc. from engine
compartment.
V01A08A
1
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Section 02 MAINTENANCE
Subsection 04 (STORAGE/PRE-SEASON PREPARATION)
02-04-1
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 manufac-
turer’s instructions for proper use.
If above fuel stabilizer is not used, drain fuel sys-
tem including fuel tank and carburetor.
CAUTION: Fuel stabilizer should be added pri-
or 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 stor-
age 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 tempera-
ture.
– 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 car-
buretor 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 en-
gine (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 cyl-
inder.
– Turn the fuel valve to OFF and drain carburetor.
– Reinstall the spark plugs, baffles, foam, air filter
and air box cover.
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 prepara-
tion.
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 Kimberly-
Clark.
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.
m WARNING
This procedure must only be performed in a
well-ventilated area. Do not run engine dur-
ing storage period.
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Section 02 MAINTENANCE
Subsection 04 (STORAGE/PRE-SEASON PREPARATION)
02-04-2
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, ac-
etone, 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 protec-
tion 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.
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Section 02 MAINTENANCE
Subsection 04 (STORAGE/PRE-SEASON PREPARATION)
02-04-3
PRE-SEASON PREPARATION
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.
SYSTEM PRE-SEASON OPERATIONS TO BE PERFORMED BY REFER TO
CUSTOMER DEALER
ENGINE/
TRANSMISSION
Test Run Vehicle. Check Clutch and Transmission Operation N.A.
Engine Oil and Filter Oil Replacement Section 02-02
Coolant Replacement and Pressurization of System Section 03-04
Condition of Seals N.A.
Spark Arrester Section 02-02
Exhaust System Condition Section 03-02
Rewind Starter, Rope Condition Section 03-05
Rags Removal (Intake and Exhaust) Section 02-03
FUEL SYSTEM Fuel Line and Connectors Condition Section 04-02
Carburetor Adjustment Section 04-03
Throttle and Choke Cable Inspection/Adjustment
Air Filter Cleaning/Replacement Section 02-02
ELECTRICAL Spark Plug Replacement Section 05-05
Battery Condition/Charging and Installation Section 05-04
Starter Connections and Routing
Operation of Lighting System Section 05-07
DRIVE TRAIN Drive Shaft Boot Inspection
Section 06-02
and 06-03
Front Propeller Shaft Lubrication
Front Differential and Rigid Axle Oil Level and Vent Tube
Condition
STEERING/
CONTROL
SYSTEM
Steering System Inspection and Adjustment Section 07-02
Handle Bar Fastener Tightness
Wheel Tightness
Section 02-02Tire Pressure
Tire Condition
SUSPENSION Suspension System Inspection
Section 08-02
and 08-03
Bearing Condition
Swing Arm Condition
BRAKES Brake Fluid Change
Section 09-02Brake Condition
Brake Cable Adjustment
BODY/FRAME Frame and Skid Plate Condition
Section 10-02
and 10-03
Hitch/Trailer Ball Condition
Front Cover Compartment Cover Latch Condition
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Section 03 ENGINE
Subsection 01 (TABLE OF CONTENTS)
VMR9932_03_01TOC.FM 03-01-1
TABLE OF CONTENTS
REMOVAL AND INSTALLATION .......................................................................................... 03-02-1
ENGINE REMOVAL ........................................................................................................... 03-02-2
ENGINE INSTALLATION ................................................................................................... 03-02-4
ANTI-VIBRATION SYSTEM............................................................................................... 03-02-4
EXHAUST SYSTEM .......................................................................................................... 03-02-5
SHIFTING SYSTEM............................................................................................................ 03-02-6
COOLING SYSTEM ............................................................................................................... 03-03-1
COOLING SYSTEM LEAK TEST ....................................................................................... 03-03-2
INSPECTION ...................................................................................................................... 03-03-2
DRAINING THE SYSTEM .................................................................................................. 03-03-2
COOLING SYSTEM REFILLING ........................................................................................ 03-03-2
PRESSURE CAP................................................................................................................. 03-03-3
RADIATOR ......................................................................................................................... 03-03-3
THERMOSTAT ................................................................................................................... 03-03-3
COOLANT TANK ............................................................................................................... 03-03-4
FAN AND OUTLET DEFLECTOR....................................................................................... 03-03-4
TEMPERATURE SENDER.................................................................................................. 03-03-4
REWIND STARTER ................................................................................................................ 03-04-1
REWIND STARTER ............................................................................................................ 03-04-2
STARTING PULLEY ........................................................................................................... 03-04-4
MAGNETO SYSTEM ............................................................................................................. 03-05-1
MAGNETO ......................................................................................................................... 03-05-2
ROTOR ............................................................................................................................... 03-05-2
SPARG CLUTCH ................................................................................................................ 03-05-3
CYLINDER AND HEAD .......................................................................................................... 03-06-1
1, CYLINDER HEAD ......................................................................................................... 03-06-2
2, PUSH ROD ................................................................................................................... 03-06-2
3, ROCKER ARM .............................................................................................................. 03-06-2
4, VALVE SPRING............................................................................................................ 03-06-3
5, VALVE........................................................................................................................... 03-06-4
6, VALVE STEM SEAL ..................................................................................................... 03-06-4
7, CYLINDER .................................................................................................................... 03-06-5
8, LIFTER .......................................................................................................................... 03-06-6
9, PISTON......................................................................................................................... 03-06-6
10, PISTON RINGS ............................................................................................................ 03-06-7
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Section 03 ENGINE
Subsection 01 (TABLE OF CONTENTS)
03-01-2 VMR9932_03_01TOC.FM
CRANKSHAFT/BALANCER SHAFT ....................................................................................... 03-07-1
1, CAMSHAFT..................................................................................................................... 03-07-2
2, BALANCER SHAFT......................................................................................................... 03-07-3
3, CRANKSHAFT ................................................................................................................ 03-07-3
LUBRICATION SYSTEM......................................................................................................... 03-08-1
TROUBLESHOOTING......................................................................................................... 03-08-2
ENGINE PRESSURE TEST................................................................................................. 03-08-2
OIL CHANGE AND OIL FILTER REPLACEMENT .............................................................. 03-08-2
OIL STRAINER .................................................................................................................... 03-08-3
ENGINE OIL PRESSURE REGULATOR............................................................................. 03-08-3
OIL PUMP ........................................................................................................................... 03-08-4
CLUTCH OIL PRESSURE REGULATOR ............................................................................ 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 .................................................................................................................... 03-10-1
GEAR SHIFT SYSTEM........................................................................................................ 03-10-1
TRANSMISSION ................................................................................................................. 03-10-2
GEAR SHIFT MECHANISM................................................................................................ 03-10-3
TRANSMISSION................................................................................................................. 03-10-4
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Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)
VMR9932_03_02.FM 03-02-1
REMOVAL AND INSTALLATION
V01C15S
10
8
7
10
9
7
11
10
8
9
7
914
78
10
19
15
30 2
32
4
31
32 26
1
28
27
25
25
24
25
25
24
23 6
33
17
13
12
29
11
16
21
21
21
20
20
20
22
18
17
5Therma Lube
grease
Therma Lube
grease
Therma Lube
grease
12
48 Nm
(35 lbfft)
48 Nm
(35 lbfft)
24 Nm
(17 lbfft)
24 Nm
(17 lbfft)
10 Nm
(97 lbfin)
24 Nm
(17 lbfft) 48 Nm
(35 lbfft)
10 Nm
(97 lbfin)
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Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)
03-02-2 VMR9932_03_02.FM
ENGINE REMOVAL
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
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.
UNDER ENGINE
1. Engine oil plug
2. Engine coolant plug
Remove seat, front and rear fenders, inner fend-
ers, side panels, shifter guide cover and skid plate.
Refer to BODY 10-02.
Disconnect BLACK negative cable from battery,
then RED positive cable.
Front Part Preparation
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 com-
pletely.
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.
2
V01C0DA 431 6
5
1
3
V01C0EA 24
WARNING
Always disconnect battery or starter cables
exactly in the specified order, BLACK nega-
tive cable first. It is recommended to discon-
nect electrical connections prior to discon-
necting fuel lines.
V01A0AC
1
2
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Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)
VMR9932_03_02.FM 03-02-3
Engine Preparation
Unplug spark plug cables.
Unplug oil pressure sensor.
Remove exhaust pipe no. 4. Refer to Exhaust Sys-
tem section.
Remove radiator inlet hose.
Disconnect breather hose at PCV valve.
Unplug temperature sensor.
1. Spark plug cables
2. Exhaust pipe
3. Radiator inlet hose
4. Breather hose
5. Temperature sensor
6. PCV valve
Remove carburetor no. 5. Refer to FUEL PUMP
AND CARBURETOR 04-03.
Remove engine impulse line.
1. Engine impulse line
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 09-
02.
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 connec-
tor.
Remove radiator outlet hose.
Remove starter.
Remove engine coolant hose (the hose with the
starter clamp).
Separate rear air intake tube from air intake silenc-
er.
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.
V01C16A
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412
6
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V01C0FA V01C0HA
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Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)
03-02-4 VMR9932_03_02.FM
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 restrict-
ed. According to your needs, close or widen the
frame slightly.
Torque interlock cable lightly.
For the adjustment from interlock, refer to HY-
DRAULIC BRAKES 09-02.
Reattach cables, hoses, harness wiring, etc.
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.
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.
Use punch to remove the other bushing.
CAUTION: Do not use a screwdriver for anti-
vibration bushing removal.
LH Anti-Vibration System
Insert a punch in hole of anti-vibration bushing
no. 13 and push support bushing no. 14 and anti-
vibration 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.
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. Bolt
2. Washers (3)
3. Nut
V01C17A
V01C0SA
V01C0TA
1 2 2 3
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Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)
VMR9932_03_02.FM 03-02-5
EXHAUST SYSTEM
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).
Step : Bottom screw
Step : Rear screw
Step : Screws on top
Exhaust Pipe Removal
Remove the exhaust pipe nuts no. 15.
Remove screw from exhaust pipe bracket no. 16.
Remove springs no. 17 retaining exhaust pipe and
muffler no. 18.
1. Retaining springs
Pull exhaust pipe forward.
WARNING
Never touch exhaust system components im-
mediately after the engine has been run be-
cause these components are very hot.
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Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)
03-02-6 VMR9932_03_02.FM
Exhaust Pipe Installation
For installation, reverse the removal procedure,
paying attention to the following details.
Use a new exhaust pipe gasket no. 19 and make
sure that it is properly installed.
1. Exhaust pipe gasket
With muffler secured in its rubber mounts, fit ex-
haust 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 in-
stall retaining springs after pushing muffler for-
ward in exhaust pipe.
Tighten exhaust pipe support bolt.
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.
1. Muffler
2. Retaining rod
Muffler Installation
For the installation, reverse the removal proce-
dure.
NOTE: Check rubber bushings no. 20 for cracks
or other damages, change if necessary.
SHIFTING SYSTEM
NOTE: Always set the PARK position before re-
move any parts from shifting system.
Shifter Tie-Rod Removal
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.
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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Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)
VMR9932_03_02.FM 03-02-7
1. Shifter tie-rod
2. Jam nut
3. Ball joint
A. Shifter tie-rod length 150 mm (5-29/32 in)
B. 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.
LEVER SPRING INSTALLATION
Shifter Column Removal
Remove shifter lever no. 1.
Remove shifter tie-rod no. 23.
Shifter Column Installation
For installation, reverse the removal procedure.
Shifting Rod Removal
Remove fuel tank. Refer to FUEL CIRCUIT 04-02.
NOTE: Separate fuel tank from frame, do not re-
move tank completely.
Separate shifting rod no. 2 from shifting engine
rod. Unscrew bolt no. 30 and pull shifting rod for-
ward.
1. Shifting rod
Unscrew elastic nuts from RH ball joint.
Remove retaining clamp no. 31 and half rings
no. 32.
Shifting Rod Installation
For installation, reverse the removal procedure.
1
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Section 03 ENGINE
Subsection 03 (COOLING SYSTEM)
VMR9933_03_03.FM 03-03-1
COOLING SYSTEM
V01C1AS
1
2
45
3
11 12
10
6
7
8
9
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Section 03 ENGINE
Subsection 03 (COOLING SYSTEM)
03-03-2 VMR9933_03_03.FM
COOLING SYSTEM LEAK TEST
Install special plug (radiator cap) (P/N 529 021 400)
and hose pincher (P/N 529 009 900) on overflow
hose no. 8. Pressurize all system through coolant
reservoir to 103 kPa (15 PSI).
Check all hoses, radiator and cylinder/base for cool-
ant leaks. Spray a soap/water solution and look for
air bubbles.
NOTE: The rear fender removal is not necessary.
INSPECTION
Check general condition of hoses and clamp tight-
ness.
DRAINING THE SYSTEM
To drain cooling system, unscrew plug under en-
gine and remove pressure cap.
1. Cooling plug
COOLING SYSTEM REFILLING
Recommended Coolant
Use a blend of 60% antifreeze with 40% water.
Do not reinstall pressure cap.
CAUTION: To prevent rust formation or freez-
ing 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 en-
gines.
System Capacity
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.
WARNING
Never drain or refill cooling system when en-
gine is hot.
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Section 03 ENGINE
Subsection 03 (COOLING SYSTEM)
VMR9933_03_03.FM 03-03-3
When engine has completely cooled down, re-
check 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 pres-
sure).
RADIATOR
Removal
Drain cooling system.
Remove rear fender. Refer to BODY 10-02.
Remove inlet no. 6 and outlet no. 7 hoses.
1. Radiator inlet hose
2. Radiator outlet hose
Remove overflow hose no. 8.
Remove mounting bolts no. 10 on the top.
Unplug temperature sender no. 3.
Inspection
Check radiator air passage for clogging or damage.
Remove insects, mud or other obstructions with
compressed air or low pressure water.
Check for any coolant leakage from radiator and
hoses.
Installation
For installation, reverse the removal procedure.
Paying attention to the following detail.
Install hose pincher on coolant hose at thermostat
outlet. Unscrew bleeder on top of thermostat
housing.
Refill radiator and when coolant overflows by the
thermostat cover hole, reinstall the screw.
THERMOSTAT
The thermostat is a single action type.
Removal
The thermostat is located on the top of engine.
Remove screws and pull thermostat cover with
hose.
1. Remove screws
Remove gasket.
Test
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.
1
2
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Section 03 ENGINE
Subsection 03 (COOLING SYSTEM)
03-03-4 VMR9933_03_03.FM
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.
Installation
The installation is the reverse of the removal pro-
cedure.
FAN AND OUTLET DEFLECTOR
Test
Refer to INSTRUMENTS AND ACCESSORIES 05-
07.
Fan Removal
Remove rear fender. Refer to BODY 10-02.
Remove bolts no. 12 and fan supports no. 11. Dis-
card bolts.
1. Remove bolts
2. Fan support
Unplug fan connector.
1. Fan connector
Fan Installation
For the installation, reverse the removal proce-
dure.
NOTE: When fan is reinstalled, use new self-
locking bolts.
Outlet Deflector Removal
Remove fan no. 5.
Remove radiator.
Pull outlet deflector upward no. 4.
Outlet Deflector Installation
The installation is the reverse of the removal pro-
cedure.
TEMPERATURE SENDER
Test
Refer to INSTRUMENTS AND ACCESSORIES 05-
07 for proper procedure.
Removal
Unplug temperature sender connectors.
Unscrew temperature sender no. 3.
Installation
The installation is the reverse of the removal pro-
cedure, 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.
2
2
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Section 03 ENGINE
Subsection 04 (REWIND STARTER)
VMR9934_03_04A.FM 03-04-1
REWIND STARTER
V01C1BS
15
Loctite
242
1
2
Silicone
compound
grease
3
4
6
7
8
10
12 14
911
13
Loctite
242
5
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Section 03 ENGINE
Subsection 04 (REWIND STARTER)
03-04-2 VMR9934_03_04A.FM
REWIND STARTER
Removal
Remove fuel tank cover and skid plate. Refer to
BODY 10-02.
Remove seat pivot bar and unplug clutching and
clutch modulator valve connector.
Remove rewind mounting bolts no. 15 and pull re-
wing starter.
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.
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.
TYPICAL
1. Outer end into guide notch
NOTE: Due to dust accumulation, rewind starter
must be periodically cleaned, inspected and relu-
bricated.
CAUTION: It is of the utmost importance that
the rewind starter spring(s) be lubricated peri-
odically using specific lubricants. Otherwise,
rewind starter component life will be short-
ened and/or rewind starter will not operate
properly under very cold temperatures.
Lubricate spring assembly with silicone com-
pound 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.
TYPICAL
1. Grease inside spring guide
WARNING
Since the spring is tightly wound inside the
guide it may fly out when rewind is handled.
Always handle with care.
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Section 03 ENGINE
Subsection 04 (REWIND STARTER)
VMR9934_03_04A.FM 03-04-3
CAUTION: The use of standard multi-purpose
grease could result in rewind starter malfunc-
tion.
To install a new rope no. 5, insert rope into sheave
orifice and lock it with the key no. 4 as illustrated.
TYPICAL
1. 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 tem-
porarily make a knot to hold it. One turn preload
will give 7 turns of tension when fully extended.
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.
TYPICAL
1. Spring coated with MOLYKOTE G-n paste
Install locking ring.
CAUTION: This lubricant must NOT be used on
rewind springs as it does not stay on when dry.
Installation
Thread starter rope no. 5 through rope guide when
applicable.
Reinstall rewind starter assembly on engine.
NOTE: Before torque mounting bolts no. 15, ap-
ply 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.
TYPICAL
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Section 03 ENGINE
Subsection 04 (REWIND STARTER)
03-04-4 VMR9934_03_04A.FM
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)
VMR9956_03-05A.FM 03-05-1
MAGNETO SYSTEM
V01C1NS
Engine
oil
13
11
9
10
12 8
4
9 Nm
(80 lbfin)
Loctite 243
567
3
27 Nm
(62 lbfin)
1
Loctite
243
7 Nm
(62 lbfin)
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Section 03 ENGINE
Subsection 05 (MAGNETO SYSTEM)
03-05-2 VMR9956_03-05A.FM
MAGNETO
Removal
Remove engine. Refer to REMOVAL AND IN-
STALLATION 03-02.
Install engine on engine stand (P/N 529 035 646).
Remove water pump. See the instructions as fol-
low.
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 counter-
clockwise.
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 magne-
to 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 re-
taining magneto, apply Loctite 243 on threads.
Install a new gasket on ignition cover.
Place hydraulic piston properly before install igni-
tion cover. If it has a space between ignition cover
and crankcase, remove ignition cover and replace
the hydraulic piston.
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 re-
move 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).
1
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Section 03 ENGINE
Subsection 05 (MAGNETO SYSTEM)
VMR9956_03-05A.FM 03-05-3
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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Section 03 ENGINE
Subsection 06 (CYLINDER AND HEAD)
VMR9957_03-06A.FM 03-06-1
CYLINDER AND HEAD
NOTE: For cylinder head, cylinder and piston removal, it is not necessary to remove engine from vehicle.
V01C1CS
10 Nm
(89 lbfin)
50 Nm
(37 lbfft)
10 Nm
(89 lbfin)
Engine
oil
Multi-purpose
grease
22 Nm
(16 lbfft)
Engine oil
Engine oil
Engine oil
14
15
12
13
11
10
1
2
3
4
5
67
8
17
9
16
18
19
20
21
22 21
10 Nm
(89 lbfin)
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Section 03 ENGINE
Subsection 06 (CYLINDER AND HEAD)
03-06-2 VMR9957_03-06A.FM
1, CYLINDER HEAD
Removal
Remove engine oil and coolant.
Disconnect temperature sensor.
Unplug radiator inlet hose.
Remove screws retaining air box.
Unscrew the clamp retaining carburetor adaptor to
engine. Pull back the air box with carburetor as-
sembly.
Remove:
– exhaust pipe (refer to REMOVAL AND INSTAL-
LATION 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
1. Flanged nuts
Pull up cylinder head.
Inspection
Check for crack between valve seats, if so, replace
cylinder head.
Installation
For installation, reverse the removal procedure.
Install a new gasket no. 15 between cylinder head
and cylinder base no. 7.
Install the flanged nuts no. 13 in first then flanged
bolts no. 14.
2, PUSH ROD
Removal
Remove cylinder head no. 1.
Pull the push rods out of cylinder base no. 7.
Inspection
Check push rod end for wear or damage.
Check push rod for bends by placing the rod on a
flat metal plate. Rotate rod and measure the de-
flection with a dial indicator.
If the rod is bent, it should be replaced.
Installation
For installation, reverse the removal procedure.
NOTE: Apply engine oil on push rod.
3, ROCKER ARM
Removal
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
V01C1DA
1PUSH ROD BEND
SERVICE LIMIT 0.2 mm (0.008 in)
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Section 03 ENGINE
Subsection 06 (CYLINDER AND HEAD)
VMR9957_03-06A.FM 03-06-3
1. Rocker arm shaft
2. Flanged bolt
3. Rocker arm
Inspection
Rocker Arm
Inspect each rocker arm for cracks and scored fric-
tion surfaces. If so, replace parts.
Measure rocker bore diameter. If diameter is out
of specification, change the rocker arm.
A. 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.
Any area worn excessively will require part replace-
ment.
Installation
For installation, reverse the removal procedure.
NOTE: Apply engine oil on rocker arm shaft.
4, VALVE SPRING
Removal
Remove:
– cylinder head no. 1
–rocker arm no. 3
Compress valve spring with an universal C-clamp
spring compressor such a Snap-on CF811.
1. Valve spring
2. Valve spring retainer
3. Valve cotters
4. C-clamp spring compressor
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 BORE DIAMETER
SERVICE LIMIT 13.76 mm (0.542 in)
ROCKER ARM SHAFT DIAMETER
SERVICE LIMIT 13.67 mm (0.538 in)
12
3
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VALVE SPRING FREE LENGTH
SERVICE LIMIT 38 mm (1-1/2 in)
VALVE SPRING MAXIMUM SQUARENESS
SERVICE LIMIT 1.1 mm (0.043 in)
V01C1GA
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Section 03 ENGINE
Subsection 06 (CYLINDER AND HEAD)
03-06-4 VMR9957_03-06A.FM
Installation
For installation, reverse the removal procedure.
5, VALVE
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.
Valve Stem and Valve Guide Clearance
Check valve stem and valve guide for wear or fric-
tion surfaces, if so, replace parts.
Measure valve stem and valve guide in three plac-
es, using a micrometer and a small hole gauge.
NOTE: Clean valve guide to remove carbon de-
posits before measuring.
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.
Measure valve seat width, using a caliper.
If valve seat contact width is too wide, too narrow
or has spots, the seat must be ground or cylinder
head replaced.
A. Valve face contact width
B. Valve seat contact width
Installation
For installation, reverse the removal procedure.
NOTE: Apply engine oil on valve stem.
6, VALVE STEM SEAL
Removal
Remove valve.
Remove circlip on the bottom of valve stem seal.
VALVE STEM DIAMETER mm (in)
SERVICE LIMIT
Exhaust
6.95 mm (0.274 in)
Intake
VALVE GUIDE CLEARANCE mm (in)
SERVICE LIMIT
Exhaust
0.13 mm (0.005 in)
Intake
VALVE SEAT CONTACT WIDTH mm (in)
SERVICE LIMIT
Exhaust 2 mm (0.078 in)
Intake 1.8 mm (0.07 in)
V01C1HA
B
A
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Section 03 ENGINE
Subsection 06 (CYLINDER AND HEAD)
VMR9957_03-06A.FM 03-06-5
1. Circlip
2. Valve stem seal
Inspection
Inspection of valve stem seals is not needed as
new seals should always be installed whenever a
cylinder head is diassembled.
Installation
For installation, reverse the removal procedure.
7, CYLINDER
Removal
Remove:
– flanged bolts no. 23 retaining cylinder to crank-
case housing
– cylinder head no. 1
– water cooling hose from cylinder no. 20
– push rods no. 2
– all flanged screws retaining cylinder to the crank-
case housing
Pull cylinder.
Inspection
Cylinder
Check cylinder for cracks, scoring, rust and wear
ridges on the top and bottom of the cylinder.
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. Measure at three points
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 be-
tween measurements should not exceed 0.10 mm
(0.004 in). If so, replace cylinder.
A. Perpendicular to crankshaft axis
B. Parallel to crankshaft axis
1
2
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Section 03 ENGINE
Subsection 06 (CYLINDER AND HEAD)
03-06-6 VMR9957_03-06A.FM
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.
8, LIFTER
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 di-
ameter from lifter bore diameter to determine
clearance.
If the clearance is out of specified tolerance change
lifter and/or crankcase.
Installation
For installation, reverse the removal procedure.
9, PISTON
Removal
Remove cylinder no. 7.
Remove both piston pin circlips no. 21 then push
piston pin no. 22 out of piston.
Detach piston from connecting rod.
Inspection
Inspect piston for scoring, cracking or other dam-
ages.
Using a micrometer, measure piston at 16 mm
(5/8 in) perpendicularly (90°) to piston pin axis.
TYPICAL
1. Measuring perpendicularly (90°) to piston pin axis
A. 16 mm (5/8 in)
The measured dimension should be as described
in the previous table. If not, replace piston.
Piston/Cylinder Clearance
NOTE: Make sure used piston is not worn. See
PISTON MEASUREMENT TABLE above.
Adjust and lock a micrometer to the piston dimen-
sion.
LIFTER AND LIFTER BORE mm (in)
SERVICE LIMIT
Lifter 22.19 mm (0.874 in)
Lifter bore 22.27 mm (0.876 in)
LIFTER BORE CLEARANCE
SERVICE LIMIT 0.08 mm (0.003 in)
PISTON MEASUREMENT
SERVICE LIMIT 88.9 mm (3.5 in)
PISTON/CYLINDER CLEARANCE
SERVICE LIMIT 0.13 mm (0.005 in)
F01D0NA 1
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Section 03 ENGINE
Subsection 06 (CYLINDER AND HEAD)
VMR9957_03-06A.FM 03-06-7
1. Micrometer set to the piston dimension
With the micrometer set to the dimension, adjust
a cylinder bore gauge to the micrometer dimen-
sion and set the indicator to 0 (zero).
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
TYPICAL
1. Indicator set to 0 (zero)
Position the dial bore gauge at 16 mm (5/8 in) be-
low cylinder top edge, measuring perpendicularly
(90°) to piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance. If clearance exceeds specified toler-
ance, replace cylinder or rebore. See previous ta-
ble.
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Installation
For installation, reverse the removal procedure.
Paying attention to the following details.
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
Secure piston pin with both piston pin circlips.
NOTE: Do not align the end gap of the piston pin
circlips with the cutout in the piston bore.
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.
F00B08A
1
F00B09A
1
2
F00B0AA
1
RING/PISTON CLEARANCE mm (in)
SERVICE LIMIT 0.15 mm (0.006 in)
http://ReadManuals.com
Section 03 ENGINE
Subsection 06 (CYLINDER AND HEAD)
03-06-8 VMR9957_03-06A.FM
A. Measure here
Ring End Gap
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.
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.
1. Top ring (rectangular, black/gray color)
2. Second ring (scraper, chrome/stainless steel looking ring)
3. Oil ring
CAUTION: Ensure that top and second rings are
not interchanged.
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.
1. DO NOT align ring gap with piston trust side axis
2. DO NOT align ring gap with piston pin bore axis
A. 120°
RING END GAP mm (in)
SERVICE LIMIT 1.5 mm (0.06 in)
A
V01C1LA
A31C2NA
1
2
3
A31C2OA
1
2
AA
A
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Section 03 ENGINE
Subsection 07 (CRANKSHAFT/BALANCER SHAFT)
VMR9958_03-07A.FM 03-07-1
CRANKSHAFT/BALANCER SHAFT
V01C1WS
Loctite
243
7
22 Nm
(16 lbfft)
6
8
9
Engine
oil
10
Molykote
G-N
1
Anti-seize
lubricant
14
13
12
Loctite
243
150 Nm
(111 lbfft)
11
Loctite
243
240 Nm
(178 lbfft)
4
5
Engine
oil
Molykote
G-N
3
15
Anti-seize
lubricant
2
Molykote
G-N
Molykote
G-N
http://ReadManuals.com
Section 03 ENGINE
Subsection 07 (CRANKSHAFT/BALANCER SHAFT)
03-07-2 VMR9958_03-07A.FM
1, CAMSHAFT
Removal
Remove engine from vehicle (refer to INSTALLA-
TION 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 con-
trol gear no. 13 and balancing shaft gear no. 14.
Remove the both gears
– oil pump gear
– holding strip retaining oil pipe
1. Crankshaft gear nut
2. Crankshaft gear
3. Cam shaft gear
4. Control gear
5. Balancing shaft gear
6. Oil pump gear
– all bolts and socket screws retaining crankcase
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.
1. Measure here
Measure the camshaft bore in both housing.
Subtract the camshaft end diameter from the
proper bore diameter to find clearance.
If necessary, change camshaft and/or crankcase.
1
V01C1XA 2 6 435
CAMSHAFT ENDS mm (in)
SERVICE LIMIT
Clutch side 31.95 mm (1.258 in)
Magneto side 17.96 mm (0.707 in)
CAMSHAFT BORE mm (in)
SERVICE LIMIT
Clutch housing 32.036 mm (1.261 in)
Magneto housing 18.035 mm (0.71 in)
CAMSHAFT END CLEARANCE mm (in)
SERVICE LIMIT
Clutch side 0.086 mm (0.0034 in)
Magneto side 0.075 mm (0.0029 in)
V01C1ZA
11
http://ReadManuals.com
Section 03 ENGINE
Subsection 07 (CRANKSHAFT/BALANCER SHAFT)
VMR9958_03-07A.FM 03-07-3
Installation
For installation reverse the removal procedure.
NOTE: Always install a new crankcase gasket.
2, BALANCER SHAFT
Removal
Refer to CAMSHAFT REMOVAL section above.
Use the same procedure.
Remove balancer shaft.
Inspection
Check balancer shaft bearing in the front and rear
housing for excessive play and smooth operation.
Replace if necessary.
Installation
For installation, reverse the removal procedure.
3, CRANKSHAFT
Removal
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 indi-
cator.
Check crankshaft deflection on V-shaped blocks.
If deflection exceeds the specified tolerance,
change it.
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/Piston Pin Clearance
Measure piston pin. Compare to inside diameter
of connecting rod.
Installation
For installation, reverse the removal procedure.
CRANKSHAFT DEFLECTION mm (in)
SERVICE LIMIT
Clutch side 0.08 mm (0.003 in)
Magneto side 0.05 mm (0.002 in)
CONNECTING ROD BIG END mm (in)
SERVICE LIMIT
Axial play 1.3 mm (0.05 in)
CONNECTING ROD SMALL END DIAMETER
SERVICE LIMIT 22.05 mm (0.868 in)
PISTON PIN DIAMETER
SERVICE LIMIT 21.99 mm (0.866 in)
PISTON PIN BORE CLEARANCE
SERVICE LIMIT 0.06 mm (0.002 in)
1
V01C21A
1
http://ReadManuals.com
Section 03 ENGINE
Subsection 08 (LUBRICATION SYSTEM)
VMR9959_03-08A.FM 03-08-1
LUBRICATION SYSTEM
V01C1SS
11
12
13
14
15
16
17
18
5
4
3
6
2
1
1
22
21
20
10
9
87
Engine oil
Engine oil
18 Nm
(159 lbfin)
10 Nm
(89 lbfin)Loctite 243
21 Nm
(15 lbfft)
Engine oil
23
19
10 Nm
(89 lbfin)
http://ReadManuals.com
Section 03 ENGINE
Subsection 08 (LUBRICATION SYSTEM)
03-08-2 VMR9959_03-08A.FM
TROUBLESHOOTING
Oil Level Low
– external oil leak
– worn or incorrect piston rings installation
– worn valve seal
– oil pump worm or damaged
Low or No Oil Pressure
– clogged oil orifice(s)
– incorrect oil being used
– defective oil pump
– leaking oil seal
– oil strainer
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. Oil pressure gauge
2. Oil filter
The engine pressure should be between 101 kPa
(14.7 PSI) and 608 kPa (88 PSI).
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 CHANGE AND OIL FILTER
REPLACEMENT
Oil and filter are to be replaced at the same time.
Oil change should be done with a warm engine.
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.
1. Oil drain plug
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.
1
V01C1TA
2
WARNING
The engine oil can be very hot. Wait until en-
gine oil is warm.
V01A0AB
1
http://ReadManuals.com
Section 03 ENGINE
Subsection 08 (LUBRICATION SYSTEM)
VMR9959_03-08A.FM 03-08-3
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 en-
gine 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 neces-
sary.
Dispose oil as per your local environmental regu-
lations.
OIL STRAINER
Removal
Ensure vehicle is on a level surface.
Remove:
– skid plate under vehicle
– engine oil
–screws no. 1 retaining oil strainer cover no. 2
– oil collector no. 3 and O-ring no. 4
– oil strainer no. 5
Cleaning and Inspection
Clean oil strainer with the parts cleaner then use
an air gun to dry it.
Inspect O-ring and oil strainer gasket no. 6 for
damage. Change if necessary.
Installation
For installation, reverse the removal procedure.
ENGINE OIL PRESSURE
REGULATOR
The engine oil pressure regulator is located near
exhaust pipe bracket.
1. Engine oil pressure regulator
Removal
Remove the plug screw no. 7, sealing ring no. 8,
compression spring no. 9 and piston no. 10.
Inspection
Inspect piston for scoring or other damages.
Check compression spring for free length, square-
ness or other damage.
Installation
For installation, reverse the removal procedure.
NOTE: Always install a new sealing ring when the
oil pressure regulator is removed.
COMPRESION SPRING FREE LENGTH
SERVICE LIMIT 42 mm (1.65 in)
1
V01C1UA
http://ReadManuals.com
Section 03 ENGINE
Subsection 08 (LUBRICATION SYSTEM)
03-08-4 VMR9959_03-08A.FM
OIL PUMP
The oil pump is located on the clutch side of the
crankcase housing.
Removal
Remove engine. Refer to REMOVAL AND IN-
STALLATION 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 be-
tween oil pump rotor and inner rotor.
1. Oil pump rotor
2. Inner rotor
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 neces-
sary.
Check compression spring for free length, square-
ness or other damage.
Installation
For installation, reverse the removal procedure.
V01C1VA
2 1
C
B
A
OIL PUMP ROTOR AND INNER ROTOR
CLEARANCE mm (in)
SERVICE LIMIT
A
0.25 mm (0.009 in)B
C
COMPRESION SPRING FREE LENGTH
SERVICE LIMIT 59.5 mm (2.34 in)
http://ReadManuals.com
Section 03 ENGINE
Subsection 09 (CLUTCH)
VMR9960_03-09A.FM 03-09-1
CLUTCH
V01D01S
Loctite
243
14
5
Engine
oil
2
3
21 7
20
9
10
150 Nm
(111 lbfft)
6
7 Nm
(62 lbfin)
150 Nm
(111 lbfft)
8
11
12
13
Engine
oil
Engine
oil
14
15
16 17
Engine
oil
18
19
http://ReadManuals.com
Section 03 ENGINE
Subsection 09 (CLUTCH)
03-09-2 VMR9960_03-09A.FM
CLUTCH DRUM, CLUTCH WEIGHT
AND SPRAG CLUTCH
Disassembly
Remove:
– engine oil and coolant
– rewind starter
– clutch cover
Install the crankshaft locking bolt (P/N 529 035
645).
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.
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.
Inspect sparg clutch no. 5 for smooth operation
and roller for excessive wear. Change sparg clutch
if necessary.
Weight Lining
Measure weight lining thickness. The weight lin-
ing thickness must have 2.0 mm (5/64 in).
A. Weight lining
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 long-
er than 21.6 mm (0.85 in), change springs.
A. 21.6 mm (0.85 in)
Check weight springs for wear or other damage.
Replace if necessary.
1
V01D02A
A
V01D03A
A
V01D0EA
http://ReadManuals.com
Section 03 ENGINE
Subsection 09 (CLUTCH)
VMR9960_03-09A.FM 03-09-3
Assembly
For installation, reverse the removal procedure.
Paying attention to the following details.
Install weight springs with the open ends down.
Install sparg clutch in clutch drum with its OUT
SIDE mark facing out. Apply engine oil on sprag
clutch.
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
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).
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.
1
V01D04A
7
1
V01D05A
268 4
910 5 3
1
V01D06A 23
http://ReadManuals.com
Section 03 ENGINE
Subsection 09 (CLUTCH)
03-09-4 VMR9960_03-09A.FM
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
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.
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.
Clutch Basket
Check slots of clutch basket for damage or wear
caused by friction drive plates.
Change if necessary.
FRICTION DRIVE PLATE
MINIMUM THICKNESS 2.7 mm (0.11 in)
V01D07A
STEEL DRIVEN PLATE
MAXIMUM WARPAGE 0.25 mm (0.01 in)
V01D08A
V01D09A
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Section 03 ENGINE
Subsection 09 (CLUTCH)
VMR9960_03-09A.FM 03-09-5
Clutch Hub
Check grooves of clutch hub for damage or wear
caused by steel driven plates.
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.
1. Retaining plate bearing
Clutch Spring
Measure each clutch springs free length.
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.
1. Last friction drive plate
2. Retaining plate
3. Clutch basket
V01D0AA
1
V01D0BA
CLUTCH SPRING
MINIMUM LENGTH 32.5 mm (1.28 in)
V01D0CA
2
V01D0DA
13
http://ReadManuals.com
Section 03 ENGINE
Subsection 09 (CLUTCH)
03-09-6 VMR9960_03-09A.FM
Install 2 clutch springs. Remove clutch hub as-
sembly from clutch basket.
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
651), select an other position than PARK.
1. Sub-transmission positioner
Install clutch hub. Move the output shaft slowly
and push clutch hub.
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.
Replace the transmission in PARK position.
At the time of indicator shaft installation, refer to
TRANSMISSION 03-10 for the proper procedure.
V01D0FA
V01D0GA 1
1
V01D0HA
V01D0IA
http://ReadManuals.com
Section 03 ENGINE
Subsection 10 (TRANSMISSION)
VMR9961_03-10A.FM 03-10-1
TRANSMISSION
GEAR SHIFT SYSTEM
V01E0BS
4
5
67
2
3
22
23
15
17
16
21
18
20
9
10
12
11
13
14
8
1
19
Engine
oil
Engine
oil
Engine
oil
Engine
oil
Engine
oil
Engine
oil
Engine
oil
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
Engine
oil
http://ReadManuals.com
Section 03 ENGINE
Subsection 10 (TRANSMISSION)
03-10-2 VMR9961_03-10A.FM
TRANSMISSION
V01E0CS
15
24
23
22
Anti-seize
lubricant
Anti-seize
lubricant
18
17
19
21
16
20
Loctite
243
Anti-seize
lubricant
Anti-seize
lubricant
Anti-seize
lubricant Molykote
GN
Loctite
243
Anti-seize
lubricant
Anti-seize
lubricant
Anti-seize
lubricant
Anti-seize
lubricant
10 Nm
(89 lbfin)
Anti-seize
lubricant
http://ReadManuals.com
Section 03 ENGINE
Subsection 10 (TRANSMISSION)
VMR9961_03-10A.FM 03-10-3
GEAR SHIFT MECHANISM
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.
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, in-
dex 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.
Remove the tension spring no. 13 then pull shift
shaft with pawl no. 14 out of housing.
1. Shift drum gear
2. Index lever
3. Tension spring
4. 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. Index gear
2. Shift shaft
V01C1RA
1
2
3
V01E0DA
4
123
V01E0EA
1
2
http://ReadManuals.com
Section 03 ENGINE
Subsection 10 (TRANSMISSION)
03-10-4 VMR9961_03-10A.FM
After clutch housing installation, align mark on
shift shaft with mark on indicator shaft.
1. Indicator shaft
2. Shift shaft
3. Transmission actuating lever
Rear Side
Reassemble in the reverse order of disassembly.
TRANSMISSION
Disassembly
Remove gear shift mechanism.
Separate both housing of crankcase.
Remove the shift fork shafts no. 15, no. 16 and
no. 17.
Remove shift fork no. 18 then pull shift drum no. 19.
At the same time, pull all gears and shafts.
Inspection
Turn the inner race of each bearing with your fin-
ger. The bearings should turn smoothly and quiet-
ly. Replace if necessary.
During and after transmission disassembly, in-
spect the condition of each parts closely. In partic-
ular, check for:
– gear teeth damage
– worn or scored bearing surfaces
– worn or scored shifting fork
– worn or scored shift fork shaft
– rounded engagement dogs and slots
– bent shift forks
– bent shift fork shaft
– worn shift fork engagement pins
– worn tracks on shift drum
– worn splines on shafts and gears
Assembly
Reassemble in the reverse order of disassembly.
Paying attention to the following details.
NOTE: Install all shafts and gears together.
Place the shift forks no. 20, no. 21, no. 22 and
no. 23 in the proper shift drum tracks before install
the transmission in half housing.
When the transmission is installed, place the last
shift fork no. 18.
Install the shift drum.
NOTE: Check if the shaft pin is properly installed
in drum slot before housing installation.
V01E0FA
1
23
V01E0GA
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Section 03 ENGINE
Subsection 10 (TRANSMISSION)
VMR9961_03-10A.FM 03-10-5
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.
V01E0IA
21
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04-01-1
Section 04 FUEL SYSTEM
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
FUEL CIRCUIT........................................................................................................................ 04-02-1
FUEL LINES........................................................................................................................ 04-02-2
FUEL TANK STRAINER ..................................................................................................... 04-02-2
FUEL VALVE ...................................................................................................................... 04-02-3
FUEL TANK ........................................................................................................................ 04-02-3
FUEL GAUGE..................................................................................................................... 04-02-4
FUEL SYSTEM PRESSURIZATION ................................................................................... 04-02-4
CARBURETOR AND FUEL PUMP......................................................................................... 04-03-1
CARBURETOR ................................................................................................................... 04-03-1
REMOVAL .......................................................................................................................... 04-03-1
CLEANING AND INSPECTION.......................................................................................... 04-03-2
CARBURETOR FLOAT LEVEL ADJUSTMENT................................................................. 04-03-2
INSTALLATION.................................................................................................................. 04-03-3
CARBURETOR ADJUSTMENTS....................................................................................... 04-03-4
FUEL PUMP ....................................................................................................................... 04-03-7
REMOVAL .......................................................................................................................... 04-03-7
VERIFICATION.................................................................................................................... 04-03-7
CLEANING AND INSPECTION.......................................................................................... 04-03-7
INSTALLATION.................................................................................................................. 04-03-7
AIR INTAKE SILENCER.......................................................................................................... 04-04-1
AIR FILTER BOX ................................................................................................................ 04-04-2
REAR AIR INTAKE TUBE................................................................................................... 04-04-2
FRONT AIR INTAKE TUBE ................................................................................................ 04-04-2
PCV VALVE ........................................................................................................................ 04-04-2
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)
04-02-1
FUEL CIRCUIT
V01N0BS
4
5
6
8
10
9
11 10
8
Body
11
1
9
7
12
3
2
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)
04-02-2
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.
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.
USE SCREWDRIVER ONLY IF GROMMET IS TOO TIGHT
Inspection
Ensure that fuel tank strainer no. 8 and fuel line
are clean and not damaged, as per following pho-
to.
TYPICAL
1. Fuel tank strainer
2. Fuel line
Installation
NOTE: To ease grommet insertion, apply BOM-
BARDIER 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.
m WARNING
Whenever working on fuel system, always
verify for water or dust infiltration in reser-
voir. Replace any damaged, leaking or deteri-
orated fuel lines.
m WARNING
Use of improper fuel lines could compromise
fuel system integrity.
m WARNING
When draining a fuel tank or whenever a fuel
line is disconnected, obstruct line with a hose
pincher (P/N 295 000 076) or equivalent de-
vice. Fuel is flammable and explosive under
certain conditions. Ensure work area is well
ventilated. Do not smoke or allow open flames
or sparks in the vicinity.
V01N02A
A31I03A
1 2
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)
04-02-3
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.
FUEL VALVE
Removal
NOTE: To ease reinstallation, mark all hoses be-
fore removing fuel valve no. 1.
From outside body, remove plastic cap from valve
no. 1.
Unscrew valve nut, as shown in the next photo.
UNSCREW VALVE NUT
Unplug all 3 hoses from fuel valve.
Remove valve.
Installation
Reinstall fuel valve by positioning rubber washer
inside and nut outside vehicle. See next photo.
1. Rubber washer inside
2. Nut outside
Replug all hoses according to the following table.
FUEL TANK
Removal
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
2
V01N03A 1
V01N04A
HOSE VALVE POSITION
Fuel tank top hose ON
To fuel pump OUT
Fuel tank bottom hose RES
1
V01N05A 2
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)
04-02-4
Unplug fuel hoses from tank and disconnect fuel
vent line no. 5.
Remove both fuel tank top screws, as shown in
the next photo.
1. Remove both top fuel tank screws
Remove fuel tank bottom nut located beside re-
wind starter.
Inspection
Visual
Inspect fuel tank for any damage or cracks which
may result in fuel leaks. If so, replace tank with
new one.
Pressure Test
Refer to next section FUEL SYSTEM PRESSUR-
IZATION for complete detailed procedure.
Installation
Reverse removal procedure, however pay atten-
tion to the following:
Ensure that main fuel tank hose no. 11 and re-
serve 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.
1. Nut
2. Frame bracket
3. Fuel tank holding tab
4. Spacer
5. Washer
6. Screw head
Perform fuel system pressurization as described
in the following procedure.
FUEL GAUGE
Removal
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 pro-
cedure.
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).
1
V01N06A
2
V01N07A
1
3
456
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)
04-02-5
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.
HOSE PINCHER INSTALLED ON FUEL TANK VENT LINE
HOSE PINCHER INSTALLED ON FUEL PUMP OUTLET
Using air pump from engine leak test kit (P/N 861
749 100) inject air into fuel tank. See next photo.
1. Special cap on tank
2. Air pump
Pressurize fuel system to 21 kPa (3 PSI). That pres-
sure 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 com-
ponents, bubbles will indicate leak location(s).
V01N08A
V01N09A
2
V01N0AA 1
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Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND FUEL PUMP)
04-03-1
CARBURETOR AND FUEL PUMP
CARBURETOR
CAUTION: Although some jets be replaced by
other jets from other carburetors, such modifica-
tions shouldn’t be performed. They can greatly
affect engine calibration and can cause severe
damage to engine. Use only recommended jet-
ting 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 be-
fore unplugging.
Loosen both carburetor and air box clamps.
Loosen air box bolts and move backward.
Pull out carburetor.
Choke Cable Removal
Put carburetor on a clean rag.
Unscrew choke plastic nut from carburetor, as
shown in the next photo.
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. Open key end here
Pull choke cable to remove choke plunger from
carburetor.
Throttle Cable Removal
With carburetor on a clean rag, remove carburetor
side cover.
Using thumb, release tension on throttle lever.
With long nose pliers, rotate cable end bushing so
that cable aligns with throttle lever recess, then lift
cable end. See next photo.
1. Release tension on throttle lever
2. Cable end bushing
3. Throttle lever recess
V01F09A
1
V01B01A
231
V01F0AA
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Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND FUEL PUMP)
04-03-2
Separate cable end bushing from throttle cable
end, as shown in the next photo. Keep bushing.
REMOVE CABLE END BUSHING
Loosen throttle cable nut, as shown in the next
photo.
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 be-
fore disassembly.
CAUTION: Heavy duty carburetor cleaner may
be harmful to the float material and to the rub-
ber parts, O-rings, etc. Therefore, it is recom-
mended to remove those parts prior to cleaning.
Carburetor body and jets should be cleaned in a
carburetor cleaner following manufacturer’s in-
structions.
CARBURETOR FLOAT LEVEL
ADJUSTMENT
Correct fuel level in float chamber is vital toward
maximum engine efficiency. To check for correct
float level proceed as follows:
– Remove float bowl and gasket from carburetor.
– Make sure that float arm is symmetric-not dis-
tored.
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.
1. Gauge tips
2. “L” arm
A. Height H
V01F0BA
1
V01F0CA
2
m WARNING
Solvent with a low flash point such as gaso-
line, naphtha, benzol, etc., should not be used
as they are flammable and explosive.
22
A
1
V01F0TA
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Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND FUEL PUMP)
04-03-3
GAUGE ALIGNED WITH MAIN JET
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.
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 CARBU-
RETOR ADJUSTMENTS.
– Reinstall carburetor on engine.
When reinstalling carburetor on engine, pay atten-
tion to the following:
CAUTION: The rubber flanges must be checked
for cracks and/or damage. At assembly, the rub-
ber 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.
CARBURETOR SIDE — RUBBER FLANGE INSTALLATION
1. Flange recess aligned with carburetor notch
Install rubber flange on air box side so that its re-
cess aligns with air box notch, as shown in the
next photo.
AIR BOX SIDE — RUBBER FLANGE INSTALLATION
1. Notch aligned with recess
V01F0EA
90°
1
V01F0FA
V01F0GA 1
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Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND FUEL PUMP)
04-03-4
CARBURETOR ADJUSTMENTS
BOTTOM VIEW
1. Idle speed screw
2. Pilot screw
3. Drain plug and screw
Pilot Screw Preliminary Adjustment
NOTE: The pilot screw is factory pre-set. Adjust-
ment is not necessary unless the carburetor is
overhauled or replaced.
Completely close the pilot screw (until a slight
seating resistance is felt) then back off as speci-
fied.
Refer to TECHNICAL DATA 11-02 for specifications.
Idle Speed Preliminary Adjustment
Adjust throttle screw to 1-1/2 turn or so that throt-
tle valve closes bypass hole by half, as shown in
the next photo.
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.
V01F0HA
2
1
3
1
V01F0WA
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Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND FUEL PUMP)
04-03-5
Choke
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 plung-
er positioning.
Pilot Screw Adjustment
NOTE: The pilot screw is factory pre-set. Adjust-
ment is not necessary unless the carburetor is
overhauled or replaced. Warm the engine to oper-
ating 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.
FULLY CLOSED POSITION
1. Plunger end must be here
HALFWAY POSITION
1. Plunger end must be here
A. Opening to specification value
V01F0JS
1
1
A
V01F0KT
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Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND FUEL PUMP)
04-03-6
FULLY OPENED POSITION
1. Plunger end must be here
Plunger Adjustment
If plunger needs to be adjusted use cable adjuster,
as shown in the next photo.
USE CABLE ADJUSTER TO ADJUST PLUNGER POSITION
1. Choke plunger
NOTE: For the proper adjustment at halfway posi-
tion, use a bit with diameter to opening specifica-
tion.
Diaphragm Installation
Carefully replace diaphragm in its original position.
Make sure spring is located properly in carburetor
cover before screwing.
NOTE: Check and place correctly the indexation
lob.
Throttle
Before adjusting the throttle cable, adjust idle
speed (preliminary adjustment) and choke.
On the carburetor, loosen lock nut and adjust throt-
tle cable.
Make sure the throttle lever, at the full position,
doesn’t lean against carburetor body.
THROTTLE LEVER AT THE FULL POSITION
A. 1 mm (1/32 in)
Retorque lock nut.
V01F0LS
1
1
V01F0MA
m WARNING
Ensure the key is turned OFF, prior to per-
forming the throttle cable adjustment.
V01F0RA
A
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Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND FUEL PUMP)
04-03-7
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 com-
ing from fuel valve at fuel valve location.
Unplug fuel hose going to carburetor.
Disconnect impulse hose no. 12.
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 re-
lease with pressure and hold under vacuum.
Repeat the same procedure at the outlet nipple.
This time the outlet valve should hold with pres-
sure and release under vacuum.
Check impulse diaphragm and gasket on high-
supply fuel pump with twin outlets as follows:
Connect a clean plastic tubing to the impulse nip-
ple 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 gen-
eral purpose solvent and dried with compressed
air.
Inspect diaphragm. The pumping area should be
free of holes, tears or imperfections.
Replace pump as needed.
INSTALLATION
To install fuel pump, reverse removal procedure.
However, pay attention to fuel hose position. Re-
fer to arrows on fuel pump.
1
23
V01F0NA
m WARNING
Solvent with a low flash point such as gaso-
line, naphtha, benzol, etc., should not be used
as each is flammable and explosive.
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Section 04 FUEL SYSTEM
Subsection 04 (AIR INTAKE SILENCER)
04-04-1
AIR INTAKE SILENCER
V01C13S
Engine
Engine
Valve Cover
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
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Section 04 FUEL SYSTEM
Subsection 04 (AIR INTAKE SILENCER)
04-04-2
AIR FILTER BOX
Removal
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
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.
Inspection
Inspect air intake tube for cracks, blisters or any
other damage. Change if necessary.
Installation
For installation, reverse the removal procedure.
FRONT AIR INTAKE TUBE
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
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 in-
take 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.
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Section 04 FUEL SYSTEM
Subsection 04 (AIR INTAKE SILENCER)
04-04-3
Removal
Remove and discard clamps no. 14 and no. 15.
Separate PCV valve no. 13 from breather hose
no. 6 and from connecting tube no. 16.
1. PCV valve
2. Clamps
3. Breather hose
4. Connecting tube
Installation
For installation, reverse the removal procedure.
NOTE: Install PCV valve with the new clamps.
V01C14A
1
2
3
42
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05-01-1
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............................................................................................................. 05-03-1
TESTING PROCEDURE ..................................................................................................... 05-03-1
STARTING SYSTEM.............................................................................................................. 05-04-1
BATTERY ............................................................................................................................ 05-04-1
TROUBLESHOOTING........................................................................................................ 05-04-1
BATTERY TESTING ........................................................................................................... 05-04-1
REMOVAL........................................................................................................................... 05-04-2
CLEANING ......................................................................................................................... 05-04-2
INSPECTION ...................................................................................................................... 05-04-2
BATTERY STORAGE.......................................................................................................... 05-04-2
ACTIVATION OF A NEW BATTERY................................................................................... 05-04-3
TIPS FOR CHARGING A USED BATTERY ........................................................................ 05-04-4
CHARGING 2 OR MORE BATTERIES AT A TIME ............................................................ 05-04-5
INSTALLATION .................................................................................................................. 05-04-5
STARTING SYSTEM TROUBLESHOOTING..................................................................... 05-04-6
STARTING SYSTEM TESTS ............................................................................................. 05-04-7
ELECTRIC STARTER.......................................................................................................... 05-04-9
REMOVAL .......................................................................................................................... 05-04-9
INSTALLATION.................................................................................................................. 05-04-9
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Section 05 ELECTRICAL
Subsection 01 (TABLE OF CONTENTS)
05-01-2
IGNITION SYSTEM ................................................................................................................ 05-05-1
IGNITION SYSTEM TESTING PROCEDURE..................................................................... 05-05-1
GENERAL............................................................................................................................ 05-05-1
IGNITION SYSTEM TEST .................................................................................................. 05-05-1
OTHER IGNITION SYSTEM PROBLEMS .......................................................................... 05-05-4
IGNITION TIMING .............................................................................................................. 05-05-4
SPARK PLUG ...................................................................................................................... 05-05-5
DISASSEMBLY ................................................................................................................... 05-05-5
HEAT RANGE...................................................................................................................... 05-05-5
FOULING............................................................................................................................. 05-05-5
SPARK PLUG ANALYSIS ................................................................................................... 05-05-5
SPARK PLUG INSTALLATION ........................................................................................... 05-05-6
NGK SPARK PLUG SYMBOL EXPLANATION .................................................................. 05-05-7
ELECTRIC SHIFT SYSTEM ..................................................................................................... 05-06-1
GENERAL............................................................................................................................ 05-06-1
TROUBLESHOOTING ......................................................................................................... 05-06-1
DIAGNOSTIC/CALIBRATION MODE ................................................................................ 05-06-1
PREPARATION ................................................................................................................... 05-06-2
TESTING ............................................................................................................................. 05-06-3
VALVE REMOVAL/INSTALLATION.................................................................................. 05-06-9
SHIFTING VALVE ............................................................................................................... 05-06-9
CLUTCHING VALVE ........................................................................................................... 05-06-9
CLUTCH MODULATOR VALVE ......................................................................................... 05-06-10
SENSOR REMOVAL/INSTALLATION............................................................................... 05-06-11
STPS (SUB-TRANSMISSION POSITION SENSOR) ......................................................... 05-06-11
GBPS (GEAR BOX POSITION SENSOR)........................................................................... 05-06-11
VSS (VEHICLE SPEED SENSOR) ....................................................................................... 05-06-11
VALVES/SOLENOIDS TESTS............................................................................................ 05-06-13
CLUTCHING VALVE AND CLUTCH MODULATOR VALVE TESTS ................................. 05-06-13
UPSHIFT/DOWNSHIFT SOLENOIDS TESTS .................................................................... 05-06-13
SENSOR TESTS ................................................................................................................. 05-06-15
STPS (SUB-TRANSMISSION POSITION SENSOR)
AND GBPS (GEAR BOX POSITION SENSOR) TESTS ..................................................... 05-06-15
VSS (VEHICLE SPEED SENSOR) TESTS........................................................................... 05-06-15
UPSHIFT/DOWNSHIFT SWITCH TESTS .......................................................................... 05-06-16
UPSHIFT/DOWNSHIFT SWITCH ....................................................................................... 05-06-16
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05-01-3
Section 05 ELECTRICAL
Subsection 01 (TABLE OF CONTENTS)
INSTRUMENTS AND ACCESSORIES .................................................................................. 05-07-1
REMOVAL AND INSTALLATION...................................................................................... 05-07-1
12-VOLT AUXILIARY POWER OUTLET............................................................................ 05-07-1
12-VOLT POWER OUTLET ................................................................................................ 05-07-1
HEADLIGHT ....................................................................................................................... 05-07-1
IGNITION SWITCH ............................................................................................................ 05-07-2
INDICATOR LIGHTS .......................................................................................................... 05-07-3
MPEM................................................................................................................................. 05-07-3
SPEEDOMETER ................................................................................................................. 05-07-3
TESTS................................................................................................................................. 05-07-5
12-VOLT AUXILIARY POWER OUTLET............................................................................ 05-07-5
12-VOLT POWER OUTLET ................................................................................................ 05-07-5
COOLING FAN OPERATION TEST ................................................................................... 05-07-5
HEADLIGHT ....................................................................................................................... 05-07-5
HI-LO SWITCH ................................................................................................................... 05-07-5
INDICATOR LIGHTS .......................................................................................................... 05-07-6
SPEEDOMETER ................................................................................................................. 05-07-6
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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
05-02-1
OVERVIEW
GENERAL OPERATION INFORMATION
The electrical system consist of different sub-
systems 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 compo-
nents.
MPEM
(Multi-Purpose Electronic Module)
The MPEM itself is not a system, it is rather part
of other systems in the electrical system. There-
fore, the MPEM functions will be described spe-
cifically 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 pow-
er 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 sys-
tem 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 in-
tensity 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 ac-
cessory 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 trans-
forms magnetic field into electric current through
a 3 phase, “Y” wound stator on 18 poles.
The magneto supplies unregulated AC current (al-
ternative current) to the voltage regulator/rectifier.
1. Magneto flywheel
2. Stator
3. Voltage regulator/rectifier
4. Battery
1
2
3
4
VO1G0IA
http://ReadManuals.com
Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
05-02-2
Voltage Regulator/Rectifier
A 3-phase full-wave shunt-type voltage regulator/
rectifier receives the AC voltage and rectifies (con-
verts) it into DC. The voltage is also regulated to a
maximum of 14.5 volts (DC).
Battery
The battery supplies the entire vehicle and partic-
ularly the MPEM which then distributes the cur-
rent 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.
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 en-
gine with the transmission lever in any position
when holding any brake lever while pressing the
start button.
IGNITION SYSTEM
An IDI (Induction Discharge Ignition) system is uti-
lized. The ignition system is made up of the follow-
ing components:
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.
MPEM
(Multi-Purpose Electronic Module)
The MPEM is fed by the battery but the ignition is
activated by the ignition switch. The MPEM re-
ceives 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.
V01G0JA
1
3
4
5
6
2
V01G0KA
1
3
6
2
4
5
7
8
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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
05-02-3
Magneto Flywheel/Trigger Coil
The magneto flywheel features six protrusions
that are working with the trigger coil. The trigger
coil sends the signals to the MPEM to be pro-
cessed for the ignition system. The MPEM also
uses these signals to accurately calculate the en-
gine RPM and among other things, control the
maximum engine RPM.
Ignition Coil/Spark Plugs
The ignition coil receives its signal from the
MPEM. The ignition coil steps up the input voltage
for the IDI system and the end result is firing of
the spark plugs. It is a double coil that provides a
separate spark to each spark plug. The double con-
trol 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 compo-
nents:
1. Battery
2. Ignition switch
3. Upshift/downshift switch
4. Sensor
5. MPEM
6. Solenoid/valve
Battery/Ignition Switch
The ignition switch allows battery to supply the
MPEM. The MPEM then supplies the solenoids
for the shifting system.
Upshift/Downshift Switch
When the upshift or downshift button is pressed,
the MPEM activates the proper solenoid (up or
down) that moves the shared hydraulic valve.
Sensor
Many sensors are used to assist the MPEM to ac-
quire 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
The MPEM is responsible to properly engage/
disengage/modulate the clutch and to shift gears.
Although the shift system is performed by hy-
draulic 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, con-
trol the shift timing and modulation depending on
the sensors reading to accomplish an accurate
shifting adapted to each specific condition.
Solenoid/Valve
The solenoids/valves combo are the electro-hydraulic
devices that actually activate the mechanical oper-
ations. 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.
GAUGES/ACCESSORIES
The battery supplies the DC current to all accesso-
ries. Some are fed directly by the battery or through
the fuse block and some are fed through the MPEM.
V01G0LA
13
4
5
6
2
http://ReadManuals.com
Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
05-02-4
GENERAL TESTING/TROUBLESHOOTING INFORMATION
The following gives general electrical-related prob-
lems. 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 re-
move 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 inspec-
tion could lead to false results — and solidity
(close to battery). Also visually examine harness
and connections.
CAUTION: It is recommended to always dis-
connect 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 trou-
bleshooting procedures cover problems not re-
sulting from one of these causes.
Before replacing a MPEM, always check electrical
connections. Make sure that they are very tight and
they make good contact and that they are corrosion-
free. 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 appropri-
ate lubricant (except if otherwise specified) when
reassembling them. See connectors information
below.
It is recommended to always disconnect the bat-
tery 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 con-
trols. 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 fol-
lows.
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, mea-
sure 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 cor-
rect the fault.
SERVICING PACKARD
CONNECTORS
To remove terminal from Packard connector hous-
ing, use Snap-on TT600-4 tool.
m WARNING
Ensure all terminals are properly crimped on
wires and connector housings are properly
fastened.
F01B1JA
http://ReadManuals.com
Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
05-02-5
SERVICING DEUTSCH
CONNECTORS
Waterproof Connector Housing
Female and Male Connector Housing
To remove:
– Using a long nose pliers, pull out the lock.
FEMALE HOUSING
1. Female lock
MALE HOUSING
1. Male lock
NOTE: Before extraction, push wire forward to re-
lieve pressure on retaining tab.
– Insert a 4.8 mm (0.189 in) wide screwdriver
blade inside the front of the contact cavity.
– Pry back the retaining tab while gently pulling
wire back until contact is removed.
FEMALE CONNECTOR HOUSING
1. Retaining tab
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 re-
tention fingers are holding the contact.
– After all required contacts have been inserted,
the lock must be installed.
CAUTION: Never apply dielectric grease on con-
tacts 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 con-
nectors in order to prevent any malfunction of the
system.
1
V01G0OA
V01G0PA 1
V01G0QA
1
1
http://ReadManuals.com
Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
05-02-6
Identification
Parts
1. Plug assembly
2. Cover assembly
3. Mating seal
4. Wedge lock
5. Header assembly
6. Seal plug
7. Power wire
8. Signal wire
9. 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.
TYPICAL
1. AMP connectors
2. Identification numbers
Each plug assembly is mechanically keyed to mate
only with identical mechanical keyed header on
the MPEM.
TYPICAL
1. Mechanically keyed
To remove plug connector from the header as-
sembly 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 di-
mension of 1.7 mm (0.067 in) and a maximum di-
mension 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 sur-
face within 25 mm (1 in) from the tip of the con-
tact must be smooth.
F00H0WA
2
3
4
5
6
7
8
9
1
1
V0IG0MA
2
F00H12A 1
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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
05-02-7
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.
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 cavi-
ties be sealed with a seal plug, even if they are not
pierced.
1. Seal plug
2. Wire seal
CAUTION: Do not pierce the diaphragm with a
sharp point for electrical troubleshooting. The
resulting pin holes in the insulation will allow
moisture to penetrate the system and possibly
result in system failure.
Contact Removal
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 re-
moved from the housing for insertion or re-
moval of the signal wire contacts.
1. Wedge lock
2. Locking tab
1. Wedge lock in open position
F00B0EA
F00H10A
1
2
F00H0OB
12
F00H0PA
1
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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
05-02-8
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.
1. Rotate wire back and forth
2. Pull wire
Power Contact
NOTE: The wedge lock must be removed to ex-
tract power contact.
Pull both locking tabs and remove wedge lock
from plug assembly.
1. Pull locking tab (both sides)
Before extraction, push wire forward to relieve
pressure on retaining tab.
Insert a 4.8 mm (0.189 in) wide screwdriver blade
inside the front of the contact cavity.
Pry back the retaining tab while gently pulling wire
back until contact is removed.
Contact Installation
For insertion of signal contact, make sure the
wedge lock is in the open position.
NOTE: For insertion of power contact, the wedge
lock may or may not be on the open position.
Insert contact into appropriate circuit cavity and
push as far as it will go.
Pull back on the contact wire to be sure the reten-
tion 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 con-
tacts in plug connector. The use of dielectric
grease will create hydrolock and poor sealing.
F00H0QA
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2
F00H0RA
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F00H0ZA
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Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
05-02-9
Apply a thin coat of DEOXIT contact lubricant to
the pins of the header on the MPEM only.
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.
IDENTIFICATION OF FUSE BLOCK
ON VEHICLE
Fuses are located in engine compartment on LH
side of battery.
1. Battery
2. Fuse holder
Fuses are identified by a number located beside the
fuses.
1. Ignition system
2. Accessories (power outlet and auxiliary supply)
3. Solenoids
4. Fan
5. MPEM (Multi-Purpose Electronic Module)
6. Charging system
IDENTIFICATION OF MAJOR
CONNECTOR PINS
AMP Connectors of MPEM
F00H11A
1
1
V01G04A 2
1
V01G02A
2
3
4
5
6
28 25 24
23
15
8
16
9
1
F04H6FA
http://ReadManuals.com
Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
05-02-10
AMP Connectors of Wiring Harness
F04H6GA
9
http://ReadManuals.com
Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
05-02-11
Other Deutsch and Packard Connectors Pin-Out
V01G0ES
DEUTSCH
2
1
1
2
3
3
A
B
C
A
B
C
1
2
3
4
5
6
12
11
10
9
8
7
12
11
10
9
8
7
1
2
3
4
5
6
1
2
36
5
4
1
2
3
6
5
4
1
2
4
3
4
31
2
2
1
1
2
A
B
A
B
B
A
2
1
85
87
30
86
87a
A
B
C
A
BC
A
B
A
C
B
A
B
AB
C
A
B
C
A
B
B
A
A
BC
A
D
CB
B
CA
D
AB
A
D
CB
A
B
C
A
B
PACKARD
B
A
B
A
BA
C
BA
C
BA
C
D
B
A
C
D
A
B
C
D
E
F
B
CDA
A
B
C
D
E
F
http://ReadManuals.com
Section 05 ELECTRICAL
Subsection 03 (CHARGING SYSTEM)
05-03-1
CHARGING SYSTEM
TESTING PROCEDURE
NOTE: First, ensure that battery is in good condi-
tion prior to performing the following test using a
current inductive ammeter such as Snap-on MT
110.
If the battery is regularly discharged, check charg-
ing 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
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 mul-
timeter 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 in-
creased.
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 bat-
tery 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 pre-
ceding 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 loca-
tion 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.
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 specifica-
tion and the stator test good, the voltage regulator/
rectifier is defective.
V01G0SA
http://ReadManuals.com
Section 05 ELECTRICAL
Subsection 03 (CHARGING SYSTEM)
05-03-2
Stator
STATIC TEST: CONTINUITY
1. Disconnect the magneto wiring harness con-
nector. 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.
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 specifi-
cation, the stator will need to be replaced.
TYPICAL
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 con-
tinuity (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.
TYPICAL
DYNAMIC TEST
1. Unplug magneto connector at engine.
2. Connect the 6-pin magneto test harness (P/N
295 000 136) between the unplugged connec-
tors.
3. Connect test probes of the multimeter to two
of the YELLOW wires of the 6-pin magneto har-
ness 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.
F01H4WA
YL
YL-WH
BK-YL
YL
YL
BK
F01H4XA
YL
YL
YL
BK
BK-YL
YL-WH
F01H4YA
YL
YL
YL
BK
BK-YL
YL-WH
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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
05-04-1
STARTING SYSTEM
BATTERY
TROUBLESHOOTING
* To test charging system, refer to CHARGING SYS-
TEM 05-03.
BATTERY TESTING
There are 2 types of battery tests: unloaded and
loaded. An unloaded test is made on a battery
without discharging current. It is the simplest and
commonly used. However, be aware that the volt-
age test can be good while the battery has not
enough power to start the engine. A load test
gives more accuracy of the battery condition.
Unload Test
Check charge condition using either a hydrometer
or a multimeter.
With a multimeter, voltage readings appear in-
stantly to show the state of charge. Always re-
spect 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.
TYPICAL
1. Specific gravity 1.265
A hydrometer measures the charge of a battery in
terms of specific gravity of the electrolyte. Most
hydrometers give a true reading at 21°C (70°F).
In order to obtain correct readings, adjust the initial
reading by adding .004 points to the hydrometer
readings for each 5.5°C (10°F) above 21°C (70°F)
and by subtracting .004 point for every 5.5°C
(10°F) below 21°C (70°F).
This chart will be useful to find the correct reading.
EXAMPLE NO. 1 EXAMPLE NO. 2
Temperature below 21°C (70°F): Temperature above 21°C (70°F):
Hydrometer reading: 1.250 Hydrometer reading: 1.235
Electrolyte temperature: -1°C (30°F) Electrolyte temperature: 38°C (100°F)
Subtract .016 Sp. Gr. Add .012 Sp. Gr.
Corrected Sp. Gr. is 1.234 Corrected Sp. Gr. is 1.247
SYMPTOM: DISCHARGED OR WEAK BATTERY
CAUSE REMEDY
1. Battery posts and/or
cable terminal oxidized.
Clean and coat with
dielectric grease.
2. Loose or bad
connections.
Check wiring and
connector cleanliness,
damaged or short circuit.
3. Faulty battery
(sulfated, doesn’t keep
a full charge, damaged
casing, loose rectifier).
Replace.
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.
ELECTROLYTE
TEMPERATURE OPERATION TO PERFORM
°C °F
38 100
add
.012
to the
reading
32 90 .008
27 80 .004
21 70 correct reading
16 60
subtract
.004
from the
reading
10 50 .008
4 40 .012
- 1 30 .016
A17E0JA
1
http://ReadManuals.com
Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
05-04-2
Load Test
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 bat-
tery voltage; if battery is in good condition, it will
have at least 10.5 Vdc.
REMOVAL
Remove seat.
Disconnect negative BLACK cable first then posi-
tive cable.
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.
CAUTION: Should any electrolyte spillage oc-
cur, immediately wash off with a solution of
baking soda and water.
CLEANING
Clean the battery casing, caps, cables and battery
posts using a solution of baking soda and water.
Remove corrosion (if so) from battery cable termi-
nals and battery posts using a firm wire brush.
Rinse with clear water and dry well.
INSPECTION
Visually inspect battery casing for cracks or other
possible damage. If casing is damaged, replace
battery and thoroughly clean battery rack with wa-
ter and baking soda.
Inspect battery rack mounting.
Inspect battery posts for security of mounting.
Inspect for cracked or damaged battery caps, re-
place defective caps.
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 us-
ing a wire brush. Apply a light coat of dielectric
grease (P/N 413 701 700) or petroleum jelly on ter-
minals.
Clean battery casing and caps using a solution of
baking soda and water. Do not allow cleaning so-
lution 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.
m WARNING
Always respect this order for disassembly;
disconnect BLACK negative cable first. Elec-
trolyte or fuel vapors can be present in engine
compartment and a spark may ignite them
and possibly cause personal injuries.
m WARNING
Electrolyte is poisonous and dangerous. Avoid
contact with eyes, skin and clothing. Wear pro-
tective eyeglasses and a suitable pair of non-
absorbent gloves when removing the battery
by hand.
m WARNING
Electrolyte is poisonous, dangerous and ex-
plosive. It contains sulfuric acid and can cause
severe burns. Avoid contact with eyes, skin and
clothing.
m WARNING
Should the battery casing be damaged, wear
a suitable pair of non-absorbent gloves when
removing the battery by hand.
m WARNING
Battery caps do not have vent holes. Make sure
that vent tube is not obstructed.
http://ReadManuals.com
Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
05-04-3
During the storage period, recheck electrolyte lev-
el 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).
ACTIVATION OF A NEW BATTERY
CAUTION: Prior to charging the battery, always
remove it from the vehicle to prevent electro-
lyte spillage.
A new battery is factory fresh dry charged. For
storage purposes, it is fitted with a temporary seal-
ing 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.
1. Battery electrolyte
2. Remove caps and fill battery to UPPER LEVEL
line with electrolyte (specific gravity: 1.260 at
20°C (68°F)).
3. Allow the battery to stand for 30 minutes MIN-
IMUM so that electrolyte soaks through bat-
tery cells.
4. Allow gas bubbles to escape by lightly shaking
battery by hand.
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.
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 spill-
age using a solution of baking soda and water.
m WARNING
Never charge or boost battery while installed
on vehicle.
m WARNING
Failure to remove the sealing tube could re-
sult in an explosion.
A17E0FA
1
m WARNING
Gases given off by a battery being charged
are highly explosive. Always charge in a well
ventilated area. Keep battery away from cig-
arettes or open flames. Always turn battery
charger off prior to disconnecting cables.
Otherwise a spark will occur and battery
might explode.
A17E0HA
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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
05-04-4
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
For best results, battery should be charged when
the electrolyte and the plates are at room temper-
ature. 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 suspect-
ed to be frozen, keep it in a heated area for about
2 hours before charging.
The time required to charge a battery will vary de-
pending on some factors such as:
–Battery temperature: The charging time is in-
creased 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 near-
ly pure water in a completely discharged bat-
tery, it cannot accept current as well as electro-
lyte. This is the reason the battery will not accept
current when the charging cycle first begins. 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 ac-
cept 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 bat-
tery 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 increas-
es. 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 charg-
er leads are connected to the correct battery ter-
minals. 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 manufactur-
er’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 bat-
tery should be replaced.
m WARNING
Prior to charging the battery, always remove
it from vehicle.
m WARNING
Do not place battery near open flame.
A17E0LA
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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
05-04-5
– 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 return-
ing it to service.
CHARGING 2 OR MORE
BATTERIES AT A TIME
Connect all positive battery posts together and
use a charger with a capacity (rated) equal to num-
ber of battery to be charged.
TYPICAL
1. Two batteries connected in parallel
INSTALLATION
Reinstall battery and fasten making sure to rein-
stall the vent tube.
NOTE: Place the positive RED cable between hold-
ing straps and battery.
1. Cable between battery and strap
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m WARNING
Connect positive RED cable first then negative
cable. Always connect RED positive cable first.
V01G05A 1
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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
05-04-6
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.
Starter turns; but does
not crank the engine.
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.
Starter turns, but overrunning
clutch pinion does not mesh
with ring gear.
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.
Starter motor keeps running. Shorted starting solenoid switch
winding.
Replace starter solenoid.
Melted solenoid contacts. Replace starter solenoid.
Sticking or defective starter clutch. Lubricate or replace electric starter.
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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
05-04-7
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 ca-
bles or connections or the MPEM.
Check these components before removing starter.
Consult also the Starting System Troubleshooting ta-
ble above for a general view of possible problems.
Fuses
Make sure the solenoids fuse no. 3 (includes the
starting system) and the MPEM fuse no. 5, in the
fuse block, are in good condition. If they test good,
continue the other tests.
Battery
To check battery condition, refer to Battery above.
If it tests good, continue the other tests.
Ignition Switch
A quick test to validate it is working. If the lights
turn on in the cluster display just after turning on
the key, the ignition switch is good. Otherwise,
refer to IGNITION SYSTEM, section 05-05 for test-
ing procedure. If it tests good, continue the other
tests.
STPS
(Sub-Transmission Position Sensor)
Ensure the transmission lever is either in PARK or
in NEUTRAL. To quickly check the STPS, tempo-
rarily 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 multi-
function switch connector.
1. Unplug connector
2. RED wiring harness
Using a multimeter, measure the resistance be-
tween the following wires.
Replace switch if defective.
If switch tests good, check wiring going to MPEM.
If it tests good, continue the other tests.
m WARNING
Short circuiting electric starter is always a dan-
ger, therefore disconnect the battery ground
cable before carrying out any kind of mainte-
nance on starting system. Do not place tools
on battery.
POSITION WIRE RESISTANCE
Switch released
BLACK and
YELLOW
Infinite (0.L)
Switch depressed
and held 0.4 Ω max.
1
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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
05-04-8
Starting Solenoid
NOTE: Solenoid is located on frame, behind fuse
block.
Ensure the solenoid receives electric current as fol-
lows. Using a multimeter, measure the voltage be-
tween the following wires when pressing the
start/stop button with the ignition key turned on.
If solenoid does not properly receive current, the
MPEM can be suspected. See MPEM below.
If voltage is adequate, test the MPEM as follows. Us-
ing 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 con-
necting 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. Sole-
noid condition can be checked with an ohmmeter.
Install test probes on large connectors of solenoid.
Measure resistance when current is applied to
small connectors; if it is more than a few ohms,
replace solenoid.
If solenoid test good, check the electric starter. If
starter test good, the MPEM can be suspected.
See MPEM below.
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 elec-
tric starter. See below.
Electric Starter
NOTE: Starter is located behind LH side panel.
Remove LH side panel to give access to the start-
er. 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 sus-
pected. See MPEM below.
If starter does not turn, check for mechanical prob-
lems in the starter.
MPEM
When other components have been tested above
and are good, the MPEM can be suspected. En-
sure wiring and connectors are in good condition
prior to replacing the MPEM.
WIRE
COLOR CONNECTOR VOLTAGE
WHITE/RED Position B
On wiring
connecting
to solenoid
12 Vdc
BLACK —
Battery
ground
post (-)
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Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
05-04-9
ELECTRIC STARTER
REMOVAL
Turn OFF ignition switch.
Disconnect BLACK cable ground connection from
battery.
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.
Test starter operation.
m WARNING
Always disconnect ground cable first and re-
connect last.
m WARNING
Always connect RED positive cable first then
BLACK negative cable last. Whenever con-
necting the RED positive cable to the starter
motor make sure the battery cables are dis-
connected to prevent electric shock.
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Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)
05-05-1
IGNITION SYSTEM
IGNITION SYSTEM TESTING PROCEDURE
GENERAL
Ignition Problems
When dealing with ignition problems, the follow-
ing 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 fail-
ure, only parts replacement might solve the prob-
lem 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 re-
placed, the problem still persists, carefully repeat
the complete test procedure to find the other
faulty part.
IGNITION SYSTEM TEST
Safety Precautions
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 oth-
er 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.
m WARNING
To prevent powerful electric shocks while
cranking engine, neither touch any electronic
ignition components (ignition coil, high ten-
sion wire, wire harness, etc.) nor tester lead
clips. Also make sure that tester leads do not
touch any metallic object.
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Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)
05-05-2
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.
Tes t
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.
Use a multimeter and measure the resistance be-
tween the following wires.
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.
STATIC TEST: CONTINUITY
Check resistance with a high-sensitivity ohmme-
ter.
1. Disconnect the Deutsch 6-pin connector at en-
gine.
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 har-
ness 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.
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.
V01G0UA
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Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)
05-05-3
1. Multimeter
2. 6-pin magneto harness adapter
3. WHITE wire
4. BLACK wire
DYNAMIC TEST
1. Disconnect magneto wiring harness connector.
2. Install the 6-pin magneto harness adapter (P/N
295 000 136).
3. Connect one of the multimeter leads to the
WHITE/YELLOW wire of the 6-pin magneto har-
ness 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 mea-
surement 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.
Ignition Coil
IGNITION COIL
1. Primary side
2. Secondary side
Primary Winding
Disconnect the wire connector on the primary side
of the ignition coil.
Using a multimeter, check the resistance between
the terminals 1 and 2. Repeat a resistance test be-
tween 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 sup-
ply 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 wir-
ing 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)
05-05-4
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 suspect-
ed. Ensure wiring and connectors are in good con-
dition 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 an-
other one. Refer to INSTRUMENTS AND ACCES-
SORIES 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.
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Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)
05-05-5
SPARK PLUG
DISASSEMBLY
First unscrew the spark plug one turn.
Clean the spark plug and cylinder head with pres-
surized air then completely unscrew.
HEAT RANGE
The proper heat range of the spark plugs is deter-
mined 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 op-
erating 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 cylin-
der 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 de-
posits which might tend to foul the plug during
prolonged idle or low speed operation.
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.
A too “hot” plug will result in overheating pre-
ignition, 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 det-
onation.
FOULING
Fouling of the spark plug is indicated by irregular
running of the engine, decreased engine speed
due to misfiring, reduced performance, and in-
creased 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, de-
fective 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
TYPICAL
1. Overheated (light grey, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, grey, melted coating)
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).
A00E09A
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Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)
05-05-6
SPARK PLUG INSTALLATION
Prior to installation make sure that contact surfac-
es of the cylinder head and spark plug are free of
grime.
1. Using a wire feeler gauge, set electrode gap ac-
cording to the following chart.
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 sock-
et.
1. Proper socket
2. Improper socket
4. Torque spark plug to 22 N•m (16 lbf•ft).
A00E0BA
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Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)
05-05-7
NGK SPARK PLUG SYMBOL EXPLANATION
BP5ES15
Thread
diameter
Heat rating
numbers Reach Firing end
construction
Construction
PREFIX SUFFIX WIDE GAP
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")
19 mm
(3/4")
Taper
Seat
12.7 mm
(1/2")
11.2 mm
(7/16")
21 mm
(53/54")
E:
F:
H:
L:
Z:
2 Hot
4
5
6
7
8
9
10 Cold
18 mm
14 mm
10 mm
12 mm
8 mm
12 mm x 19 mm
Reach
A:
B:
C:
D:
E:
J:
Special Design
Single Ground
Special Alloy
Dual Ground
Special Alloy
Racing Type
Racing Version
of V Type
Half Heat Range
Standard Center
Electrode
Fine Wire Center
Electrode
Booster Gap
V Grooved Center
Electrode
A:
GV:
B:
C:
G:
L:
S:
V:
X:
Y:
Blank
18 mm ø 12 mm
(31/64")
14 mm ø 9.5 mm
(3/8")
Compact Type
Projected
Insulator Type
Resistor Type
Surface Discharge
Inductive
Suppressor Type
M:
P:
R:
U:
Z:
F02H08S
A01E1PS
Standard
Type
CROSSCUTS AND GAP STYLES OF SPARK PLUGS
Surface
Discharge Type
Projected
Insulator Type
Taper
Seat Type
V-Type
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-1
ELECTRIC SHIFT SYSTEM
GENERAL
The electric shift system controls several valves/solenoids that control the shifting and also allow an ad-
justment to the clutch pressure to modify the gear change.
It is possible to calibrate the clutch for the hardness or smoothness of shifting action. This calibration is
to be used when the clutch is slippery or is too hard.
If a new sensor or valve/solenoid is installed, the GBPS (Gear Box Position Sensor) and STPS (Sub-
Transmission 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
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-2
PREPARATION
Before going into the diagnostic/calibration mode, the ignition switch needs to be on position OFF,
the transmission in FIRST gear and shifter lever on NEUTRAL position.
To set the MPEM into the diagnostic/calibration mode, the following sequence needs to be done:
– Place a diagnostic jumper in the diagnostic connector.
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 work-
ing, and the accessory output is off.
NOTE: At any time, if the jumper is removed during the diagnostic/calibration mode, the MPEM is pow-
ered off automatically.
V01A12S
V01A0WA
1
2
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-3
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
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-4
Task 2: Clutch Modulator Calibration
The LED
“Check Engine”
blinks for a maximum time of 5 seconds or until the user begins the calibration
process or removes the jumper.
The upshift/downshift button is used to change the calibration of the clutch modulator valve. When one
of these buttons is activated, the LED
“Check Engine”
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
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.
GEAR LED
HARDNESS SMOOTHNESS
11 + 222 + 333 + 444 + 55
V01A0YS
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-5
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.
Table 2: Abnormality-Diagnosis Components
CODE
NO. DIAGNOSIS COMPONENT LED “REVERSE” LED “HI-LO BEAM”
0 No abnormal components found LED ON for 3 seconds only LED OFF
1 Starter solenoid LED ON LED blinks 1 time
2 Clutching valve LED ON LED blinks 2 times
3 Clutch modulator valve LED ON LED blinks 3 times
4 Downshift solenoid LED ON LED blinks 4 times
5 Upshift solenoid LED ON LED blinks 5 times
6 MPEM Memory LED ON LED blinks 6 times
7 Headlight supply LED ON LED blinks 7 times
8 Accessory supply LED ON LED blinks 8 times
9 Reference supply output LED ON LED blinks 9 times
V01A13S
BLINK
ON
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-6
Table 3: Abnormality Conditions
These abnormality conditions are not detected when the headlight supply output is in dimming mode.
CODE
NO. ABNORMALITY CONDITION ACTION
1
– Short circuit to battery is detected.
– Operating current on the starter output has
exceeded the overload threshold.
Refer to STARTING SYSTEM 05-04.
2
– Short circuit to battery is detected.
– Operating current on the clutch solenoid output
has exceeded the overload threshold.
Change clutching valve. Refer to VALVE
REMOVAL/INSTALLATION section.
3
– Short circuit to battery is detected.
– Operating current on the clutch modulator valve
output has exceeded the overload threshold.
Change clutch modulator valve. Refer to VALVE
REMOVAL/INSTALLATION section.
4
– Short circuit to battery is detected.
– Operating current on the downshift solenoid
output has exceeded the overload threshold.
Change shifting valve. Refer to VALVE
REMOVAL/INSTALLATION section.
5
– Short circuit to battery is detected.
– Operating current on the upshift solenoid
output has exceeded the overload threshold.
Change shifting valve. Refer to VALVE
REMOVAL/INSTALLATION section.
6 – Programmable parameters are corrupted. Install a new MPEM. Refer to INSTRUMENTS AND
ACCESSORIES 05-07.
7
– Short circuit to ground is detected .
– Operating current on the headlight supply
output has exceeded the overload threshold.
Check:
– Wiring condition.
– Headlight. Refer to INSTRUMENTS AND
ACCESSORIES 05-07.
8
– Short circuit to ground is detected.
– Operating current on the accessory supply
output has exceeded the overload threshold.
Check:
– Wiring condition.
– Speedometer. Refer to INSTRUMENTS AND
ACCESSORIES 05-07.
9 – Short circuit to ground is detected.
Check:
– Wiring condition.
– STPS and GBPS sensors. Refer to SENSOR TESTS
section.
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-7
Task 4: GBPS (Gear Box Position Sensor) Calibration
The LEDS
“1”
and
“Hi-Lo beam”
are ON during a maximum of 5 seconds or until the user sets the
calibration. This calibration mode sets the nominal position of sensor. The GBPS calibration is automati-
cally set when the Start/Stop button and the Hi/Lo beam button are activated at the same time.
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.
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.
V01A10S
V01A11S
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-8
Resetting the Diagnostic Components Register
Before resetting the diagnostic components registers, the MPEM needs to be in the diagnostic/calibration
mode.
The register is automatically reset when the following sequence is performed:
– The jumper on the diagnostic connector is removed while the START/STOP button is activated.
The MPEM will reset the register (See table ABNORMALITY-DIAGNOSIS COMPONENTS and table AB-
NORMALITY CONDITIONS) and after it will turn off itself.
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 button.
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.
RESET REGISTERS N.A.
Remove the jumper on the diagnostic connector and
press the button simultaneously.
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-9
VALVE REMOVAL/INSTALLATION
CAUTION: It is recommended to always discon-
nect the battery when replacing any electric or
electronic part(s).
SHIFTING VALVE
The upshift/downshift solenoids are installed on
shifting valve. This valve is located on the rear part
of engine.
1. Shifting valve
2. Upshift solenoid
3. Downshift solenoid
Tes t
Refer to VALVES/SOLENOIDS TESTS section.
Removal
Remove seat.
Unplug connector.
1. Upshift/downshift solenoid connector
Remove screws on top of shifting valve.
Pull shifting valve.
Installation
For the installation, reverse the removal proce-
dure, 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). Re-
fer to DIAGNOSTIC/CALIBRATION MODE sec-
tion, tasks 4 and 5.
CLUTCHING VALVE
The clutching valve is located on front of engine.
1. Clutching valve
2. STPS (Sub-Transmission Position Sensor)
3. Cable clip
Test
Refer to TEST section.
2
V01C0EB
13
1
V01J03C
2
V01C0DB
3
1
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-10
Removal
Remove fuel tank cover. Refer to BODY 10-02.
Unplug connector on seat pivot bar.
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 proce-
dure, paying attention to the following details:
– Apply engine oil on O-rings.
– Insert clutching valve in place.
– Tap clutching valve gently with a rubber ham-
mer.
– 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.
CLUTCH MODULATOR VALVE
The clutch modulator valve is located in front of en-
gine.
1. Clutch modulator valve
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). Re-
fer to DIAGNOSTIC/CALIBRATION MODE sec-
tion, tasks 4 and 5.
V01G0RA
1
V01C0DC
1
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-11
SENSOR REMOVAL/INSTALLATION
CAUTION: It is recommended to always discon-
nect the battery when replacing any electric or
electronic part(s).
STPS
(Sub-Transmission Position Sensor)
The STPS is located on front of engine.
Tes t
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 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.
GBPS (Gear Box Position Sensor)
The GBPS is located on rear of engine.
Tes t
Refer to SENSORS TESTS section.
Removal
Unplug GBPS.
Remove screws and lock washers.
Pull GBPS.
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 sec-
tion, task 4.
VSS (Vehicle Speed Sensor)
The VSS is located on front of engine.
Test
Refer to SENSORS TESTS section.
Removal
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.
1. Remove this bolt in first
Remove bolt retaining VSS.
Pull VSS out of engine.
V01C0DD 1
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-12
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)
05-06-13
VALVES/SOLENOIDS TESTS
CLUTCHING VALVE AND CLUTCH
MODULATOR VALVE TESTS
CAUTION: It is recommended to always dis-
connect the battery when replacing any electric
or electronic part(s).
Always place the transmission on NEUTRAL posi-
tion and select FIRST gear.
Place vehicle on level surface.
Install vehicle on jack stands to raise all four tires
off the ground.
Unplug clutching and clutch modulator valve con-
nector.
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 fol-
lowing 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 se-
lect 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.
m WARNING
Apply parking device.
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-14
– 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)
05-06-15
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:
– Check wiring condition.
– Remove sensor and turn inner parts with a fin-
ger:
• If LEDS work properly, sensor is good. Con-
tinue 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 follow-
ing details:
– Measure voltage between BLACK/BROWN and
PINK wires on speedometer connector under
steering cover. Place vehicle on NEUTRAL po-
sition, 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.
SENSOR LED
STPS R and N Blinks
GBPS 1 to 5
(simultaneously) Blinks
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Section 05 ELECTRICAL
Subsection 06 (ELECTRIC SHIFT SYSTEM)
05-06-16
UPSHIFT/DOWNSHIFT SWITCH TESTS
UPSHIFT/DOWNSHIFT SWITCH
Open multi-function switch box.
Using a multimeter, measure resistance between
the following wires.
Replace switch if defective.
POSITION WIRE RESISTANCE
UPSHIFT
Switch released
BLACK and
RED
Infinite (0.L)
Switch
depressed
and held
0.4 Ω max.
DOWNSHIFT
Switch released
BLACK and
GREEN
Infinite (0.L)
Switch
depressed
and held
0.4 Ω max.
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Section 05 ELECTRICAL
Subsection 07 (INSTRUMENTS AND ACCESSORIES)
05-07-1
INSTRUMENTS AND ACCESSORIES
REMOVAL AND INSTALLATION
CAUTION: It is recommended to always dis-
connect the battery when replacing any electric
or electronic parts.
12-VOLT AUXILIARY POWER
OUTLET
The 12-volt auxiliary power outlet is located on the
LH rear part of the rear extension frame. The con-
nectors are protected by heat shrink tubing.
The 12-volt auxiliary power outlet allows the instal-
lation of additional accessories.
Tes t
Refer to TESTS section.
12-VOLT POWER OUTLET
Tes t
Refer to TESTS section.
Removal
Remove the steering cover. Refer to BODY 10-02.
Unplug the connectors of the power outlet.
Unscrew the retaining nut.
Installation
Reverse the removal procedure.
HEADLIGHT
Removal
Remove screw and lift up the sealed beam cover.
1. Remove screws
2. Lift up the sealed beam cover
Installation
Properly reinstall removed parts in the reverse or-
der of their removal.
Adjustment
Adjust beam aiming as follows:
Turn knobs to adjust beam height and side orien-
tation as explained below. Adjust both headlights
evenly.
1. Headlight
2. Beam height adjustment
3. Beam side adjustment
V01A02A 21
V01A02B 12
3
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Section 05 ELECTRICAL
Subsection 07 (INSTRUMENTS AND ACCESSORIES)
05-07-2
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.
1. Headlights center lines
2. Light beam center
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 courterclock-
wise to release.
Install the new bulb by first pushing in while turn-
ing clockwise.
1. Lens
2. Screws
IGNITION SWITCH
Test
Refer to IGNITION SYSTEM 05-05.
Removal
Lift the steering cover and unscrew the ignition
switch nut.
NOTE: Do not unplug connectors when steering
cover is lifted.
Unplug the switch connector.
1. Switch connector
Installation
For the installation, reverse the removal proce-
dure.
90°
V01I0VA
90°
2
1
V01I0UA
90°
A
1
B
1
V01L0HA
22
1
V01G0CA
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Section 05 ELECTRICAL
Subsection 07 (INSTRUMENTS AND ACCESSORIES)
05-07-3
INDICATOR LIGHTS
Tes t
Refer to TESTS section.
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
For the installation, reverse the removal procedure.
MPEM
Tes t
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.
Installation
For the installation, reverse the removal proce-
dure.
SPEEDOMETER
Test
Refer to TESTS section.
Removal
Remove the steering cover. Refer to BODY 10-02.
Remove the two nuts under speedometer and un-
plug the connector.
1. Remove the two nuts
2. Unplug the connector
V01G0FA
1
V01G06A
2
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Section 05 ELECTRICAL
Subsection 07 (INSTRUMENTS AND ACCESSORIES)
05-07-4
Speedometer Bulbs Replacement
Each bulb can be replaced individually. Proceed as
follows:
Using a small screwdriver, pry cap out to expose
bulb socket.
1. Speedometer
2.
Insert a small screwdriver in socket slot and turn
counterclockwise until stopped.
Use small long nose pliers to pull bulb out or care-
fully pry out using a small screwdriver.
1. Pull bulb out
Reinstall new bulb using long nose pliers. Turn
bulb socket clockwise to lock.
Installation
For the installation, reverse the removal proce-
dure.
1
V01I0EA 2
1
V01I0DA
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Section 05 ELECTRICAL
Subsection 07 (INSTRUMENTS AND ACCESSORIES)
05-07-5
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.
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. 12-volts power outlet
2. Power outlet connectors
– No voltage:
• Check fuse and wiring condition.
– Voltage is good:
• Change power outlet.
COOLING FAN OPERATION TEST
Unplug the temperature sender connectors.
Install a jumper wire end in each connector. Re-
place the fan if it does not work.
HEADLIGHT
Using a multimeter, measure the voltage between
GREEN/ORANGE and BLACK wires.
Start the engine. The obtained value should be be-
tween 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.
HI-LO SWITCH
Open multi-function switch box.
Using a multimeter, measure the resistance be-
tween the following wires.
Replace switch if defective.
12
V01G0GB
POSITION WIRE RESISTANCE
Switch released
BLACK
and
BLUE
Infinite (0.L)
Switch
depressed
and held
0.4 Ω max.
V01G0DA
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Section 05 ELECTRICAL
Subsection 07 (INSTRUMENTS AND ACCESSORIES)
05-07-6
INDICATOR LIGHTS
Remove steering cover. If switch tests good,
check wiring condition and MPEM.
Unplug indicator light connector.
1. Indicator lights connectors
Test each LEDS with two 1.5 V battery (AA), con-
nected in series.
– LEDS are good
• Check wiring condition.
• Check AMP connectors.
• Change MPEM.
– LEDS are burned
• Change indicator lights.
SPEEDOMETER
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.
– No voltage on speedometer:
• Check VSS (Vehicle Speed Sensor), refer to
ELECTRIC SHIFT SYSTEM 05-06. If VSS volt-
age is good, check fuse no. 3 and wiring con-
dition.
– 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.
1
V01G0GA
V01G0HA
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06-01-1
Section 06 DRIVE TRAIN
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
FRONT DIFFERENTIAL.......................................................................................................... 06-02-1
FRONT DRIVE SHAFT ....................................................................................................... 06-02-2
FRONT DIFFERENTIAL...................................................................................................... 06-02-3
FRONT PROPELLER SHAFT .............................................................................................. 06-02-4
REAR AXLE ............................................................................................................................ 06-03-1
RIGID AXLE........................................................................................................................ 06-03-2
REAR PROPELLER SHAFT................................................................................................. 06-03-4
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Section 06 DRIVE TRAIN
Subsection 02 (FRONT DIFFERENTIAL)
06-02-1
FRONT DIFFERENTIAL
V01H0VS
13
11
140 Nm
(103 lbfft)
(MINIMUM)
12
9
10
21
8
7
22
2
4
3
45 Nm
(33 lbfft)
1
14
5
6
15
16
20
19 17 18
42 Nm
(31 lbfft)
8
11
140 Nm
(103 lbfft)
(MINIMUM)
13
12
21
10
9
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Section 06 DRIVE TRAIN
Subsection 02 (FRONT DIFFERENTIAL)
06-02-2
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, cas-
tellated nut no. 11, flat washer no. 10 and O-ring
no. 21.
CHECK THE O-RING FOR DAMAGE, REPLACE IF NECESSARY
Remove cotter pin and castellated nut from upper
and lower suspension arms.
1. Castellated nut
2. Cotter pin
3. Lower suspension arm
4. Upper suspension arm
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 dam-
age 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.
1. Stop ring
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).
V01H0DA
4
V01H0EA
1
2
3
1
2
V01H0FA 1
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Section 06 DRIVE TRAIN
Subsection 02 (FRONT DIFFERENTIAL)
06-02-3
Drive Shaft Boot
Removal
Remove:
– clamps from rubber boot using boot clamp pli-
ers (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 bear-
ing. Do not remove circlip.
1. Circlip
2. Shaft
Remove boot from drive shaft.
Inspection
Check bearing in plunging joint or CV joint. If bear-
ing 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.
FRONT DIFFERENTIAL
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
1. Front mounting bolt M10 x 200
2. Differential mounting bracket bolts
3. Bracket
4. Rear mounting bolt M10 x 60
1
V01H0XA 2
V01H0GA
3 1
2
4
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Section 06 DRIVE TRAIN
Subsection 02 (FRONT DIFFERENTIAL)
06-02-4
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.
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 ax-
ial play.
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.
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.
1. Drain plug
2. Filler plug
Clean drain plug area then reinstall plug.
Lower vehicle.
Use a funnel and refill front differential at the prop-
er level with the recommended oil. Refer to TECH-
NICAL DATA 11-02.
Reinstall filler plug.
FRONT PROPELLER SHAFT
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 differ-
ential side no. 19 and 20. Discard bolts.
Remove vent tube no. 15 on the top from the front
differential.
V01H0IA
2
V01H0WA 1
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Section 06 DRIVE TRAIN
Subsection 02 (FRONT DIFFERENTIAL)
06-02-5
Pull differential forward then separate propeller
shaft from differential and engine.
Inspection
Check propeller shaft for wear or damage, replace
if necessary.
Installation
Installation is the reverse of removal procedure.
1. 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 ve-
hicle 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.
1. Snap ring
Support inner yoke in vice and drive other yoke
down with a soft hammer.
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.
1
V01H0JA 2
1
V01H0YA
V01H0ZA
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Section 06 DRIVE TRAIN
Subsection 02 (FRONT DIFFERENTIAL)
06-02-6
Tighten vise to force bearing caps in.
Using a suitable arbor, fully seat bearing cap in one
side. Continually, check for free movement of
bearing cross as bearing caps are assembled.
Install snap ring.
Repeat procedure for other sides.
Grease U-joint, using a grease gun with SHELL,
Alvania EP-2 grease only.
V01H10A
V01H11A
V01H12A
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Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
06-03-1
REAR AXLE
V01H0US
1
140 Nm
(103 lbfft)
minimum
2
3
4
6
4
8
9
10
5
7
12
13
14
15
18
17
20
19
12
13
14
21
11
16
43 Nm
(32 lbfft)
43 Nm
(32 lbfft)
33 Nm
(24 lbfft)
50 Nm
(37 lbfft)
27 Nm
(20 lbfft)
38 Nm
(28 lbfft)
140 Nm
(103 lbfft)
minimum
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Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
06-03-2
RIGID AXLE
Removal
Lift rear of the vehicle until rear shock absorbers
are fully extended. Install jack stands under frame
to support vehicle.
Remove the rear wheels.
Remove lower shock absorber bolts and elastic
flanged nuts.
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.
1. Brake hose
2. Vent tube
Remove the M8 x 10 flanged bolts no. 4 retaining
protector no. 2 under rear rigid axle center sec-
tion.
Remove the M10 x 25 socket screws no. 7 retain-
ing rigid axle center section to swing arm.
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.
1. Remove flanged bolts and elastic flanged nuts
Detach rigid axle from swing arm.
Installation
Installation is essentially the reverse of removal
procedure. Paying attention to the following de-
tails.
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.
1
V01J03B
V01J04A
1
2
1
V01J05A
1
V01J06A
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Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
06-03-3
Secure rear axle tube to swing arm with bolts. Do
not tighten yet.
When all bolts are installed, torque in a criss-cross
sequence.
RIGID AXLE CENTER SECTION
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
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.
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.
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.
1
V01J05B
2
3
4
1
V01J06B
2
3
4
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Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
06-03-4
Rear Rigid Axle Center Section Oil Level
Lift back of vehicle. Place swing arm to the hori-
zontal position.
Clean filler plug prior to check oil level. Check oil
level by removing filler plug. Oil level must reach
lower edge.
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.
1. Drain plug
2. Filler plug
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.
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.
1
V01H0RB
2
V01H0RA 1
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Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
06-03-5
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 06-
02.
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07-01-1
Section 07 STEERING/CONTROL SYSTEMS
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
STEERING/CONTROL SYSTEMS......................................................................................... 07-02-1
HANDLE BAR..................................................................................................................... 07-02-2
STEERING COLUMN......................................................................................................... 07-02-2
TIE-ROD.............................................................................................................................. 07-02-2
STEERING COLUMN BEARING........................................................................................ 07-02-3
MULTI-FUNCTION SWITCH ............................................................................................. 07-02-3
THROTTLE HANDLE.......................................................................................................... 07-02-4
LH HANDLE BRAKE........................................................................................................... 07-02-4
RH HANDLE BRAKE .......................................................................................................... 07-02-5
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Section 07 STEERING/CONTROL SYSTEMS
Subsection 02 (STEERING/CONTROL SYSTEMS)
07-02-1
STEERING/CONTROL SYSTEMS
V01I0XS
7
12
1
1
6
5
23
25
11
19
18
21
21
19 18
20
19
18
20
19
18
21
21
10 9
14
1617
16
15
13
13
8
4
3
2
24
22
22
22
22
26
20
20
2
24 Nm
(18 lbfft)
24 Nm
(18 lbfft)
75 Nm
(55 lbfft)
75 Nm
(55 lbfft)
75 Nm
(55 lbfft)
75 Nm
(55 lbfft)
19 Nm
(168 lbfin)
75 Nm
(55 lbfft)
http://ReadManuals.com
Section 07 STEERING/CONTROL SYSTEMS
Subsection 02 (STEERING/CONTROL SYSTEMS)
07-02-2
HANDLE BAR
Removal
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 steer-
ing clamp no. 6
– handle bar no. 7
Inspection
Inspect the handle bar for damage, cracks or bend-
ing, replace if any problems is detected.
Installation
For the installation, reverse the removal procedure.
NOTE: Replace screws retaining handle bar grip by
a new self-locking screws.
STEERING COLUMN
Removal
Remove:
– steering cover (refer to BODY 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, sep-
arate 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 col-
umn no. 12
Separate steering column and tie-rods no. 13. Re-
fer 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.
Inspection
Inspect steering column for damage, cracks or bend-
ing, replace if any problems is detected.
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 ex-
cessive, replace.
Installation
For the installation, reverse the removal proce-
dure. Pay attention to the following details.
At the time of the reinstallation or the new tie-
rod(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:
NOTE: Torque the ball joint lock nut no. 22 to 36
N•m (27 lbf•in).
MODEL A B
mm 20 ± 5 311 ± 1
TRAXTER in 25/32 ± 0.197 12 1/4 ± 0.039
B
V01I0YA
AA
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Section 07 STEERING/CONTROL SYSTEMS
Subsection 02 (STEERING/CONTROL SYSTEMS)
07-02-3
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.
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.
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 ACCESSO-
RIES 05-07 for Hi-Lo Beam button.
Removal
Remove bolts.
1. Remove the bolts
V01I0NA 1 2
V01I0OA
1
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Section 07 STEERING/CONTROL SYSTEMS
Subsection 02 (STEERING/CONTROL SYSTEMS)
07-02-4
Separate multi-function switch no. 5 from handle
bar no. 7.
Remove steering cover. Refer to BODY 10-02.
Unplug multi-function switch connector. The con-
nector is located under steering cover.
UNDER STEERING COVER
1. Unplug this connector
Installation
For installation, reverse the removal procedure.
If replaced, the calibration is required. Refer to ELEC-
TRIC SHIFT SYSTEM 05-06.
THROTTLE HANDLE
Removal
Remove screws no. 26.
1. Remove screws
Separate throttle handle no. 3 from handle bar no. 7.
Remove throttle cable from housing.
1. Throttle handle housing
2. Throttle cable
Slide cable in clip slot and remove the end of the
cable from clip.
Installation
For installation, reverse the removal procedure.
Refer to CARBURATOR AND FUEL PUMP 04-03 for
adjustment procedure.
LH HANDLE BRAKE
Removal
Remove screws.
1. Remove the screws
Separate handle brake no. 2 from handle bar no. 7.
If necessary, cut locking tie.
1
V01I0PA
V01I0ZA
1
V01I10A
12
1
V01I0SA
http://ReadManuals.com
Section 07 STEERING/CONTROL SYSTEMS
Subsection 02 (STEERING/CONTROL SYSTEMS)
07-02-5
Cable Removal
Refer to HYDRAULIC BRAKES 09-02 for specifics
instructions.
Installation
For installation, reverse the removal procedure.
RH HANDLE BRAKE
Removal
Remove screws.
1. Remove the screws
Separate handle brake no. 2 from handle bar no. 7.
If necessary, unplug connectors under steering cov-
er and cut locking tie.
Hose Removal
Refer to HYDRAULIC BRAKES 09-02 for specifics
instructions.
Installation
For installation, reverse the removal procedure.
V01I11A
1
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08-01-1
Section 08 SUSPENSION
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
FRONT SUSPENSION .......................................................................................................... 08-02-1
SHOCKS ASSEMBLY ........................................................................................................ 08-02-2
UPPER A-ARM ................................................................................................................... 08-02-3
LOWER A-ARM.................................................................................................................. 08-02-4
KNUCKLE ........................................................................................................................... 08-02-5
WHEEL BEARING CONDITION ......................................................................................... 08-02-6
REAR SUSPENSION............................................................................................................. 08-03-1
REAR SHOCK..................................................................................................................... 08-03-2
SWING ARM ...................................................................................................................... 08-03-3
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Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION )
08-02-1
FRONT SUSPENSION
V01J0BT
75 Nm
(55 lbfft)
1
6
5
4
7
8
2
67 Nm
(49 lbfft)
8
3
7
67 Nm
(49 lbfft)
1
6
67 Nm
(49 lbfft)
5
7
78
4
2
67 Nm
(49 lbfft)
8
3
75 Nm
(55 lbfft)
48 Nm
(35 lbfft)
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Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION )
08-02-2
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. Remove bolts
2. Front shock assembly
Disassembly
For shock spring disassembly use shock spring re-
mover (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 horizon-
tal position by changing the position of the clevis
pin.
TYPICAL
1. Clevis pin
2. Bar
3. Handle horizontal
Push down on the handle until it locks. Remove
spring stopper then release handle.
Inspection
Inspect the spring for damage. Replace if neces-
sary.
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 follow-
ing 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 com-
pression and extension stroke.
Replace shock if any of these conditions are
found.
V01J0IA
1
2
1
A01B4LA
2
3
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Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION )
08-02-3
Installation
For assembly, reverse the disassembly and re-
moval procedures.
NOTE: Do not interchange left and right tires.
Check direction of rotation mark on tires.
DIRECTION OF ROTATION
Torque wheel nuts to 75 N•m (55 lbf•ft) in a criss-
cross sequence.
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.
1. Upper A-arm
2. Detach brake hose from tubing
3. Brake hose
4. Remove nut and bolt
Remove cotter pin and castellated nut from upper
ball joint no. 4.
1. Remove cotter pin
2. Castellated nut
3. Upper ball joint
Use a suitable ball joint remover and detach upper
A-arm from knuckle.
Remove bolts no. 7 and nuts retaining upper A-
arm to frame.
1. Upper A-arm
2. Remove nuts and bolts
Remove upper A-arm from vehicle.
V01J0KA
2
V01J0CA
1
3
4
V01J0DA
213
2
V01J0EA 1
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Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION )
08-02-4
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 assem-
bly if ball joint is damaged.
RH UPPER A-ARM ASSEMBLY
Check upper A-arm for distortion or damage. Re-
place as required.
Inspect pivot bushings for wear or damages.
Replace A-arms if necessary.
Installation
Position upper A-arm and install bolts and nuts.
Do not torque yet.
Install bolt and nut retaining shock absorber to up-
per A-arm.
NOTE: Position the upper A-arm in order to have
a distance of 311 mm (12 in) between shock ab-
sorber retaining bolts (center to center). Use spe-
cial A-arm tool (P/N 529 035 611).
1. Torque nuts to 65 N•m (48 lbf•ft)
A. 311 mm (12 in)
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.
DIRECTION OF ROTATION
Torque wheel nuts to 75 N•m (55 lbf•ft) in a criss-
cross sequence.
LOWER A-ARM
Removal
Remove cotter pin and castellated nut retaining
lower A-arm no. 3 to ball joint on the knuckle.
1. Lower A-arm
2. Castellated nut
3. Lower ball joint
4. Knuckle
V01J0JA
1
V01J0HA
A
V01J0KA
4
V01J0FA 321
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Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION )
08-02-5
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.
1. Lower A-arm
2. Remove nuts and bolts
Remove lower A-arm from vehicle.
Inspection
Check ball joint rubber on lower A-arm for crack or
any other damage. Inspect ball joint end for dam-
ages. Ensure it’s moving freely. Replace lower A-
arm 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 proce-
dure. 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 castel-
lated nut and new cotter pin.
NOTE: Do not interchange left and right tires.
Check direction of rotation mark on tires.
DIRECTION OF ROTATION
Torque wheel nuts to 75 N•m (55 lbf•ft) in a criss-
cross sequence.
KNUCKLE
Removal
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 neces-
sary.
Remove hub. Refer to HYDRAULIC BRAKES 09-
02.
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.
1
V01J0GA 2
V01J0KA
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Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION )
08-02-6
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 as-
sembly.
NOTE: Be careful not to misjudge play in the sus-
pension ball joint. Refer to STEERING/CONTROLS
SYSTEMS 07-02 for inspection.
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Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
08-03-1
REAR SUSPENSION
V01J01S
2
8
7
3
6
5
6
4
5
6
1011
12
13
17
16
15
9
18
14
1
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Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
08-03-2
REAR SHOCK
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.
RIGHT SIDE SHOWN
1. Upper bolt and nut
2. Lower bolt and nut
3. Rear shock absorber RH
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 compres-
sor.
Close and lock bar. Adjust handle horizontal by
changing position of clevis pin.
Push down on handle until it locks. Remove spring
stopper and cap then release handle.
TYPICAL
1. Clevis pin
2. Bar
3. Handle horizontal
At installation, cap opening no. 8 must be 180°
from spring stopper opening no. 7.
TYPICAL
1. Cap opening
2. Spring stopper opening
3
V01J02A
2
1
1
A01B4LA
2
3
A03F12A
1
2
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Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
08-03-3
Inspection
Secure the shock body end no. 2 in a vise with its
rod upward.
TYPICAL
1. Clamp here
CAUTION: Do not clamp directly on shock body.
Examine each shock for leaks. Extend and com-
press the piston several times over its entire
stroke. Check that it moves smoothly and with uni-
form 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 com-
pression and extension stroke.
Renew if any faults are present.
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.
1. Rear brake caliper
2. Remove bolts
3. Brake hose
4. Swing arm
5. Vent tube
Detach brake hose from brackets on rear axle tube
and on swing arm.
Disconnect vent tube.
1. Brake hose
2. Vent tube
A14F0BA
1
51
2
V01J03A
4
32
V01J04A
1
2
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Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
08-03-4
Remove M8 flanged screws retaining master cyl-
inder.
CAUTION: Don’t let caliper hang by the hose
and don’t stretch or twist brake hose.
1. Remove bolts
2. Master cylinder
3. Remove spring
4. 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.
1. Swing arm
2. Pivot bolt LH
3. Jam nut
Unscrew and remove RH pivot bolt no. 14.
1. Swing arm bellows
2. Pivot bolt RH
Pull back rear train assembly to detach swing arm
assembly from the frame and disengage the pro-
peller shaft.
Remove the M10 x 25 socket screws retaining
rear rigid axle center section to swing arm.
1. Remove M10 x 25 socket screws
4
3
2
1
V01K05A
1
V01J08A 23
V01J07A
1
2
1
V01J05A
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Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
08-03-5
Remove M10 nuts and bolts retaining swing arm
to rear axle tube.
1. Remove nuts and bolts
Detach swing arm no. 9 from rear drive system
assembly.
Inspection
Check condition of swing arm. Inspect for distor-
tion or damage.
Check swing arm bellows for cracks or damage.
Check oil seals no. 11 for wear or damage. Re-
place swing arm if necessary.
Check condition of bearings no. 10. Make sure
they turn smoothly. Replace swing arm if neces-
sary.
Ensure outer race of bearing fits tightly inside
swing arm pivot.
1. Swing arm bellows
2. Oil seal
3. Cone bearing
Installation
Installation is essentially the reverse of removal
procedure. However, pay attention to the follow-
ing details.
Secure rear rigid axle center section to swing arm
with socket screws. 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.
RIGID AXLE CENTER SECTION
REAR AXLE TUBE
Install cone bearings into cavity. Pack bearing cav-
ities with Therma Lube grease (P/N 293 550 018).
1
V01J06A
1
2
V01J09A 3
1
V01J05B
2
3
4
1
V01J06B
2
3
4
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Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
08-03-6
Apply grease (P/N 293 550 019) to spring and
splines before insert the end of the propeller shaft
into swing arm.
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. RH pivot bolt
2. Pivot bearing
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.
Attach swing arm bellows to engine and install
clamp. Torque to 5 N•m (4 lbf•ft).
Reinstall master cylinder. Check brake pedal ad-
justment. Refer to HYDRAULIC BRAKES 09-02 for
complete adjustment procedure.
Route brake hose and secure to the brackets.
Connect vent hose.
Reinstall shock absorbers.
V01H09A
1
2
2
V01J0AA
1
m WARNING
The LH pivot bolt must have more than 2
threads out of jam nut.
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09-01-1
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
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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
09-02-1
HYDRAULIC BRAKES
FRONT BRAKES
V01K06T
4
34 Nm
(25 lbfft)
11
12
5
10
6
8
10 9
10
7
13
3
1211 2
3
1
11
12
13
14
24 Nm
(18 lbfft)
24 Nm
(18 lbfft)
25
24 Nm
(18 lbfft)
9
24 Nm
(18 lbfft)
25
34 Nm
(25 lbfft)
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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
09-02-2
REAR BRAKE
V01K07T
3
34 Nm
(25 lbfft)
23
11
12
16
15
18
24
22
20
17
14
13
19
21
1
12
11
24 Nm
(18 lbfft)
25
24 Nm
(18 lbfft)
24 Nm
(18 lbfft)
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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
09-02-3
GENERAL
Hydraulic Brakes System
The brake system consists of two separate cir-
cuits. Each system has its own master cylinder
and reservoir.
Both front and rear brakes are disc type.
Parking Device
The parking device operates the rear brake only. It
is activated by a locking mechanism on LH brake
lever.
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.
1. Oil level mark
2. Bolt
3. Sealing washers
4. Remove screws
Rear Brake
Remove seat to have access to master cylinder
reservoir no. 15.
Unscrew reservoir cover.
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.
2
V01K0KA
1
V01K12A
2
314
2
V01K0HA
3
1
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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
09-02-4
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.
1. Master cylinder
2. Flexible hose
3. Rear brake hose
4. Push rod
5. Remove bolts
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.
1. Rear master cylinder
2. Pusher
3. Boot
Installation
For the installation, reverse the removal proce-
dure, 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, po-
sition cylinder reservoir parallel to the ground.
Tighten upper bolt in first.
Connect brake hose to master cylinder with bolt
and new sealing washers.
Rear Brake
Install master cylinder to frame.
Install rear brake hose to master cylinder using
new sealing washers.
Connect flexible hose from reservoir and secure
with new locking tie.
Fill up reservoir with clean brake fluid.
CAUTION: Do not mix different types of brake
fluid. Use only DOT 4 brake fluid.
Bleed both front and rear brake systems.
Check for leaks and make sure the brakes operate
normally before driving.
CALIPER
Removal
Loosen wheel nuts.
Raise vehicle and support it securely.
Remove wheels.
4
3
V01K0JA
2
15
1
V01K16A 32
V01K13A
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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
09-02-5
RH FRONT BRAKE
1. Caliper
2. Brake hose
Remove bolt no. 12 with sealing washers no. 11
and detach brake hose from caliper.
Catch spilled fluid with a rag. Attach the brake
hose in a position to prevent the fluid from flowing
out.
Unscrew bolts no. 25 retaining caliper to knuckle
and remove caliper. Discard bolts.
1. Remove bolt and washers
2. Unscrew bolts
3. Brake hose
Disassembly
Only brake pads are available as spare parts. If cal-
iper is damaged, replace as an assembly.
Installation
For the installation, reverse the removal proce-
dure, paying attention to the following details.
Use new sealing washers when installing bolt re-
taining brake hose to caliper.
Install caliper to knuckle with the new self-locking
bolts.
If hose was disconnected, bleed the brakes.
Check for leaks and make sure the brakes operate
normally before driving.
BRAKE PADS
Removal
Raise vehicle and support it securely.
Remove wheels.
Remove caliper from knuckle.
Remove retaining clip.
While holding spring, pull out pin retaining brake
pads.
V01K14A
2
1
3
V01K15A 12
V01K0CA
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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
09-02-6
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
1. Clip
2. Pin
3. Retaining spring
4. Brake pads
CAUTION: Do not clean brake pads in petro-
leum 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.
CAUTION: Brake pads must always be re-
placed in pairs.
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 con-
tact with the disc.
Check for leaks and make sure the brakes operate
normally before driving.
BRAKE DISC
Inspection
Brake discs no. 13 can be inspected without re-
moving from the vehicle.
Raise vehicle and support it securely. Remove
wheels and visually inspect disc surfaces for scratch-
es or grooves. Make sure to check both sides of disc.
Measure thickness of the disc. Minimum thick-
ness is 4.7 mm (0.18 in).
Replace disc if not within specifications.
CAUTION: Brake discs should never be ma-
chined.
Turn the disc by hand and check run out.
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 vehi-
cle to replace brake disc no. 13.
Remove cotter pin and unscrew castellated nut.
Remove O-ring.
1. Remove O-ring
BRAKE PAD MINIMUM
THICKNESS 1 mm (1/32 in)
m WARNING
Avoid getting oil or grease on brake pads.
Contaminated brake pads can affect stopping
capacities.
2
V01K0FA
4
31
DISC MINIMUM
THICKNESS 4.7 mm (0.18 in)
DISC RUN OUT (MAX.) 0.25 mm (0.01 in)
1
V01H0BA
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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
09-02-7
Using a suitable puller, pull out wheel hub with
disc.
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 re-
moval.
Installation
Install brake disc on wheel hub and tighten in a
criss-cross sequence.
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).
BRAKE PEDAL
Removal
Remove RH side panel with foot peg.
Refer to section 10-02 BODY for removal proce-
dure.
Unhook the return spring no. 21.
Unhook the brake cable no. 17, interlock cable and
push rod from brake pedal.
1. Brake light switch
2. Interlock cable
3. Master cylinder
4. Return spring
5. Brake cable
6. Brake pedal
Remove cotter pin and washer then remove pedal
no. 20 from pivot.
Installation and Adjustment
Place a shim between brake pedal lever and
switch nut. The tightness of the shim must be 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.
12
V01K0AA
V01K0BA
3
2
4
1
4
V01K0IA
32 561
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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
09-02-8
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. Adjusting nut
2. Brake cable
It may be necessary to hold the rod with locking
pliers to prevent it from turning.
Release cable housing from frame bracket.
Brake Handle
Unscrew the bolt retaining the parking lever lock
from brake lever no. 18 and remove the lever.
Release the tension on brake lever. Rotate cable
end bushing so that cable aligns with the brake
lever recess, then lift cable end.
Inspection
Inspect cable ends for wear or deterioration. Re-
place if necessary.
Installation and Adjustment
Installation is the reverse of the removal proce-
dure.
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 ad-
justment 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. Adjustment nut
2. Stopper
3. Max. 1 mm (1/32 in) gap
INTERLOCK CABLE
Removal
NOTE: Before removing interlock cable from vehi-
cle, note cable routing for reinstallation.
Remove the fuel tank. Refer to FUEL CIRCUIT 04-
02.
1
V01K0YA 2
1
V01K0MA
2
2
V01K0ZA
13
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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
09-02-9
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.
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. Re-
place if necessary.
Installation and Adjustment
Installation is the reverse of the removal proce-
dure.
NOTE: Under shifter lever, torque interlock cable
lightly.
Adjust cable so that the pin end from interlock ca-
ble is flush with the shifter lever plate. Use the
interlock cable adjustment.
1. Interlock pin end
2. Sifter lever plate
Torque nut and jam nut.
BRAKE HOSES AND BRAKE
TUBES
Removal
Front Flexible Brake Hoses
Remove front luggage rack and front fender as-
sembly.
Remove fuel tank cover.
Refer to BODY 10-02 for complete procedure.
Unscrew the brake tube no. 6 from the hose fit-
ting no. 7.
V01K10A
1
3
2
V01E04A 1 2
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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
09-02-10
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 de-
tach hoses from the frame or upper swing arm.
Remove bolt no. 12 from caliper or master cylin-
der and discard sealing washers no. 11.
RIGHT HAND SIDE
1. Flexible hose
2. Tube clip
LEFT HAND SIDE
1. Flexible hose
2. Tube clip
Rear Flexible Brake Hose
Remove bolt no. 12 retaining flexible hose no. 23
on top of rear master cylinder no. 19.
1. Disconnect brake hose
3
V01K0NA
1
2
V01K0RA
12
1
V01K0SA 2
1
V01K0JA
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Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
09-02-11
Remove bolt no. 12 and washers no 11 retaining
hose to rear caliper.
1. Rear brake caliper
2. Flexible brake hose
Detach hose no. 23 from swing arm and remove
from vehicle.
Brake Tubes
Disconnect the brake tubes no. 6 and no. 8 from
fitting on flexible hoses no. 9.
Remove tube clip no. 10 retaining left flexible
hose to frame.
1. Vertical tube
2. Horizontal tube
3. Left flexible hose
4. Right flexible hose
5. Unscrew tube fitting
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. Al-
ways use new washers on both sides of the fit-
ting.
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 re-
taining the brake hose to the frame.
Tighten the brake tube fitting, paying attention not
to twist tubes.
BRAKE SYSTEM BLEEDING
If the brake hoses have been disconnected at the
master cylinder, or if air has entered the system
due to low fluid level, it will be necessary to bleed
complete system.
If a brake hose has been disconnected only at one
wheel, only that caliper must be bled.
Remove cover and fill reservoir with DOT 4 brake
fluid.
Check the fluid level often during the bleeding op-
eration. 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.
1
2
V01K0WA
1
V01K0TA
3
52
4
http://ReadManuals.com
Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
09-02-12
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 cal-
iper.
NOTE: Front and rear brakes must be bled sepa-
rately as they are separate systems.
Refill the master cylinder to proper level at the end
of the operation.
REAR BRAKE MASTER CYLINDER
FRONT BRAKE MASTER CYLINDER
1. Indicator level
Install cover on master cylinder.
Check for leaks and make sure the brakes operate
normally before driving.
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.
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.
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.
MAX
MIN
V01K0UA
V01K12B
1
1
V01K0XA
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10-01-1
Section 10 BODY/FRAME
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
BODY...................................................................................................................................... 10-02-1
BODY PARTS ..................................................................................................................... 10-02-1
SEAT................................................................................................................................... 10-02-3
SEAT/ENGINE COVER....................................................................................................... 10-02-4
STORAGE/STEERING/SHIFTER GUIDE COVER .............................................................. 10-02-5
FRONT SKID PLATE/BUMPER/LUGGAGE RACK ............................................................ 10-02-5
FRONT FENDER/MUDGUARD/FACIA .............................................................................. 10-02-6
INNER FENDER.................................................................................................................. 10-02-8
FUEL TANK COVER/SIDE PANEL ..................................................................................... 10-02-8
REAR LUGGAGE RACK..................................................................................................... 10-02-9
REAR FENDER/REAR FENDER COVER ............................................................................ 10-02-10
REAR MUDGUARD/FACIA................................................................................................ 10-02-11
SKID PLATE ....................................................................................................................... 10-02-12
ARM PROTECTOR ............................................................................................................. 10-02-12
LATCH LEVER/LATCH BASE/SPRING .............................................................................. 10-02-12
SEAT ADJUSTMENT ........................................................................................................ 10-02-13
SEAT COVER REPLACEMENT .......................................................................................... 10-02-13
STORAGE COVER LATCH................................................................................................. 10-02-13
SEAT CLEANING ............................................................................................................... 10-02-14
DECALS REPLACEMENT .................................................................................................. 10-02-14
HITCH/TRAILER BALL ....................................................................................................... 10-02-14
PLASTIC MAINTENANCE ................................................................................................. 10-02-15
MAINTENANCE ................................................................................................................. 10-02-15
PLASTIC REPAIR................................................................................................................ 10-02-16
REPAIR................................................................................................................................ 10-02-16
FRAME ................................................................................................................................... 10-03-1
1, FOOTREST ..................................................................................................................... 10-03-2
2, REMOVABLE BRACE..................................................................................................... 10-03-2
3, REAR EXTENSION FRAME........................................................................................... 10-03-2
4, WINCH PLATE ............................................................................................................... 10-03-3
5, FRAME ........................................................................................................................... 10-03-3
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Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-1
BODY
BODY PARTS
V01L2FS
13
19 44
45
17
46
49
48
18
47
41
14
10
35
34
50
52
51
20
39
12
33
28
6
36
28
38
11
9
5
37
16
4
26
15 Nm
(133 lbfin)
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-2
V01L2GS
15
42
43
32
8
7
31
30
29
3
27
27
15 Nm
(133 lbfin)
15 Nm
(133 lbfin)
24 Nm
(17 lbfft)
24 Nm
(17 lbfft)
15 Nm
(133 lbfin)
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-3
SEAT
V01L2HS
58
1
21
54
53
23
22
55
56
57
24
2
25
24 Nm
(17 lbfft)
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-4
SEAT/ENGINE COVER
Removal
1, Seat
Pull latch upward while gently lifting rear of seat.
Continue lifting movement until you can release
the front retaining devices, then, completely re-
move seat.
2, Engine Cover
Remove seat and screws no. 24.
On the inside, remove bolts no. 25.
Installation
Installation is the reverse order of removal.
V01L0AA
V01L0GA
V01L1QA
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-5
STORAGE/STEERING/SHIFTER
GUIDE COVER
Removal
3, Storage Cover
Unlatch cover, lift then remove cover.
4, Steering Cover
Remove screws under handle bar.
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.
Inspection
Check latches no. 27 from storage cover for
cracks or other damages. Change if necessary.
Installation
Installation is the reverse order of removal.
FRONT SKID PLATE/BUMPER/
LUGGAGE RACK
Removal
6, Front Skid Plate
Remove bolts no. 28.
7, Front Bumper
Remove front skid plate.
Remove bolts no. 29 and no. 30.
V01L0WA
V01L0XA
V01L0YA
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-6
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.
Cut locking tie holding the cable of the sealed
beam.
NOTE: Install a new locking tie at the time of lug-
gage rack installation.
Pull upside.
Installation
Installation is in the reverse order of removal.
FRONT FENDER/MUDGUARD/
FACIA
Removal
9, Front Fender
Remove front luggage rack and shifter guide cov-
er.
Remove screws no. 33 and no. 34 on each side.
Remove fuel cap.
V01L0ZA
V01L12A
V01L13A
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-7
10, Front Mudguard
Remove screws no. 34 and no. 35.
Remove screw no. 36 near the front facia.
11, Front Facia
Remove sealed beams.
Remove the screws no. 37 under facia.
Remove the screws no. 38 on the top of facia.
Remove bolts no. 28, no. 29 and no. 30.
Pull front bumper forward.
Installation
Installation is the reverse order of removal.
V01L1PA
V01L15A
V01L16A
V01L0YB
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-8
INNER FENDER
Removal
12, Inner Fender
Remove front wheel.
Remove screws no. 39, two on bottom side and
one behind shock.
Installation
Install in first, the upper screw; secondly, the low-
er front screw and then the lower rear screw.
NOTE: Install all screws before torque.
FUEL TANK COVER/SIDE PANEL
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.
Remove screw on the LH side and separate from
dart on the RH side.
1. Screw
2. Dart
V01L17A
V01L1AA
V01L2KA
1 2
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-9
Remove latches no. 40. Three by side.
14, Side Panel
Remove seat.
Remove footpeg.
Remove plastic pin and screws retaining the side
panel with front and rear fender.
On front and rear mudguards, remove the three
first screws no. 35 and screws no. 34 retaining
side panel with mudguards.
Installation
Installation is the reverse order of removal.
REAR LUGGAGE RACK
Removal
15, Rear Luggage Rack
Remove bolts no. 42 under rear facia.
V01L14A
V01L1CA
V01L1DA
V01L1EA
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-10
Under rear fender, remove bolts no. 43. One on
each side.
Pivot the bottom of rear luggage rack toward in-
side of ATV.
Pull the rear luggage rack toward back.
Step : Pivot botton of rear rack toward inside
Step : Pull rear rack toward back
Installation
Installation is the reverse order of removal.
NOTE: Install all bolts before torque.
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.
Remove plastic pin of rear fender.
Remove screws no. 33 and no. 34.
Disconnect brake light.
V01L1FA
1
V01L1GA
2
1
2
V01L1HA
V01L1IA
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-11
Rear Fender Cover
Remove rear luggage rack.
Remove screws no. 44 under rear facia.
Lift the rearward of the rear fender and remove
the ten latches no. 46.
Installation
Installation is the reverse order of removal.
REAR MUDGUARD/FACIA
Removal
18, Rear Mudguard
Remove screws no. 47 retaining mudguard and
rear fender.
Remove screws retaining mudguard and side pan-
el.
Remove screw no. 48 near rear facia.
19, Rear Facia
Remove rear luggage rack.
Unfasten screws no. 44 and no. 49.
V01L1HB
V01L1LA
V01L1IB
V01L1MA
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-12
Installation
Installation is the reverse order of removal. How-
ever, pay attention to the following details.
For the rear facia installation, install the flat wash-
ers between rear fender and rear facia with a nee-
dle nose pliers.
SKID PLATE
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
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.
ARM PROTECTOR
Removal
Remove the bolts.
Instalation
Installation is the reverse order of removal.
LATCH LEVER/LATCH BASE/
SPRING
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.
23, Spring
Remove latch base.
Separate spring from latch base and latch lever.
V01L1OA
V01L1NA
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-13
SEAT ADJUSTMENT
For latch stud no. 56 adjustment, unscrew the
latch stud nut no. 57 and screw or unscrew the
latch stud to the best height. See the following
illustration.
1. Lock pin
2. Adjustment nut (apply Loctite 271)
A. 38 ± 1 mm (1-1/2 ± 3/64 in)
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 Ar-
row tacker no. ETN-50 or with a manual tacker
such as Arrow tacker no. T-50.
NOTE: For an easier installation, it’s highly recom-
mended to use an electric tacker.
Ensure that the seat rest firmly against a hard sur-
face such as a piece of wood. This is done to get
the staples completely pushed in place.
TYPICAL
1. Piece of wood
2. ETN-50 (electric) or T-50 (manual)
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.
1
V01L1SA
A
2
F01L3YA 2
1
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-14
SEAT CLEANING
It is recommended to clean the seat with a solu-
tion of warm soapy water, using a soft clean
cloth.
CAUTION: Avoid use of harsh detergents such
as strong soaps, degreasing solvents, abrasive
cleaners, paint thinners, etc. 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 sec-
onds 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 ACRYL-
ICLEAN 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 de-
cal on plastic parts.
Remove back protective film from decal and care-
fully 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.
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Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-15
PLASTIC MAINTENANCE
MAINTENANCE
Clean the vehicle thoroughly, removing all dirt and
grease accumulation.
To clean use a soft clean cloth and either soapy
water or isopropyl alcohol.
To remove grease, oil or glue use isopropyl alco-
hol.
CAUTION: Do not apply isopropyl alcohol or ac-
etone directly on decals.
CAUTION: The following products must not be
used to clean or wax any of the plastic compo-
nents 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
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Section 10 BODY/FRAME
Subsection 02 (BODY)
10-02-16
PLASTIC REPAIR
REPAIR
The very first step before repairing plastic materials is to find out exactly which type of material is involved.
Refer to following chart.
CAUTION: Consult the plastic maintenance chart carefully, some maintenance products are not com-
patible with certain plastics.
PART
IRREPARABLE
HIGH MOLECULAR
WEIGHT
POLYETHYLENE
HIGH DENSITY
POLYETHYLENE
LOW DENSITY
POLYETHYLENE
Fuel tank cover
Front and rear facia
Front and rear fender
Rear fender cover
Side panel
Steering cover
Storage cover
Front and rear mudguard
Inner fender
Front skid plate
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Section 10 BODY/FRAME
Subsection 03 (FRAME)
10-03-1
FRAME
V01L2IS
12
13
4
13
3
11
11
10
5
9
1
7
2
6
8
1
10
48 Nm
(35 lbfft)
24 Nm
(17 lbfft) 24 Nm
(17 lbfft)
24 Nm
(17 lbfft)
24 Nm
(17 lbfft)
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 03 (FRAME)
10-03-2
1, FOOTREST
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.
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.
Installation
For the installation, reverse the removal procedure.
3, REAR EXTENSION FRAME
Removal
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. Radiator with ventilator
2. Muffler
3. Voltage regulator
4. Ignition coil retaining bolt
1
V01L20A
V01L23A
3
2
1
4
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 03 (FRAME)
10-03-3
Remove M10 x 55 mounting flanged bolts no. 10
and the flanged nuts no. 11.
1. Remove the M10 x 55 mounting flanged bolts
Inspection
Check for crack, bent tube or other damage. Re-
pair 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.
1. Remove M8 x 20 flanged bolts
Inspection
Check for crack or other damage. Change if neces-
sary.
Installation
Installation is the reverse of removal procedure.
5, FRAME
Cleaning
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)
V01L2JA
1
V01L0YC
1
http://ReadManuals.com
Section 10 BODY/FRAME
Subsection 03 (FRAME)
10-03-4
CAUTION: Before performing electrical weld-
ing anywhere on the vehicle, unplug the multi-
ple connector at the MPEM. Also unplug the
negative cable and the voltage regulator. This
will protect the MPEM and battery against
damage caused by flowing current when weld-
ing.
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 alu-
minum foil to prevent damage.
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Section 11 TECHNICAL DATA
Subsection 01 (SI METRIC INFORMATION GUIDE)
11-01-1
TECHNICAL DATA
SI* METRIC INFORMATION GUIDE
* 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.
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
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Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)
11-02-1
ENGINE AND VEHICLE
VEHICLE MODEL 7400/7401 7413/7414 7415/7416/7417/7418
ENGINE
Engine type BOMBARDIER-ROTAX 511, longitudinal mount, liquid cooled
Starting system Electric and manual
Number of cylinder(s) 1
Number of valves 2 valves with hydraulic lifters (no adjustment)
Decompressor type Automatic
Bore Standard mm (in) 89 (3.5)
Stroke mm (in) 80 (3.15)
Displacement 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 Cleanable synthetic panelette
Exhaust system Type Nelson, stainless steel
Spark arrester USDA approved
ELECTRICAL
Magneto/generator 400 W @ 6000 RPM
Ignition system type I.D.I. (Inductive Discharge Ignition)
Spark plug Make and type NGK BR8EA
Gap mm (in) 0.65 (.026)
Trigger coil Ω190 – 300
Battery charging coil Ω0.4 ± 01
Ignition coil Primary Ω0.4 to 0.9 @ 20°C (68°F)
Secondary kΩNot measurable
Engine RPM limiter 7500
Battery
Type Electrolyte battery type
Voltage 12 volts
Nominal rating 19 A•h (21 optional)
Power starter output 0.6 KW
Fuses
Ignition 15 A
Accessories 15 A
Solenoids 15 A
Fan 15 A
MPEM 20 A
Charging system 30 A
CARBURETION
Carburetor Type Mikuni constant depressurant type with manual choke and ECS
(Enricher Coating System)
Model BST34-232
Fuel pump Type Mikuni
Model External (vacuum-operated)
Idle engine speed RPM 1050 ± 50 1100 ± 100 1100 ± 100
Needle jet 0-7M (850)
Jet needle 5GBF61-2
Clip position number Middle
Choke plunger position Opening
Halfway
± 0.5 mm 2.5 2.5 Variable choke
± .039 in 0.098 0.098
Adjustment
Throttle cable 0.5 mm (0.02 in)
Preliminary pilot screw turn 2.25 turn (see section 04-03 for setting procedure)
Float level ± 0.5 mm 10.6
± 0.020 in 0.417
Fuel Type Regular unleaded gasoline
Octane no. 87 (Ron + Mon)/2
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Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)
11-02-2
VEHICLE MODEL 7400/7401 7413/7414 7415/7416/7417/7418
COOLING
Fan Thermostatic
Fan thermostat Opening temperature 96°C (205°F)
Closing temperature 102°C (221°F)
Engine thermostat Opening temperature 85°C (185°F)
Closing temperature 75°C (167°F)
Radiator cap opening pressure 90 kPa (13 PSI)
DRIVE TRAIN
Transmission
Type Dual range (HI-LO) with park, neutral and reverse
Speeds 5
Model Electronically controlled hydraulic shift
Normal oil operating pressure of engine 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 1300 1600 1600
Front differential Shaft driven/single Auto-Lock differential (pump driven)
Front differential ratio 3.6:1
Rear axle Shaft driven/solid axle
Rear axle ratio 3.6:1
STEERING/
CONTROL
Turning radius 3.3 m (11 ft)
Total toe (vehicle on ground) ± 0.3° 0°
Camber angle 0°
Tie-rod maximum length unengaged ± 5 mm 20
± 0.197 in 0.787
SUSPENSION
FRONT
Suspension type Independent suspension — double A-arm
Suspension travel 178 mm (7 in)
Shock absorber Qty 2
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 191 mm (8 in)
Shock absorber Qty 2
Type Oil
Spring free length 355 mm (14 in)
Spring color code Blue/Black/Black
Rear preload adjustment N.A.
BRAKES
Front brake Qty 2
Type Brembo hydraulic
Rear brake Qty 1
Type Brembo hydraulic
Parking brake 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)
Caliper Fixed
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Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)
11-02-3
VEHICLE MODEL 7400/7401 7413/7414 7415/7416/7417/7418
TIRES AND WHEELS
TIRE
Pressure
Front Recommended 48 kPa (7 PSi)
Minimum 45 kPa (6.5 PSi)
Rear Recommended 38 kPa (5.5 PSi)
Minimum 34.5 kPa (5 PSi)
Minimum tire thread depth 4 mm (0.16 in)
Size 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)
WHEELS
Size Front 305 x 165 mm (12 x 6.5 in)
Rear 305 x 203 mm (12 x 8 in)
DIMENSION
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)
CAPACITIES
LIQUID
Fuel tank 20 L (5.7 U.S. gal)
Fuel tank reserve 6 L (1.6 U.S. gal)
Engine/transmission oil Capacity 3 L (0.8 U.S. gal)
Recommended SAE 10W40, a 4 stroke mineral based oil SH or SJ
Differential oil Capacity Front 650 mL (22 U.S. oz)
Rear 300 mL (10 U.S. oz)
Recommended Synthetic polyolester oil 75W90 (API GL5)
CV joint grease TEXACO, HTBJ grease (M3014), ONLY
Propeller shaft grease SHELL, Alvania EP-2, ONLY
Hydraulics brakes Capacity 250 mL (8.5 U.S. oz)
Recommended Brake fluid DOT 4, ONLY
Cooling system 2.5 L (0.7 U.S. gal)
Ethylene-glycol concentration 60%
BODY AND FRAME
Weight distribution Front/rear 49/51
Front storage tray 10 kg (22 lb)
Rack 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)
Tongue (included with rear rack weight) 14 kg (30 lb)
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Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)
11-02-4
VEHICLE MODEL 7400/7401 7413/7414 7415/7416 7417/7418
MATERIAL
Frame Material Steel
Color Black
Front/rear rack Material Steel
Color Red Black
Front bumper Material Steel
Color Silver
Front/rear fender Material High density polyethylene
Color Red Green
Fuel tank cover Material High density polyethylene
Color Black
Steering cover Material High density polyethylene
Color Black
Storage compartment cover Material High density polyethylene
Color Black
Front/rear facia Material High density polyethylene
Color Black
Side panel Material High density polyethylene
Color Black
Mudguard Material Low density polyethylene
Color Black
Seat cover Material Thermoformed vinyl
Color Black
TORQUE
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)
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 140 N•m (103 lbf•ft) (MINIMUM)
Front differential Front 48 N•m (35 lbf•ft)
Rear 48 N•m (35 lbf•ft)
Rear differential socket screws 48 N•m (35 lbf•ft)
Propeller shaft screw Engine side 32 N•m (24 lbf•ft)
Differential side 42 N•m (31 lbf•ft)
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Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)
11-02-5
VEHICLE MODEL 7400/7401 7413/7414 7415/7416 7417/7418
TORQUE
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)
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 24 N•m (17 lbf•ft)
Front rack Front 24 N•m (17 lbf•ft)
Rear 15 N•m (133 lbf•in)
Rear rack 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)
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Section 12 WIRING DIAGRAM
Subsection 01 (WIRING DIAGRAM)
12-01-1
WIRING DIAGRAM
WIRING CONNECTORS CODING
1. Wire colors
2. Connector housing area
3. Housing number per area
4. 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.
THE SHADED PART INDICATES THE WIRE COLOR
Example: YL/BK is a YELLOW wire with a BLACK
stripe.
CONNECTOR HOUSING AREA
THE SHADED PART INDICATES THE CONNECTOR HOUSING
AREA
m WARNING
Ensure all terminals are properly crimped on
the wires and all connector housings are
properly fastened.
COLOR CODE
BK — BLACK
BL — BLUE
BR — BROWN
GN — GREEN
GY — GREY
OR — ORANGE
PK — PINK
RD — RED
TA — TAN
VI — VIOLET
WH — WHITE
YL — YELLOW
A00I04A
XX/XX
1-02D
1
2 3 4
A00I04B
1-02D
XX/XX
XX/XX AREA LOCATION
1 Front of engine compartment
2 RH side of engine compartment
3 LH side of engine compartment
4 Behind fuel tank
5 Under steering cover
6 Front of vehicle
7 Rear of vehicle
8 Near radiator hoses
XX/XX
A00I04C
1 -02D1
1
1
V01L25B
5
6 7
2
3
8
4
Section 12 WIRING DIAGRAM
Subsection 01 (WIRING DIAGRAM)
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Section 12 WIRING DIAGRAM
Subsection 01 (WIRING DIAGRAM)
12-01-2
CONNECTOR LOCATION IN
HOUSING
This is the wire position in the connector. The number
or letter given refers to the physical identification
stamped on the connector.
THE SHADED PART INDICATES THE CONNECTOR LOCATION IN
HOUSING
TYPICAL
See connector housing illustration to OVERVIEW 05-
02.
XX/XX
A00I04D
D
D
1-02
A00E4WB
B
A
B
A
B
A
CC
B
A
B
C
D
B
CA
A
B
C
B
C
D
A
A
Repa r or
change connector
or w r ng
Recheck e ectr c
sh ft system
Is the prob em
pers st ng ?
Change MPEM
Check
upsh ft/downsh ft
sw tch
V01A15S
Problem with the shifting system
(Electric Components)
Is emergency sh fter shaft mov ng wh e
press ng upsh ft/downsh ft button ?
Check fuse(s)
Is fuse burned ?
Start the d agnost c/
ca brat on mode
(see task 1 to 5 be ow)
Change fuse
REFER TO
Prob em w th the
sh ft ng system
(Hydraulic/Mechanical
Components)
YES
NO
YES
YES
Task 1:
Ind cator ghts test
Task 2:
C utch modu ator
ca brat on
Task 3:
Sensors and
so eno ds test
Task 4 and 5:
GBPS (Gear Box
Pos t on Sensor) and
STPS (Sub Transm ss on
Pos t on Sensor)
ca brat on
Are ghts good ?
Is adjustment
performed g ve
sat sfactory resu ts ?
Abnorma t (s)
detected ?
Change nd cator
ght(s)
Try another
sett ng
Change
component(s) NO
If a pos t ons
are bad
The e ectr c
sh ft system s
now good
NO
Check va ve/
so eno d w th
test ng too
Check AMP
connectors and
w r ng
Change va ves/
so eno ds
Change sw tch
Are va ves/
so eno ds good ?
Is sw tch good ?
Are connectors
and w r ng good ?
Ca brate GBPS
and STPS
Refer to
VALVES/SOLENOIDS
TESTS sect on
Refer to
DIAGNOSTIC/
CALIBRATION MODE
sect on
Recheck e ectr c
sh ft system
Is the prob em
pers st ng ?
NO
YES YES NO
NO NO YES
YES
YES
NO
YES
YES
NO
YES
YES
NO
YES
YES
Recheck e ectr c
sh ft system
Is the prob em
pers st ng ?
Recheck e ectr c
sh ft system
Is the prob em
pers st ng ?
Recheck e ectr c
sh ft system
Is the prob em
pers st ng ?
Recheck e ectr c
sh ft system
Is the prob em
pers st ng ?
ANNEX 1
ANNEX 2
V01A14S
NO
Problem with the shifting system
(Hydraulic/Mechanical Components)
Is emergency shifter shaft moving when
pressing upshift/dowshift button ?
Check the engine/transmision oil level.
Is engine oil
level good ?
The engine/transmission oil
and filter oil replacement
may be a solution. Change if
necessary. Refer to the
MAINTENANCE CHART.
Check the
engine/transmission
oil pressure.
Is engine/transmission
oil pressure good ?
Check for engine leakage.
Leakage ?
Refill engine
with oil.
REFER TO:
Problem with the
shifting system
(Electric Components)
Call
SERVICE
REPRESENTATIVE.
The problem
is resolved !
Recheck electric
shift system. Is the
problem persisting ?
NO
YES
NO
YES
YES NO
NO
YES
YES

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