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BOMBARDIER DS 650, Shop Manual

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BOMBARDIER DS 650 Shop Manual Download Page 141

Section 05

ELECTRICAL

Subsection 01

(TABLE OF CONTENTS)

VMR2004_033_05_01ATOC.FM

05-01-1

TABLE OF CONTENTS

0

OVERVIEW.............................................................................................................................

05-02-1

GENERAL OPERATION INFORMATION ...........................................................................

05-02-1

CHARGING SYSTEM.........................................................................................................

05-02-1

STARTING SYSTEM ..........................................................................................................

05-02-1

IGNITION SYSTEM............................................................................................................

05-02-2

ACCESSORIES ...................................................................................................................

05-02-2

GENERAL TESTING/ TROUBLESHOOTING INFORMATION .........................................

05-02-2

FUSES LOCATION.............................................................................................................

05-02-3

SERVICING PACKARD CONNECTORS ............................................................................

05-02-3

SERVICING DEUTSCH CONNECTORS ............................................................................

05-02-3

IDENTIFICATION OF MAJOR CONNECTOR PINS ..........................................................

05-02-5

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

05-04-1

CLEANING .........................................................................................................................

05-04-1

INSPECTION ......................................................................................................................

05-04-2

BATTERY STORAGE..........................................................................................................

05-04-2

ACTIVATION OF A NEW BATTERY...................................................................................

05-04-2

INSTALLATION ..................................................................................................................

05-04-2

STARTING SYSTEM TROUBLESHOOTING.....................................................................

05-04-3

STARTING SYSTEM TESTS .............................................................................................

05-04-4

GENERAL ...........................................................................................................................

05-04-4

ELECTRIC STARTER ..........................................................................................................

05-04-5

REMOVAL ..........................................................................................................................

05-04-5

INSTALLATION..................................................................................................................

05-04-5

CABLE TERMINAL INSTALLATION ....................................................................................

05-04-5

Summary of Contents for DS 650

Page 1: ......

Page 2: ...Shop Manual 2004 DS 650TM DS 650TM BAJA DS 650TM BAJA X ...

Page 3: ...nc Bombardier Inc 2003 Technical Publications Bombardier Inc Valcourt Québec Canada Printed in Canada Registered trademarks of Bombardier Inc and its subsidiaries This document contains the trademarks of the following companies Kimtowels is a trademark of Kimberly Clark Loctite is a trademark of Loctite Corporation Molykote is a trademark of Dow Corning Corporation Snap on is a trademark of Snap o...

Page 4: ...tem 03 07 1 08 Cylinder and head 03 08 1 09 Crankshaft balancer shaft 03 09 1 10 Clutch 03 10 1 11 Transmission 03 11 1 04 FUEL SYSTEM 01 Table of contents 04 01 1 02 Fuel circuit 04 02 1 03 Carburetor and air intake silencer 04 03 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 Accessories 05 06 1...

Page 5: ...E 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 DIAGRAMS 01 Wiring diagrams 12 01 1 SECTION SUBSECTION PAGE TABLE OF CONTENTS ...

Page 6: ...ombardier parts is most strongly recommended when considering replacement of any com ponent Dealer and or distributor assistance should be sought in case of doubt The engines and the corresponding components identified in this document should not be utilized on product s other than those mentioned in this document This manual emphasizes particular information denoted by the wording and symbols CAU...

Page 7: ...ardier made 2004 ATVs 2004 Models TYPICAL 1 Model number VEHICLE AND ENGINE SERIAL NUMBER LOCATION TYPICAL 1 Vehicle 2 Engine DS 650TM 7717 DS 650TM Baja 7718 DS 650TM Baja X 7995 DS 650TM Intl 7719 DS 650TM Baja Intl 7720 DS 650TM Baja X Intl 7997 1 V02A0PA 1 2 V02A0QA INTRODUCTION ...

Page 8: ...r cm square centimeter cm 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 in square inch in cubic inch k kilo thousand kg kilogram km h kilometer per hour kPa kilo pascal L liter lb pound lbf pound force LH left hand m meter MAG magneto Max maximum Min minimum ...

Page 9: ...ase nut must be torqued to 10 N m or 89 lbf in 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 V02A0TS Illustration number for publishing process Subsection title indicates beginning of the subsection Drop represents a liquid product to be applied to a surface P...

Page 10: ...h connector Removal Remove the upper support bracket no 10 com pletely Install engine lifting tool P N 529 035 610 then install a hoist Remove upper engine support bolt no 11 lower bolts no 12 retaining the engine support no 13 on either side then remove supports front lower mounting bolt no 14 rear lower mounting bolt no 15 rear upper mounting bolt no 16 Remove engine from vehicle Installation Fo...

Page 11: ...ric and must not be replaced by customary fasteners or vice versa Mismatched or incorrect fasteners could cause damage to the vehicle or possible personal 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 concerning the proce dure A number of procedures throughout the boo...

Page 12: ...s bolt and nut and allow to dry for 30 seconds 3 Choose proper strength Loctite threadlocker 4 Apply several drops along the threaded hole and at the bottom of the hole 5 Apply several drops on bolt threads 6 Tighten as required Stud in Blind Holes 1 On threads 2 On threads and in the hole 3 Onto nut threads 1 Clean threads stud and hole with solvent 2 Apply Loctite Primer N P N 293 800 041 on thr...

Page 13: ...similar product 4 No curing period is required Mounting in Tandem 1 Apply retaining compound on internal element bore 2 Continue to assemble as shown above Case In Components Metallic Gaskets 1 Proper strength Loctite 1 Clean inner housing diameter and outer gasket diameter 2 Spray housing and gasket with Loctite Primer N P N 293 800 041 3 Apply a strip of proper strength Loctite on lead ing edge ...

Page 14: ...s ex locking tab elastic stop nut self locking fasteners etc must be installed or replaced with new ones where specified If the efficiency of a locking device is impaired it must be renewed TIGHTENING TORQUE STRENGTH GRADE GRADE 5 8 GRADE 8 8 GRADE 10 9 GRADE 12 9 DIMENSION M4 1 5 to 2 N m 13 to 18 lbf in 2 5 to 3 N m 22 to 27 lbf in 3 5 to 4 N m 31 to 35 lbf in 4 to 5 N m 35 to 44 lbf in M5 3 to ...

Page 15: ...______________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address _________________________________...

Page 16: ...tions After Sales Service 565 de la Montagne Street Valcourt Québec Canada J0E 2L0 Technical Publications After Sales Service 565 de la Montagne Street Valcourt Québec Canada J0E 2L0 Technical Publications After Sales Service 565 de la Montagne Street Valcourt Québec Canada J0E 2L0 ...

Page 17: ...Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 TABLE OF CONTENTS VMR2004_033_01_01ATOC FM 01 01 1 TABLE OF CONTENTS 0 SERVICE TOOLS 01 02 1 SERVICE PRODUCTS 01 03 1 ...

Page 18: ...CE TOOLS VMR2004_002_01_02A FM 01 02 1 SERVICE TOOLS 0 This is a list of tools to properly service ATV vehicles If you need to replace or add to your tool inventory these items can be ordered through the regular parts channel Following mention points out new tool NEW ...

Page 19: ...076 Large Hose Pincher 529 032 500 Fuel System Pressure Tester 529 033 100 All Models RECOMMENDED Low Speed Screw Adjuster 529 035 732 Float Level Gauge 529 035 520 Carburetor Kit 404 112 000 1 2 3 4 All Models RECOMMENDED Valve Spring Compressor 529 035 724 Insertion Jig Handle 420 877 650 Vacuum Pressure Pump 529 021 800 Leak Down Tester 529 035 661 ...

Page 20: ... 01 02 3 All Models RECOMMENDED Multimeter 529 035 868 Oil Pressure Adapter 529 035 652 Oil Pressure Gauge 529 035 709 Connection Tool 529 035 714 All Models RECOMMENDED Terminal Remover Snap On TT660 4 Shock Tool 529 035 636 Handle Grip Insertion Tool 529 035 897 Crimp Plier 529 035 730 NEW NEW ...

Page 21: ...738 DS 650 Baja X Outlander 330 Outlander 400 Quest 500 650 Rally 200 MANDATORY Crankshaft Locking Bolt 529 035 617 DS 650 Baja X Outlander 330 Outlander 400 Quest 500 650 Rally 200 RECOMMENDED Valve Stem Seal Pliers Snap On YA 8230 Valve Spring Compressor Cup 529 035 764 DS 650 Baja X Outlander 330 Outlander 400 Quest 500 650 Traxter MANDATORY Caillau Pliers 295 000 054 CV Boot Clamp Installation...

Page 22: ...ally 200 Traxter RECOMMENDED Shock Spring Disassembly Tool 529 035 504 Outlander 330 Outlander 400 Quest 500 650 Rally 200 RECOMMENDED Needle Bearing Installer main shaft in crankcase 529 035 762 Outlander 330 Outlander 400 Quest 500 650 Traxter MANDATORY 41 mm Socket PROTO 5541 Hub Puller 529 035 612 Outlander 330 Outlander 400 Quest 500 650 Traxter RECOMMENDED Differential Spanner Socket 529 035...

Page 23: ...ander 330 Outlander 400 MANDATORY Engine Installation and Removal Tool 529 035 619 DS 650 Baja X Outlander 330 Quest 500 650 RECOMMENDED Valve Stem Seal Installer 529 035 687 Outlander 330 Outlander 400 Quest 500 650 MANDATORY Bevel Gear Lock Pin Driven Clutch Expander 529 035 747 Drive Clutch Puller 529 035 746 Driven Clutch Holding Tool 529 035 771 Outlander 330 Outlander 400 Quest 500 650 RECOM...

Page 24: ... Seal Installer 529 035 941 Quest 500 650 Rally 200 RECOMMENDED Valve Guide Installer 529 035 853 Blind Hole Bearing Puller Snap On Quest 500 650 Traxter MANDATORY 6 Pin Harness for Magneto 529 035 604 NEW Rally 200 Traxter MANDATORY 46 mm Socket for Crankshaft Driven Pulley 529 035 648 DS 650 Baja X MANDATORY Magneto Cover Removal Tool 529 035 622 UP to 2003 models 64 mm 2 1 2 in Crow foot Rear A...

Page 25: ...tch Shaft Seal Installer 529 035 693 Ball Joint Guide 529 035 705 Ball Joint Drive 529 035 706 UP to 2003 models Swing Arm Key 529 035 696 Rear Hub Seal Installer 529 035 634 DS 650 Baja X RECOMMENDED Front Knuckle Wear Ring Installer 529 035 637 UP to 2003 models Brake Hub Remover 529 035 695 Shock Charging Tool 529 035 570 Gas fill tool kit needle type 503 190 102 Rear Axle Wear Ring Installer 5...

Page 26: ...OT AVAILABLE Youth models MANDATORY Flywheel Puller 4 stroke engines 529 035 792 Valve Gap Adjuster 4 stroke engines 529 035 793 Oil Filter Rotor Puller 4 stroke engines 529 035 795 MANDATORY Magneto Puller 4 stroke engines 529 035 798 Youth models RECOMMENDED Crankshaft Bearing Puller 4 stroke engines 529 035 791 Valve Seat Remover Installer 4 stroke engines 529 035 794 Crankcase Puller 2 stroke ...

Page 27: ...9 035 800 Outlander 330 Outlander 400 MANDATORY Trailing Arm Socket 529 035 925 Engine Lifting Tool 529 035 898 Outlander 330 Outlander 400 RECOMMENDED Camshaft Locking Tool 529 035 926 Valve Guide Remover 529 035 924 Piston Ring Compressor 529 035 919 Piston Circlip Installer 529 035 921 Crankshaft Plain Bearings Remover Installer 529 035 917 Crankshaft Support MAG side 529 035 916 Clutch Holding...

Page 28: ...Trailing Arm Bearing Remover Installer wheel side 529 035 918 Trailing Arm Bearing Remover Installer frame side 529 035 920 Trailing Arm Bearing Removal Support 529 035 922 Outlander 330 Outlander 400 RECOMMENDED Wear Ring Installer front drive shafts 529 035 927 Wear Ring Installer rear drive shafts 529 035 915 Adaptor Kit for Shock Spring Remover P N 529 035 504 529 035 928 Quest 500 650 MANDATO...

Page 29: ...eal Installer water pump shaft oil seal 529 035 757 Piston Circlip Installer 529 035 765 Crankcase Plain Bearing Remover Installer CVT side 529 035 752 Quest 500 650 RECOMMENDED Crankcase Plain Bearing Remover Installer MAG side 529 035 753 Crankcase Support MAG side 529 035 755 Rally 200 MANDATORY Clutch Holding Tool 529 035 862 Clutch Support 529 035 863 51 mm 2 in Open Wrench 529 035 866 51 mm ...

Page 30: ...Seal Installer 529 035 849 Shifter Oil Seal Installer 529 035 851 Valve Guide Remover 529 035 852 Gearbox Oil Seal Installer 529 035 854 Magneto Puller use bolt from magneto puller P N 529 035 748 529 035 883 Rally 200 RECOMMENDED Crankshaft Plain Bearing Remover Installer 529 035 855 Needle Bearing Installer 529 035 858 Piston Circlip Installer 529 035 859 Allen Wrench 529 035 861 Rear Axle Beari...

Page 31: ...10 Jumper for Self Diagnosis 529 035 605 Crankshaft Locking Bolt 529 035 645 Spanner Tool for Clutch Basket 529 035 647 T Harness for Solenoids Dianosis 529 035 653 Traxter RECOMMENDED Crimping Tool for AMP connectors 295 100 164 Lifting Ring 529 035 644 UP to 2000 Front Suspension Spacer Bar 529 035 611 Valve Spring Compressor Cup 529 035 725 ...

Page 32: ...ODUCTS VMR2004_003_01_03A FM 01 03 1 SERVICE PRODUCTS 0 This is a list of products to properly service ATV vehicles If you need to replace or add to your tool inventory these items can be ordered through the regular parts channel Following mention points out new tool NEW ...

Page 33: ...0 Loctite 609 Retaining Compound Loctite RC 10 mL green 413 703 100 Loctite Primer Primer N 128 g 5 oz 293 800 041 Loctite Anti Seize Lubricant 236 mL 293 800 070 All Models Loctite 567 Pipe Sealant 250 mL 293 800 013 Suspension Synthetic Grease 400 g 293 550 033 Synthetic Grease 400 g 293 550 010 Bombardier ATV Tire Sealant 946 mL 715 000 130 Brake Fluid DOT 4 354 mL 293 600 062 ...

Page 34: ...izer 12 x 8 oz 413 408 600 Bombardier Premixed Coolant 50 50 37 C 35 F 16 x 1 L 293 600 038 Bombardier Storage Oil 350 g spray can 12 x 350 g Canada 413 711 600 U S 413 711 900 All Models BOMBARDIER LUBE 12 x 14 oz 293 600 016 Bombardier Pulley Flange Cleaner 320 g 413 711 809 Bombardier Heavy Duty Cleaner 293 110 001 400 g 293 110 002 4 L ...

Page 35: ...r Filter Oil 1 L 293 600 058 Silicone Dielectric Grease 3 oz 293 550 004 DS 650 Baja X Quest 500 650 Traxter Loctite 271 High Strength Threadlocker 10 mL red 293 800 005 Rally 200 Loctite 277 High Strength Retaining Compound 10 mL red 293 800 073 Loctite 518 Paste Gasket Gasket Eliminator 50 mL 293 800 038 Loctite 384 Thermally Conductive Adhesive 300 mL 293 800 099 CAUTION This product must be st...

Page 36: ...2 x 355 mL 413 803 300 DS 650 Baja X Outlander 330 Outlander 400 Rally 200 Traxter Loctite 648 High Temperature and Strength Retaining Compound 5 mL green 413 711 400 DS 650 Baja X Quest 500 650 Rally 200 Traxter Loctite Chisel Gasket Paint Remover 510 g 18 oz 413 708 500 Cable Lubricant 400 g 293 600 041 DS 650 Baja X Outlander 330 Outlander 400 Quest 500 650 Traxter Synthetic Grease 60 g 293 550...

Page 37: ...bsorber oil 293 600 035 Marvin shock absorber oil 503 190 103 Quest 500 650 Traxter Loctite 406 Instant Adhesive must be used with tapered tip 20 g 293 800 095 Smoothflow Tapered Tips 16ga 511 rtt b not sold by Bombardier call EFD Inc 1 800 556 3484 Outlander 330 Outlander 400 Loctite 5900 RTV Silicone Sealant 300 mL 293 800 066 Loctite Maxi Coat Heavy Duty Rustproofing 340 g 293 800 105 ...

Page 38: ...DS 650 Baja X Traxter Loctite 515 Paste Gasket Gasket Eliminator 50 mL 413 702 700 Outlander 330 Outlander 400 Quest 500 650 Traxter Bombardier Differential Oil 946 mL 293 600 043 Rally 200 Traxter Molykote G n Paste 50 g 711 297 433 Outlander 330 Outlander 400 Traxter Molykote PG 54 10 g 420 899 763 DS 650 Baja X Rally 200 Traxter Molykote 111 150 g 413 707 000 Super Lube Grease 293 550 030 111 ...

Page 39: ...CHART 02 02 2 MAINTENANCE LUBRICATION 02 03 1 ADJUST VALVE CLEARANCE 02 03 1 CLUTCH ADJUSTMENT 02 03 1 DRIVE CHAIN 02 03 2 AIR FILTER CLEANING DRAINING 02 03 3 BOLTS FASTENERS AND NUTS 02 03 4 ENGINE OIL AND FILTER 02 03 4 SPARK ARRESTER 02 03 5 TIRES AND WHEELS 02 03 6 ENGINE AREA 02 03 7 STORAGE PRESEASON PREPARATION 02 04 1 STORAGE 02 04 1 FUEL STABILIZER 02 04 1 ENGINE LUBRICATION 02 04 1 RAGS...

Page 40: ... 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 conduct...

Page 41: ... Coolant level EVERY INSPECTION Coolant I I R Cooling System Radiator cap cooling system pressure test I I Radiator condition cleanliness radiator fines I I Clutch and transmission operation I Clutch and or Transmission FUEL SYSTEM Air filter C R Maintenance Lubrication Fuel lines and connections I I Fuel Circuit Fuel tank strainer replacement R Carburetor I I Carburetor and Air Intake Silencer EL...

Page 42: ...aintenance Lubrication Front wheel hub EVERY INSPECTION Wheel nuts and studs I I Wear and condition of tires I I SUSPENSION Swing arm I I Front Suspension and or Rear Suspension Swing arm lubrification EVERY INSPECTION A arm I I L Ball joint boot I I Ball joint I I Shock absorber I BRAKE Brake fluid front rear I I L Hydraulic Brakes Brake system discs hoses etc I Brake pads I Brake line fittings I...

Page 43: ...17 NOTE Check tightness with the allen key To adjust valves remove the camshaft bridges and the camshafts Remove adjusting plates blow clean with com pressed air Installation NOTE Before installation check thickness of ad justing plates with micrometer For installation reverse the removal procedure CLUTCH ADJUSTMENT Loosen cable tension Adjust clutch release mechanism The release lever must locate...

Page 44: ...using 1 Drive chain 2 Adjuster lock 3 Sprocket hub 4 Eccentric axle housing Turn the axle forward to increase or backward to decrease chain slack NOTE Correct chain slack adjustment is 19 to 25 4 mm 3 4 to 1 in at midway between sprockets Tighten the rear axle lock bolts to 23 N m 17 lbf ft Use the following sequence to tighten the rear axle lock bolts correctly Lift rear of vehicle without driver...

Page 45: ...re found squeeze the clamp and remove Pull drain tube out CAUTION Do not start engine when a liquid is found in the drain tube When liquid deposits are found air filter must be inspected dried replaced depending on its condition Remove air filter as explained below Air Filter Removal CAUTION Never remove or modify any compo nent in the air box Always use genuine parts or suitable equivalent when r...

Page 46: ...s at the regular in tervals Check that all bolts and nuts are tightened to the proper torque ENGINE OIL AND FILTER 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 Ensure vehicle is on a level surface Remove dipstick Clean the reservoir drain plug area Drain all oil from oil tank by removing oil tank drain plug Wipe...

Page 47: ...t idle for a few minutes Check if the RED indicator lamp stays ON If so stop engine and bleed system by removing oil fil ter and bleeding screw See procedure below Ensure oil filter area hose and drain plug areas are not leaking Stop engine and check oil level Refill as necessary Dispose oil as per your local environmental regula tions Bleeding Engine Oil Circuit Remove oil filter Unfasten pressur...

Page 48: ...is in place when inserting grill Align grill properly in bottom of muffler shell TIRES AND WHEELS Tire Pressure Check pressure when tires are cold before using the vehicle 1 1 2 V02C06A 1 3 V02C07A 2 WARNING When the tires are replaced never install a bias tire with a radial tire This combined ap plication may create handling and or stability problems Do not mix tires of different size and or desi...

Page 49: ... a different size Besides these tires are directional and their rotation must be kept in a specific direction for proper operation 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 ...

Page 50: ...r Press start button 1 or 2 seconds maxi mum to lubricate cylinder Stop the engine and remove the battery Store it in dry and cool place out of the sun Turn the fuel valve to OFF and drain carburetor Reinstall the spark plugs foam air filter and air box cover RAGS IN AIR INTAKE AND EXHAUST SYSTEM At storage preparation block air intake inlets and exhaust system outlets using clean rags The air int...

Page 51: ...lastic components and vehicle finish COOLANT DENSITY Test the density of the coolant using an antifreeze hydrometer NOTE Followmanufacturer sinstructionsforproper use A 50 50 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 a...

Page 52: ... Removal and Installation Rags Removal intake and exhaust Maintenance Lubrication FUEL SYSTEM Fuel Line and Connectors Condition Fuel Circuit Carburetor Adjustment Carburetor and Air Intake Silencer Throttle and Choke Cable Inspection Adjustment Air Filter Cleaning Replacement Maintenance Lubrication ELECTRICAL Spark Plug Replacement Ignition System Battery Condition Charging and Installation Star...

Page 53: ...3 1 DIAGNOSE 03 03 3 INSTALLATION 03 03 3 REMOVAL AND INSTALLATION 03 04 1 GENERAL 03 04 2 ENGINE REMOVAL 03 04 2 ENGINE INSTALLATION 03 04 4 COUNTERSHAFT SPROCKET 03 04 4 EXHAUST SYSTEM 03 04 5 OIL TANK 03 04 5 COOLING SYSTEM 03 05 1 RADIATOR 03 05 1 WATER PUMP 03 05 2 COOLING SYSTEM LEAK TEST 03 05 3 INSPECTION 03 05 3 DRAINING THE SYSTEM 03 05 3 COOLING SYSTEM REFILLING 03 05 4 PRESSURE CAP 03 ...

Page 54: ...3 07 3 OIL CHANGE AND OIL FILTER REPLACEMENT 03 07 3 OIL TANK STRAINER 03 07 5 ENGINE OIL PRESSURE REGULATOR 03 07 5 RETURN OIL PUMP 03 07 6 PRESSURE OIL PUMP 03 07 7 ENGINE OIL STRAINER 03 07 7 OIL TANK 03 07 8 CYLINDER AND HEAD 03 08 1 CYLINDER AND HEAD 03 08 1 VALVE 03 08 2 GENERAL 03 08 3 CYLINDER HEAD COVER 03 08 3 ADJUST VALVE CLEARANCE 03 08 4 CAMSHAFT 03 08 4 CENTRIFUGAL DECOMPRESSOR 03 08...

Page 55: ...9 7 CRANKSHAFT BUSHING 03 09 7 BALL BEARINGS IN HOUSING 03 09 7 RECENTER CRANKSHAFT 03 09 8 RECENTER BALANCER SHAFT 03 09 8 CLUTCH 03 10 1 GENERAL 03 10 2 CLUTCH ADJUSTMENT 03 10 2 CLUTCH COVER 03 10 2 PRESSURE PLATE 03 10 3 PRESSURE PLATE BEARING 03 10 3 FRICTION DRIVE PLATE STEEL DRIVEN PLATE AND CLUTCH BASKET 03 10 4 CLUTCH RELEASE SHAFT 03 10 6 TRANSMISSION 03 11 1 SHIFTING MECHANISM 03 11 2 T...

Page 56: ... defective does not open when engine gets hot Replace thermostat 4 Check weep hole water pump housing area if coolant leaks a Coolant leaking from weep hole means a damaged water pump rotary seal Replace rotary seal refer to COOLING SYSTEM and MAGNETO COVER 5 Check coolant bleeding screw on water pump housing a Screw looses and or gasket ring is missing Retighten screw and or place gasket ring 6 C...

Page 57: ...ure a Ignition coils damaged Replace ignition coils b Connector is corroded or ignition coils shows electrical failure Clean ignition coils area and replace ignition coils c Wire harness is brittle or hard no connection Replace 3 Check wire harness for cracks or other damages a Harness shows electrical failure and or other damages Replace wire harness 4 Check magneto for damage and or electrical f...

Page 58: ...aking due to damage Rebuild engine with new crankcase and gasket parts Use Bombardier recommended oil refer to TECHNICAL DATA b Crankcase is leaking due to loose screws Retighten screws with recommended torque c Sealing rings O rings and or gaskets are brittle and or hard or damaged Replace damaged parts 2 Check oil drain plug on engine bottom a Plug is loosed and or gasket ring is missing Retight...

Page 59: ...nation Replace oil and oil filter if necessary refer to MAINTENANCE or LUBRICATION 9 Check oil pump operation a Oil pump rotor is out of wear limit Replace oil pump shaft refer to LUBRICATION b Oil pump seized due to oil leakage and or air inclusion Replace oil pump refer to LUBRICATION c Gears driving oil pump are broken or otherwise damaged Replace gears d Incorrect oil being used Use Bombardier...

Page 60: ...ssible damages inside the engine a Oil contamination due to metal or plastic particles Replace possibly damaged parts Use Bombardier recommended oil refer to TECHNICAL DATA SYMPTOM UNUSUAL ENGINE NOISE AND OR VIBRATION IN IDLE SPEED CONDITION NORMAL USE Test Inspection 1 Check operation of decompressor located on camshaft a Decompressor shaft stucks and or torsion spring is damaged Replace spring ...

Page 61: ...BRICATION b Connecting rod small end bearing is damaged and or out of specification Replace damaged and or worn out part s c Connecting rod big end clearance is out of specification Replace damaged and or worn out part s d Crankshaft plain bearing MAG PTO side is damaged and or out of specification Replace crankshaft and plain bearing MAG PTO at the same time refer to CRANKSHAFT 2 Check ball beari...

Page 62: ...NDICATION FAILS CONDITION NORMAL USE Test Inspection 1 Check contact screws on MAG side for damage and or wear a Shifting indicator switch pin is worn and or otherwise damaged Replace shifting indicator switch b Contact is corroded and or contact screw for wire harness got loose Clean contact surface and retighten contact screw with recommended torque c Isolating washer located on the shift drum i...

Page 63: ...choke in use a Idle speed is to high CVT starts to work Adjust idle speed b Choke is in use and increases the engine RPM Release choke SYMPTOM ENGINE BACKFIRES CONDITION NORMAL USE Test Inspection 1 Check spark plug and or electrical system a Carbon accumulation caused by defective spark plug Clean carbon accumulation and replace spark plug b Electrical system has failure Replace defective part s ...

Page 64: ... jets and carburetor float chamber from contamination e Fuel line clogged and or bent Clean fuel supply from contamination and or replace defective part s f Fuel supply insufficient at high RPM Clean fuel supply from contamination 4 Perform engine leak test Refer to ENGINE LEAK TEST procedure Check for possible piston seizure a Damaged head gasket and or seal and or leaking inlet exhaust valve s R...

Page 65: ...en piston due to excessive piston cylinder clearance or engine overreving Replace piston Check piston cylinder clearance refer to CYLINDER AND HEAD 10 Check piston rings and cylinder surface for grooves a Poor oil quality Use Bombardier recommended oil b Contamination like sand through engine intake Replace defective part s and use new air filter 11 Check crankshaft movement a Oil pump failure due...

Page 66: ... a There is water in fuel or contaminated fuel Drain fuel system search for leakage and refill it with appropriate fuel 7 Check engine compression a Worn piston s and or piston ring s Replace refer to CYLINDER AND HEAD SYMPTOM ENGINE TURNS OVER BUT FAILS TO START CONDITION NORMAL USE Test Inspection 1 Check if single spark ignition coil fits on spark plug refer to ENGINE DOES NOT START NO SPARK AT...

Page 67: ... Check condition and heat range of spark plug a Melted spark plug tip or inadequate heat range Replace SYMPTOM STARTER TURNS BUT ENGINE DOES NOT CRANK CONDITION NORMAL USE Test Inspection 1 Check gear condition on electric starter a Worn and or damaged starter gear Replace electric starter and or starter drive 2 Check condition of starter pinion gear a Worn and or damaged starter pinion and or rin...

Page 68: ...n of ignition coils a Mechanically damaged part Vibration problem Electrically damaged part Replace ignition coil s 5 Verify condition of trigger coil a Mechanically damaged part Vibration problem Electrically damaged part Replace trigger coil and or tighten mounting screw s 6 Check magneto for damage and or electrical failure a Windings of stator have electrical failure no charging causes an empt...

Page 69: ...ifications Drain engine oil and refill with the recommended oil 2 Check clutch discs condition a Clutch discs stuck together Clean or replace b Clutch discs or support plate distorted Replace 3 Check clutch cable or clutch release mechanism adjustment a Clutch cable or clutch release mechanism not adjusted correctly Adjust clutch cable and or clutch release mechanism see MAINTENANCE or CLUTCH Sect...

Page 70: ...YSTEM coolantescapingfromwaterpumphousingmeans damaged gasket s and or loosened screws refer to COOLING SYSTEM NOTE For all the above mentioned check see the appropriate engine section to diagnose and repair the engine LEAK TEST PROCEDURE PREPARATION AND TEST NOTE The following procedures should be done with a cold engine Disconnect battery Unplug and remove one spark plug only On RH side remove c...

Page 71: ...ak test check oil level and refill if necessary Using an Allen key through the MAG cover bring crankshaft to TDC compression stroke Torque the crankshaft locking bolt to lock crank shaft Remove radiator cap and dipstick Connect leak tester to adequate air supply Set needle of measuring gauge to zero NOTE Each tester will have specific instruction on the gauge operation and required pressure Instal...

Page 72: ... means leaking cylin der head gasket air coolant escaping from cylinder head means damaged gasket s and or loosened screws refer to CYLINDER AND HEAD air escaping into crankcase area means exces sively worn cylinder and or broken piston rings NOTE For all the check mentioned above see the appropriate engine section to diagnose and repair the engine INSTALLATION NOTE At reassembly use the torque va...

Page 73: ...Loctite 277 2 5 N m 22 lbf in 2 17 64 N m 47 lbf ft 19 N m 14 lbf ft 4 3 Loctite Ultra Copper 28 32 31 30 34 29 26 N m 19 lbf ft 25 26 27 33 10 N m 89 lbf in 25 N m 18 lbf ft 11 25 N m 18 lbf ft 64 N m 47 lbf ft 39 23 10 N m 89 lbf in Loctite 271 Loctite 271 8 9 7 N m 62 lbf in 16 135 N m 100 lbf ft 140 N m 103 lbf ft 10 14 12 13 26 N m 19 lbf ft 15 21 20 19 11 N m 97 lbf in 6 15 N m 133 lbf in 64...

Page 74: ...les oil pressure sensor on the top of oil filter housing temperature sensor and temperature sender located near thermostat housing magneto and trigger coil wiring harness connec tors 1 Spark plug cables 2 Oil pressure sensor 3 Temperature sensor 4 Temperature sender 5 Magneto and trigger coil connectors On left side of vehicle remove or disconnect the following items oil tank vent no 1 on the top ...

Page 75: ...6 and no 7 refer to EXHAUST SYSTEM section radiator inlet hose oil line vent hose brake pedal refer to HYDRAULIC BRAKES RH footrest refer to BODY countershaft sprocket cover no 8 metallic chain guard no 9 countershaft sprocket no 10 refer to COUNTERSHAFT SPROCKET section RH SIDE OF ENGINE 1 Exhaust pipes 2 Radiator inlet hose 3 Vent oil line 4 Brake pedal 5 Footrest carburetor and carburetor adapt...

Page 76: ...e bleeding screw Torque to 25 N m 18 lbf ft Install oil filter This operation activated the oil pump Check if ve hicle runs correctly COUNTERSHAFT SPROCKET Removal Slack drive chain Remove countershaft sprocket cover no 8 and metallic chain guard no 9 Select the first gear Unlock tab washer then unscrew the retaining nut NOTE Discard the tab washer Remove countershaft sprocket no 10 and drive chai...

Page 77: ... is properly aligned inside muffler ball socket then in stall retaining springs after pushing muffler for ward in exhaust pipe Do not torque yet Install RH exhaust pipe Torque all flange nuts Muffler Removal Remove exhaust pipes no 6 and no 7 Remove screw no 25 washer no 26 and spacer no 27 Under rear fender remove screw no 28 washer no 29 bushing no 30 another washer no 31 and spacer no 32 Remove...

Page 78: ...5A FM 03 05 1 COOLING SYSTEM 0 RADIATOR V02C4ES 11 N m 97 lbf in 25 Loctite 271 9 2 1 3 5 N m 31 lbf in 21 19 8 28 31 32 30 1 5 N m 14 lbf in 2 5 N m 22 lbf in 2 5 N m 22 lbf in 17 2 5 N m 22 lbf in 18 2 5 N m 22 lbf in 11 N m 97 lbf in 34 29 27 11 N m 97 lbf in 20 ...

Page 79: ...ubsection 05 COOLING SYSTEM 03 05 2 VMR2004_009_03_05A FM WATER PUMP V02C4FS 6 N m 53 lbf in 23 24 22 7 12 N m 106 lbf in 26 35 N m 26 lbf ft 33 10 N m 89 lbf in 11 Molykote 111 13 4 3 12 10 6 5 10 N m 89 lbf in 14 15 16 ...

Page 80: ...ution and look for air bubbles INSPECTION Check general condition of hoses and clamp tight ness Check the weep hole if there is oil or water NOTE Water indicates a damaged seal no 3 Oil out of the weep hole indicates a non working oil seal no 4 1 Weep hole 2 Water pump housing DRAINING THE SYSTEM To drain cooling system unscrew cooling plug no 5 on water pump cover no 6 and remove ra diator pressu...

Page 81: ...if necessary Check coolant concentration freezing point with proper tester PRESSURE CAP Check if radiator pressure cap no 1 pressurizes the system If not install a new 110 kPa 16 PSI radiator pressure cap do not exceed this pres sure WATER PUMP Removal Drain coolant Remove water pump cover no 6 from water pump with O ring no 10 Drive out spring pin no 11 and remove impeller no 12 Remove left engin...

Page 82: ...is a single action type Removal The thermostat is located on the RH side of engine Unfasten cover no 23 from thermostat housing RH SIDE OF ENGINE 1 Remove screws Pull out thermostat Catch spilled coolant Remove O ring no 24 Check O ring for damage and change if necessary Test To check thermostat put in water and heat water Thermostat should begin to open when water temperature reaches 75 C 167 F I...

Page 83: ...em 25 A fan relay no 28 Baja model only see procedure below 1 Fan relay 2 Electronic box 3 Fuel tank cover wiring harness and connectors If the fan does not work after all tests replace it Fan Relay Testing Procedure Baja Model Only The relay is located near the electronic box on the left side of vehicle Use the following points to check the fan relay Remove relay Jump the temperature switch conne...

Page 84: ... Apply Loctite 271 on threads TEMPERATURE SWITCH 1 Temperature switch Removal Unplug temperature switch connectors Unscrew temperature switch no 26 Test Using a multimeter measure the resistance be tween both temperature switch connectors The multimeter should indicate an infinite resis tance O L if not change the temperature switch If the resistance is infinite O L heat the temper ature sender ab...

Page 85: ...e be tween connector on the top of temperature sen sor and threads The multimeter should indicate an infinite resis tance O L if not change the temperature sensor If the resistance is infinite O L heat the temper ature sensor above 115 C 239 F The resistance should be 0 1 Ω If not change the temperature sensor Installation The installation is the reverse of the removal pro cedure CAUTION Do not ap...

Page 86: ...TEM 0 V02C0MT 10 N m 89 lbf in 5 6 1 7 10 N m 89 lbf in Loctite 243 2 10 12 Engine oil Loctite 648 10 N m 89 lbf in 3 Engine oil Loctite 648 11 10 N m 89 lbf in 14 180 N m 133 lbf ft 9 4 2 15 Loctite 243 8 N m 71 lbf in 8 N m 71 lbf in Sealing Compound Dreibond Sealing Compound Dreibond 13 ...

Page 87: ...l 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 7 retaining stator to ignition cover then pull stator Installation For installation reverse the removal procedure Pay attention to the following details Seal rubber grommet no 8 on electrical line with sealing compound Dreibond P N 420 297 906 Screw hand...

Page 88: ...8 to taper on rotor hub no 11 CAUTION Taper on crankshaft and rotor must be free of grease Oil sprag clutch no 3 in sprag clutch housing no 12 Slide rotor onto crankshaft The woodruff key and groove must be aligned in one line Rotate starter double gear counterclockwise to enable the sprag clutch no 3 to slide on the collar of sprag clutch gear no 13 1 Starter double gear 2 Sprag clutch gear Insta...

Page 89: ... trigger coil with taptite screws and fix screws with Loctite 243 Twist rotor no 2 until guide piece faces towards trigger coil Use feeler gauge to measure gap between guide piece and trigger coil 1 Guide piece 2 Trigger coil 3 Feeler gauge If necessary correct gap by bending the retaining plate Coat rubber grommet on trigger coil and line from magneto in ignition cover beside sealing face with se...

Page 90: ...6 MAGNETO SYSTEM VMR2004_010_03_06A FM 03 06 5 Installation Reinstall all parts Before torque check if the protrusion of rotor is aligned with the key way in the center of rotor hub 1 Rotor protrusion 2 Rotor hub key way 1 V02C4UA 2 ...

Page 91: ... 0 ENGINE LUBRICATION V02C3VS 10 N m 89 lbf in 8 9 1 11 25 N m 18 lbf ft Loctite 243 3 10 N m 89 lbf in 16 15 14 13 10 N m 89 lbf in 10 N m 89 lbf in 10 N m 89 lbf in 25 N m 18 lbf ft 8 N m 71 lbf in 28 Loctite 243 29 27 30 N m 22 lbf ft 7 10 23 24 25 22 21 20 18 19 6 N m 53 lbf in Loctite 243 17 26 ...

Page 92: ...SYSTEM 03 07 2 VMR2004_011_03_07A FM OIL TANK Loctite pipe sealant Loctite 277 12 6 20 N m 15 lbf ft Loctite pipe sealant 3 5 N m 31 lbf in 30 2 4 5 2 5 N m 22 lbf in 2 5 N m 22 lbf in 5 N m 44 lbf in Loctite pipe sealant V02C3WS 20 N m 15 lbf ft ...

Page 93: ...d with the recommended oil at the proper level Remove the oil pressure switch no 3 above oil filter and install the engine oil pressure adapter P N 529 035 652 and the oil pressure gauge P N 529 035 709 1 Oil pressure adapter 2 Oil pressure gauge The engine pressure should be 50 kPa 7 PSI min imum at idle and 300 kPa 44 PSI at 6000 RPM NOTE The maximum oil pressure is 600 kPa 87 PSI If the engine ...

Page 94: ...ver 2 Oil filter 3 O ring Wipe out any oil spillage on engine Change gasket no 10 on engine drain plug Clean gasket area on engine and drain plug then reinstall plug Refill oil tank at the proper level with the recommended oil Refer to TECHNICAL DATA for capacity Start engine and let idle for a few minutes Ensure oil filter area hoses and drain plug areas are not leaking Check if the RED indicator...

Page 95: ...Unscrew and remove oil tank strainer Cleaning and Inspection Clean oil tank strainer with a parts cleaner then use an air gun to dry it Installation For installation reverse the removal procedure NOTE Apply Loctite pipe sealant on oil tank strainer threads ENGINE OIL PRESSURE REGULATOR The engine oil pressure regulator no 13 is located in magneto side of the crankcase housing 1 Engine oil pressure...

Page 96: ...her no 21 1 Snap ring 2 Oil pump gear 3 Needle pin 4 Thrust washer oil pump cover no 22 oil pump shaft no 23 oil pump rotor no 24 inner rotor no 25 1 Oil pump cover 2 Oil pump shaft 3 Oil pump rotor 4 Inner rotor Inspection Inspect oil pump for marks or other damages spe cially scratches in crankcase between inlet and outlet parts Using a feeler gauge measure the clearance be tween oil pump rotor ...

Page 97: ...ated near the return oil pump 1 Pressure oil pump gear For removal inspection and installation use the same procedures that return oil pump ENGINE OIL STRAINER The engine oil strainer no 27 is located between both crankcase housings Removal Separate both crankcase housings Refer to CRANKSHAFT BALANCER SHAFT section Unscrew the bolts no 28 retaining the oil strainer guide no 29 Cleaning and Inspect...

Page 98: ...er front facia near the headlight Removal Drain oil tank Remove the front facia Unscrew headlight then disconnect and remove it Remove nut no 30 Unscrew bolts retaining fuel tank cover and oil tank to the frame Unplug all hoses then remove oil tank Installation The installation is the reverse of the removal pro cedure ...

Page 99: ...YLINDER AND HEAD VMR2004_012_03 08A FM 03 08 1 CYLINDER AND HEAD 0 CYLINDER AND HEAD V02C47S 10 N m 89 lbf in 10 N m 89 lbf in 33 N m 24 lbf ft 10 N m 89 lbf in 10 N m 89 lbf in 60 N m 44 lbf ft Engine oil 1 6 21 29 20 19 18 30 2 3 22 ...

Page 100: ...3 08 2 VMR2004_012_03 08A FM VALVE V02C4YS Engine oil 23 24 25 28 26 27 Engine oil Engine oil 8 7 15 17 16 10 11 13 14 4 9 9 5 12 10 N m 89 lbf in Loctite 243 Loctite 648 50 N m 37 lbf ft 40 N m 30 lbf ft Super Lube grease 31 32 32 Anti seize lubricant ...

Page 101: ...ssembly as a group If you find a defective component it will be much easier to find the cause of the fail ure among its group of parts eg you found a worn valve guide A bent spring could be the cause it will be easy to know which one of the springs is the cause and to replace it if you grouped the parts of the same assembly at disassembly Besides since used parts have matched together during the e...

Page 102: ...529 035 617 NOTE Check tightness with the allen key To adjust valves remove the camshaft bridges and the camshafts Remove adjusting plates blow clean with com pressed air Installation NOTE Before installation check thickness of ad justing plates with micrometer For installation reverse the removal procedure CAMSHAFT Removal Using the crankshaft locking bolt P N 529 035 617 lock the crankshaft into...

Page 103: ...cle diameter and lobe height using a micrometer Measure clearance between camshaft and cam shaft carriers using the plastic feeler gauge NOTE The plastic feeler gauge is available at au tomotive parts retailer Tighten camshaft carrier to specified torque Unfasten camshaft carrier and determine clear ance using comparative scale V02C49A V02C4AA CAMSHAFT DIAMETER MINIMUM 21 950 mm 864 in CAMSHAFT LO...

Page 104: ...he screw plug with sealing ring Torque to 24 N m 18 lbf ft CENTRIFUGAL DECOMPRESSOR Inspection Hold down exhaust camshaft no 7 in horizontal position with cam tips facing downwards The spring no 15 must press the lever upwards to dimension A replace spring if necessary A 11 5 mm 45 in NOTE Never stretch spring since this alters the defined spring force When activated the amount of lifting arm prot...

Page 105: ...otters no 24 Remove spring compressor valve spring retainer no 25 and valve spring no 26 Inspection Check valve spring for rust or corrosion and free length Installation For installation reverse the removal procedure VALVE Removal Remove valve spring no 26 Push the valve stem then pull valve no 27 out of cylinder head Inspection Valve Clearance Refer to MAINTENANCE LUBRICATION Valve Inspect valve ...

Page 106: ...28 with a special pliers such as Snap On YA 8230 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 VALVE GUIDE Inspection Insert a new valve in valve guide until it contacts the seal NOTE Clean valve guide to remove carbon de posits before measuring Meas...

Page 107: ... installer P N 529 035 852 remove valve guide no 32 1 Valve guide remover installer 2 Valve guide 3 Hammer Installation For installation reverse the removal procedure Pay attention to the following details Clean the valve guide bore before reinstalling the valve guide into cylinder head Install circlip no 31 on the valve guide Use valve guide remover installer P N 529 035 852 to install valve guid...

Page 108: ...itex usa sandvik com www titex com NOTE Use cutting oil and ensure to turn reamer the right way clockwise as shown below 1 Valve guide A Valve guide diameter Apply some lapping compound to valve face and work valve on its seat with a lapping tool TYPICAL 1 Valve seat 2 Valve face contact surface to valve seat 3 Turn valve while pushing again cylinder head NOTE Ensure to seat valves properly Apply ...

Page 109: ...e at three points Difference between measurements should not exceed 0 10 mm 004 in If so replace cylinder Cylinder Out of Round Measurecylinderboreatdistanceof60 mm 2 3 8 in from the upper edge with an internal micrometer at three points Difference between measurements should not exceed 0 10 mm 004 in If so replace cylinder Installation Coat piston rings with oil and slide the ring com pressor ove...

Page 110: ...CER SHAFT VMR2004_013_03 09A FM 03 09 1 CRANKSHAFT BALANCER SHAFT 0 Anti seize lubricant Anti seize lubricant 3 8 2 1 8 180 N m 133 lbf ft Engine oil 13 7 6 10 9 Engine oil 11 5 4 15 12 Loctite 243 V02C3FT 14 Anti seize lubricant Anti seize lubricant ...

Page 111: ... diameter Installation For installation reverse the removal procedure Pay attention to the following details Apply anti seize lubricant on the piston pin Insert piston pin into piston and connecting rod Secure piston pin with a new piston pin circlip NOTE Do not align the end gap of the piston pin circlips with the cutout in the piston bore PISTON Removal Remove piston pin no 1 Detach piston from ...

Page 112: ...linder 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 clear ...

Page 113: ...ed toler ance See above table Installation For installation reverse the removal procedure Pay attention to the following details NOTE Use a piston 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 si...

Page 114: ...all bolts retaining housing NOTE Do not forget the bolts inside the oil filter housing 1 Bolts to be removed Lift up clutch side of engine housing striking alter nate gentle blows with plastic hammer on main shaft countershaft and balancer shaft to ensure that these remain on magnet side CAUTION Do not tilt engine housing this can cause damage to bearing cup Remove shims no 10 and no 15 on cranksh...

Page 115: ...verse the removal procedure Pay attention to the following detail Heat balancer gear to 80 C 176 F CRANKSHAFT Removal Use the same removal procedure that balancer shaft Inspection Crankshaft Bearing Radial Play Measure bearing journal diameter The minimum di ameter for bearing journal is 47 975 mm 1 888 in If the measure exceeds specified tolerance replace the crankshaft Measure the interior diame...

Page 116: ...sup port face for the thrust washer CRANKSHAFT BUSHING Removal Heat engine housing to 100 C 212 F Drive out bushing with punch P N 529 035 688 Installation Heat engine housing to 100 C 212 F Coat bushing with Klueber grease P N 711 297 616 and drive home with punch P N 529 035 689 strik ing from inside CAUTION Mark position of oil hole in bushing on housing Align mark on punch with mark on housing...

Page 117: ...he end float of crankshaft plus shim thick ness Select suitable shim to ensure the correct end float is obtained RECENTER BALANCER SHAFT NOTE Only fit shim on clutch end Place balancer shaft into left engine housing clutch side Do not install shim on clutch side Using depth gauge measure distance between the top of balancer gear and housing joint This is the dimension B Determine dimension between...

Page 118: ...UTCH 0 V02D06U 9 10 N m 89 lbf in 10 1 2 3 12 11 4 15 13 Loctite 243 140 N m 103 lbf ft 14 16 Engine oil 17 18 Super Lube grease 21 22 8 N m 71 lbf in 19 6 20 10 N m 89 lbf in 8 10 N m 89 lbf in 7 10 N m 89 lbf in Super Lube grease Super Lube grease Anti seize lubricant 5 ...

Page 119: ...djustment is necessary after any works in the clutch system Loosen cable tension Adjust clutch release mechanism The release lever must locate on the spline in such a way that dimension A is obtained See the fol lowing illustration NOTE If necessary unscrew the Allen socket screw and remove release lever Replace the lever at the appropriate position then tighten socket screw to 8 N m 71 lbf in A 6...

Page 120: ...pressure plate no 1 crosswise Lift off pressure plate completely Inspection Check pressure plate for crack or other damage Change if necessary Installation For installation reverse the removal procedure CAUTION Never pull clutch release lever back wards The pressure plate bearing may come out of pressure plate PRESSURE PLATE BEARING Inspection Check the pressure plate bearing no 2 for exces sive p...

Page 121: ...re plate bearing may come out of pressure plate FRICTION DRIVE PLATE STEEL DRIVEN PLATE AND CLUTCH BASKET Disassembly Remove the pressure plate no 1 Remove friction drive plates no 3 and steel driven plates no 4 from clutch basket no 5 1 Friction drive plate 2 Steel driven plate 3 Clutch basket Unlock the tab washer no 13 then install spanner tool for clutch basket P N 529 035 618 Unscrew the clut...

Page 122: ...The friction drive plate maximum warpage should fall through a slot of 3 75 mm 148 in Steel Driven Plate The steel driven maximum warpage should fall through a slot of 1 63 mm 064 in The wear limit of the whole package is 11 5 mm 453 in Clutch Basket Check slots of clutch basket for damage or wear caused by friction drive plates Change if necessary TYPICAL FRICTION DRIVE PLATE MINIMUM THICKNESS FO...

Page 123: ...edle bearing underneath Coat spline on countershaft with Loctite anti seize First install steel driven plate then friction drive plate in alternate order NOTE Place the last friction drive plate in short slots of clutch basket 1 Last friction drive plate 2 Retaining plate 3 Clutch basket CLUTCH RELEASE SHAFT Removal Detach clutch cable Remove clutch cover Remove the retaining ring no 19 1 Retainin...

Page 124: ...OTE With a heat gun heat the clutch cover near bearings area Installation Drive in lower and upper needle bearing together using the punch P N 529 035 691 Insert clutch release shaft Using punch P N 529 035 693 drive in seal Install clutch cover and do not forget gasket CAUTION Never pull clutch release lever back wards The pressure plate bearing may come out of pressure plate V02D0BA 1 2 V02D0CA ...

Page 125: ... TRANSMISSION VMR2004_015_03 11A FM 03 11 1 TRANSMISSION 0 V02E07S 15 16 18 19 17 20 13 Anti seize lubricant 4 8 7 3 2 10 11 12 9 5 6 21 22 23 24 14 Anti seize lubricant Engine oil Super Lube grease Engine oil Engine oil Engine oil 1 ...

Page 126: ... from shift forks nos 6 7 and 8 Swivel shift forks outwards and remove Withdraw shift drum no 9 Inspection Check for worn or scored shifting forks rounded engagement dogs and slots bent shift forks bent shift fork shafts worn tracks on shift drum Measure the shift fork claw thickness A Shift fork claw thickness Measure the O D of the shift fork shaft in three places using an outside micrometer Ins...

Page 127: ...allowing selector lever to return to its orig inal position The clicking noise of the engaging shift pawl must be clearly audible Install engine TRANSMISSION Removal Remove the shifting mechanism Refer to the above section Remove shift fork shafts nos 4 and 5 Swivel shift forks nos 6 7 and 8 outwards and remove Withdraw shift drum no 9 Using a plastic mallet tap mainshaft no 13 to as sist withdraw...

Page 128: ...d mainshaft together and coat main bearing points with Loctite anti seize Seat shafts fully home by tapping them into place with a plastic hammer NOTE Before installation of the transmission shafts remove crankshaft to simplify assembly operation Install the shifting mechanism TRANSMISSION SHAFT BEARINGS Removal Heat left or right engine housing to 80 100 C 170 212 F Using the suitable bearing ext...

Page 129: ... CONTENTS 0 FUEL CIRCUIT 04 02 1 FUEL LINE 04 02 2 FUEL TANK 04 02 2 FUEL VALVE 04 02 2 FUEL SYSTEM PRESSURIZATION 04 02 3 CARBURETOR AND AIR INTAKE SILENCER 04 03 1 CARBURETOR 04 03 1 AIR INTAKE SILENCER 04 03 2 GENERAL 04 03 3 CARBURETOR 04 03 3 THROTTLE CABLE 04 03 6 AIR INTAKE SILENCER 04 03 8 ...

Page 130: ...Section 04 FUEL SYSTEM Subsection 02 FUEL CIRCUIT VMR2004_016_04_02A FM 04 02 1 FUEL CIRCUIT 0 V02F0JS 7 N m 62 lbf in 5 N m 44 lbf in 6 4 1 2 5 3 ...

Page 131: ...following Check so that the vent hose is not pinched Perform fuel system pressurization as described further in this section FUEL VALVE Removal Remove fuel tank Place fuel tank on the side Unscrew bolts no 5 retaining fuel valve to fuel tank Remove fuel valve Inspection Check strainer on each end of fuel valve rods If one strainer is damaged change fuel valve Check gasket between fuel valve and fu...

Page 132: ... shown in the following photos 1 Hose pincher installed on fuel tank vent line 1 Hose pincher installed on fuel pump outlet Using air pump P N 529 021 800 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 lo...

Page 133: ...Section 04 FUEL SYSTEM Subsection 03 CARBURETOR AND AIR INTAKE SILENCER VMR2004_017_04_03A FM 04 03 1 CARBURETOR AND AIR INTAKE SILENCER 0 CARBURETOR V02F0BS 10 8 11 12 7 5 4 3 2 6 9 ...

Page 134: ...LENCER 04 03 2 VMR2004_017_04_03A FM AIR INTAKE SILENCER Engine V02F0CS 24 16 15 17 19 17 19 13 14 22 20 25 28 27 26 23 18 18 Super Lube grease 10 N m 89 lbf in 10 N m 89 lbf in 1 2 N m 10 lbf in 0 6 N m 5 lbf in 1 2 5 N m 22 lbf in 0 6 N m 5 lbf in 1 2 N m 10 lbf in ...

Page 135: ...prior to cleaning Carburetor body and jets should be cleaned in a carburetor cleaner following manufacturer s in structions Check the diaphragm for crack or other damages Replace if necessary 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 no 2 and gasket no 3 from ...

Page 136: ...r on engine When reinstalling carburetor on engine pay atten tion to the following CAUTION The carburetor adaptor must be checked for cracks and or damage At assembly thecarburetoradaptormustbeperfectlymatched with the carburetor and intake adaptor or severe engine damage will occur Install clamps in a way that their tightening bolts are staggered not aligned Carburetor Adjustments BOTTOM VIEW 1 I...

Page 137: ... attempt to set the idle speed by using the pilot screw Refer to TECHNICAL DATA for idle speed specifi cations 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 counterclo...

Page 138: ...no 12 so that cable aligns with throttle lever re cess then lift cable end See next photo 1 Release tension on throttle lever 2 Cable end bushing Separate cable end bushing from throttle cable end as shown in the next photo Keep bushing REMOVE CABLE END BUSHING Loosen throttle cable nut 1 Loosen this nut Pull cable out from carburetor Before adjusting the throttle cable adjust idle speed prelimina...

Page 139: ...tor side cover Install the cable luber P N 529 035 738 on the cable Insert the needle of lubricant can on the cable lu ber hole NOTE Place a rag around the cable luber to pre vent the lubricant splash Put the lubricant until it passes through the cable Reinstall the cable Spray a little quantity of lubricant on the throttle lever mechanism then close the housing Adjust the throttle lever Throttle ...

Page 140: ...r box latches no 22 for cracks or other damages Change the air filter box latches if necessary Installation For installation reverse the removal procedure Air Intake Tube Removal Remove air filter box Separate air intake tube no 15 from air filter box Inspection Check air intake tube for cracks or other damages Change it if necessary Installation For installation reverse the removal procedure Carb...

Page 141: ...ECTORS 05 02 3 SERVICING DEUTSCH CONNECTORS 05 02 3 IDENTIFICATION OF MAJOR CONNECTOR PINS 05 02 5 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 1 CLEANING 05 04 1 INSPECTION 05 04 2 BATTERY STORAGE 05 04 2 ACTIVATION OF A NEW BATTERY 05 04 2 INSTALLATION 05 04 2 STARTING SYSTEM TROUBLESHOOTIN...

Page 142: ... DISASSEMBLY 05 05 5 FOULING 05 05 5 SPARK PLUG ANALYSIS 05 05 5 SPARK PLUG INSTALLATION 05 05 5 NGK SPARK PLUG SYMBOL EXPLANATION 05 05 6 ACCESSORIES 05 06 1 REMOVAL AND INSTALLATION 05 06 1 HEADLAMP 05 06 1 TAILLIGHT 05 06 2 AUXILIARY HEADLAMP 05 06 2 TACHOMETER 05 06 3 IGNITION SWITCH 05 06 3 INDICATOR LIGHTS 05 06 3 TESTS 05 06 4 COOLING FAN OPERATION TEST 05 06 4 HEADLAMP 05 06 4 MULTI FUNCTI...

Page 143: ...neto flywheel 2 Stator 3 Voltage regulator rectifier 4 Battery Voltage Regulator Rectifier A 3 phase full wave series 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 7 0 4 volts DC Battery The battery supplies the entire vehicle Therefore DC current only is used in the entire electrical system STARTING SYS...

Page 144: ...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 havi...

Page 145: ... electrical system Pay attention to grounding wires 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 T...

Page 146: ... 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 grea...

Page 147: ...H 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 3 6 5 4 6 5 4 1 2 3 1 2 4 3 4 3 1 2 2 1 1 2 A B A B B A 2 1 85 87 30 86 87a A B C A B C A B A C B A B A B C A B C A B B A A B C A D C B B C A D A B A D C B A B C A B PACKARD B A B A B A C B A C B A C D B A C D A B C D E F B C D A A B C D E F A B ...

Page 148: ...ngine Connect a multimeter to battery posts Set mul timeter to Vdc scale Bring engine to approximately 3500 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 th...

Page 149: ... 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 wiring harness connector 2 On magneto side connect test probes of the multimeter to two of the YELLOW ...

Page 150: ... check bat tery voltage if battery is in good condition it will have at least 10 5 Vdc REMOVAL Disconnect BLACK cable first then positive cable Remove bolts retaining battery holder from rack 1 Battery holder 2 Rack CLEANING Clean the battery casing 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...

Page 151: ...charge every two weeks Make sure battery is stored out of reach of children Clean battery terminals and cable connections using a wire brush Apply a light coat of dielectric grease P N 293 550 004 on terminals Clean battery casing using a solution of baking soda and water Rinse battery with clear water and dry well using a clean cloth Store battery on a wooden shelf in a cool dry place Such condit...

Page 152: ...es 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 re place electric starter Burnt commutator Turn commutator in a lathe or replace electric starter Worn commutator segmen...

Page 153: ... unplug the multi function switch connector Using a multimeter measure the resistance be tween the following wires Replace multi function switch if defective If switch tests good check wiring If it tests good continue the next tests Start Button If engine does not turn when pressing the start button test the switch as follows Remove the front facia and unplug the multi function switch connector Us...

Page 154: ...nic Module When other components have been tested above and are good the electronic module can be sus pected Ensure wiring and connectors are in good condition prior to replacing the electronic module ELECTRIC STARTER REMOVAL Turn OFF ignition switch Disconnect BLACK cable from battery Disconnect RED cable from starter Clean starter area Remove starter mount screws Pull starter out INSTALLATION In...

Page 155: ...After positioning the crimp plier crimp the termi nal already installed on wire CRIMPING OF WIRE PROPERLY CRIMPED WIRE To verify if the wire is properly crimped hold the wire with one hand and the terminal with the other and pull with some force CAUTION Never weld the wire to the terminal Welding can change the property of the wire and it can become brittle and break Install the protective heat sh...

Page 156: ...ts carefully repeat the complete test procedure to find the other faulty part IGNITION SYSTEM TEST Safety Precautions Main Fuse Condition Check main fuse 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 ...

Page 157: ...es at the electric module with the ignition switch in ON position Poor connections of circuit connectors Measure ignition coil primary peak voltage NOTE This method is applicable only with a multimeter and a peak voltage adaptor Inspect ignition coil Faulty ignition switch Faulty engine stop switch Broken wire harness or poor connections of circuit connectors CORRECT CORRECT INCORRECT LOOSENESS IN...

Page 158: ...xt 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 Primary Winding Disconnect the wire connector on the primary side of the ignition coil Using a multimeter check the resistance between the terminal and the igni...

Page 159: ...hange continuously Χ No open circuit value pointer do not register any change Value pointer changer and move to If a fault is detected the electronic module must be replaced IGNITION TIMING It is impossible to check the ignition timing with a timing lamp because there is no access window or mark NEGATIVE TESTER LINE A B C D E F POSITIVE TESTER LINE A 2 18 MΩ 2 18 MΩ UP to 2 18 MΩ 2 18 MΩ B O L 259...

Page 160: ...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 inspec...

Page 161: ...Section 05 ELECTRICAL Subsection 05 IGNITION SYSTEM 05 05 6 VMR2004_021_05_05A FM NGK SPARK PLUG SYMBOL EXPLANATION V04G0DS ...

Page 162: ...t Push and turn counterclockwise bulb retaining ring then remove it Detach bulb and replace Properly reinstall removed parts in the reverse or der of their removal NOTE Align the bulb socket tab with the notch in the headlamp housing 1 Bulb socket tab Removal Remove front facia and dashboard Refer to BODY Unscrew the bolts retaining headlamp then un plug the connector Installation Properly reinsta...

Page 163: ...t to your convenience then re install the front facia TAILLIGHT Bulb Replacement Unscrew lens screws to expose bulb 1 Lens 2 Screws Push bulb in and hold while turning courterclock wise to release Install the new bulb by first pushing in while turn ing clockwise AUXILIARY HEADLAMP Baja and Baja X Models Bulb Replacement Disconnect the auxiliary headlamp then remove it from support 1 Auxiliary head...

Page 164: ...ave a film on the bulb TACHOMETER Baja and Baja X Models Bulb Replacement The bulb in the tachometer is not replaceable If the tachometer bulb is burnt replace the tachometer Removal Remove dashboard Unplug wires under tachometer Push the tachometer out of dashboard Installation The installation is the reverse of removal proce dure NOTE Make sure the retainer is inserted be tween the tachometer an...

Page 165: ...en the following wires Replace switch if defective INDICATOR LIGHTS Remove steering cover Neutral Indicator Light GREEN Unplug the neutral indicator light connectors Put the RED probe of the multimeter to the posi tive connector on the LED and the black probe to the other connector Select the testing diodes continuity function on the multimeter NOTE Do not use Ω function to check LED The measure s...

Page 166: ...EEL HUB 06 02 2 WHEEL HUB BEARING 06 02 2 KNUCKLE 06 02 3 REAR AXLE 06 03 1 GENERAL 06 03 2 DRIVE CHAIN 06 03 2 SLIDER SHOE 06 03 3 CHAIN ROLLER 06 03 3 REAR WHEEL HUB 06 03 3 REAR SPROCKET 06 03 4 BRAKE DISC HUB 06 03 4 REAR AXLE 06 03 7 REAR SPROCKET HUB 06 03 8 ECCENTRIC AXLE HOUSING 06 03 9 ECCENTRIC AXLE BEARINGS 06 03 11 PROTECTORS 06 03 12 ...

Page 167: ...IVE VMR2004_023_06_02A FM 06 02 1 FRONT DRIVE 0 V02H18S 4 Synthetic grease 5 2 1 7 2 6 3 Synthetic grease 3 6 2 7 1 2 5 4 Synthetic grease 135 N m 100 lbf ft MINIMUM Synthetic grease 52 5 N m 39 lbf ft 135 N m 100 lbf ft MINIMUM 52 5 N m 39 lbf ft ...

Page 168: ...align with cotter pin hole Install a new cotter pin Both ends of cotter pin must be folded CAUTION Make sure each end of cotter pin does not protrude too far and rubs against the wheel cap Reinstall wheel cap WHEEL HUB BEARING Inspection Check inner race of each bearing no 2 with a fin ger The bearing should turn smoothly and quietly Check if bearing outer race fits tightly in the hub Remove and d...

Page 169: ...tellated nut 3 Cotter pin 4 Hardened washer 5 Upper A arm 6 Lower A arm Use a ball joint remover and detach upper and low er A arm from knuckle CAUTION Never hit the knuckle with a hammer Inspection Check knuckle for damage cracks or pitting Re place as necessary Installation The installation is the reverse of the removal pro cedure However pay attention to the following details Install knuckle on...

Page 170: ... 3 20 29 4 21 24 7 6 10 26 27 9 28 8 25 22 235 N m 173 lbf ft V02H19S Synthetic grease XL845 Grease Texaco Grease Texaco Grease Texaco 23 N m 17 lbf ft 4 N m 35 lbf in Synthetic grease XL845 53 N m 39 lbf ft Synthetic grease XL845 4 N m 35 lbf in Synthetic grease XL845 80 N m 59 lbf ft 53 N m 39 lbf ft 235 N m 173 lbf ft 23 N m 17 lbf ft 23 22 Loctite 609 ...

Page 171: ...xle lock bolts Insert adjuster lock from the vehicle s tool kit through rear hub and into eccentric axle housing Turn the axle forward to increase or backward to decrease chain free play TYPICAL 1 Drive chain 2 Adjuster lock 3 Sprocket hub 4 Eccentric axle housing NOTE Correct chain free play adjustment is 19 to 25 4 mm 3 4 to 1 in midway between sprockets Tighten the rear axle lock bolts to 23 N ...

Page 172: ...ket no 2 and engine sprocket Installation Installation is the reverse of the removal Adjust drive chain Refer to ADJUSTMENT for the proper procedure SLIDER SHOE Removal Remove swing arm Refer to REAR SUSPENSION Remove slide shoe Installation Installation is the reverse of the removal CHAIN ROLLER Removal Unscrew bolt no 19 retaining the chain roller no 11 Remove the chain roller with ball bearings...

Page 173: ...32 610084 Using adifferent nutcould cause damages to the rim Put vehicle back on the ground Adjust chain tension Refer to DRIVE CHAIN above REAR SPROCKET Removal Lift rear of vehicle and install jack stands under the frame to support the rear of vehicle off the ground Remove RH rear wheel and wheel hub no 3 Unfasten bolts no 14 and nuts no 15 retaining chain sprocket no 2 to rear sprocket hub Remo...

Page 174: ...ke Remove caliper and place it on the swing arm Re fer to HYDRAULIC BRAKES Slide out the brake disc hub Remove brake disc Refer to HYDRAULIC BRAKES Remove O ring no 29 Inspection Check brake disc hub for cracks or other damage Replace if necessary Check for worn splines and free play on the rear axle splines Check if wear ring no 21 is worn or damaged If the ring is grooved it must be replaced Rem...

Page 175: ...ase on axle threads Slide the brake disc hub over the axle Install the nut Pay attention to position the flanged side of nut against the hub 1 Flanged side against brake hub Temporarily tighten nut by hand Install brake caliper and tighten bolts to 25 N m 18 lbf ft Place transmission on first gear and or apply rear brake Use rear axle key P N 529 035 951 to tighten brake hub locking nut Ensure to ...

Page 176: ... the ground Remove rear wheels Loosen chain Refer to DRIVE CHAIN above Remove the LH wheel hub no 3 and brake disc hub no 4 Remove protector no 8 Unscrew the 6 bolts retaining the sprocket to its sprocket hub Separate the sprocket from the sprocket hub and place it away with the chain over the swing arm tube This will ease the removal and the insertion of the axle into the swing arm because the ch...

Page 177: ...t to follow the preload procedure to avoid seal and bearing damage Refer to BRAKE DISC HUB for the procedure Install sprocket and tighten bolts to 61 N m 45 lbf ft Install protector no 8 Install both rear wheels and tighten nuts to 53 N m 39 lbf ft in a criss cross sequence CAUTION Always use the recommended wheel nuts P N 732 610084 Using adifferent nutcould cause damages to the rim Perform drive...

Page 178: ... the new O ring against the flange Apply some synthetic grease P N 293 550 019 on splines IMPORTANT Do not apply grease on axle threads Using the same steel tube as for removal press hub until the C clip groove allows C clip insertion CAUTION Be careful not to press more than needed Otherwise the O ring might be dam aged Install C clip Press hub in the opposite direction until hub bot toms on the ...

Page 179: ...d seals Check for worn diameter where the caliper brack et seats Inspect O ring condition where the caliper bracket seats Inspect rubber seal condition between the split surfaces of swing arm A 75 mm 2 95 in Installation Installation is the reverse of the removal If rubber seal has been removed install it as fol lows Carefully spread swing arm split using a screw driver Insert seal in one corner o...

Page 180: ...s should turn smoothly and quietly If not change the bearings If bearings are seized on the axle the axle must be replaced or its surface cleaned Bearings must still have a slide fit on the axle otherwise it will result in a faulty re assembly and a failure may oc cur Bearing races on the axle must be in good condition Removal NOTE Bearings and seals must be replaced if re moved Pry out drive axle...

Page 181: ... eccentric axle housing Install all other parts CAUTION The preload procedure is very im portant to avoid seals and bearings damages Refer to BRAKE DISC HUB for the procedure PROTECTORS Removal LH Protector Remove brake disc hub with brake disc Unfasten socket head screws no 25 Remove LH protector no 8 from swing arm RH Protector Remove sprocket hub on rear hub socket head screws no 26 retaining t...

Page 182: ..._07_01ATOC FM 07 01 1 TABLE OF CONTENTS 0 STEERING SYSTEM 07 02 1 GENERAL 07 02 2 HANDLEBAR GUARD 07 02 2 HANDLEBAR GRIP 07 02 2 HANDLEBAR 07 02 3 STEERING COLUMN 07 02 3 TIE ROD 07 02 3 STEERING COLUMN BEARING 07 02 4 MULTI FUNCTION SWITCH 07 02 4 THROTTLE HANDLE 07 02 5 ...

Page 183: ... Loctite 406 Synthetic grease 23 N m 17 lbf ft 4 N m 3 5 lbf in 3 N m 27 lbf in 23 N m 17 lbf ft 34 N m 25 lbf ft 70 N m 52 lbf ft 38 N m 28 lbf ft Loctite 243 10 N m 89 lbf in 70 N m 52 lbf ft DS 650 Baja Baja X 9 10 11 26 26 25 24 26 25 24 31 19 18 17 12 1 14 15 16 13 15 22 21 28 33 35 8 36 23 34 32 20 2 6 7 3 27 30 Loctite 406 DS 650 DS 650 Baja Baja X 4 5 29 ...

Page 184: ... Insert the open side of a 23 mm 7 8 in wrench against the inner end of grip Using a plastic hammer tap on the side of the wrench end to make the grip sliding out Installation Clean handlebar ends and inside of handlebar grip with pulley flange cleaner P N 413 711 809 Let dry before installation Use the insertion tool P N 529 035 897 to prop erly install handlebar grip CAUTION Installing handlebar...

Page 185: ...ring column no 22 Refer to TIE ROD section Pull steering column Inspection Inspect steering column for cracks bending or oth er damages Replace if any problem is detected Check if the O rings no 23 are brittle hard or oth erwise damaged Replace if necessary Check steering column bearing for excessive play and smooth operation Replace if necessary See further in this section for the proper procedur...

Page 186: ...r and front wheels are aligned Adjust alignment with tie rod Adjust toe out to 0 5 0 5 mm 0197 0197 in on each side NOTE Take measure on the rim A B 0 5 0 5 mm 0197 0197 in on each side STEERING COLUMN BEARING Removal Place vehicle on jack stands and remove front wheels Remove steering column Remove bolts no 29 and first bearing flange no 30 Remove bearing no 31 Installation For installation rever...

Page 187: ...o 34 under throttle handle no 35 TYPICAL 1 Remove screws Separate throttle handle from handlebar Unscrew the locking nut of the cable adjuster then screw the adjuster to release the cable tension Remove throttle cable no 36 from housing TYPICAL 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 rem...

Page 188: ...CONTENTS 0 FRONT SUSPENSION 08 02 1 GENERAL 08 02 2 SHOCKS ABSORBER ASS Y 08 02 2 SHOCK ABSORBER REBUILDING 08 02 3 UPPER A ARM 08 02 7 LOWER A ARM 08 02 9 BALL JOINT 08 02 10 REAR SUSPENSION 08 03 1 GENERAL 08 03 2 SHOCK ABSORBER ASS Y 08 03 2 SHOCK ABSORBER REBUILDING 08 03 5 SWING ARM 08 03 10 ...

Page 189: ...T SUSPENSION 0 V02J1BS 3 8 9 14 16 12 11 10 12 15 4 7 6 5 17 11 10 17 13 Baja Baja X 2 1 48 N m 35 lbf ft Loctite 609 50 N m 37 lbf ft Loctite 609 50 N m 37 lbf ft Suspension synthetic grease 48 N m 35 lbf ft 63 N m 46 lbf ft Baja X Suspension synthetic grease Suspension synthetic grease ...

Page 190: ...sorber protector no 2 Remove lower bolt no 4 then upper bolt no 3 of shock 1 Remove bolts 2 Front shock assembly Disassembly Remove snap ring no 5 under spring seat no 6 Unscrew the spring seat completely and remove the spring no 7 Inspection Inspect the spring for damage Replace if necessary Inspect shock for oil leakage Extend and compress the piston several times over its entire stroke Check pi...

Page 191: ... load and a smooth road condition SHOCK ABSORBER REBUILDING Baja X Models Remove spring and adjuster See SHOCK AB SORBER ASS Y above Disassembly Clean all the parts prior to disassembling Tightly secure the shock absorber bottom eyelet in a vise with soft jaws CAUTION Never clamp on shock absorber body Remove screw on top of valve Place the needle guide of gas refill needle type shock tool P N 503...

Page 192: ... end to catch float ing piston Allow room for parts to leave shock ab sorber Using compressed air pressure in valve hole carefully push piston out Clean inner walls of shock absorber and reservoir with pulley flange cleaner P N 413 711 809 Be careful not to splash O rings piston and seals etc Dry parts with compressed air Inspection Check the following Compression bumpers for chipping cracking or ...

Page 193: ... 0 in from top 1 Floating piston 2 Machinist square A 204 mm 8 0 in from top Apply grease on O ring and reinstall valve Bleeding Pour Ryde FX slide high performance lube P N 503 190 103 in shock absorber Fill shock absorber up to bottom of threads CAUTION Use new oil only Do not reuse the same oil Do not use any other oil Allow a few minutes for air bubbles to surface NOTE Although we do not measu...

Page 194: ...o the body until the nitro gen charge is added Using an appropriate open wrench torque seal carrier cover to 75 N m 55 lbf ft Use the gas shock valve tool P N 529 035 570 and tightly install it to the nitrogen tank 1 High pressure hose 2 Two stage regulator 3 High pressure cylinder filled with industrial grade nitrogen N2 4 Gas shock valve tool Proceed as follows 1 Adjust nitrogen tank regulator t...

Page 195: ...wer the pressure too much and would require refilling Carefully inspect shock absorber for gas or oil leaks Any leak must be corrected before continuing Stroke the piston rod to ensure full travel and smooth compression and rebound action If the shaft moves in or out erratically or if you hear a gurgling sound this could indicate air is trapped inside If the piston rod does not move or has par tia...

Page 196: ...or any other damage and inspect ball joint stud for damages Ensure stud is moving freely Refer to BALL JOINT section below Installation Position upper A arm and install bolts no 14 and nuts Torque nuts to 63 N m 46 lbf ft Attach upper A arm to knuckle Install hardened washer no 12 and castellated nut no 11 Tighten castellated nut to 50 N m 37 lbf ft and further tighten until its grooves align with...

Page 197: ... wear or damages Replace pivot bushings if necessary Check ball joint bellows on lower A arm for cracks or any other damage and inspect ball joint stud for damages Ensure stud is moving freely Refer to BALL JOINT section below Installation For assembly reverse the disassembly proce dure However pay attention to the following Position lower A arm and install bolts no 16 and nuts Torque nuts to 63 N...

Page 198: ... The maximum axial play should be 1 5 mm 060 in If the axial play is out of specification change the lower ball joints no 15 LOWER BALL JOINT AXIAL PLAY A Maximum axial play measurement A 1 5 mm 060 in Upper Ball Joint Move the upper A arm vertically The maximum ax ial play should be 1 5 mm 060 in If the axial play is out of specification change the upper ball joints UPPER BALL JOINT AXIAL PLAY A ...

Page 199: ...ly a layer 0 3 mL of Loctite 609 on the outside diameter of new ball joint surface that contacts arm Wipe any excess Insert the ball joint into the template with the cor rect orientation Flat grooves of ball joint must be in contact with the flat sides of the template 1 Flat grooves Place the ball joint and the template on the A Arm and orient it into place the narrow section of the template align...

Page 200: ...en the two tubes of the A arm 1 Flat grooves Remove the template and keep the orientation of the ball joint Use both ball joint drivers P N 529 035 705 and P N 529 035 706 and a press machine to press the ball joint in place A hammer may also be used but care should be taken 1 Flat bar 2 Driver 3 Arm 4 Driver 5 Flat groove NOTE Be sure that the flat groove is perpendicu lar to rotation axis before...

Page 201: ... 13 Insert this section into shock bracket Lower A arm Index the ball joint here Bend down this section and place between the 2 tubes RIGHT upper A arm Index the ball joint here Bend down this section and place between the 2 tubes LEFT Upper A arm Index the ball joint here V02I0SS ...

Page 202: ...R2004_027_08_03A FM 08 03 1 REAR SUSPENSION 0 V02J0QS 2 6 5 3 16 17 15 17 7 8 11 10 9 12 18 18 12 13 4 Synthetic grease 14 Loctite 243 See special procedure inside 85 N m 63 lbf ft 3 5 N m 31 lbf in 85 N m 63 lbf ft Suspension synthetic grease Baja Baja X ...

Page 203: ...he vehicle Unscrew clamps no 3 retaining the reservoir no 4 Remove upper bolt no 5 retaining shock absorber Remove brake caliper and move aside Unlock disc brake hub and slide it aside to gain access to lower bolt of shock absorber Loosen chain and remove rear sprocket Refer to REAR AXLE Remove LH and RH access plugs of shock absorb er lower bolt 1 LH plug removed to access shock absorber bolt Uns...

Page 204: ...ne full com pression stroke Rebuilt if any fault is present Assembly and Installation For assembly and installation reverse the disas sembly and removal procedures On Baja and Baja X models reinstall the shock absorber protector make sure not to block venting holes Adjustment Gas Pressure Refer to SHOCK ABSORBER REBUILDING be low Spring Preload Spring preload may vary from rider to rider depend in...

Page 205: ... mm 1 8 in increments The optimum adjustment range is between 102 mm 4 in and 127 mm 5 in but for heavier or more aggressive riders it could be be tween 76 mm 3 in and 102 mm 4 in Preload Adjustment To reduce Turn the shock spring adjuster counterclock wise for a light load and smooth condition To increase Turn the shock spring adjuster clockwise for a firmer ride and rough conditions Rebound Damp...

Page 206: ...ir Place a rag over valve to protect against possible mist and to prevent gas being directed towards someone Using a small tool press valve pin to release pressure Ensure to completely empty the reservoir NOTE If a mist of oil is sprayed it indicates that the bladder is damaged Remove valve pin Using a clean soft hammer gently tap down res ervoir cover just enough to free the C clip Using a small ...

Page 207: ...g over reservoir end to catch bladder and its cover Allow room for parts to leave reservoir Using compressed air pressure in hose hole care fully push bladder out 1 Bladder 2 Cover Shock Absorber Tightly secure the shock absorber bottom eyelet in a vise with soft jaws Push piston down to empty shock absorber Note position of hose and detach hose from shock absorber Using a suitable punch in the co...

Page 208: ...ey flange cleaner P N 413 711 809 Be careful not to splash O rings piston and seals etc Dry parts with compressed air Inspection Check the following Compression bumpers for chipping cracking or missing O rings for nicks cuts or cracks Piston rod for straightness wear nicks or burrs Seal carrier and rod seals Piston seal ring for wear Valve discs for kinks or waves Innner walls of shock absorber an...

Page 209: ...orarily install bladder upside down on shock absorber Push down enough to have a tight seal Squeeze bladder to pump oil towards reservoir Ensure enough oil remain in shock absorber PUMP BLADDER TO BLEED HOSE 1 Hold reservoir higher than shock absorber 2 Bladder installed upside down Air will escape in reservoir if present Repeat the pumping twice Reservoir Add oil in reservoir to half fill Wrap re...

Page 210: ...e pushed into body This should be done slowly ensuring some oil flows out to ensure no air is trapped inside shock absorb er Push down just enough to secure C clip After the seal carrier is completely installed avoid pushing the piston rod into the body until the nitro gen charge is added Reinstal cover Nitrogen N2 can now be added in the reservoir Gas Pressure Use the Gas shock valve tool P N 529...

Page 211: ...ut erratically or if you hear a gur gling sound this could indicate air is trapped inside shock absorber If the piston rod does not move or has partial travel then it may be hydraulically locked In either event the shock must be rebuilt again Reinstall valve cap Reinstall spring and adjuster then perform adjust ments See shock absorber ASS Y SWING ARM Removal Lift rear of vehicle until rear shock ...

Page 212: ...t is lower than 19 7 mm 776 in replace shaft Installation Installation is essentially the reverse of removal procedure However pay attention to the follow ing details Insert O rings no 12 in the groove into frame Place O rings no 18 on bushings no 17 then in stall the swing arm Install the swing arm shaft no 16 then push the O rings no 18 between frame and bushings En sure the flat sides of shaft ...

Page 213: ...TENTS 0 HYDRAULIC BRAKES 09 02 1 FRONT BRAKES 09 02 1 REAR BRAKE 09 02 2 GENERAL 09 02 3 HYDRAULIC BRAKES SYSTEM 09 02 3 MASTER CYLINDER 09 02 4 CALIPER 09 02 6 BRAKE PADS 09 02 7 BRAKE DISC 09 02 8 BRAKE LEVER 09 02 9 BRAKE PEDAL 09 02 9 BRAKE LIGHT SWITCH 09 02 10 REAR CALIPER BRACKET 09 02 10 ...

Page 214: ... FRONT BRAKES V02K0NS 13 N m 115 lbf in 25 N m 18 lbf ft 34 N m 25 lbf ft 28 N m 21 lbf ft 25 N m 18 lbf ft 15 N m 133 lbf in 25 N m 18 lbf ft 28 N m 21 lbf ft 21 12 13 4 1 2 8 22 23 20 N m 15 lbf ft 10 9 11 39 38 31 35 3 36 33 29 34 28 6 33 35 39 38 30 3 35 33 31 31 35 36 34 7 29 28 45 32 37 37 32 ...

Page 215: ...02K05V 34 37 3 15 N m 133 lbf in 36 35 35 31 39 38 48 47 18 25 N m 18 lbf ft 28 N m 21 lbf ft 34 N m 25 lbf ft 28 29 8 N m 71 lbf in 46 16 25 N m 18 lbf ft 17 Loctite 567 pipe sealant 14 20 41 42 43 44 40 5 6 N m 53 lbf in Synthetic grease 26 27 24 19 15 1 2 3 N m 27 lbf in 25 5 N m 44 lbf in ...

Page 216: ...ear brake Remove reservoir cover no 1 with diaphragm no 2 Connect bleed hose to bleed valve no 3 Loosen bleed valve and pump brake lever no 4 or brake pedal no 5 until no more fluid flows out of bleed valve Brake Fluid Filling and Bleeding Close bleed valve Fill reservoir with DOT 4 brake fluid CAUTION Do not mix different types of brake fluid Use only DOT 4 brake fluid from a sealed container Do ...

Page 217: ... Do not release brake lever or brake pedal until bleed valve has been closed For the front brake system switch to LH and RH caliper Turn handle bar to full RH side when bleeding right cal iper no 6 and turn to the LH side for the left caliper no 7 This helps the bleeder to reach air into the caliper Release brake lever or brake pedal slowly Repeat the procedures until air bubbles don t ap pear in ...

Page 218: ...ders and pistons for scoring scratch es or other damage Change part s if necessary Check locking pin no 26 for excessive wear re place if necessary NOTE If master cylinder is damaged or leaking replace as an assembly Assembly Front Master Cylinder Coat master piston and piston cups with clean brake fluid Install spring onto master piston master piston into master cylinder snap ring into groove in ...

Page 219: ...nder using new sealing washers Connect flexible hose from master cylinder Fill up reservoir with clean brake fluid CAUTION Do not mix different types of brake fluid Use only DOT 4 brake fluid from a sealed container Do not use brake fluid taken from old or already opened containers Bleed rear brake system Check for leaks and make sure the brakes operate normally before driving CALIPER Removal Loos...

Page 220: ...into sliding bores and install slide pins NOTE Make sure that rubber boots no 35 are correctly installed in slide pins grooves Install pad spring caliper bracket and pads Installation For the installation reverse the removal proce dure pay attention to the following details Use new sealing washers when installing Banjo bolt retaining brake hose to caliper Install caliper to knuckle with the new se...

Page 221: ...all new brake pads Install new pad pins by pushing in the pads against pad spring to align pad slots in the pads and caliper body Install brake caliper so the disc is positioned be tween pads NOTE Be careful not to damage pads and that pads are correctly inserted in their location After the job is completed firmly depress the brake lever a few times to bring the pads in con tact with the disc Chec...

Page 222: ...r Brake Disc Refer to REAR AXLE for brake hub removal instruc tions Installation Install brake disc on hub and tighten in a criss cross sequence Install new self locking screws no 39 and torque them BRAKE LEVER Removal and Installation Use the same procedure than the front master cylinder BRAKE PEDAL Removal Remove RH side foot protector Refer to BODY for removal procedure Unhook the return spring...

Page 223: ...46 cannot be ad justed Remove RH foot protector Refer to BODY for re moval procedure Disconnect connectors Unscrew rear brake light switch no 46 from banjo fitting no 16 Catch spilled fluid with a rag Installation For installation reverse the removal procedure NOTE Apply pipe sealant on threads Bleed the brake system REAR CALIPER BRACKET Removal Remove brake hub Refer to REAR AXLE Remove the large...

Page 224: ...EADLAMP SUPPORT 10 02 5 FUEL TANK COVER 10 02 5 FOOT PROTECTOR FOOT PROTECTOR SUPPORT 10 02 6 REAR FENDER 10 02 6 REAR BUMPER 10 02 6 ENGINE SKID PLATE 10 02 6 A ARM PROTECTOR PLATE 10 02 7 NERF BAR 10 02 8 LATCH BASE LATCH LEVER SPRING 10 02 8 SEAT ADJUSTMENT 10 02 8 SEAT COVER REPLACEMENT 10 02 9 SEAT CLEANING 10 02 9 DECALS REPLACEMENT 10 02 9 PLASTIC MAINTENANCE REPAIR 10 02 10 MAINTENANCE 10 ...

Page 225: ...7 27 31 30 10 N m 89 lbf in 4 2 N m 18 lbf in 5 26 23 19 17 20 2 5 N m 22 lbf in 9 8 6 7 8 12 14 11 10 13 10 N m 89 lbf in 16 15 23 N m 17 lbf ft 6 23 N m 17 lbf ft 5 N m 44 lbf in 2 5 N m 22 lbf in 8 2 5 N m 22 lbf in 10 N m 89 lbf in 23 3 5 N m 31 lbf in 25 6 5 N m 58 lbf in 18 24 29 37 38 23 N m 17 lbf ft 2 5 N m 22 lbf in 23 N m 17 lbf ft 2 5 N m 22 lbf in 2 N m 18 lbf in 4 40 3 5 N m 31 lbf i...

Page 226: ... 18 2 5 N m 22 lbf in 25 26 10 N m 89 lbf in 29 23 23 2 N m 18 lbf in 2 5 N m 22 lbf in 3 5 N m 31 lbf in 6 5 N m 58 lbf in 36 3 5 N m 31 lbf in 39 2 N m 18 lbf in 2 5 N m 22 lbf in 5 17 19 4 21 13 10 11 14 12 23 N m 17 lbf ft 5 N m 44 lbf in 10 N m 89 lbf in 16 25 8 23 N m 17 lbf ft 8 9 23 N m 17 lbf ft 8 10 N m 89 lbf in 20 4 10 N m 89 lbf in 22 46 47 52 51 48 49 50 47 X models only 52 50 49 51 ...

Page 227: ...Section 10 BODY FRAME Subsection 02 BODY VMR2004_029_10_02A FM 10 02 3 SEAT V02L0KS Loctite 271 3 41 44 42 43 1 29 N m 21 lbf ft 2 5 N m 44 lbf in 5 5 N m 49 lbf in Loctite 271 ...

Page 228: ... lamps tachometer Baja models Remove dashboard completely Installation Installation is the reverse order of removal FRONT SKID PLATE FRONT BUMPER Removal Front Skid Plate DS 650 Models Remove screws no 6 Front Bumper Remove front skid plate no 7 DS 650 models Remove bolts no 8 then the front bumper no 9 Installation Installation is the reverse order of removal MUDGUARD FRONT FENDER SUPPORT Removal...

Page 229: ... facia bracket to the oil tank Installation For the installation reverse the removal procedure AUXILIARY HEADLAMP SUPPORT Baja Models Removal Remove front facia bolt no 21 retaining the auxiliary headlamp sup port no 22 to the upper bracket of shock ab sorber Disconnect the auxiliary headlamps Installation For installation reverse the removal procedure FUEL TANK COVER Removal Remove seat front fac...

Page 230: ...t of air box cover screws no 27 retaining foot protector to rear fender no 36 Installation Installation is the reverse order of removal REAR BUMPER Removal Remove screws no 37 then the screw retaining rear bumper no 38 and muffler Installation Installation is the reverse order of removal ENGINE SKID PLATE Inspection The skid plate protects the engine Check for dam age cracks or looseness Change if...

Page 231: ...ation For installation reverse the removal procedure However pay attention to the following Position A arm protector no 48 under A arms On frame side install U clamps over the A arm tubing and fasten with bolts no 50 and nuts no 49 Do not tighten yet On wheel side secure with a bolt no 52 and a nut no 51 Fully turn the handlebar into both directions and check for interference Fully compress front ...

Page 232: ...nut no 44 and screw or unscrew the lock pin to the best height See the following illustration 1 Lock pin 2 Lock pin nut apply Loctite 271 3 Adjustment nut apply Loctite 271 A 14 2 mm 9 16 5 64 in Torque the lock pin nut SEAT COVER REPLACEMENT Remove the old seat cover 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 ta...

Page 233: ...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 beginn...

Page 234: ...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 REPAIR The plastic parts are produced in high density poly ethylene HDPE or in low density polyethylene LDPE These materials are not reparable ...

Page 235: ...RAME VMR2004_030_10_03A FM 10 03 1 FRAME 0 10 N m 89 lbf in V02L0QS 2 23 N m 17 lbf ft 4 8 3 8 9 48 N m 35 lbf ft 5 5 6 6 10 N m 89 lbf in 10 N m 89 lbf in 1 9 48 N m 35 lbf ft 7 6 10 N m 89 lbf in 1 DS 650 DS 650 Baja Baja X 11 5 10 6 12 ...

Page 236: ...he dashboard support no 2 Inspection Check for cracks or bent tube Change or repair if necessary Installation For installation reverse the removal procedure REAR FRAME EXTENSION Removal Remove rear fender refer to BODY battery starting solenoid and all wire attached to frame extension muffler refer to REMOVAL AND INSTALLATION rear shock absorber reservoir refer to REAR SUSPENSION rear brake fluid ...

Page 237: ...mperage 70 110 A voltage 20 24 V rod E 7014 3 32 in CAUTION Before performing electrical weld ing anywhere on the vehicle unplug the elec tronic module Also unplug the negative cable and the voltage regulator This will protect the electronic module and battery against damage caused by flowing current when welding NOTE Install the ground as close as possible to the repaired area CAUTION If welding ...

Page 238: ...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 imp oz imp oz imp gal imp ga...

Page 239: ...ke mm in 5 95 24 Exhaust mm in 5 935 23 Valve Seat Angle Intake mm in 45 Exhaust mm in 30 Piston Ring End Gap New Minimum mm in 0 2 008 New Maximum mm in 0 4 016 Wear Limit mm in 1 04 Ring Piston Groove Clearance New Minimum mm in 0 03 0012 New Maximum mm in 0 065 0026 Wear Limit mm in 0 15 006 Piston Cylinder Clearance Wear Limit mm in 0 09 004 Cylinder New Minimum mm in 100 3 9371 New Maximum mm...

Page 240: ...A Main 25 A CARBURATION Carburetor Type Mikuni Constant Depression Type with Manual Choke Model BSR42 4 Idle Engine Speed RPM 1300 100 Main Jet 165 Needle Jet O0 Jet Needle 6BCY22 60 4 Needle Valve and Seat 3 0 Hi Flow Pilot Jet 40 Starter Jet No 1 and No 2 mm in 45 Ø 2 1 77 Ø 079 Main Air Jet 120 Pilot Air Jet No 1 110 Pilot Air Jet No 2 mm in 1 3 05 Clip Position Number 4 Choke Plunger Position ...

Page 241: ... 0197 0197 Camber Angle Caster Angle 0 5 7 Tie Rod Maximum Length Unengaged mm in 20 5 787 197 Tie Rod Maximum Length mm in 452 17 78 SUSPENSION FRONT Suspension Type Independent Suspension Double A Arm Suspension Travel mm in 305 12 Shock Absorber Qty 2 Type Oil Oil Gas Spring Free Length mm in 368 14 5 Spring Color Code Gold Blue Black Gold Green Black Green Blue Blue Front Preload Adjustment Se...

Page 242: ...lb 125 275 5 Wheel Base mm in 1244 49 Wheel Track Front mm in 1048 41 Rear mm in 978 38 5 Front and Under Engine Ground Clearance mm in 297 11 7 Rear Rigid Axle Ground Clearance mm in 120 4 75 CAPACITIES LIQUID Fuel Tank 12 L 3 5 U S gal Fuel Tank Reserve 2 4 L 0 6 U S gal Engine Transmission Oil Capacity 3 L 0 8 U S gal Recommended SAE 10W40 4 Stroke Mineral Based Oil SG SH or SJ or Bombardier sy...

Page 243: ...Aluminum Front Rear Fender Material High Density Polyethylene Color Yellow or Black Orange Fuel Tank Cover Material High Density Polyethylene Color Black Steering Cover Material Foam and Vinyl Color Yellow or Black Orange Front Facia Material High Density Polyethylene Color Red Black Air Box and Cover Material Low Density Polyethylene Color Black Mudguard Material Synprene Color Black Seat Cover M...

Page 244: ... Exhaust Pipe Nut 11 N m 97 lbf in Heat Shield Screws 10 N m 89 lbf in Exhaust Pipe Collar 15 N m 133 lbf in Muffler Support 26 N m 19 lbf ft Pipe Support 10 N m 89 lbf in FUEL Carburetor Mounting Clamp Engine Side 2 5 N m 22 lbf in Air Box Side DRIVE TRAIN Front Wheel Hub Nut 135 N m 100 lbf ft MINIMUM Rear Wheel Hub Nut 235 N m 173 lbf ft MINIMUM Rear Axle Adjusting Nut Refer to REAR AXLE sectio...

Page 245: ...bf ft Rear Swing Arm LH First Nut 100 N m 74 lbf ft Unscrew Nut a Quarter Turn Rear Swing Arm LH Nut 100 N m 74 lbf ft Upper Lower A Arm Lock Nut 60 N m 48 lbf ft Ball Joint Nuts 50 N m 37 lbf ft MINIMUM 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 Rear Extension Frame 48 N m 35 lbf ft Footrest 10 N m 89 lbf in Skid Plate 4...

Page 246: ...cheme is used the first color is the main color while the second color is the tracer color Example YL BK is a YELLOW wire with a BLACK stripe 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 ...

Page 247: ...D RD VI START LOW OFF BK YL BK RD VI BK YL BK WH BK BK RD RD 12V BK WH RED GREEN NEUTRAL LED OIL TEMP LED LT KEY SWITCH CC FRONT BRAKE SWITCH FV REAR BRAKE SWITCH FR TAIL LIGHT PR HEAD LIGHT PV ELECTRONIC MODULE ME IGNITION COILS BA BA TRIGGER COIL CA MAGNETO MA VOLTAGE REGULATOR RV M BATTERY CLUTCH SWITCH IE NEUTRAL SWITCH IN D1 STARTER SOLENOID SS MAIN FUSE BF1 FAN THERMOSTATIC FT OIL PRESSURE S...

Page 248: ...Section 12 WIRING DIAGRAMS Subsection 01 WIRING DIAGRAMS VMR2004_032_12_01A FM 12 01 3 DS 650 Baja Baja X DS 650 BAJA BAJA X V02Z03 ...

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