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BOMBARDIER RALLY 200 2003, Shop Manual

The BOMBARDIER RALLY 200 2003 is a powerful and versatile all-terrain vehicle (ATV). For those seeking detailed instructions on maintenance and repairs, the comprehensive Shop Manual is available for download. Get this valuable manual for free from our website, manualshive.com, ensuring you have everything you need to keep your ATV running smoothly.

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Summary of Contents for RALLY 200 2003

Page 1: ......

Page 2: ...2003 Shop Manual RALLY 200 ...

Page 3: ...court Quebec Canada Printed in Canada Registered trademarks of Bombardier Inc TM Trademarks of Bombardier Inc This document contains the registered trademarks of the following companies Kimtowels is a registered trademark of Kimberly Clark Loctite is a registered trademark of Loctite Corporation Molykote is a registered trademark of Dow Corning Corporation Snap on is a registered trademark of Snap...

Page 4: ...ystem 03 07 1 08 Cylinder and head 03 08 1 09 Crankshaft 03 09 1 10 Gearbox 03 10 1 11 CVT 03 11 1 04 FUEL SYSTEM 01 Table of contents 04 01 1 02 Fuel circuit 04 02 1 03 Carburetor 04 03 1 04 Air intake silencer 04 04 1 05 ELECTRICAL 01 Table of contents 05 01 1 02 Overview 05 02 1 03 Charging system 05 03 1 04 Starting system 05 04 1 05 Ignition system 05 05 1 06 Instruments and accessories 05 06...

Page 5: ...able 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 Technical data engine and vehicle 11 02 1 12 WIRING DIAGRAM 01 Wiring diagram 12 01 1 SECTION SUBSECTION PAGE TABLE OF CONTENTS ...

Page 6: ...as technical drawings or exact replicas of the parts The use of Bombardier 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 emphasi...

Page 7: ...tions 01 SERVICE TOOLS AND SERVICE PRODUCTS 02 MAINTENANCE 03 ENGINE 04 FUEL SYSTEM 05 ELECTRICAL 06 DRIVE TRAIN 07 STEERING CONTROL SYSTEMS 08 SUSPENSION 09 BRAKES 10 BODY FRAME 11 TECHNICAL DATA 12 WIRING DIAGRAM Each section is divided in various subsections and again each subsection has one or more division RallyTM 200 red 7550 RallyTM 200 green 7551 RallyTM 200 yellow 7552 RallyTM 200 red int...

Page 8: ...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 lbf in pound per square inch LH left hand lb pound lbf pound force m meter MAG magneto Max maximum Min minimum ml milliliter mm millimeter MPH mile per hour N newton N A not applicable no number 00 0 continuity 0 L overload open circuit O D outside diameter OHC Over he...

Page 9: ...ion 04 REMOVAL AND INSTALLATION subsection 1 First page of this subsection CAUTION Pay attention to torque specifications Some of these are in lbf in instead of lbf ft Use appropriate torque wrench Document number for publishing process VMR2001 037_03 04A FM V04C0VS 10 N m 89 lbf in 26 23 22 21 5 24 6 11 N m 97 lbf in 13 N m 115 lbf in 19 18 19 13 N m 115 lbf in 24 N m 18 lbf ft 13 N m 115 lbf in ...

Page 10: ...ng cover to about 1 R610motr12A Installation For installation also heat the magneto housing up to about 100 o C 212 o F to put ball bearing in place Place new ball bearing in freezer for 10 minutes approximately Reinstall other removed parts in the reverse order STATOR AND TRIGGER COIL Removal Remove magneto housing cover no 7 100 o C 212 o F for an easy ball bearing removal screw no 11 and 12 sta...

Page 11: ...t be replaced by customary fasteners or vice versa Mismatched or incorrect fasteners could cause damage to the vehicle or possible per sonal injury As many of the procedures in this manual are in terrelated we suggest that before undertaking any task you read and thoroughly understand the entire section or subsection in which the proce dure is contained A number of procedures throughout the book r...

Page 12: ...s bolt and nut and allow to dry for 30 sec onds 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 th...

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: ...pply torque on nut 3 Torque at the recommended torque value NOTE Always torque screws bolts and or nuts in a criss cross sequence TIGHTENING TORQUES FOR 8 8 GRADE BOLTS AND NUTS WARNING Torque wrench tightening specifications must strictly be adhered to Locking devices ex locking tabs elastic stop nuts self locking fasteners etc must be installed or replaced with new ones where specified If the ef...

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: ... 01 TABLE OF CONTENTS VMR2003 033_01 01ATOC FM 01 01 1 TABLE OF CONTENTS 0 SERVICE TOOLS 01 02 1 MANDATORY SPECIAL TOOL 01 02 1 RECOMMENDED SPECIAL TOOL 01 02 8 SERVICE PRODUCTS 01 03 1 MANDATORY SERVICE PRODUCTS 01 03 1 RECOMMENDED SERVICE PRODUCTS 01 03 2 ...

Page 18: ... 02 1 SERVICE TOOLS 0 MANDATORY SPECIAL TOOL All Models Traxter Rally TOOL DESCRIPTION P N Small Hose Pincher 295 000 076 Large Hose Pincher 529 032 500 Fuel System Pressure Tester 529 033 100 A01B2IY F01B23Y A01B5EY TOOL DESCRIPTION P N 46 mm Socket for Crankshaft Driven Pulley 529 035 648 V01B0AY ...

Page 19: ...E TOOLS 01 02 2 VMR2003 002 01 02A FM DS 650 Baja Quest 500 650 Traxter TOOL DESCRIPTION P N Caillau Pliers 295 000 054 CV Boot Clamp Installation and Removal Tool 295 000 069 Crankshaft Protector 420 876 557 Flywheel Puller 529 035 748 F01B1TY F01D18Y V02B05Y V04B02Y ...

Page 20: ...S Subsection 02 SERVICE TOOLS VMR2003 002 01 02A FM 01 02 3 Rally TOOL DESCRIPTION P N Clutch Holding Tool 529 035 862 Clutch Support 529 035 863 51 mm 2 in Open Wrench 529 035 866 51 mm 2 in Crow Foot 529 035 884 V00B0KY V00B0LY V00B0OY V00B0PY ...

Page 21: ... VMR2003 002 01 02A FM Traxter TOOL DESCRIPTION P N Lifting Bar 529 035 610 Jumper for Self Diagnostics 529 035 605 Crankshaft Locking Bolt 529 035 645 Spanner Tool for Clutch Basket 529 035 647 T Harness for Diagnoses of Solenoids 529 035 653 V01B09Y V01B0MY V01B0CY V01B0BY V01B0LY ...

Page 22: ...OOLS VMR2003 002 01 02A FM 01 02 5 DS 650 Baja TOOL DESCRIPTION P N Magneto Cover Removal Tool 529 035 622 Engine Installation and Removal Tool 529 035 619 64 mm 2 1 2 in Crow Foot Rear Axle Nut 529 035 729 Clutch Basket Holder 529 035 618 V02B02Y V02B0NY V02B0VY V02B03Y ...

Page 23: ...03 002 01 02A FM Quest 500 650 TOOL DESCRIPTION P N Bevel Gear Lock Pin Driven Clutch Expander 529 035 747 Drive Clutch Puller 529 035 746 Driven Clutch Holding Tool 529 035 771 Drive Clutch Colding Tool 529 035 745 Bearing Aligment Tool 529 035 806 V04B06Y V04B05Y V04B03Y V04B04Y V04H0GY ...

Page 24: ...2 01 02A FM 01 02 7 Quest 500 650 Traxter DS 650 Baja Quest 500 650 Rally TOOL DESCRIPTION P N 6 Pin Harness for Magneto 529 035 604 41 mm Socket for Swing Arm Nut PROTO 5541 Hub Puller 529 035 612 TOOL DESCRIPTION P N Crankshaft Locking Bolt 529 035 617 F01B28Y V01B0TY V01B0OY V02B04Y ...

Page 25: ...ll Models TOOL DESCRIPTION P N Ring Compressor Snap On RC980 Low Speed Screw Adjuster 529 035 732 Float Level Gauge 529 035 520 Carburetor Kit 404 112 000 Valve Spring Compressor 529 035 724 Insertion Jig Handle 420 877 650 Flexible Spout for Oil Container 414 837 300 V04B08Y V04B0AY 1 2 3 4 A00B4NY A00B2FY V00B04Y A00C3VY F04B04Y ...

Page 26: ...CTS Subsection 02 SERVICE TOOLS VMR2003 002 01 02A FM 01 02 9 All Models Continued TOOL DESCRIPTION P N Vacuum Pressure Pump 529 021 800 Cable Luber 529 035 738 Leak Down Tester 529 035 661 Multimeter 529 035 868 V00B08Y V04B0JY V00B0CY V00B0HY ...

Page 27: ... 01 02A FM Quest 500 650 Rally Quest 500 650 Traxter TOOL DESCRIPTION P N Blind Hole Bearing Puller Snap On Needle Bearing Installer Main Shaft in Crankcase 529 035 762 R610outi03Y V00B0QY TOOL DESCRIPTION P N Ball Joint Remover 529 035 873 Differential Spanner Socket 529 035 649 V00B1JY V01B0SY ...

Page 28: ...01 02A FM 01 02 11 Quest 500 650 Traxter Continued TOOL DESCRIPTION P N Choke Nut Tool 529 035 660 Ball Joint Installer Support 529 035 875 Ball Joint Installer 529 035 874 Terminal Remover Snap On TT660 4 Shock Spring Disassembly Tool 529 035 504 V01B0GY V00B1LY V00B1KY F01B1JY A01B4OY ...

Page 29: ...00 650 Rally DS 650 Baja Quest 500 650 DS 650 Baja Quest 500 650 Traxter TOOL DESCRIPTION P N Valve Spring Compressor Cup 529 035 764 V04B09Y TOOL DESCRIPTION P N Valve Stem Seal Pliers Snap On YA 8230 V02B06Y TOOL DESCRIPTION P N Oil Pressure Adapter 529 035 652 Digital Inductive Type Tachometer 529 014 500 V00B07Y F01B1GY ...

Page 30: ...bsection 02 SERVICE TOOLS VMR2003 002 01 02A FM 01 02 13 DS 650 Baja Quest 500 650 Traxter Continued TOOL DESCRIPTION P N Exhaust Spring Installer Remover 529 035 401 Oil Pressure Gauge 529 035 709 Connection tool 529 035 714 A01B58Y V00B06Y F12B0GY ...

Page 31: ...D SERVICE PRODUCTS Subsection 02 SERVICE TOOLS 01 02 14 VMR2003 002 01 02A FM DS 650 Baja TOOL DESCRIPTION P N Front Hub Seal Installer 529 035 632 Ball Joint Guide 529 035 705 Ball Joint Drive 529 035 706 V02B0TY V02B0PY V02B0QY ...

Page 32: ...FM 01 02 15 DS 650 Baja Continued TOOL DESCRIPTION P N Swing arm key 529 035 696 Shock Tool 529 035 636 Rear Hub Seal Installer 529 035 634 Front Knuckle Wear Ring Installer 529 035 637 Shock Charging Tool 529 035 570 Brake Hub Remover 529 035 695 V02B0KY V00B0BY V02B0UY V02B0RY A02F13Y V02B0MY ...

Page 33: ...bsection 02 SERVICE TOOLS 01 02 16 VMR2003 002 01 02A FM DS 650 Baja Continued TOOL DESCRIPTION P N Rear Axle Wear Ring Installer 529 035 694 Crankshaft Bushing Installer 529 035 689 Primary Crankshaft Gear Puller 529 035 624 V02B0SY V00B1GY V00B0RY ...

Page 34: ...aja Continued Quest 500 650 TOOL DESCRIPTION P N Clutch Shaft Bearing Installer 529 035 691 Clutch Shaft Seal Installer 529 035 693 Crankshaft Bushing Remover 529 035 688 V00B0DY V00B0EY V00B1FY TOOL DESCRIPTION P N Water Pump Ceramic Seal Installer 529 035 766 Valve Stem Seal Installer 529 035 687 V04B0CY V04B0HY ...

Page 35: ...MR2003 002 01 02A FM Quest 500 650 Continued TOOL DESCRIPTION P N Lifting Ring 529 035 770 Torque Angle Snap On TA 362 Oil Seal Installer Crankshaft Oil Seal on Crankcase 529 035 760 Needle Bearing Installer Starter Drive Pinion in Crankcase 529 035 756 V04B07Y V04B0I4Y V00B0TY V00B0XY ...

Page 36: ...3 002 01 02A FM 01 02 19 Quest 500 650 Continued TOOL DESCRIPTION P N Oil Seal Installer Main Shaft Oil Seal on Crankcase 529 035 761 Oil Seal Installer Water Pump Shaft Oil Seal 529 035 757 Oil Seal Installer Crankshaft Oil Seal on Magneto Cover 529 035 759 V00B0SY V00B0UY V00B0VY ...

Page 37: ...st 500 650 Continued TOOL DESCRIPTION P N Oil Seal Installer Shift Shaft Oil Seal on Magneto Cover 529 035 758 Needle Bearing Installer Bevel Gear Shaft in Crankcase 529 035 763 Piston Circlip Installer 529 035 765 Crankcase Plain Bearing Remover Installer CVT Side 529 035 752 V00B0WY V00B0YY V04B0BY V00B0ZY ...

Page 38: ... 02 SERVICE TOOLS VMR2003 002 01 02A FM 01 02 21 Quest 500 650 Continued TOOL DESCRIPTION P N Crankcase Plain Bearing Remover Installer MAG Side 529 035 753 Crankcase Support CVT Side 529 035 754 Crankcase Support MAG Side 529 035 755 V00B10Y V00B11Y V00B12Y ...

Page 39: ... TOOLS 01 02 22 VMR2003 002 01 02A FM Traxter TOOL DESCRIPTION P N Crimping Tool for AMP Connectors 295 100 164 Lifting Ring 529 035 644 Front Suspension Spacer Bar Model Year 1999 2000 529 035 611 Valve Spring Compressor Cup 529 035 725 F00B0EY V01B0FY V01B0NY V00B05Y ...

Page 40: ...ION P N Clutch Holding Support 529 035 864 Crankshaft Oil Seal Installer 529 035 847 Water Pump Oil Seal Installer 529 035 849 Shifter Oil Seal Installer 529 035 851 Valve Guide Remover 529 035 852 Valve Guide Installer 529 035 853 Gearbox Oil Seal Installer 529 035 854 V00B0MY V00B13Y V00B14Y V00B15Y V00B16Y V00B17Y V00B18Y ...

Page 41: ...DESCRIPTION P N Magneto Puller used bolt from magneto puller P N 529 035 748 529 035 883 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 Bearing Puller 420 276 930 V00B0NY V00B19Y V00B1AY V00B1MY V00B1EY V00B1HY ...

Page 42: ... F01B124 Medium strength threadlocker P N 293 800 060 Loctite 243 Threadlocker 10 ml blue medium strength F00A0O4 Gasket paint remover P N 413 708 500 Loctite Chisel 510 g 18 oz A00B574 Loctite primer P N 293 800 041 Primer N 128 g 5 oz A00B3N4 Synthetic grease P N 293 550 010 400 g F01B154 Molykote G n paste P N 711 297 433 50 g A00B5P4 High strength retaining compound P N 293 800 073 Loctite 277...

Page 43: ...300 ml V00B1I4 Fuel stabilizer P N 413 408 600 12 x 8 oz A00B604 Premixed coolant 50 50 37 C 35 F P N 293 600 038 16 x 1 l A00B5X4 Chaincase oil P N 413 801 900 16 x 250 ml A00B5Y4 Storage oil P N 413 711 600 350 g spray can 12 x 350 g A00B634 Synthetic chaincase oil P N 413 803 300 12 x 355 ml A00B5Z4 BOMBARDIER LUBE P N 293 600 016 12 x 14 oz A00B624 Molykote 111 P N 413 707 000 A00B3W4 111 ...

Page 44: ...293 550 004 3 oz A00B1X4 Pulley flange cleaner P N 413 711 809 320 g A00B5V4 Heavy duty cleaner P N 293 110 001 400 g P N 293 110 002 4 l A00B614 Plastic vinyl cleaner P N 413 711 200 6 x 1 l A00B5W4 High temperature and strength retaining compound P N 413 711 400 Loctite 648 5 ml green A00B3D4 Pipe sealant P N 293 800 013 Loctite 567 250 ml A00B2W4 Loctite 5150 P N 293 800 086 A00B5S4 Paint for f...

Page 45: ..._003_01_03A FM RECOMMENDED SERVICE PRODUCTS continued Bombardier Cleaner P N 293 110 001 400 g P N 293 110 002 4 l F01B2J4 Bombardier Synthetic 4 Stroke Oil 5W 40 P N 293 600 039 12 x 1 l V00B094 Super Lube grease P N 293 550 030 V00B0I4 Bombardier Cable Lubricant P N 293 600 041 400 g V00B0A4 ...

Page 46: ...N AND MAINTENANCE CHART 02 02 2 MAINTENANCE LUBRICATION 02 03 1 SPECIAL PROCEDURES 02 03 1 AIR BOX 02 03 1 AIR FILTER 02 03 1 BOLTS FASTENERS AND NUTS 02 03 2 ENGINE OIL AND FILTER 02 03 2 OIL STRAINER 02 03 4 SPARK ARRESTER 02 03 4 TIRES AND WHEELS 02 03 5 ENGINE AREA 02 03 5 STORAGE PRESEASON PREPARATION 02 04 1 STORAGE 02 04 1 FUEL STABILIZER 02 04 1 ENGINE LUBRICATION 02 04 1 RAGS INTO INLET A...

Page 47: ...or 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 condu...

Page 48: ...ator condition cleanliness radiator fins I I Drive belt I CVT Centrifugal clutch I Cleaning condition of drive and driven pulleys C CVT air inlet duct condition cleanliness and sealing I I Air filter C R Maintenance lubrication Fuel lines and connections I I Fuel circuit Fuel valve strainers R Carburetor I I Carburetor Choke I I Spark plug I R Ignition system Battery electrolyte level connection a...

Page 49: ...at the spark plug gap is correct N A Not Available I Inspect verify clean adjust lubricate replace if necessary C Clean L Lubricate R Replace INITIAL 10 HOURS OR 200 KM 125 m EVERY REFER TO THE SUBSECTION 25 HOURS OR 500 KM 310 m 50 HOURS OR 1000 KM 620 m 100 HOURS OR 2000 KM 1250 m OR ONCE A YEAR 200 HOURS OR 4000 KM 2485 m OR 2 YEARS Swing arm I Front and rear suspension Shock absorber I A arm I...

Page 50: ... all parts of CVT before starting engine Refer to CVT section AIR BOX Draining Periodically inspect air filter box drain plug for water or deposits Refer to the maintenance chart TYPICAL 1 Air filter box 2 Drain plug 3 Clamp NOTE If vehicle is used in dusty area inspect more frequently than specified in maintenance chart If water deposits are found squeeze the clamp and remove Pull drain tube out ...

Page 51: ...s in the reverse order of their removal Reinstall the air filter with the grey part on top NOTE Checkif theairfilterbroachisproperlylocated before installing air filter BOLTS FASTENERS AND NUTS Check that all fasteners bolts and nuts are tightened to the proper torque For installation use the torque values and Loctite products from exploded views Clean threads before using Loctite product when ins...

Page 52: ...placed at the same time Oil change should be done with a warmed up engine Ensure vehicle is on a level surface Clean the drain plug area Remove dipstick Place a drain pan under the engine magnetic drain plug area Clean the magnetic drain plug area Unscrew magnetic drain plug CAUTION Pay attention not to lose gasket ring on magnetic drain plug 1 Magnetic drain plug Allow enough time for oil to flow...

Page 53: ...OIL STRAINER Refer to LUBRICATION section SPARK ARRESTER The muffler must be periodically purged of accu mulated carbon Select a well ventilated area and make sure the muffler is cool Place transmission on NEUTRAL position and apply parking brake Remove the screw retaining the spark arrester to muffler Pull the spark arrester out of muffler 1 Spark arrester 2 Muffler Using a brush remove the carbo...

Page 54: ... wear Measure thread height It shouldbe4mm 5 32in minimum Replace if damaged or worn A 4 mm 5 32 in NOTE Do not make a tire rotation The front and rear tires have a different size Besides these tires are directional and their rotation must be kept in a specific direction for proper operation Wheel Removal Untighten nuts then lift vehicle where needed Place a support under vehicle Remove nuts then ...

Page 55: ...il the engine reaches its operating tempera ture Stop the engine Changeengineoilandfilter RefertoMAINTENANCE LUBRICATION Remove the intake adaptor between carburetor and air box to spray storage oil P N 413 711 600 into carburetor bore Restart engine and run at idle speed Inject storage oil until the engine stalls or until a sufficient quantity of oil has entered the en gine approximately a quarte...

Page 56: ... Sunshine Makers Inc available at hardware stores or at automotive parts retailer For vinyl and plastic parts use Vinyl Plastic Cleaner P N 413 711 200 6 x 1 l CAUTION Never clean plastic parts with strong detergent degreasing agent paint thinner ac etone products containing chlorine etc Inspect the vehicle and repair any damage Touch up all metal spots where paint has been scratched off Spray all...

Page 57: ... Replacement and Pressurization of System Cooling System Condition of Seals N A Exhaust System Condition Removal Installation CVT System Condition CVT Rags in CVT Hoses Maintenance Fuel Line and Connectors Condition Fuel Circuit Carburetor Adjustment Carburetor Throttle Cable Inspection Adjustment Lubrication Air Filter Cleaning Replacement Maintenance Spark Plug Replacement Ignition System Batter...

Page 58: ...STEM 03 04 1 EXHAUST SYSTEM 03 04 2 GENERAL 03 04 3 ENGINE 03 04 3 ENGINE SPROCKET 03 04 9 FRONT ANTI VIBRATION SYSTEM 03 04 10 EXHAUST PIPE 03 04 10 MUFFLER 03 04 11 TRANSMISSION LEVER 03 04 11 COOLING SYSTEM 03 05 1 WATER PUMP 03 05 1 COOLING SYSTEM 03 05 2 GENERAL 03 05 3 COOLING SYSTEM LEAK TEST 03 05 3 INSPECTION 03 05 3 DRAINING THE SYSTEM 03 05 3 COOLANT REPLACEMENT 03 05 4 THERMOSTAT 03 05...

Page 59: ...STRAINER 03 07 5 ENGINE OIL PRESSURE REGULATOR 03 07 6 OIL PUMP 03 07 7 CYLINDER AND HEAD 03 08 1 GENERAL 03 08 3 SPARK PLUG 03 08 3 THERMOSTAT 03 08 3 VALVE COVER 03 08 3 VALVE ADJUSTMENT 03 08 4 CHAIN TENSIONER 03 08 5 BREATHER 03 08 5 CAMSHAFT TIMING GEAR 03 08 6 ROCKER ARM 03 08 7 TIMING CHAIN 03 08 9 CYLINDER HEAD 03 08 9 CAMSHAFT 03 08 11 VALVE SPRING 03 08 12 VALVE 03 08 13 VALVE GUIDE PROC...

Page 60: ...EARBOX 03 10 1 CRANKCASE 03 10 2 GENERAL 03 10 3 OIL CHANGE 03 10 3 OIL SEALS 03 10 3 CRANKCASE 03 10 5 GEAR BOX 03 10 8 SHIFTING INDICATOR SWITCH 03 10 15 CVT 03 11 1 GENERAL 03 11 2 DRIVE BELT REPLACEMENT 03 11 2 CVT COVER 03 11 3 CVT COVER BEARING 03 11 4 DRIVE PULLEY 03 11 4 DRIVEN PULLEY 03 11 7 ...

Page 61: ...inder head a Thermostat defective does not open when engine gets hot Replace thermostat 4 Check weep hole oil pressure switch area MAG side if coolant leaks a Coolant leaking from weep hole means a damaged oil seal and or O ring on water pump housing Replace both oil seals and O rings refer to COOLING SYSTEM and MAGNETO COVER 5 Check coolant bleeding screw on thermostat housing a Screw looses and ...

Page 62: ...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 failure a Radial position of rotor wrong due to a broken woodruff key Replace woodruff key b Connector on magneto is damaged and or has electrical failure Repair and clean c...

Page 63: ...damaged and or sealing lip is hard and or brittle Replace all valve stem seals 2 Check oil filter for contamination a Oil filter clogged Replace oil filter and oil at the same time Use a high quality oil refer to TECHNICAL DATA 3 Check oil pressure regulator valve spring function a Valve spring damaged valve always open Replace spring b Valve stays open in crankcase PTO due to contamination metali...

Page 64: ...earings at the same time refer to CRANKSHAFT SYMPTOM OIL CONTAMINATION WHITE APPEARANCE CONDITION NORMAL USE Test Inspection 1 Check weep hole oil pressure switch area MAG side if water and oil leaks a Leakage of oil water mixture from weep hole means damaged oil seals and or O rings on water pump housing Replace sealing rings O rings and refill with recommended oil and or coolant refer to COOLING...

Page 65: ...heck noise coming from cylinder head area a Check valve timing Readjust valve timing and or replace failure part s b Chain guide worn out Replace chain guide c Stretched chain and or worn out sprocket Replace chain and sprocket at the same time d Sprocket screw got loose Retighten screw with recommended torque e Rocker arm s is are worn out valve adjustment Readjust valve clearance and or replace ...

Page 66: ...a Bearing s do es not move freely Replace bearing s 2 Check oil level in gearbox a Oil leakage through plug cover area near speed sensor support Replace O ring and retighten screw with recommended torque b Oil leakage in gearbox cover gasket area Replace gasket and do the torque procedure refer to GEARBOX 3 Check chain condition a Reverse gear chain shows heavy wear rolles chain links Replace chai...

Page 67: ...ged Repair and or replace damaged part s 3 Check index spring placed on gearbox cover a Indexation fails due to broken and or damaged index spring Clean gearbox from metal particles replace index spring and or damaged part s SYMPTOM GEAR S IS ARE HARD TO SHIFT CONDITION NORMAL USE Test Inspection 1 Check shift plate and or shift forks for wear and or damages a Shift plate has worn out and or damag...

Page 68: ...ce centrifugal clutch assembly 3 Check roller on drive pulley inner half a Rollers are worn and or wrong installed and or otherwise damaged refer to CVT Replace all rollers at the same time roller kit 4 Check function of sprag clutch on driven pulley a Sprag clutch is clogged and or worn out refer to CVT Replace sprag clutch together with ball bearing and oil seal refer to CVT SYMPTOM ENGINE MAXIM...

Page 69: ...ring s do es not move freely Replace bearing s and oil seal inside driven pulley at the same time SYMPTOM DRIVE PULLEY NOISE WHEN ACCELERATING DECELERATING CONDITION NORMAL USE Test Inspection 1 Check items 1 to 5 of DRIVE PULLEY NOISE IN IDLE SPEED 2 Check if belt runs in dry conditions a Drive pulley area is wet contaminated due to water dirt intrusion Clean driven pulley area and or drain water...

Page 70: ...oo weak Replace SYMPTOM BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE CONDITION NORMAL USE Test Inspection 1 Check if drive pulley air intake is clogged a Drive pulley area heats up due to contamination Clean air intake from contamination 2 Check if pulley halves are clean a Oil on pulley surfaces Clean pulley halves and replace belt SYMPTOM BELT WORN EXCESSIVELY IN TOP WIDTH CONDITION NORMAL...

Page 71: ...ECHNICAL DATA SYMPTOM BELT DISINTEGRATION CONDITION NORMAL USE Test Inspection A00DOEY 1 Check drive belt identification number a Excessive belt speed Using unspecified type of belt Replace belt with proper type of belt refer to TECHNICAL DATA 2 Check if pulley halves are clean a Oil on pulley surfaces Clean pulley surfaces with fine emery cloth and wipe clean using Pulley Flange Cleaner P N 413 7...

Page 72: ...b Electrical system has failure Replace defective part s 2 Check leakage on intake manifold a Air leak on intake system Retighten screws and or replace intake manifold 3 Check exhaust air leaking a Exhaust gasket is leaking Retighten screws and or replace exhaust gasket 4 Check intake valve s for leaking a Intake valve s is are leaking Repair or replace valve s 5 Check if fuel supply is to less at...

Page 73: ...e Fuel supply to less at high RPM Clean fuel supply from contamination 3 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 Replace and or repair defective parts 4 Piston seizure a Spark plug heat range is too low Install spark plug with appropriate heat range refer to TECHNICAL DATA ...

Page 74: ...ike sand through engine intake Replace defective part s and use new air filter 8 Check connecting rod crankshaft rocker arm rollers movement a Connecting rod failure due to leak of oil Repair and replace defective parts and use a high quality oil b Crankshaft failure due to leak of oil Repair and replace defective parts and use a high quality oil c Oil contamination due to clogged oil filter Repla...

Page 75: ... or replace 4 Check spark plug type a Improper spark plug heat range Install recommended spark plug refer to TECHNICAL DATA 5 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 Replace and or repair defective parts 6 Check for water in fuel wrong fuel a There is water in fuel or wrong...

Page 76: ...ve clearance SYMPTOM HIGH ENGINE OPERATING TEMPERATURE CONDITION NORMAL USE Test Inspection 1 Check if cooling system shows any failure see COOLING SYSTEM a System is leaking Repair and or replace damaged part s 2 Check condition and heat range of spark plug a Melted spark plug tip or inadequate heat range Install recommended spark plug refer to TECHNICAL DATA 3 Check air inlet and outlet of the C...

Page 77: ...ition a Defective trigger coil Corroded connector terminal Replace trigger coil Clean terminals and apply silicone dielectric grease 4 Verify condition of ignition coil a Mechanically damaged part Vibration problem Electrically damaged part Replace ignition coil 5 Verify condition of trigger coil a Mechanically damaged part Vibration problem Electrically damaged part Replace trigger coil and or ti...

Page 78: ...r hole means a dam aged oil seal on water pump shaft refer to COOLING SYSTEM NOTE For all the checkpoints mentioned above see the appropriate engine section to diagnose and repair the engine LEAK TEST PROCEDURE Preparation NOTE The following procedures should be done with a cold engine Disconnect battery Remove radiator cap CVT hose inlet NOTE To ease reaching cylinder head area it is recommended ...

Page 79: ...Remove the RH engine side panel Remove magneto cover and the rotor on crank shaft until piston is at TDC Install crankshaft locking bolt P N 529 035 617 refer to CRANKSHAFT 1 Crankshaft locking bolt 2 Thread in the area of electrical starter Test Connect leak tester P N 529 035 661 to adequate air supply Set needle of measuring gauge to zero NOTE Each tester will have specific instruction on the g...

Page 80: ...nd 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 checkpoints mentioned above see the appropriate engine section to diagnose and repair the engine Installation NOTE At reassembly use the torque values and Loctite products from the exploded views refer to particular engine sections For insta...

Page 81: ... REMOVAL AND INSTALLATION VMR2003_008_03_04A FM 03 04 1 REMOVAL AND INSTALLATION 0 ENGINE SYSTEM V06C0MS 1 1 5 N m 13 lbf in 8 48 N m 35 lbf ft 1 5 N m 13 lbf in 1 5 N m 13 lbf in 3 6 8 5 2 1 5 N m 13 lbf in 7 17 10 N m 89 lbf in 18 ...

Page 82: ...Section 03 ENGINE Subsection 04 REMOVAL AND INSTALLATION 03 04 2 VMR2003_008_03_04A FM EXHAUST SYSTEM V06C0NS 13 12 12 11 N m 97 lbf in 11 N m 97 lbf in 14 9 11 10 14 15 16 16 15 N m 133 lbf in ...

Page 83: ...Turn fuel valve on OFF position Drain engine oil and engine coolant 1 Oil drain plug 1 Cooling drain plug On right side of vehicle do the following Remove RH footwell and RH cover refer to BODY 1 Footwell 2 RH cover WARNING Always disconnect battery or starter cables exactly in the specified order BLACK cable first WARNING Torque wrench tightening specifications must strictly be adhered to Locking...

Page 84: ... Insert adjuster lock through sprocket hub and into chain tensioner 1 Drive chain 2 Adjuster lock 3 Sprocket hub 4 Chain tensioner Slacken drive chain tightness Disconnect water temperature sensor oil pressure sensor breather hose on valve cover coolant engine outlet hose NOTE Catch any coolant spillage 1 Water temperature sensor 2 Oil pressure sensor 3 Coolant engine outlet hose 4 Breather hose 2...

Page 85: ...utral switch 3 Reverse switch On left side of vehicle remove the following LH footwell and LH cover refer to BODY 1 Footwell 2 LH cover CVT inlet no 1 and oulet no 2 hoses 1 CVT inlet hose 2 CVT outlet hose spark plug cable fuel line carburetor vent hose 1 Spark plug cable 2 Fuel line 3 Carburetor vent hose 2 V06C0PA 3 1 1 V06L07A 2 1 V06C0QA 2 1 2 V06C0RA 3 ...

Page 86: ...st pipe no 4 see EXHAUST PIPE further in this section From the top side do the following Remove seat refer to BODY fuel tank refer to FUEL CIRCUIT Unplug the magneto connector 1 Magneto connector Remove air box and the air intake hose Remove starter From bottom side do the following Install engine lifting strap under CVT housing 1 CVT housing 2 Engine lifting strap NOTE Check local specialized sup...

Page 87: ...y 25 mm 1 in to clear front mounting brackets Turn engine 90 cylinder head towards right side of vehicle Rest engine onto frame and relocate engine lifting strap Relift engine and move away from vehicle Installation Lift engine and move towards vehicle Rest engine onto frame and relocate lifting strap to opposite side of frame Start lifting engine up turn engine 90 cylinder head towards front of v...

Page 88: ...nd swing arm bushings on both side 1 Frame 2 Swing arm 3 O ring Install O rings between swing arm bushing and washers One on each side SWING ARM BOLT SIDE SHOWN 1 O ring 2 Washer 3 Swing arm 4 Swing arm bolt Torque the front engine mounting bolt no 5 Remove lifting strap Install drive chain on engine sprocket From the top side do the following Connect the magneto connector Install starter air box ...

Page 89: ...vehicle Set carburetor Stop engine and reverify coolant and oil levels are correct Adjust drive chain refer to REAR AXLE Test drive to confirm all is working well ENGINE SPROCKET Removal Remove RH footwell refer to BODY caliper and disc refer to BRAKES Unlook the tab washer no 18 Unscrew the sprocket nut then remove the tab washer Slack the drive chain Remove the chain roller then remove the drive...

Page 90: ... clamp no 9 retaining exhaust pipe no 4 to muffler no 10 Unscrew exhaust pipe nuts no 12 1 Exhaust pipe nuts Pull exhaust pipe forward then remove it from ve hicle Remove the gasket no 13 in the exhaust port and the muffler gasket no 11 Installation For installation reverse the removal procedure pay attention to the following details Using a new exhaust pipe gasket no 11 install the exhaust pipe i...

Page 91: ...fler for cracks or other damages Replace if necessary Check if rubber bushings no 16 are brittle hard cracked or otherwise damaged change them if necessary Installation For the installation reverse the removal procedure TRANSMISSION LEVER Removal Unscrew transmission lever retaining bolt no 17 and remove lever no 7 NOTE Mark the lever position for easier installa tion Installation For installation...

Page 92: ...3_05A FM 03 05 1 COOLING SYSTEM 0 WATER PUMP R175motr165S 24 23 11 N m 97 lbf in 15 N m 133 lbf in Loctite 243 8 5 N m 44 lbf in 3 7 2 4 N m 35 lbf in 4 6 5 19 17 18 15 16 Loctite 243 6 N m 53 lbf in 14 12 11 10 13 9 1 Multi purpose grease Engine oil Engine oil ...

Page 93: ...2 VMR2003_009_03_05A FM COOLING SYSTEM V06C12S 21 26 30 25 2 5 N m 22 lbf in 34 31 34 Loctite 384 27 36 35 3 N m 27 lbf in 32 Pipe sealant 2 5 N m 22 lbf in 2 5 N m 22 lbf in 22 37 20 Pipe sealant Pipe sealant Pipe sealant 28 29 29 28 11 N m 97 lbf in 33 ...

Page 94: ...SPECTION Check general condition of hoses and clamp tight ness Check the weep hole if there is oil and or water and replace oil seals in water pump housing if nec essary refer to WATER PUMP HOUSING further NOTE Flowing water and or oil out of the weep hole indicates non working oil seal s no 1 1 Weep hole 2 Oil pressure switch area DRAINING THE SYSTEM Remove the front luggage rack Refer to BODY Re...

Page 95: ...TA Coolant Replacement Procedure Drain the system completely see procedure above Pinch engine outlet hose no 25 between radiator and thermostat housing with a large hose pincher P N 529 032 500 Unscrew bleeding screw on top of thermostat housing NOTE Do not remove the bleeding screw com pletely 1 Bleeding screw With vehicle on a flat surface engine cold refill ra diator no 22 When the coolant come...

Page 96: ... Remove bleeding screw no 2 on thermostat cover only turn loose thermostat housing screws no 3 and pull ther mostat cover no 4 1 2 screws 2 Bleeding screw 3 Gasket 4 Thermostat housing thermostat with gasket out of the hole 1 Thermostat with gasket Test To check thermostat put in water and heat water Thermostat should open when water temperature reaches 65 C 149 F Check if the gasket is not brittl...

Page 97: ...ead has a tapper thread Test To check temperature switch put in water and heat water Temperature switch should operate when water temperature reaches 115 C 239 F Replace temperature switch if necessary Installation For installation reverse the removal procedure pay attention to the following detail Do not apply Loctite 243 in the front area of the switch 1 Loctite area WATER PUMP HOUSING It is loc...

Page 98: ... to oil pump shaft NOTE Do not collide splines of water pump gear no 12 with splines of sprag clutch gear 1 Direction of needle pin 2 Possible collision of water pump gear and sprag clutch gear 3 Place to lift water pump gear needle pin no 13 and thrust washer no 14 1 Needle pin 2 Thrust washer screw no 9 retaining water pump housing no 15 1 Allen socket screw water pump housing no 15 1 R175motr16...

Page 99: ...p housing Inspection Check if O rings are brittle hard or damaged and replace if necessary 1 2 O rings 2 Weep hole Inspect water pump gear for wear and damage on the snap mechanism to the needle pin Replace if necessary Installation The installation is the opposite of the removal pro cedure Push oil seals no 1 in place by using the handle for insertion jig P N 420 877 650 and the oil seal pusher P...

Page 100: ...r pump shaft bore CAUTION To prevent leaking take care that the O rings are exactly in grooves when you reinstall the water pump housing Install water pump gear CAUTION Donotforgettoplaceshimsno 11 and no 14 1 Shim 2 Water pump gear 3 Shim Install a new retaining ring CAUTION Never use the retaining ring a second time WATER PUMP IMPELLER Removal Remove water pump housing no 15 refer to WATER PUMP ...

Page 101: ...haft no 18 WATER PUMP SHAFT Removal Remove water pump housing no 15 refer to WATER PUMP HOUSING above impeller no 17 together with water pump shaft no 18 Inspection Water pump shaft must rotate freely Otherwise replace it NOTE When removing water pump shaft always replace together retaining ring oil seals water pump shaft with new parts Installation For installation reverse the removal procedure P...

Page 102: ...section to the COOLANT REPLACEMENT PRO CEDURE COOLANT TANK Overflow Coolant Tank The coolant expands as the temperature up to 100 110 C 212 230 F and pressure rise in the system If the limiting system working pressure cap is reached 110 kPa 16 PSI the pressure re lief valve in the pressure cap is lifted from its seat and allows coolant to flow through the overflow hose into the overflow coolant ta...

Page 103: ...hose no 33 of block heater 1 Inlet hose 2 Outlet hose Turn fuel valve OFF then unplug the fuel line 1 Fuel valve on OFF position 2 Fuel line Come out the carburetor overflow drain hose from its location 1 Carburetor overflow drain hose Unplug the carburetor vent hose 1 Carburetor vent hose 2 Fuel line 1 V06C17A 2 1 V06C18A 2 1 V06C19A 2 1 V06C1AA ...

Page 104: ...r box Free carburetor from the intake adaptor 1 Unscrew these clamps Unscrew the valve piston assembly then remove the block heater inlet hose no 32 1 Valve piston assembly 2 Block heater inlet hose Use the following procedure if the block heater and carburetor separation is necessary ex block heater or carburetor replacement With the carburetor removed unscrew the screw no 35 then remove the bloc...

Page 105: ...Apply 2 ml 06 oz of Loctite 384 P N 293 800 099 on the block heater Spread the Loctite 384 every where on the contact surface of the block heater Install the block heater in accordance with the fol lowing illustration Install the block heater lock and torque screw Reinstall carburetor Reverse the removal proce dure NOTE Leave the Loctite 384 dries before install ing the carburetor on the vehicle R...

Page 106: ...MAGNETO SYSTEM 11 14 13 7 Loctite 648 Engine oil 9 10 8 30 N m 22 lbf ft Loctite 243 Loctite 648 12 4 Engine oil Engine oil 15 16 Anti seize lubricant Lithium base grease 5 6 2 1 30 N m 22 lbf ft 10 N m 89 lbf in 10 N m 89 lbf in 10 N m 89 lbf in Silicone sealant 30 N m 22 lbf ft R175motr145S 3 ...

Page 107: ...footwell and the seat refer to BODY Lift up the fuel tank refer to FUEL CIRCUIT Unplug magneto connector from wire harness WIRES LOCATION IN THE CONNECTOR 1 Wire WHITE YELLOW for trigger coil 2 Wire BLUE YELLOW for trigger coil 3 Wire BLACK YELLOW for ground 4 Wires YELLOW for charge Remove magneto cover screws no 1 1 Magneto cover screws Withdraw magneto cover no 2 1 Magneto cover 2 Rotor 3 Gaske...

Page 108: ... procedure However pay attention to the following IMPORTANT Apply small amount of silicon on mating surface in grommet area before placing the gasket 1 Grommet Install a new gasket on the magneto cover Tightening sequence for screws on magneto cover is as per following illustration STATOR AND TRIGGER COIL Removal Remove RH footwell refer to BODY magneto housing cover no 2 screws nos 5 and 6 stator...

Page 109: ...CHARGING SYSTEM for the stator and IGNITION SYSTEM for the trigger coil Installation For installation reverse the removal procedure However pay attention to the following There is only one position for the stator notch in the magneto cover 1 Notch for stator ROTOR Removal Lock crankshaft with locking bolt P N 529 035 617 Refer to CRANKSHAFT BALANCER SHAFT 1 Crankshaft locking bolt P N 529 035 617 ...

Page 110: ... sleeve no 4 and starter inter mediate gear no 12 1 Rotor 2 Sprag clutch gear 3 Starter intermediate gear 4 Distance sleeve sprag clutch refer to SPRAG CLUTCH further Inspection Check woodruff key and keyway on the crankshaft for wear or damages Replace if necessary Installation For installation reverse the removal procedure However pay attention to the following CAUTION When installing the rotor ...

Page 111: ...ch housing no 13 in vise then remove screws retaining the sprag clutch housing to the rotor CAUTION Use protector on the vise jaws to avoid damaging the sprag clutch housing 1 Rotor 2 3 screws M8 3 Vise jaw protectors Separate sprag clutch housing and rotor Push the sprag clutch no 14 out of sprag clutch housing no 13 1 Sprag clutch 2 Sprag clutch housing Inspection Check contact surface of sprag ...

Page 112: ... However pay attention to the following Sprag clutch has a snap mechanism to the sprag clutch housing Press the sprag clutch until the mechanism is locked CAUTION Before reassemble the sprag clutch housing clean threads with a tap from remain ing Loctite 1 Push until snap mechanism works 2 Thread to be clean STARTER Removal Remove wire from starter no 15 screws no 16 starter 1 Starter 2 O ring BUS...

Page 113: ...hard or otherwise dam aged Replace if necessary Installation For installation reverse the removal procedure However pay attention to the following Always apply the anti seize lubricant on the sup port of the starter which is shown in the exploded view 1 Starter 2 Support to crankcase MAG 3 Spline 3 R175motr164A 2 1 ...

Page 114: ...M VMR2003_011_03_07A FM 03 07 1 LUBRICATION SYSTEM 0 R175motr124S 10 N m 89 lbf in 11 12 14 13 15 5 6 7 4 2 3 8 9 10 30 N m 22 lbf ft 20 N m 15 lbf ft 30 N m 22 lbf ft 19 18 Loctite 243 15 N m 133 lbf in Loctite 243 6 N m 53 lbf in 16 17 Engine oil 1 ...

Page 115: ... regulator valve 6 Bypass back to bottom of crankcase 7 Oil line to pressure switch crankcase MAG side 8 Oil pressure switch 9 Cylinder stud screw bore as oil supply to camshaft 10 Camshaft plain bearing 11 Lubrication for rocker arms 12 Chain tensioner 13 Crankshaft plain bearing 14 Oil line to crank pin and sprag clutch gear 15 Big end connecting rod plain bearing 16 Plug screw to separate metal...

Page 116: ...se MAG side and install the oil pres sure gauge P N 529 035 709 1 Oil pressure switch 2 Oil filter cover NOTE Oil pressure switch works between 15 kPa 2 PSI and 35 kPa 5 PSI The engine oil pressure should be as following value at warm engine condition 80 C 176 F approxi mately If the engine oil pressure is out of specifications check the points described in TROUBLESHOOT ING section To install oil ...

Page 117: ...capacity after operat ing the vehicle a few minutes Oil level should be within the foreseen area 1 Full 2 Add 3 Operating range OIL FILTER Removal Remove engine oil refer to Oil Change oil filter screws no 4 oil filter cover no 5 oil filter no 7 1 Oil filter screws 2 Oil filter cover 3 Oil filter 4 O ring 5 Oil pressure switch Inspection Check oil filter cover O ring no 6 change it if nec essary C...

Page 118: ...ion Clean oil strainer with a part cleaner then use an air gun to dry it On engine clean the oil strainer area CAUTION To avoid contaminate the oil pump and furthermore engine inside never use an air gun to clean the hole Clean both contact surfaces of plug screw Installation For installation reverse the removal procedure Refill engine at the proper level with the recom mended oil Refer to TECHNIC...

Page 119: ...on oil pressure regulator plug Extract the ball from the engine NOTE To easily remove the ball use an air gun 1 Valve housing 2 Compression spring 3 Ball 4 Oil pressure regulator port Clean and Inspection Clean oil pressure regulator bore from contamina tion with an air gun NOTE Contamination has to pass oil filter or goes back to bottom of crankcase The dirt will not reach the oil circulation ins...

Page 120: ...pump housing refer to COOLING SYSTEM Removal Remove RH footwell and seat engine oil NOTE No need to drain cooling system magneto cover and rotor refer to MAGNETO SYSTEM 1 Water pump gear 2 Oil pump powered by crankshaft screws no 18 oil pump assembly no 19 1 2 screws 2 Oil pump gear 1 Oil pump system 2 R175motr136A 1 2 R175motr137A 1 1 R175motr138A ...

Page 121: ...lter 3 Plain bearing in crankcase MAG Inspection Inspect oil pump assembly for marks or other dam ages Check inner rotor for damages If so replace oil pump assembly Ensure to also check oil pump housing If damaged replace the complete oil pump assembly 1 Bore of oil pump outer rotor 2 Contact surface between inner and outer rotor 3 Mark on outer rotor 4 Oil pump shaft Using a feeler gauge measure ...

Page 122: ...oil pump shaft assembly increases the oil pressure de creases less discharge Check the inside of oil pump housing and crank case area for scoring or other damages If so change the complete oil pump assembly NOTE If the surface only shows a small groove use a grindstone to burnish burrs When the oil pump is seized replace crankcase assembly and complete oil pump 1 Oil pump contact surface Clean the...

Page 123: ...moval it is not necessary to remove engine from vehicle R175motr60S 24 24 23 26 25 24 N m 18 lbf ft 10 N m 89 lbf in Loctite 243 Loctite 243 10 N m 89 lbf in 10 N m 89 lbf in 1 2 3 10 N m 89 lbf in 37 38 21 35 N m 26 lbf ft 18 19 20 36 Anti seize lubricant Engine oil Engine oil Engine oil Engine oil 10 N m 89 lbf in Engine oil 15 N m 133 lbf in ...

Page 124: ...Engine oil R175motr61S 5 N m 44 lbf in 10 9 8 7 28 13 15 16 17 Engine oil 11 4 30 N m 22 lbf ft 6 14 17 10 N m 89 lbf in 13 Engine oil 12 16 11 Engine oil Engine oil 42 39 41 40 22 27 14 5 40 Engine oil Loctite 243 Engine oil 31 Engine oil 33 Anti seize lubricant 29 35 32 34 31 30 ...

Page 125: ...ause of the failure among its group of parts eg you found a worn valve guide A bent spring could be the cause and it will be easy to know which one among the springs is the cause to replace it if you grouped them at disassem bly Besides since used parts have matched togeth er during the engine operation they will keep their matched fit when you reassemble them together within their group Intake po...

Page 126: ... a criss cross sequence VALVE ADJUSTMENT Lock crankshaft at the TDC compression position refer to CRANKSHAFT Remove valve cover refer to VALVE COVER above Hold adjusting screw no 14 and loosen locking nut no 13 Using feeler gauge check the valve clearance 1 Adjustment screws 2 Locking nuts 3 Feeler gauge Hold the adjusting screw at the proper position and torque the locking nut Repeat the procedur...

Page 127: ...sary Check spring condition Replace if broken or worn Install NEW gasket ring no 19 Installation For installation reverse the removal procedure BREATHER Removal Remove valve cover breather no 4 with V ring no 5 NOTE Use flat screwdriver to remove breather as per following illustration 1 Flat screwdriver 2 Breather Inspection Check V ring no 5 and or breather If they are brit tle cracked or hard re...

Page 128: ...rse the removal procedure Pay attention to the following details Clean mating surface and threads of camshaft pri or assemble camshaft timing gear 1 Mating surface on camshaft 2 Threads for timing gear bolt Camshaft timing gear must be at TDC position be fore installing the timing chain Install camshaft timing gear so that the timing gear tab is located into the camshaft groove The point ed end of...

Page 129: ...n screws 4 Camshaft retaining plate rocker arm shafts no 11 rocker arm assembly exhaust side no 12 and intake side no 15 with adjustment screws no 14 and nuts no 13 1 2 rocker arm shafts 2 Rocker arm assembly exhaust 3 Rocker arm assembly intake 4 4 adjustments screws 5 4 nuts thrust washers no 16 and spring washers no 17 CAUTION Pay attention not to lose thrust washer and spring washer 1 2 thrust...

Page 130: ...pecification change the rocker arm assembly Check adjustment screws for free movement cracks and or excessive play 1 Free movement of adjustment screw top Rocker Arm Shaft Check forscoredfrictionsurfaces if so replaceparts Measure rocker arm shaft diameter A Measure rocker arm shaft diameter here Any area worn excessively will require parts replacement ROCKER ARM BORE DIAMETER NEW MINIMUM 10 036 m...

Page 131: ...er no 17 and push rocker arm shaft to end position TIMING CHAIN Refer to CRANKSHAFT section CYLINDER HEAD Removal Lock crankshaft at TDC compression position refer to CRANKSHAFT Drain coolant refer to COOLING SYSTEM Disconnect spark plug cable temperature sensor connector Remove RH footwell exhaust pipe refer to REMOVAL AND INSTALLATION engine outlet hose carburetor refer to CARBURETOR chain tensi...

Page 132: ...ing journal PTO side Installation For installation reverse the removal procedure Pay attention to the following details Ensure dowel pins are in place Torque cylinder head nuts no 23 in criss cross se quence at half of the recommended torque value in the exploded view Finish tightening hexagonal nuts no 23 criss cross with the recommended values in the explod ed view Torque cylinder head screws no...

Page 133: ... rocker arms see ROCKER ARM above camshaft no 28 NOTE Rotatecamshaftforgrooveshowstocylinder head intake side to ease removal of the camshaft 1 Direction of rotation 2 Groove exhaust port 3 Camshaft Inspection Check each lobe and bearing journal of camshaft for scoring scuffing cracks or other signs of wear Measure camshaft bearing journal diameter and lobe height using a micrometer A Camshaft lob...

Page 134: ...035 724 and valve spring compressor cup P N 529 035 725 CAMSHAFT LOBE EXHAUST INTAKE VALVE NEW MINIMUM 30 887 mm 1 216 in NEW MAXIMUM 31 087 mm 1 224 in SERVICE LIMIT 30 800 mm 1 212 in CAMSHAFT BEARING JOURNAL MAG SIDE NEW MINIMUM 31 950 mm 1 2579 in NEW MAXIMUM 31 975 mm 1 2589 in SERVICE LIMIT 31 930 mm 1 2571 in CAMSHAFT BEARING JOURNAL PTO SIDE NEW MINIMUM 19 959 mm 7858 in NEW MAXIMUM 19 980...

Page 135: ... spring for visible damages If so replace valve spring Check valve spring for free length and straightness Replace valves if not within specifications A Valve spring length Installation For installation reverse the removal procedure Pay attention to the following details Colored area of the valve spring must be placed on top NOTE Valve cotter must be properly engaged in valve stem grooves 1 Positi...

Page 136: ...never cylinder head is removed Valve Inspect valve surface check for abnormal stem wear and bending If out of specification replace by a new one Valve Stem and Valve Guide Clearance Measure valve stem and valve guide in three places using a micrometer and a small bore gauge NOTE Clean valve guide to remove carbon depos its before measuring Change valve if valve stem is out of specification or has ...

Page 137: ...pping tool see VALVE GUIDE PROCE DURE below Measure valve face contact width NOTE The location of contact area should be in center of valve seat Measure valve seat width using a caliper If valve seat contact width is too wide or has dark spots replace the cylinder head A Valve face contact width B Valve seat contact width VALVE STEM DIAMETER mm in NEW MINIMUM EXHAUST 3 96 mm 1559 in INTAKE 3 97 mm...

Page 138: ...es CAUTION An improperly locked valve spring will cause engine damage VALVE GUIDE PROCEDURE Removal Remove cylinder head see CYLINDER HEAD above valve spring see VALVE SPRING above valve see VALVE above NOTE Clean valve guide area from contamination before removal Heat the valve guide area during approximately 10 minutes to 100 C 212 F Usingvalveguide remover P N529 035 852 remove valve guide no 3...

Page 139: ... paste to ease checking contact pattern CYLINDER Removal Lock crankshaft at TDC compression position refer to CRANKSHAFT Remove chain tensioner see CHAIN TENSIONER above breather see BREATHER above camshaft timing chain cylinder head see CYLINDER HEAD above Pull cylinder no 37 Discard cylinder gasket no 38 1 Cylinder 2 Piston assembly 3 Cylinder base gasket 4 Camshaft timing chain Inspection Cylin...

Page 140: ...nder Take an other measurement 90 from first one and compare NOTE Take the same measuring points like described in CYLINDER TAPER above A Perpendicular to crankshaft axis B Parallel to crankshaft axis CAUTION Always replace gasket no 38 before installing the cylinder Installation For installation reverse the removal procedure Pay attention to the following details Apply engine oil in the bottom ar...

Page 141: ...Piston 2 Piston pin Detach piston no 42 from connecting rod Inspection Piston Inspect piston for scoring cracking or other damages Replace piston and piston rings if necessary Using a micrometer measure piston at 9 mm 354 in perpendicularly 90 to piston pin 1 Measuring perpendicularly 90 to piston pin A 9 mm 354 in The measured dimension should be as described in the following table If not replace...

Page 142: ...ston is not worn See Piston Measurement above If clearance exceeds specified tolerance replace cylinder NOTE Make sure the cylinder bore gauge indicator is set exactly at the same position as with the micrometer otherwise the reading will be false Piston Pin Using synthetic abrasive woven clean piston pin from deposits Inspect piston pin for scoring cracking or other damages Measure piston pin See...

Page 143: ...will be installed with the punched arrow on piston top to the exhaust side 1 Arrow should indicate to the exhaust side 2 Area of timing chain compartment Use the piston circlip installer P N 529 035 859 to assemble the piston circlip as per following proce dure CAUTION Secure piston pin with new piston circlips place circlip no 40 in sleeve as per following illustration 1 Circlip 2 Sleeve 3 Assemb...

Page 144: ...der piston pin Inspection Ring Piston Groove Clearance Using a feeler gauge measure each ring piston groove clearance If the clearance is too large the piston and the piston rings should be replaced 1 Piston 2 Feeler gauge 4 R175motr103A 6 3 2 5 1 R610motr134B RING PISTON GROOVE CLEARANCE mm in NEW MINIMUM RECTANGULAR 0 03 mm 0012 in TAPER FACE 0 03 mm 0012 in OIL SCRAPER RING 0 01 mm 0004 in NEW ...

Page 145: ...ith the word N and TOP facing up 1 Rectangular ring 2 Taper face ring 3 Oil scraper ring CAUTION Ensure that top and second rings are not interchanged NOTE Use a ring expander to prevent breakage during installation The oil ring must be installed by hand Check that rings rotate smoothly after installation Space the piston ring end gaps 120 apart and do not align the gaps with the piston pin bore o...

Page 146: ...03_09A FM 03 09 1 CRANKSHAFT 0 R175motr01S 6 Anti seize lubricant 7 5 Engine oil 1 2 Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil 30 N m 22 lbf ft 6 N m 53 lbf in 10 N m 89 lbf in Loctite 243 ...

Page 147: ...n 8 Engine oil Molykote G N 10 11 10 N m 89 lbf in 15 Engine oil 3 4 Anti seize lubricant Loctite 243 Multi purpose grease Multi purpose grease Multi purpose grease 10 N m 89 lbf in 15 N m 133 lbf in 3 5 N m 31 lbf in 20 N m 15 lbf ft 5 N m 44 lbf in Loctite 243 Engine oil 12 N m 106 lbf in 12 N m 106 lbf in Loctite 518 Loctite 518 ...

Page 148: ...w 2 Copper shim Turn rotor fixed on crankshaft MAG side to TDC compression position refer to CYLINDER AND HEAD Use a screwdriver to check if groove in crankshaft is aligned with the hole 1 Screwdriver Lock crankshaft with crankshaft locking bolt P N 529 035 617 1 Crankshaft locking bolt 2 Hole in the area of electrical starter WARNING Torque wrench tightening specifications must strictly be adhere...

Page 149: ...ly worn or damaged replace it as a set camshaft timing gear and timing chain Check chain tensioner guide no 2 for excessive wear on contact surface to timing chain replace if necessary 1 Bearing screw 2 Chain tensioner guide Removal Remove RH foot well Drain engine oil refer to LUBRICATION SYS TEM see OIL CHANGE NOTE No need to drain cooling system Remove valve cover refer to CYLINDER AND HEAD Loc...

Page 150: ...ignition TDC refer to CYLINDER AND HEAD CAUTION Crankshaft and camshaft must be locked on ignition TDC position to place cam shaft timing gear and timing chain in the proper position NOTE Place chain according to marks on timing chain and crankcase MAG for proper chain posi tion after reassembling Install chain then adjust chain tension refer to CYLINDER AND HEAD CAUTION Improper valve timing will...

Page 151: ...f crankshaft and crankcases MAG PTO side for excessive wear Remove timing chain drive pulley refer to CVT see DRIVE PULLEY screws no 8 and screws no 9 1 Screws 12 MAG crankcase see CRANKCASE below CAUTION Pay attention not to damage plain bearing on MAG side with timing gear on crank shaft 1 Crankcase MAG 2 Lifting direction 3 Timing gear on crankshaft MAG crankshaft locking bolt shim no 7 on MAG ...

Page 152: ...ise damaged 1 Crankshaft timing gear 2 Crankshaft gear for oil pump Connecting Rod Big End Axial Play Using a feeler gauge measure distance between butting face of connecting rod and crankshaft counterweight If the distance exceeds specified tolerance replace the crankshaft 1 Measure here with feeler gauge R175motr11A 5 3 2 1 4 1 R175motr17A 2 CONNECTING ROD BIG END mm in NEW MINIMUM 0 3 mm 012 in...

Page 153: ...TO side Compare to inside diameter of MAG PTO bushing see CRANKCASE below 1 Measure here with a micrometer CONNECTING ROD SMALL END DIAMETER NEW MINIMUM 15 005 mm 5907 in NEW MAXIMUM 15 015 mm 5911 in SERVICE LIMIT 15 06 mm 593 in PISTON PIN DIAMETER NEW MINIMUM 14 997 mm 5904 in NEW MAXIMUM 15 000 mm 5905 in SERVICE LIMIT 14 990 mm 5902 in 1 R175motr13A A A R610motr137A PISTON PIN BORE CLEARANCE ...

Page 154: ...clearance of crankshaft with a feeler gauge on the PTO side between PTO crankcase and shim no 6 Install a new gasket no 15 and readjust axial clear ance with proper shim on PTO side Hand torqued crankcase screws as per following se quence Repeat procedure retightening all screws to 10 N m 89 lbf in NOTE Always degrease taperon crankshaft MAG before reinstalling rotor CRANKCASE Disassembly Remove e...

Page 155: ...ement is out of specification 1 MAG plain bearing with groove 2 Oil bore 3 Split of the plain bearing halves 4 Cylinder base direction A Plain bearing inside diameter to be measured in area of oil bore 1 PTO plain bearing without groove 2 Oil bore 3 Split of the plain bearing halves 4 Cylinder base direction A Plain bearing inside diameter to be measured in area of oil bore Check oil seal no 14 if...

Page 156: ...ith the plain bearing remover installer P N 529 035 855 PUSH PLAIN BEARINGS OUTSIDE 1 Plain bearing remover installer 2 Plain bearing 3 Crankcase MAG To install the plain bearing turn the plain bearing remover installer up side down NOTE Apply Molykote grease in crankcase bore to ease installing the plain bearing halves Mark plain bearing oil bore position together with crankcase thrust surface 1 ...

Page 157: ... procedure However pay attention to the following details Always install new gasket no 15 Clean oil passages and make sure they are not clogged Clean all metal components in a solvent Crankcase mating surfaces are best cleaned using a combination of the Chisel gasket remover P N 413 708 500 and a brass brush Brush a first pass in one direction then make the final brushing per pendicularly 90 to th...

Page 158: ... purpose grease Loctite 243 Anti seize lubricant Anti seize lubricant Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil 25 N m 18 lbf ft 8 9 6 10 12 13 26 Anti seize lubricant 11 35 34 33 14 18 22 25 21 20 24 29 31 30 27 23 32 28 19 15 Loctite 648 Engine oil Loctite 243 6 N m 53 lbf in 8 N m 71 lbf in ...

Page 159: ...bf in 8 Engine oil Molykote G N 10 11 10 N m 89 lbf in 15 Engine oil 3 4 Anti seize lubricant Loctite 243 Multi purpose grease Multi purpose grease Multi purpose grease 10 N m 89 lbf in 15 N m 133 lbf in 3 5 N m 31 lbf in 20 N m 15 lbf ft 5 N m 44 lbf in Loctite 243 Engine oil 12 N m 106 lbf in 12 N m 106 lbf in Loctite 518 Loctite 518 ...

Page 160: ...ion not to lose gasket ring no 2 on drain plug and or O ring no 4 Wait a while to allow oil to flow out of gear box Inspection Oil condition gives information about the teeth condition inside the gear box See TROUBLE SHOOTING section Clean the drain plug from metal shavings and dirt Presence of debris gives an indication of failure inside the gear box Check gear box to correct the problem Change g...

Page 161: ... seal on shift shaft Inspection Check bearings behind each oil seal for contami nation and or metal shavings Check surface on CVT main shaft in oil seal area for grooves and replace if necessary see GEAR BOX below Installation The installation is the reverse of removal proce dure Pay attention to the following details CAUTION Place a small rag to avoid ball bear ing contamination due to metal shav...

Page 162: ...r 2 Soft hammer CRANKCASE Disassembly Drain gear box oil see OIL CHANGE above Remove sprocket nut no 8 engine sprocket no 9 NOTE Due to vibrations it is recommended to check retorque gear box cover screws no 10 if only replacing the engine sprocket engine from vehicle refer to REMOVAL AND INSTALLATION screws no 10 retaining gear box cover NOTE To ease removing screws no 10 it is rec ommended to wa...

Page 163: ...sembly see GEAR BOX below Inspection NOTE To check some parts it is recommended to remove all components in both crankcase hous ing Visually check gasket no 12 for any damage Re place if necessary Clean crankcase from contaminations and blow the oil with compressed air Check bearings no 16 and no 17 for excessive play and smooth operation Replace if necessary 1 Ball bearing main shaft 2 Ball beari...

Page 164: ... to install ball bearings and or needle bearings Use press machine only Always heat crankcase housing up to 100 C 212 F before installing ball bearings and or needle bear ings Place new bearing in freezer for 10 minutes before installation Install needle bearing no 15 with the needle bear ing installer P N 529 035 762 and insertion jig handle P N 420 877 650 1 Intermediate shaft needle bearing 2 N...

Page 165: ...RBOX General During and after gear box disassembly inspect the condition of each part closely In particular check for gear teeth damage worn or scoured bearing surfaces worn or scoured shift fork worn or scoured shift fork shaft rounded engagement dogs and slots bent shift forks bent shift fork shaft worn shift fork engagement pins worn tracks on shift shaft plate worn shift fork engagement groove...

Page 166: ...in shaft NOTE Disengage shift fork no 20 from shift shaft plate no 21 1 Shift fork 2 Engagement pin on shift fork 3 Shift shaft plate Remove intermediate shaft no 22 together with output shaft no 23 shift fork no 20 1 Shift fork reverse neutral high 2 Engagement groove for shift fork pin 3 2 R175tran01A 4 1 3 R175tran02A 2 1 R175tran03A 1 2 R175tran05A ...

Page 167: ...tion shows engagement grooves for spring plate no 26 and the respective shifting position 1 High gear position 2 Neutral position 3 Reverse position NOTE In neutral position the spring plate engages deeper in the shift shaft groove The spring plate arm pushes against the intermediate shaft gear and retards its motion in idle 1 Shift shaft plate 2 Spring plate 3 Spring plate arm 4 Contact area to s...

Page 168: ...ork claw thickness 1 Micrometer A Shift fork claw thickness Check shift shaft plate track for scouring or heavy wear like rounded engagement slots 1 Shift shaft plate 2 Shift fork position for high gear 3 Shift fork position for neutral gear 4 Shift fork position for reverse gear SHIFT FORK CLAW THICKNESS NEW MINIMUM 4 800 mm 189 in NEW MAXIMUM 4 900 mm 193 in SERVICE LIMIT 4 750 mm 187 in R175tra...

Page 169: ... Thrust washer PTO Check intermediate shaft for wear limit and thick ness of thrust washer no 28 GAP OF SHIFT FORK ENGAGEMENT GROOVE NEW MINIMUM 5 00 mm 197 in NEW MAXIMUM 5 10 mm 201 in SERVICE LIMIT 5 20 mm 205 in OUTPUT SHAFT SERVICE LIMIT MAG SIDE 24 960 mm 983 in PTO SIDE SPROCKET 21 960 mm 866 in PTO SIDE CRANKCASE 14 960 mm 589 in R175tran12A A 1 R175tran13A 3 2 1 THRUST WASHER THICKNESS SE...

Page 170: ...2 thrust washer no 28 and thrust washer no 18 NOTE Check axial measurement of intermediate shaft including thrust washer no 18 and no 28 If out of measurement check for wrong and or miss ing thrust washers MAG PTO 1 Intermediate shaft 2 Thrust washer PTO 3 Thrust washer MAG A Axial measurement output shaft no 23 with main gear no 24 shim no 29 needle bearing no 30 reverse gear sprocket no 31 and t...

Page 171: ...st washer no 18 1 Shift fork 2 Neutral position 1 Shift fork shaft Install gearbox cover see CRANKCASE above NOTE Run all gears as a final function check The same time check output shaft and main shaft axial play Refill recommended oil see System Capacity above 2 1 R175tran05B 2 1 R175tran19A OUTPUT SHAFT AXIAL PLAY NEW MINIMUM 0 05 mm 002 in NEW MAXIMUM 0 69 mm 027 in MAIN SHAFT AXIAL PLAY NEW MI...

Page 172: ... Check wiring harness and replace if brittle or hard Using a multimeter measure the resistance of the shifting indicator switches Use the following pro cedure Reinstall screw on each switch Place one probe of multimeter on switch screw and the other on the engine NOTE The alligator clip is recommended Apply the end of switch on the engine If the resistance is infinite O L replace the shift ing ind...

Page 173: ... is a lubrication free drive pulley R175motr28S 13 14 13 20 21 22 23 24 25 26 11 10 5 9 8 Loctite 243 60 N m 44 lbf ft 7 6 19 18 Loctite 243 17 Anti seize lubricant 55 N m 41 lbf ft Anti seize lubricant 16 15 4 Anti seize lubricant 60 N m 44 lbf ft 2 1 10 N m 89 lbf ft Shell Retinax ...

Page 174: ...llation procedure Inspection Inspect belt for cracks fraying or abnormal wear Replace if necessary 1 Cracks inside the belt Check drive belt width Replace if it is out of spec ification see table below A Drive belt width WARNING Never touch CVT while engine is running Nev er drive vehicle when CVT cover is removed WARNING Any drive pulley repairs must be performed by an authorized Bombardier ATV d...

Page 175: ...ulley Installation for the proper procedure Install the CVT cover See below for the procedure CVT COVER Unscrew clamps retaining CVT cover to CVT inlet and exhaust hoses Remove screws no 1 1 Center top screw 2 CVT drain plug 3 CVT air inlet hose 4 CVT air outlet hose CVT cover no 2 and gasket no 3 1 CVT cover 2 Gasket 3 Ball bearing NOTE Remove the center top screw last This screw allows to suppor...

Page 176: ...VER BEARING Inspection Check if the CVT cover bearing must turn smooth ly and freely Otherwise replace it Removal Heat up CVT cover to about 100 C 212 F for an easy bearing removal CAUTION Do not overheat Using a slide hammer with the proper attachment remove the bearing Installation Place the new bearing in freezer for 10 minutes Heat the CVT cover to about 100 C 212 F to put the bearing in place...

Page 177: ...faces with paper towel and cleaning solvent Use Bombardier pulley flange cleaner P N 413 711 809 Wipe off the mounting surfaces with a clean dry paper towel Only use petrol base cleaner when cleaning bush ings inside sliding half CAUTION Do not use acetone to clean bushing Inspection of Drive Pulley Drive Pulley Drive pulley should be inspected annually Roller Check roller kit no 11 for roundness ...

Page 178: ...easure bushing diame ter Measuring point must be at least 5 mm 1 4 in from each bushing edge 1 Bushing 2 Drive pulley sliding half A Bore diameter of bushing Replace sliding half if bushing s is are out of spec ification Visually inspect coatings Fixed Half Check fixed half for scorings and other damages If so replace fixed half Check for any marks on fixed half spline Replace if necessary 1 Splin...

Page 179: ...bed in CLEAN ING above Install drive pulley on crankshaft extension NOTE Do not forget shim no 7 1 Shim 2 Drive pulley nut Install crankshaft locking bolt P N 529 035 617 or clutch holding tool P N 529 035 862 and torque screw to 60 N m 44 lbf ft 1 Drive pulley outer half 2 Clutch holding tool DRIVEN PULLEY Removal of Driven Pulley Remove driven pulley nut no 15 lock washer no 16 1 Clutch holding ...

Page 180: ...haft locking bolt Disassembly of Driven Pulley NOTE The following procedure is not necessary except if clutch no 18 must be removed Refer to Inspection before proceed Remove nut no 19 as per following procedure Fix clutch support P N 529 035 863 in a vise and place driven pulley assembly 1 Clutch holding tool 2 Vise 3 Driven pulley assembly 4 Nut wrench size 46 1 R175motr47A 2 1 R175motr48A 2 3 2 ...

Page 181: ...oid contact between cleaner and oil seals because damage may occur Inspection Nut Measure nut no 15 for wear on outside diameter and replace if necessary 1 Nut A Wearing diameter Centrifugal Clutch Check levers on centrifugal clutch no 18 for free movement and lining wear NOTE When lining thickness is getting less higher RPM is needed for centrifugal clutch engagement 1 Lining thickness next to le...

Page 182: ...lley For installation reverse the removal procedure Pay attention to following details Heat ball bearing area up to 100 C 212 F before installing ball bearing no 23 or one way clutch no 21 NOTE Place new ball bearing in a freezer for 10 min utes before installation Install ball bearing no 23 by pushing only on the outer ring For installation of one way clutc h no 21 and oil seal no 20 use bearing ...

Page 183: ...ntrifugal clutch assembly 3 Driven pulley assembly Installation of Driven Pulley For installation reverse the removal procedure Pay attention to the following details CAUTION Always use a new spring washer no 16 at the time of driven pulley installation NOTE Driven pulley end play is 0 zero Install clutch holding tool P N 529 035 862 to torque driven pulley nut to 60 N m 44 lbf ft WARNING Centrifu...

Page 184: ... CIRCUIT 04 02 1 GENERAL 04 02 2 FUEL LINE 04 02 2 FUEL TANK 04 02 2 FUEL VALVE 04 02 3 CARBURETOR 04 03 1 GENERAL 04 03 2 CARBURETOR 04 03 2 CARBURETOR ADJUSTMENTS 04 03 4 THROTTLE CABLE 04 03 4 AIR INTAKE SILENCER 04 04 1 GENERAL 04 04 2 AIR FILTER AND CLEANING 04 04 2 AIR BOX 04 04 2 AIR FILTER HOUSING 04 04 4 ...

Page 185: ...Section 04 FUEL SYSTEM Subsection 02 FUEL CIRCUIT VMR2003_016_04_02A FM 04 02 1 FUEL CIRCUIT 0 V06F05S 5 6 2 3 1 9 N m 80 lbf in 4 5 N m 44 lbf in ...

Page 186: ...omplete draining remove cap no 5 When the tank is empty turn valve OFF Removal Drain fuel tank Remove following items from body Refer to BODY for complete detailed procedure seat console Unscrew the bolts no 6 retaining fuel tank to frame WARNING Always disconnect battery exactly in the specified order BLACK cable first It is rec ommended to disconnect electrical connec tions prior to disconnectin...

Page 187: ...of leak testing kit P N 529 033 100 Using air pump from engine leak test kit P N 861 749 100 inject air into fuel tank See next photo 1 Special cap on tank 2 Air pump Pressurize fuel system to 21 kPa 3 PSI That pres sure must not drop during 3 minutes If pressure drops locate fuel leak s and repair replace leaking component s To ease locating leak s at fuel tank vent fitting fuel gauge or fuel cap...

Page 188: ...rs Inspection Check fuel valve strainers If one strainer is dam aged change fuel valve Check gasket between fuel valve and fuel tank for damage If so change fuel valve Installation For installation reverse the removal procedure Clean fuel valve strainers Perform fuel system pressurization as described in the Fuel System Pressurization section 2 V06F09A 1 3 V06F0AA 1 2 ...

Page 189: ...Section 04 FUEL SYSTEM Subsection 03 CARBURETOR VMR2003_017_04_03A FM 04 03 1 CARBURETOR 0 V06F0BS 2 4 5 1 7 3 6 ...

Page 190: ...ub ber parts O rings etc Therefore it is recom mended to remove those parts prior to cleaning Carburetor body and jets should be cleaned in a carburetor cleaner following manufacturer s in structions Float Level Adjustment Correct fuel level in float chamber is vital toward maximum engine efficiency To check for correct float level proceed as follows Remove float bowl and gasket from carburetor Ma...

Page 191: ...OR ADJUSTMENTS below in this section Carefully replace carburetor cap no 2 in its original position Make sure valve piston no 5 groove passes the inside protrusion in carburetor no 3 before clos ing the carburetor cap no 2 1 Protrusion 2 Valve piston Reinstall carburetor on engine When reinstalling carburetor on engine pay atten tion to the following 2 V06F0HA A 1 90 V06F0IA CARBURETOR FLOAT LEVEL...

Page 192: ...temper ature Turn the pilot screw clockwise until it sits lightly then unscrew of 3 4 turn CAUTION Take care when screwing the pilot screw the feeling is very slight Adjust the idle speed see below for procedure 1 Pilot screw Idle Speed Adjustment Start engine and allow it to warm then adjust idle speed to specifications by turning idle speed screw clockwise to increase engine speed or countercloc...

Page 193: ...he cable in a vertical position during approx imately 15 minutes or until no lubricant flow out of cable Reinstall and adjust cable see below Installation For installation reverse the removal procedure Adjustment Slide rubber protector back to expose throttle ca ble adjuster Loosen lock nut then turn the adjuster to obtain correct throttle lever free play NOTE Measure throttle free play at the tip...

Page 194: ...YSTEM Subsection 04 AIR INTAKE SILENCER VMR2003_018_04_04A FM 04 04 1 AIR INTAKE SILENCER 0 V06F0JS 5 N m 44 lbf in 2 5 N m 44 lbf in 1 5 N m 13 lbf in 5 N m 44 lbf in 2 5 N m 22 lbf in 1 4 3 5 8 7 6 2 1 5 N m 13 lbf in ...

Page 195: ...Properly reinstall removed parts in the reverse order of their removal Reinstall the air filter with the grey part on top NOTE Checkif theairfilterbroachisproperlylocated before installing air filter AIR BOX Draining Periodically inspect air box drain tube for water or deposits TYPICAL 1 Air box 2 Drain tube 3 Clamp NOTE If vehicle is used in dusty area inspect more frequently than specified in Ma...

Page 196: ...l Unclamp vent hose no 4 on RH side RIGHT SIDE SHOWN 1 Air box 2 Vent hose 3 Clamp Turn off the fuel valve Unclamp the carburetor intake adaptor no 3 from carburetor and remove it from air box Disconnect carburetor vent hose and carburetor fuel line Remove and place carburetor off to one side to get access of the torx screw retaining the air box to the frame LEFT SIDE SHOWN 1 Fuel valve on OFF pos...

Page 197: ... of their removal AIR FILTER HOUSING Removal Air filter housing can be removed as follows Remove RH side cover and console cover Refer to BODY Unclamp vent hose no 4 from air filter housing no 5 Pull out the breather vent hose no 7 from air filter housing no 5 Unscrew the screw no 8 and pull upwards air fil ter housing no 5 1 Air filter housing 2 Vent hose 3 Screw Installation Properly reinstall r...

Page 198: ...3 SERVICING DEUTSCH CONNECTORS 05 02 4 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 2 CLEANING 05 04 2 INSPECTION 05 04 2 BATTERY STORAGE 05 04 3 ACTIVATION OF A NEW BATTERY 05 04 3 TIPS FOR CHARGING A USED BATTERY 05 04 4 INSTALLATION 05 04 5 ST...

Page 199: ... PLUG 05 05 5 DISASSEMBLY 05 05 5 HEAT RANGE 05 05 5 FOULING 05 05 6 SPARK PLUG ANALYSIS 05 05 6 SPARK PLUG INSTALLATION 05 05 6 NGK SPARK PLUG SYMBOL EXPLANATION 05 05 7 INSTRUMENTS AND ACCESSORIES 05 06 1 GENERAL 05 06 1 HEADLIGHT 05 06 1 HEADLIGHT BEAM AIMING 05 06 2 TAILLIGHT 05 06 3 IGNITION SWITCH 05 06 3 INDICATOR LAMP 05 06 3 ELECTRONIC MODULE 05 06 4 TEST 05 06 4 MULTI FUNCTION SWITCH 05 ...

Page 200: ...ulator 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 sys tem STARTING SYSTEM When ignition switch is turned ...

Page 201: ...nal sensors to then compute the output actions to the related systems GENERAL TESTING TROUBLESHOOTING INFORMATION The following gives general electrical related prob lems For specific system related problems refer to proper system section It is possible that a component seems to operate in static condition but in fact it is defective In this case the best way to solve this problem is to re move th...

Page 202: ...troubleshooting the 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 a...

Page 203: ... Pry back the retaining tab while gently pulling wire back until contact is removed FEMALE CONNECTOR HOUSING 1 Retaining tab To install For insertion of signal contact make sure the lock is removed Insert contact into appropriate circuit cavity and push as far as it will go Pull back on the contact wire to be sure the re tention fingers are holding the contact After all required contacts have been...

Page 204: ... 2 3 3 A C B A C B 12 11 10 9 8 7 1 2 3 4 5 6 12 11 10 9 8 7 1 2 3 4 5 6 1 2 3 1 2 3 6 5 4 6 5 4 1 2 4 3 4 3 1 2 2 1 1 2 A B A B A B 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 AMP MULTILOCK A B ...

Page 205: ...PM Depending on battery charge current reading should be approximately 5 amperes If not check magneto output prior to concluding that voltage regulator rectifier is faulty Voltage Test Proceed as follows Start engine Connect a multimeter to battery posts Set mul timeter to Vdc scale Bring engine to approximately 3500 RPM If multimeter reads over 15 volts voltage regulator rectifier is defective Re...

Page 206: ...ads disconnected insert either meter test probe onto AC 1 and ground the other meter test probe to the engine or the stator iron core and note the reading There should be no con tinuity infinity between the stator insulated coils and ground If there is a reading the stator coils and or the wiring from the coils is grounded and needs to be replaced repaired respectively TYPICAL DYNAMIC TEST 1 Unplu...

Page 207: ...true reading at 21 C 70 F In order to obtain correct readings adjust the initial reading by adding 004 points to the hydrometer readings for each 5 5 C 10 F above 21 C 70 F and by subtracting 004 point for every 5 5 C 10 F below 21 C 70 F This chart will be useful to find the correct reading EXAMPLE NO 1 EXAMPLE NO 2 Temperature below 21 C 70 F Temperature above 21 C 70 F Hydrometer reading 1 250 ...

Page 208: ... damage If casing is damaged replace battery and thoroughly clean battery rack with wa ter and baking soda Inspect battery rack mounting Inspect battery posts for security of mounting Inspect for cracked or damaged battery caps re place defective caps WARNING Always respect this order for disassembly disconnect BLACK cable first Electrolyte or fuel vapors can be present in engine compart ment and ...

Page 209: ...s necessary keep the battery at its upper level line and near full charge as possible trickle charge ACTIVATION OF A NEW BATTERY CAUTION Prior to charging the battery always remove it from the vehicle to prevent electro lyte spillage A new battery is factory fresh dry charged For storage purposes it is fitted with a temporary seal ing tube Do not remove the sealing tube or loosen battery caps unle...

Page 210: ...to be frozen keep it in a heated area for about 2 hours before charging The time required to charge a battery will vary de pending on some factors such as Battery temperature The charging time is in creased as the temperature goes down The current accepted by a cold battery will remain low As the battery warms up it will accept a higher rate of charge State of charge Because the electrolyte is nea...

Page 211: ...try even though the leads are connected properly This will make it appear that the battery will not accept a charge Fol low the charger manufacturer s instruction on how to bypass or override this circuitry so that the charger will turn on and charge a low voltage battery Since the battery chargers vary in the amount of voltage and current they provide the time required for the battery to accept m...

Page 212: ...erminal s Poor battery ground cable connection Clean and tighten Burntorpoorcontactof solenoidswitch contact disc Replace starting solenoid Poor contact of brush Straighten commutator and brush or replace electric starter Burnt commutator Turn commutator in a lathe or replace electric starter Worn commutator segments Undercut mica or replace electric starter Shorted armature Replace electric start...

Page 213: ...to small connectors if it is more than a few ohms replace solenoid If solenoid test good check the electric starter If starter test good the NEUTRAL switches can be suspected Ignition Switch A quick test to validate it is working Turn the igni tion switch ON If the lights turn on the ignition switch is good Otherwise refer to IGNITION SYSTEM for testing procedure If it tests good continue the next...

Page 214: ... REMOVAL Turn OFF ignition switch Disconnect BLACK cable connection from bat tery Disconnect RED cable connection from battery Remove LH footwell Refer to BODY FRAME Remove Carburetor Refer to CARBURETOR Disconnect all cables from starter Remove starter mount screws Pull starter out 1 Starter 2 Red battery cable 3 Black cable 4 Mounting screws INSTALLATION Installation is essentially the reverse o...

Page 215: ... ignition coil 7 electronic module Intermittent Ignition Problems In dealing with intermittent problems there is no easy diagnosis For example problems that occur only at normal engine operating temperature have to be tested under similar conditions In most cases of temperature and or vibration fail ure only parts replacement might solve the prob lem as most of these failures return to normal when...

Page 216: ...res 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 I...

Page 217: ... wires Replace switch if defective If switch is good continue the other tests Trigger Coil Voltage Testing NOTE The trigger coil is not adjustable STATIC TEST CONTINUITY Check resistance with a high sensitivity ohmmeter 1 Disconnect the large connector from the elec tronic module 2 Connect multimeter probes to the BLACK YELLOW wire and to the BLACK wire 3 Measure resistance it should be between 19...

Page 218: ...ak voltage is lower than the specification check the ignition coil resistance Ignition Coil Resistance Disconnect both connectors from the ignition coil Using a multimeter check the resistance in both primary and secondary windings For checking the resistance of primary windings do as follows Connect the RED probe of multimeter to the WHITE GREEN wire location and BLACK probe of multimeter to the ...

Page 219: ...ean the spark plug and cylinder head with pres surized air Reinstall ignition coil unscrew spark plug complete ly then remove it HEAT RANGE The proper heat range of the spark plugs is deter mined by the spark plugs ability to dissipate the heat generated by combustion The longer the heat path between the electrode tip to the plug shell the hotter the spark plug op erating temperature will be and i...

Page 220: ...l de fective ignition system incorrect ignition timing incorrect spark plug gap lubricating oil entering the combustion chamber or too cold spark plug The plug face of a fouled spark plug has either a wet black deposit or a black carbon fouling Such coatings form a conductive connection between the center electrode and ground SPARK PLUG ANALYSIS TYPICAL 1 Overheated light grey white 2 Normal light...

Page 221: ...Section 05 ELECTRICAL Subsection 05 IGNITION SYSTEM VMR2003_022_05_05A FM 05 05 7 NGK SPARK PLUG SYMBOL EXPLANATION V04G0DS ...

Page 222: ...dlight TYPICAL Rotate bulb socket counterclockwise then remove headlight bulb TYPICAL 1 Unlock 2 Lock Properly reinstall removed parts in the reverse order of their removal Removal NOTE Use the same procedure for RH or LH head light Unplug the headlight connector Remove both knobs Remove the last screw retaining headlight holder TYPICAL 1 Knobs 2 Retaining screw 3 Headlight holder 4 Headlight hous...

Page 223: ...djustment HEADLIGHT BEAM AIMING Select high intensity Beam aiming is correct when center of high beam is 131 mm 5 in below the headlight horizontal cen ter line scribed on a test surface 5 m 17 ft away NOTE Sit down the driver or place the same weight on the vehicle Measure headlight center distance from ground Scribe a line at this height on test surface wall or screen Light beam center should be...

Page 224: ...clockwise IGNITION SWITCH Test Refer to IGNITION SYSTEM Removal Lift the dash board and unscrew the ignition switch nut NOTE Do not unplug connectors when steering cover is lifted Unplug the switch connector 1 Switch connector Installation For the installation reverse the removal procedure INDICATOR LAMP Test Refer to TESTS section Replacement Remove the dash board Unplug wires on indicator lamp P...

Page 225: ...n headlight switch Using a multimeter measure the voltage between GREEN and BLACK wires The obtained value should be between 12 and 14 5 Vdc Place the headlight switch selector on high beam position Measure the voltage between BLUE and BLACK wires The obtained value should be between 12 and 14 5 Vdc No voltage Check wiring condition and headlight switch Voltage is good Change headlight bulb s Usin...

Page 226: ...icator light connector Test each LEDS The TEMPERATURE OIL RE VERSE and NEUTRAL LEDS can be tested with 12 Vdc LEDS are good Check wiring condition Check connectors LEDS are burned Change indicator lights SWITCH WIRE RESISTANCE Engine stop switch on STOP position BLACK WHITE and BLACK 0 2 0 2 Ω max Engine stop switch on RUN position Infinite O L SWITCH WIRE RESISTANCE Override switch pushed VIOLET ...

Page 227: ...TOC FM 06 01 1 TABLE OF CONTENTS 0 REAR AXLE 06 02 1 GENERAL 06 02 2 DRIVE CHAIN 06 02 2 REAR SPROCKET 06 02 3 REAR SPROCKET HUB 06 02 4 REAR WHEEL HUB 06 02 5 REAR AXLE 06 02 5 CHAIN TENSIONER 06 02 6 CHAIN TENSIONER BEARINGS 06 02 6 SLIDER SHOE 06 02 8 CHAIN ROLLER 06 02 8 ...

Page 228: ...R2003_024_06 02A FM 06 02 1 REAR AXLE 0 V06H08S 16 1 17 18 15 19 18 25 N m 18 lbf ft 13 4 12 13 9 140 N m 103 lbf ft Loctite 277 14 11 14 12 8 10 5 Synthetic grease 7 3 2 25 N m 18 lbf ft 6 12 13 11 135 N m 100 lbf ft 70 N m 52 lbf ft 43 N m 32 lbf ft ...

Page 229: ...ssary Check for damage or missing O ring or rollers Lubrication and Cleaning CAUTION Never wash the chain with a high pres sure washer or gasoline Damage to the O ring will result causing premature wear and drive chain failure Clean the side surfaces of the chain with a dry cloth NOTE Do not brush chain Lubricate only with an approved O ring chain lubri cant Other commercial chain lubricants may c...

Page 230: ... repeat the above procedure to check the deflection several times at different spots on the chain Replacement With the chain installed on vehicle measure the distance between a span of 13 links from pin cen ter to pin center Change drive chain if the distance exceeds the service limit A 404 mm 15 29 32 in CAUTION Replace chain engine sprocket and rear sprocket together to prevent rapid chain and s...

Page 231: ... time the engine sprocket is removed NOTE The drive pinion must be installed with the lip toward the outside of vehicle Installation CAUTION Replace chain engine sprocket and rear sprocket together to prevent rapid chain and sprockets wear Install a new tab washer each time the engine sprocket is removed For installation reverse the removal procedure REAR SPROCKET HUB Removal Lift rear of vehicle ...

Page 232: ...ock bolts REAR AXLE Removal Lift rear of vehicle and install jack stands under the frame to support the rear of vehicle out off the ground Remove rear wheels Remove the LH and RH wheel hubs no 6 Remove locking nuts no 9 Unscrew the chain tensioner lock bolts no 8 Remove the chain roller Install adjuster lock and release the drive chain tension Remove drive chain from rear sprocket Slide out the ax...

Page 233: ...ensioner out from the swing arm 1 Chain tensioner 2 Swing arm 3 Pry bar Inspection Look at the chain tensioner for damage The bore must be free of scratches in order to receive new bearings and seals Installation Installation takes place in the reverse order of re moval Carefully slide the chain tensioner over the axle and seat it against the sprocket hub the 3 hole side of the chain tensioner goe...

Page 234: ...f bearings it is possible to heat the chain tensioner at 212 F 100 C 30 min utes in oven Press the bearing into the chain tensioner The seal must press into a dry bore Use brake cleaner to make sure the bore is free of grease where the seal goes CAUTION If the seal is pressed into a slippery bore it will misalign or pop out when the vehi cle will be running which will lead to a bearing failure Pre...

Page 235: ...ION Remove slide shoe no 16 Installation Installation takes place in the reverse order of re moval CHAIN ROLLER Removal Unscrew bolt no 17 retaining the chain roller no 15 Remove the chain roller with ball bearings no 18 and bushing no 19 Installation For installation reverse the removal procedure Torque bolt no 17 to 25 N m 18 lbf ft ...

Page 236: ...003_033_07_01ATOC FM 07 01 1 TABLE OF CONTENTS 0 STEERING CONTROL SYSTEMS 07 02 1 HANDLEBAR 07 02 2 STEERING COLUMN 07 02 2 TIE ROD 07 02 2 STEERING COLUMN BEARING 07 02 4 MULTI FUNCTION SWITCH 07 02 4 THROTTLE HANDLE 07 02 5 LH HANDLE BRAKE 07 02 6 RH HANDLE BRAKE 07 02 7 ...

Page 237: ...3_025_07_02A FM 07 02 1 STEERING CONTROL SYSTEMS 0 V06I06S 18 19 10 1 8 7 6 1 4 2 11 3 5 15 14 12 13 20 12 9 25 26 27 28 26 17 22 23 16 24 21 25 26 23 N m 17 lbf ft 23 N m 17 lbf ft 10 N m 89 lbf in 58 N m 43 lbf ft 41 N m 30 lbf ft 41 N m 30 lbf ft Synthetic grease Synthetic grease ...

Page 238: ...he removal procedure STEERING COLUMN Removal Place the vehicle on jack stands Remove console and seat refer to BODY fuel tank refer to FUEL CIRCUIT tie rods on the steering column side see further in this section hexagonal flange screws no 11 half bushing no 12 bushingsno 13 stopper plate no 14 and elastic flange nuts no 15 cotter pin no 19 hexagonal stop nut no 18 flat washer no 17 1 Cotter pin 2...

Page 239: ...in the following chart NOTE Torquetheballjointlocknut no 28to 22N m 16 lbf ft Torque elastic stop nut to 41 N m 31 lbf ft Install a new cotter pin Both ends of cotter pin must be folded Toe Adjustment Place vehicle on level surface Check that handlebar is straight Check pressure in each tires Always follow recom mended pressure Place a rope around the vehicle and using an elas tic link both ends t...

Page 240: ...o 20 Refer to TIE ROD earlier in this section Remove the cotter pin no 19 elastic nut no 18 and washer no 17 Lift up the steering column until the end of steer ing column is out of bearing Remove screws no 21 and nuts no 23 Lift up the upper bearing flange no 22 to reach the bearing Remove bearing no 16 1 Frame support 2 Screw 3 Bearing flange Installation For installation reverse the removal proc...

Page 241: ...plug multi switch connectors Separate multi function switch no 5 from handle bar no 10 Installation For installation reverse the removal procedure THROTTLE HANDLE Removal Remove throttle cover screws throttle clip screws Move back rubber cap Tighten adjustment screw to its maximum Remove throttle cable from housing Slide cable in clip slot and remove the end of the cable from clip Remove cable 1 T...

Page 242: ...g Installation For installation reverse the removal procedure Refer to CARBURETOR for adjustment proce dure Lubrication Refer to CARBURETOR LH HANDLE BRAKE Removal Remove multi switch Remove handlebar grip Remove cable brake screw 1 Multi switch 2 Handlebar grip 3 LH brake screw Separate handle brake no 3 from handlebar no 10 If necessary unplug connectors under steering cov er cut locking tie Ins...

Page 243: ...brake Cable Removal Refer to HYDRAULIC BRAKES for specifics in structions 1 RH handle brake screws Separate handle brake no 24 from handlebar no 10 On some vehicles unplug connectors under steer ing cover and cut locking tie Hose Removal Refer to HYDRAULIC BRAKES for specifics in structions Installation For installation reverse the removal procedure V06I0LA 1 ...

Page 244: ...F CONTENTS VMR2003_033_08_01ATOC FM 08 01 1 TABLE OF CONTENTS 0 FRONT SUSPENSION 08 02 1 GENERAL 08 02 2 FRONT SHOCK 08 02 2 LH RH A ARM 08 02 3 A ARM BUSHINGS 08 02 3 REAR SUSPENSION 08 03 1 GENERAL 08 03 2 REAR SHOCK 08 03 2 SWING ARM 08 03 3 ...

Page 245: ...SPENSION VMR2003_026_08_02A FM 08 02 1 FRONT SUSPENSION 0 V06J06S 3 2 1 4 6 7 3 8 2 8 5 6 1 7 41 N m 31 lbf ft 48 N m 35 lbf ft 48 N m 35 lbf ft 48 N m 35 lbf ft 41 N m 31 lbf ft 48 N m 35 lbf ft Synthetic grease Synthetic grease Synthetic grease ...

Page 246: ...ion of the clevis pin TYPICAL 1 Clevis pin 2 Bar 3 Handle horizontal Push down on the handle until it locks Remove spring stopper then release handle Inspection Inspect the spring for damage Replace if necessary Inspect shock for oil leakage Extend and compress the piston several times over its entire stroke Check that it moves smoothly and with uniform resistance with its rod upwards Any of the f...

Page 247: ...1 to A arm Remove cotter pin on the axle screw and then remove axle screw no 7 fromknuckle no 6 Discard the cotter pin NOTE Do not remove knuckle no 6 tie rod and brake from the wheel Remove bolts no 8 retaining A arm to frame 1 A arm 2 Bolts Remove A arm from vehicle Installation Position front A arm then install bolts and nuts Do not torque yet Install bolt and nut retaining shock absorber to fr...

Page 248: ... measure 1 Tape 2 Radiator 3 Middle of tire Push on the top side of tire until all play is elim inated without moving handlebar Measure the distance between the middle of tire and radiator side PUSH TOWARD VEHICLE The difference between both measurements must be lower than 8 mm 1 mm 315 in 039 in If the difference is out of specification replace the both bushings O rings and the pivot bush ing Che...

Page 249: ...ection 03 REAR SUSPENSION VMR2003_027_08_03A FM 08 03 1 REAR SUSPENSION 0 V06J09S 48 N m 35 lbf ft 5 12 12 12 12 10 10 13 13 8 9 7 6 8 2 3 4 11 11 11 11 1 48 N m 35 lbf ft 4 Synthetic grease Synthetic grease 100 N m 74 lbf ft 14 ...

Page 250: ...ndle until it locks Remove spring stopper and cap then release handle TYPICAL 1 Clevis pin 2 Bar 3 Handle horizontal Inspection Secure the shock body end no 7 in a vise with its rod upward TYPICAL 1 Clamp here CAUTION Do not clamp directly on shock body Examine each shock for leaks Extend and com press the piston several times over its entire stroke Check that it moves smoothly and with uni form r...

Page 251: ...g arm Removal Lift rear of vehicle until rear shock absorber no 1 is fully extended Install a jack stands or a blocks under the frame to support the vehicle Remove lower nut no 4 and bolts no 3 retaining shock to swing arm 1 Lower nut 2 Lower bolts 3 Swing arm Remove RH footwell refer to BODY Loosen chain tensioner lock bolts 1 Chain tensioner lock bolts Insert adjuster lock through sprocket hub a...

Page 252: ... details Insert O rings no 11 in the groove into frame Place cushions no 12 and bushings no 10 then install the swing arm Install the swing arm bolt no 8 with washers no 13 then push the O rings no 11 between frame and bushings 1 O ring Install nuts no 9 Torque to 100 N m 74 lbf ft NOTE Check if the swing arm moves freely Install the other nut no 14 and torque to 100 N m 74 lbf ft NOTE Take the fi...

Page 253: ...IC BRAKES 09 02 1 FRONT BRAKES 09 02 1 REAR BRAKE 09 02 2 GENERAL 09 02 3 BRAKE FLUID 09 02 3 MASTER CYLINDER 09 02 4 FRONT BRAKE CALIPERS 09 02 5 REAR BRAKE CALIPER 09 02 7 BRAKE PADS 09 02 7 BRAKE DISC 09 02 9 FRONT BRAKE LEVER 09 02 10 REAR BRAKE PEDAL 09 02 10 REAR BRAKE CABLE 09 02 10 BRAKE HOSES 09 02 11 ...

Page 254: ...YDRAULIC BRAKES 0 FRONT BRAKES V06K0AS 25 N m 18 lbf ft 1 5 N m 13 lbf in 3 8 7 9 34 4 4 5 8 11 12 12 14 2 5 N m 44 lbf in 13 15 7 23 N m 17 lbf ft 8 25 N m 18 lbf ft 15 13 7 23 N m 17 lbf ft 2 5 N m 44 lbf in 12 25 N m 18 lbf ft 11 14 12 23 N m 17 lbf ft 10 10 N m 89 lbf in 6 1 16 ...

Page 255: ...RAKES 09 02 2 VMR2003_028_09_02A FM REAR BRAKE V06K0OS 25 N m 18 lbf ft 10 N m 89 lbf in 31 Synthetic grease 29 25 N m 18 lbf ft 26 27 18 30 25 N m 18 lbf ft 33 32 25 N m 18 lbf ft 28 23 25 17 20 19 24 10 N m 89 lbf in 21 23 22 50 N m 37 lbf ft ...

Page 256: ...el surface check brake fluid in reservoir for proper level It should be above MIN mark Add fluid as required Do not overfill Clean filler cap before removing CAUTION Use only DOT 4 brake fluid from a sealed container Do not use brake fluid taken from old or already opened containers NOTE A low level may indicate leaks or worn brake pads Front Brake Fluid Reservoir Turn steering in the straight ahe...

Page 257: ...rake lever no 3 If it still feels spongy bleed system again Repeat the procedures until air bubbles don t ap pear in tube and lever is stiff Fill reservoir to the upper level with DOT 4 brake fluid Install cover on reservoir If vacuum pump is not available use the following procedure Install a tube to bleed valve Open bleeder Fill reservoir and pump brake lever until fluid freely flows out of the ...

Page 258: ...ever and locking mechanism NOTE Apply silicone grease on lever pivot bolt Installation For the installation reverse the removal procedure pay attention to the following details Position cylinder holding bracket with the UP mark upward Install bolts and tighten loosely With the handlebar in straight ahead position po sition cylinder reservoir parallel to the ground Tighten upper bolt first Connect ...

Page 259: ...iston grooves in caliper Coat piston with clean brake fluid and install into cylinder with the closed end toward caliper body Apply silicone grease into sliding bores and install slide pins NOTE Make sure that rubber boots are correctly installed in slide pins grooves Install pad spring caliper bracket and pads Installation For the installation reverse the removal procedure pay attention to the fo...

Page 260: ...ication replace the caliper 1 Rear caliper A 5 mm 197 in Installation For installation reverse the removal procedure BRAKE PADS Removal Front Brake Pads Raise vehicle and support it securely Remove wheels Drain brake system Remove Banjo bolts no 7 Remove caliper from knuckle Push pad pins then remove pads no 13 CAUTION Don t let the caliper hang by the hose and don t stretch or twist the hose Push...

Page 261: ...talling brake pads Make sure that pad spring is in position 1 Pad spring Install new brake pads Install 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...

Page 262: ...N Brakediscsshould neverbe machined Turn the disc by hand and check run out Removal Front Brake Disc Remove front caliper as described previously After removing the caliper suspend it out of the way CAUTION Don t let the caliper hang by the hose and don t stretch or twist the hose NOTE Wheel hub has to be removed from vehicle to replace brake disc no 15 Remove cotter pin and unscrew nut 1 Cotter p...

Page 263: ...emove pedal nut no 21 Remove pivot bolt no 22 1 Brake pedal 2 Pivot bolt 3 Pedal nut 4 Pedal spring 5 Stop nut 6 Brake cable Remove washer no 25 and outer O ring no 23 then remove pedal no 24 from pivot Remove the inner O ring no 23 on the pivot Inspection Check brake pedal for cracks or distortion Check O rings for damage change if necessary Installation and Adjustment For installation reverse th...

Page 264: ... removal procedure Turn the adjustment screw no 33 until cable bar rel no 20 comes in contact with the brake pedal lever BRAKE HOSES Removal NOTE Before removing any hoses or tubes drain brake system Front Flexible Brake Hose Remove console front luggage rack Refer to BODY for complete procedure Upper Hose Disconnect brake handle hose no 9 from master cylinder and discard sealing washers Remove al...

Page 265: ... COVER 10 02 2 DASH BOARD STEERING COVER 10 02 3 FRONT BUMPER LUGGAGE RACK 10 02 3 FRONT FASCIA 10 02 4 RH LH FOOTWELLS 10 02 4 REAR LUGGAGE RACK REAR BUMPER 10 02 5 SEAT COVER REPLACEMENT 10 02 6 SEAT CLEANING 10 02 6 DECALS REPLACEMENT 10 02 6 PLASTIC MAINTENANCE 10 02 7 MAINTENANCE 10 02 7 PLASTIC REPAIR 10 02 7 FRAME 10 03 1 GENERAL 10 03 2 FRONT PLATE 10 03 2 FRAME 10 03 2 ...

Page 266: ... 2 29 20 17 17 17 17 19 18 17 7 17 17 14 11 16 15 16 15 9 9 6 25 17 5 8 4 9 30 5 4 4 9 9 8 8 3 4 9 24 23 17 17 22 26 10 11 13 12 13 12 9 N m 80 lbf in 4 9 N m 80 lbf in 9 N m 80 lbf in 9 N m 80 lbf in 2 N m 18 lbf in 2 N m 18 lbf in 9 N m 80 lbf in 9 N m 80 lbf in 2 N m 18 lbf in 24 N m 18 lbf ft V06L0JS 2 N m 18 lbf in 24 N m 18 lbf ft ...

Page 267: ...To remove the seat first of all remove the right side cover no 11 and left side cover no 10 to get access to the screws below the seat Unclamp the CVT air outlet hose Remove screws below the seat to remove the seat 1 Seat 2 Screw holes Installation Insert seat on frame Install screws below the seat When seat rests in its position install the CVT air outlet hose Install right side cover no 11 and l...

Page 268: ...le 1 Dash board 2 Electric connections Inspection Check latches no 23 from dash board for cracks or other damages Change if necessary Installation Installation is the reverse order of removal FRONT BUMPER LUGGAGE RACK Removal Front Bumper To remove front bumper no 1 unscrew screws no 2 1 Front bumper 2 Screws Front Luggage Rack CAUTION Unplug electric connections to headlight before removing lugga...

Page 269: ...SCIA Removal Remove front bumper Front Facia Remove headlights Remove the screws no 4 attaching front fascia no 3 to the luggage rack no 6 1 Front fascia 2 Screws Installation Installation is the reverse order of removal RH LH FOOTWELLS Removal LH Side Footwell Remove screws no 15 Remove plastic rivets no 17 to remove the LH side footwell no 18 1 LH side footwell 2 Screws 3 Plastic rivets 3 V06L0D...

Page 270: ...et Installation Installation is the reverse order of removal REAR LUGGAGE RACK REAR BUMPER Removal Rear Luggage Rack Remove the seat Remove screws no 4 and screws no 5 retaining rear luggage rack no 30 Remove plastic rivets no 17 retaining rear luggage rack no 30 to the RH and LH footwells 1 Rear luggage rack 2 Screws 3 Plastic rivets Withdraw rear luggage rack Rear Bumper Unlatch the rubber strap...

Page 271: ...Removal Using a heat gun warm up one end of decal for a few seconds until decal can roll off when rubbing with your finger Pull decal slowly and when necessary apply more heat to ease removal on the area that has to be peeled off If decal tears while pulling off it has to be heated for a few seconds longer If decal tends to stretch while pulling off stop heating and wait a few sec onds to let it c...

Page 272: ...When well aligned squeegee decal beginning at center and working outward using firm short overlapping strokes PLASTIC MAINTENANCE MAINTENANCE Clean the vehicle thoroughly removing all dirt and grease accumulation To clean use a soft clean cloth and either soapy water or isopropyl alcohol To remove grease oil or glue use isopropyl alcohol CAUTION Do not apply isopropyl alcohol or ac etone directly ...

Page 273: ...Section 10 BODY FRAME Subsection 03 FRAME VMR2003 030_10_03A FM 10 03 1 FRAME 0 V06L0KS 1 4 3 2 10 N m 89 lbf in ...

Page 274: ...e reverse of removal procedure FRAME Cleaning Clean frame no 1 with appropriate cleaners and rinse with high pressure hose NOTE Clean the draining holes under frame The drain holes are located at the rear of bottom side of frame Touch up all metal spots where paint has been scratched off Spray all bare metal parts of vehicle with metal protector Welding Steel Frame electric welding amperage 70 110...

Page 275: ...sure torque speed meter kilogram newton liter Celsius kilopascal newton meter kilometer per hour m kg N l C kPa N m km h PREFIXES PREFIX SYMBOL MEANING VALUE kilo centi milli micro k c m µ one thousand one hundredth one thousandth one millionth 1 000 0 01 0 001 0 000001 CONVERSION FACTORS TO CONVERT TO MULTIPLY BY in in in2 in3 ft oz lb lbf lbf in lbf ft lbf ft PSI lbf in2 imp oz imp oz imp gal im...

Page 276: ...m in 0 032 0013 New maximum mm in 0 055 0022 Wear limit mm in 0 120 0047 Valve guide diameter Wear limit mm in 4 06 16 Valve spring free length New nominal mm in 33 6 1 323 Service limit mm in 33 4 1 315 Valve seat contact width Intake New mm in 1 05 to 1 35 041 to 053 Wear limit mm in 1 6 063 Exhaust New mm in 1 25 to 1 55 049 to 061 Wear limit mm in 1 8 070 Piston measurement New nominal mm in 6...

Page 277: ... Wear limit mm in 30 800 1 252 Exhaust New minimum mm in 30 887 1 216 New maximum mm in 31 087 1 224 Wear limit mm in 30 800 1 252 Crankshaft axial clearance New minimum mm in 0 2 0078 New maximum mm in 0 4 0157 Crankshaft deflection MAG side New nominal mm in 0 04 0024 PTO side New nominal mm in 0 04 0024 Crankshaft pin diameter New minimum mm in 26 037 1 0250 New maximum mm in 26 040 1 0252 Wear...

Page 278: ...Needle jet 0 2M Jet needle 5GNY 72 3 Choke plunger position Variable Adjustment Throttle cable 4 mm 157 in Preliminary pilot screw turn 3 4 Float level 0 5 mm 15 0 020 in 591 Fuel Type Regular unleaded gasoline Octane no 87 Ron Mon 2 LUBRICATION Lubricant SAE 5W30 or 5W40 Bombardier synthetic oil mineral based Oil pressure switch 30 to 60 kPa 4 35 to 8 70 PSI Oil temperature max 120 C 248 F Oil pr...

Page 279: ...or code Silver Rear preload adjustment N A BRAKES Front brake Qty 2 discs Type Hydraulic Rear brake Qty 1 disc Type Mechanical cable Parking brake Brake lever lock on LH brake lever Caliper Floating Lining material Organic Minimum pad thickness mm in 1 04 Minimum brake disk thickness mm in 3 5 14 Maximum brake disk warpage mm in 0 25 01 TIRES AND WHEELS TIRE Pressure Front Recommended 24 kPa 3 5 P...

Page 280: ... kg 35 lb Rear including tongue weight 30 kg 65 lb Total vehicle load allowed including driver all other loads and added accessories 175 kg 386 lb Gross vehicle weight rating 369 kg 813 lb Towing 227 kg 500 lb Tongue included with rear rack weight 14 kg 30 lb MATERIAL Frame Material Steel Color Black Wheel Material Steel Color Silver Front rear rack Material High density polyethylene Color Earthen...

Page 281: ... Exhaust nut 11 N m 97 lbf in None Exhaust clamp 15 N m 133 lbf in LUBRICATION Engine drain plug 20 N m 15 lbf ft None Engine oil strainer 30 N m 22 lbf ft Oil pump housing 6 N m 53 lbf in Loctite 243 Oil pressure switch 12 N m 106 lbf in CYLINDER AND HEAD Valve cover 9 N m 80 lbf in None Cylinder head screw 10 N m 89 lbf in Cylinder head nut 25 N m 18 lbf ft Camshaft timing gear 30 N m 22 lbf ft ...

Page 282: ... 42 N m 31 lbf ft Steering column nut 58 N m 43 lbf ft Handle grip screw 1 N m 9 lbf in SUSPENSION Swing arm nut 100 N m 74 lbf ft None BRAKE Caliper brake screws 24 N m 17 lbf ft None Brake pedal 50 N m 37 lbf ft Front master cylinder cover screws 1 5 N m 13 lbf in Front master cylinder BANJO bolt 24 N m 17 lbf ft Caliper BANJO bolt Caliper bleeder valve 5 N m 44 lbf in Rear cable adjusting nut 1...

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