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Can-Am DS 450 2008, Shop Manual

The Can-Am DS 450 2008 is a high-performance off-road quad designed for thrill-seekers. This impressive machine offers superior power and agility. To keep your DS 450 running smoothly, make sure to download the free Shop Manual from manualshive.com. This comprehensive manual provides detailed instructions for maintenance and repairs, ensuring optimum performance on your adventurous rides.

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TABLE OF CONTENTS

TAILLIGHT/BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

262

NEUTRAL INDICATOR LIGHT (GREEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

263

CHECK ENGINE INDICATOR LIGHT (YELLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

265

LOW FUEL LEVEL INDICATOR LIGHT (YELLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

266

07

DRIVE SYSTEM

01 – DRIVE CHAIN/REAR AXLE . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 271

GENERAL . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 273
PROCEDURES .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 273

DRIVE CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

273

FRONT SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

276

REAR SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

277

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

278

REAR SPROCKET HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

280

CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

281

08

CHASSIS

01 – WHEELS/TIRES. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 283

GENERAL . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 284
MAINTENANCE . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 284

TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

284

PROCEDURES .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 284

TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

284

WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

285

FRONT WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

285

REAR WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

287

WHEEL BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

289

02 – STEERING . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 291

GENERAL . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 293
ADJUSTMENT .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 293

STEERING ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

293

PROCEDURES .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 294

HANDLEBAR GRIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

294

MULTIFUNCTION SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

294

THROTTLE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

295

THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

295

HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

298

STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

299

TIE-ROD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

301

KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

302

03 – FRONT SUSPENSION . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 305

GENERAL . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 307
ADJUSTMENTS . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 307

FACTORY SETTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

307

ADJUSTING SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

308

MAINTENANCE . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 309

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

309

PROCEDURES .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 310

SHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

310

UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

311

UPPER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

312

LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

313

LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

314

04 – REAR SUSPENSION . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 317

GENERAL . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 319
ADJUSTMENTS . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 319

V

Summary of Contents for DS 450 2008

Page 1: ...2008 Shop Manual DS 450 DS 450 X ...

Page 2: ... 2007 Printed in Canada Technical Publications Bombardier Recreational Products Inc BRP Valcourt Quebec Canada Trademarks of Bombardier Recreational Products Inc BRP or its affiliates Trademarks of Bombardier Inc used under license Can Am Rotax DS 450 XP S This document contains the trademarks of the following companies Loctite is a trademark of Loctite Corporation Molykote is a trademark of Dow C...

Page 3: ...ECIAL PROCEDURES 9 TURN OVER 9 ATV IMMERSION 9 02 TROUBLESHOOTING 01 TECHNICAL GUIDELINES ENGINE 11 COOLING SYSTEM 11 LUBRICATION SYSTEM 11 CLUTCH 12 CYLINDER HEAD AND CYLINDER 13 CRANKSHAFT AND BALANCER SHAFT 13 GEARBOX 14 02 DIAGNOSTIC FLOW CHART 15 FUEL SYSTEM 15 03 ENGINE 01 ENGINE REMOVAL AND INSTALLATION 17 GENERAL 18 PROCEDURES 18 ENGINE 18 02 AIR INTAKE SYSTEM 25 GENERAL 26 PROCEDURES 26 A...

Page 4: ...TOR 58 COOLING FAN 59 THERMOSTAT 60 COOLANT TEMPERATURE SENSOR CTS 60 WATER PUMP HOUSING 61 WATER PUMP IMPELLER 62 WATER PUMP SHAFT BEARING AND SEALS 62 06 MAGNETO STARTER 67 GENERAL 69 PROCEDURES 69 MAGNETO COVER 69 CRANKSHAFT POSITION SENSOR CPS 71 STATOR 71 ROTOR 76 SPRAG CLUTCH 78 SPRAG CLUTCH GEAR 79 STARTER DRIVE GEARS 79 STARTER 80 07 CYLINDER HEAD CYLINDER 85 GENERAL 89 MAINTENANCE 89 VALV...

Page 5: ...VER 144 CLUTCH DRUM 146 10 GEARBOX 149 GENERAL 152 PROCEDURES 152 NEUTRAL INDICATOR SWITCH 152 SHIFTING MECHANISM 152 GEARBOX 155 04 ENGINE MANAGEMENT SYSTEM 01 OVERVIEW 161 SYSTEM DESCRIPTION 164 CONTROLLER AREA NETWORK CAN 164 ENGINE CONTROL MODULE ECM 164 POWER DISTRIBUTION 165 02 COMMUNICATION TOOLS B U D S SOFTWARE 167 MULTI PURPOSE INTERFACE 2 MPI 2 167 B U D S SOFTWARE 168 03 MONITORING SYS...

Page 6: ... 01 IGNITION SYSTEM 225 GENERAL 225 IGNITION SYSTEM DESCRIPTION 225 IGNITION SYSTEM OPERATION 225 TROUBLESHOOTING 225 IGNITION SYSTEM TESTING 225 PROCEDURES 227 IGNITION SWITCH 227 ENGINE STOP SWITCH 229 IGNITION COIL 232 SPARK PLUG 236 02 CHARGING SYSTEM 239 GENERAL 239 SYSTEM DESCRIPTION 239 PROCEDURES 240 VOLTAGE REGULATOR RECTIFIER 240 BATTERY 243 ELECTRICAL SYSTEM MAIN GROUNDS 246 03 STARTING...

Page 7: ...PROCEDURES 284 TIRE 284 WHEEL 285 FRONT WHEEL HUB 285 REAR WHEEL HUB 287 WHEEL BEARING 289 02 STEERING 291 GENERAL 293 ADJUSTMENT 293 STEERING ALIGNMENT 293 PROCEDURES 294 HANDLEBAR GRIP 294 MULTIFUNCTION SWITCH 294 THROTTLE LEVER 295 THROTTLE CABLE 295 HANDLEBAR 298 STEERING COLUMN 299 TIE ROD 301 KNUCKLE 302 03 FRONT SUSPENSION 305 GENERAL 307 ADJUSTMENTS 307 FACTORY SETTINGS 307 ADJUSTING SUSPE...

Page 8: ...E PEDAL 342 BRAKE DISC HUB 344 REAR CALIPER BRACKET 344 FRONT BRAKE LIGHT SWITCH 345 REAR BRAKE LIGHT SWITCH 346 FLEXIBLE BRAKE HOSE 347 06 BODY 351 GENERAL 354 PROCEDURES 354 DECALS 354 SEAT 354 ACCESS COVER 356 CONSOLE 356 FRONT BUMPER 356 FRONT BODY ASSEMBLY 356 FRONT FENDER 358 FRONT GRILLE 358 SIDE PANELS 358 FRONT FASCIA 359 FOOTREST 359 FOOTREST SUPPORT 359 REAR FENDER 359 REAR BUMPER 360 E...

Page 9: ...TABLE OF CONTENTS 09 TECHNICAL SPECIFICATIONS 01 DS 450 DS 450 X 369 10 WIRING DIAGRAM 01 DS 450 DS 450 X 377 WIRING DIAGRAM 377 VII ...

Page 10: ...as of the parts The use of BRP parts is most strongly recommended when considering replacement of any component Dealer and or distributor assistance should be sought in case of doubt The engines and the corresponding components identified in this document should not be utilized on product s other than those for which it was designed WARNING Unless otherwise specified engine should be turned OFF an...

Page 11: ...ere may be some differ ences between the manufactured product and the description and or specifications in this document BRP reserves the right at any time to discontinue or change specifications designs features mod els or equipment without incurring obligation VEHICLE INFORMATION Model Number MFD DATEFAB 12 2003 2BPS1234X2V000123 1234 MODEL VIN NIV MANUFACTURED BY FABRIQUÉ PAR MADE IN FABRIQUÉ A...

Page 12: ...factory specifications EPA Emission Regulations Some ATVs manufactured by BRP are certified to the EPA as conforming to the requirements of the regulations for the control of air pollution from new ATV engines This certification is con tingent on certain adjustments being set to factory standards For this reason the factory procedure for servicing the product must be strictly followed and whenever...

Page 13: ...threadlocker Apply 2 or 3 drops along the threaded hole NOTE To avoid a hydro lock situation do not apply too much Loctite Apply several drops on screw threads Tighten as required Stud in Blind Holes 2 1 3 lmr2007 040 005_a 1 On stud threads 2 On hole threads 3 Onto nut threads Clean threads stud and hole with solvent Apply Loctite Primer N P N 293 800 041 on threads and allow to dry Put 2 or 3 dr...

Page 14: ...RM A THREAD 81668 package If a plate is used to align bolt Apply release agent on mating surfaces Put waxed paper or similar film on the surfaces Twist bolt when inserting it to improve thread con formation NOTE NOT intended for engine stud repairs Repair of Small Holes Fine Threads Option 1 Enlarge damaged hole then follow STANDARD THREAD REPAIR procedure Option 2 Apply FORM A THREAD on the screw...

Page 15: ...ng compound is always forced out when applied on shaft DO NOT use antiseize Loctite or any similar prod uct No curing period is required Mounting in Tandem Apply retaining compound on internal element bore Continue to assemble as shown above Case In Components Metallic Gaskets A00A3VA 1 1 Proper strength Loctite Clean inner housing diameter and outer gasket di ameter Spray housing and gasket with ...

Page 16: ...Always torque screws bolts and or nuts in a criss cross sequence A00A8BS Property class and head markings Property class and nut markings 5 5 8 8 10 10 12 12 4 8 4 8 4 8 8 8 8 8 8 8 9 8 9 8 9 8 10 9 10 9 10 9 12 9 12 9 12 9 12 9 FASTENER GRADE TORQUE FASTENER SIZE 5 8 Grade 8 8 Grade 10 9 Grade 12 9 Grade M4 1 5 2 N m 13 18 lbf in 2 5 3 N m N m 22 27 lbf in 3 5 4 N m 31 35 lbf in 4 5 N m 35 44 lbf...

Page 17: ...ary fasteners or vice versa Mismatched or incorrect fasteners could cause damage to the vehicle or possible personal injury As many of the procedures in this manual are inter related we suggest that before undertaking any task you read and thoroughly understand the en tire section or subsection in which the procedure is contained A number of procedures throughout the book re quire the use of speci...

Page 18: ...title Indicates applicable models Document number for publishing process Bold face number is used to identify a part referred to the text Drop represents a service product to be applied Dotted box contains parts applicable to a specific model Page number Specific torque applicable to this installation CAUTION Pay attention to torque specifications Some of these are in lbf in instead of lbf ft Use ...

Page 19: ...exploded views Clean threads before applying a threadlocker Re fer to the SELF LOCKING FASTENERS and LOC TITE APPLICATION sections at the beginning of this manual for complete procedure WARNING Torque wrench tightening specifications must be strictly adhered to Locking devices e g locking tabs elastic stop nuts self locking fasteners etc must be replaced with new ones PROCEDURES MAGNETO FLYWHEEL M...

Page 20: ......

Page 21: ...UST CLEAN INSPECT LUBRICATE REPLACE EVERY 200 HOURS OR 10000 KM 6200 mi OR 2 YEAR PART TASK REFER TO ENGINE Engine oil 1 and filter R R Oil reservoir strainer C LUBRICATION SYSTEM Engine valves I A I A CYLINDER HEAD CYLINDER Engine mounting fasteners I I ENGINE REMOVAL NSTALLATION Air filter 2 R 3 AIR INTAKE SYSTEM Exhaust system I I Spark arrester C EXHAUST SYSTEM Coolant I I 4 R Cooling system p...

Page 22: ...t disconnecting I Electrical connections and fastening ignition system starting system fuel injectors etc I I ELECTRICAL CONNECTORS Ignition switch start button and engine run stop switch I I IGNITION SYSTEM and STARTING SYSTEM Lighting system HI LO intensity brake light beam aiming etc I I FUSES LIGHTS DRIVE SYSTEM Drive chain and slider 7 Drive chain sprockets 3 I I R Drive chain tensioner 8 I I...

Page 23: ...SION Suspension arms I I L Ball joints boots I I Ball joints 3 I I Shock absorbers I FRONT SUSPENSION BRAKES Brake fluid I I R Brake pads 3 I Brake discs I Brake hoses I Brake line fittings 10 BRAKES BODY FRAME Skid plate DS 450 X 10 Frame fastener I I Frame I Operator s seat and its fasteners 10 BODY AND FRAME 1 Inspect oil level at every ride 2 Clean at every ride 3 More often under severe use s...

Page 24: ......

Page 25: ...cement Using the maintenance chart performed items in the column indicated EVERY 100 HOURS OR 5000 KM 3100 mi OR 1 YEAR vmr2008 004 001_a 1 Use this column Furthermore proceed with the following Vehicles Prepared as per Storage Procedure Remove rag from muffler Test drive vehicle to confirm proper operation Vehicles Not Prepared as per Storage Proce dure Replace engine oil and filter Drain fuel ta...

Page 26: ......

Page 27: ...NING This procedure must only be performed in a well ventilated area Do not run engine dur ing storage period Proceed as follows Start the engine and allow it to run at idle speed until the engine reaches its operating tempera ture Stop the engine Remove spark plugs and spray storage oil P N 413 711 600 into cylinder NOTE For US citizens use storage oil US P N 413 711 900 only CAUTION Do not injec...

Page 28: ...ver to prevent dust accumulation during storage CAUTION The vehicle has to be stored in a cool and dry place If vehicle is stored outside it must be covered with an opaque tarpaulin This will prevent sun rays and grime from af fecting plastic components and vehicle finish 8 vmr2008 005 ...

Page 29: ...s Look for water in Brake system replace brake fluid Chain tensioner Lubricate all cables Check if the cables operate properly Lubricate suspension arms and swing arm Lubricate drive chain Spray all metal parts with XP S Lube P N 293 600 016 ATV Submerged for a Short Time Less than Oone Hour Fuel System Drain air filter housing then clean and dry air filter Look for water in fuel tank in doubt flu...

Page 30: ......

Page 31: ... fan fuse is burnt Replace Check if cooling fan motor turns Replace Check condition of wires and connector Repair or replace 4 Defective thermostat does not open when engine gets hot Replace thermostat Refer to COOLING SYSTEM section 5 Defective water pump Check water pump impeller for broken wings Replace Check if the spring pin retaining impeller is damaged Replace 6 Faulty temperature sensor Ch...

Page 32: ...a leak down test Repair or replace defective parts Check for a broken piston ring Replace Check piston rings for heavy wear Replace Symptom OIL CONTAMINATION WHITE APPEARANCE 1 Defective water pump seals Check leak indicator hole located in clutch cover if coolant oil leaks Replace seal refer to COOLING SYSTEM 2 Cylinder head cylinder leakage Check screws and nuts tightening Tighten to recommended...

Page 33: ...eck engine oil pressure Check items 1 to 6 of LOW OR NO OIL PRESSURE Symptom UNUSUAL ENGINE NOISE AND OR VIBRATIONS WHILE OPERATING 1 Check items 1 to 4 of UNUSUAL ENGINE NOISE AND OR VIBRATION AT IDLE SPEED 2 Faulty chain guides Check chain guides for wear Replace 3 Timing chain and sprockets Check sprocket screws tightening Tighten to recommended torque Check sprockets for wear or other damages ...

Page 34: ...and smoothly Replace bearing s Check condition of needle bearings on main shaft and on clutch shaft Replace defective part s Symptom GEAR S IS ARE HARD TO SHIFT 1 Poor quality or inadequate engine oil Check engine oil Incorrect oil being used Replace with BRP recommended oil 2 Engine idle speed too high Check throttle cable adjustment Check bypass idle valve and connectors 3 Poor clutch adjustment...

Page 35: ...place Fast pressure drop Verify fuel pump check valve Fails Yes OK OK Fails Fails Repair or replace Replace fuel pump module Turn ignition key ON and set engine stop switch to RUN Fuel pump does not run Fuel pump runs for 5 sec then stops Install fuel pressure gauge on fuel pressure line Check fuses and relays Check ignition switch and engine stop switch Check fuel pump operation Repair or replace...

Page 36: ......

Page 37: ...Section 03 ENGINE Subsection 01 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION 25 N m 18 lbf ft 25 N m 18 lbf ft 48 N m 35 lbf ft vmr2008 009 001_a vmr2008 009 17 ...

Page 38: ...S ENGINE Engine Removal Disconnect the BLACK cable from battery then the RED cable WARNING Always disconnect battery cables exactly in the specified order the BLACK cable first It is recommended to disconnect electrical connections prior to disconnecting fuel lines Remove the front body assembly Refer to BODY section Drain engine oil see procedure in LUBRICATION SYSTEM section Drain engine coolant...

Page 39: ...wer protector vmr2008 009 005_a 1 Lower protector 2 Clutch cover Unscrew and remove exhaust pipe Refer to EX HAUST SYSTEM section for complete procedure vmr2008 009 006_a 1 Exhaust pipe Disconnect the crankcase vent tube vmr2008 009 007_a 1 Crankcase vent tube Disconnect the cooling hose from the cylinder vmr2008 009 008_a 1 Cooling hose 2 RH side member Disconnect the breather hose from cylinder ...

Page 40: ...ble Remove the coolant reservoir bolt and move reser voir aside to make room vmr2008 009 013_a 1 Coolant reservoir bolt Remove bolts securing upper engine supports to frame Remove the RH upper engine support vmr2008 009 014_a 1 Engine support bolts 2 RH upper engine support 3 LH upper engine support Unplug the trigger coil connector vmr2008 009 015_a 1 Trigger coil connector Remove screws securing...

Page 41: ...1 Shock absorber upper bolt Remove screws securing the LH side member Remove the LH side member from the vehicle vmr2008 009 016_a SCREW BEHIND SHOCK ABSORBER 1 Side member front screw vmr2008 009 017_a 1 Side member rear screws 2 Side member Cut all locking ties holding wiring harness to upper bar of frame Remove screws securing headlamps regulator vmr2008 009 018_a 1 Headlamp regulator screws Re...

Page 42: ...emove the clutch cover Refer to CLUTCH sec tion for complete procedure vmr2008 009 022_a 1 Clutch cover Disconnect the oil tank inlet hose vmr2008 009 023_a 1 Oil tank inlet hose 2 Oil tank Unscrew the oil tank outlet fitting from oil tank Discard O ring vmr2008 009 024_a 1 Oil tank outlet fitting screws Remove bolts securing oil tank to frame vmr2008 009 025_a 1 Oil tank bolts Remove bolt securin...

Page 43: ...2008 009 102_a 1 Shifter From the RH side push cylinder head to unplug the coolant temperature sensor CTS vmr2008 009 029_a Step 1 Push on cylinder head Step 2 Unplug CTS connector From the LH side remove engine from vehicle vmr2008 009 030_a Step 1 Lift engine Step 2 Tilt cylinder head Step 3 Remove engine Engine Installation The installation is the reverse of the removal pro cedure However pay a...

Page 44: ...e Insert the bottom of engine into the lower brace of frame Position engine in frame On RH side plug the CTS connector Install front and lower engine bolts NOTE Install all other bolts retaining engine be fore tightening them Install a NEW air intake adapter seal Install a NEW front sprocket circlip Use a NEW O ring when installing oil tank outlet fitting Apply engine oil on O ring Install all oth...

Page 45: ...TAKE SYSTEM AIR INTAKE SYSTEM SERVICE PRODUCTS Description Part Number Page air filter oil 219 700 340 26 air filter cleaner 219 700 341 26 2 5 N m 22 lbf in 5 N m 44 lbf in 5 N m 44 lbf in 2 5 N m 22 lbf in vmr2008 010 001_a vmr2008 010 25 ...

Page 46: ...gine is calibrated to operate specifically with these components Otherwise engine performance degradation or damage can occur Remove seat Release clamps and remove air filter housing cov er vmo2008 011 016_b 1 Clamps 2 Air filter housing cover Loosen clamp and remove filter vmo2008 011 043_a 1 Clamp Air Filter Cleaning Pour air filter cleaner P N 219 700 341 or an equivalent into a bucket Put the ...

Page 47: ... small quantity of air filter oil in the drain tube Air Filter Housing Removal Remove seat Remove the front body assembly Refer to BODY section Remove battery Refer to CHARGING SYSTEM section Disconnect all wires from the starting solenoid Refer to STARTING SYSTEM section Remove plastic rivet securing the air intake hose deflector vmr2008 010 002_a 1 Air intake hose 2 Deflector 3 Plastic rivet Cut...

Page 48: ...8 010 005_a 1 Air filter housing screws Remove air filter housing cover Lower the housing and pull it rearward On front section of air filter housing detach the following connectors AAPTS connector Magneto connector Rear brake light switch connector Remove air filter housing from vehicle Air Filter Housing Installation The installation is the reverse of the removal pro cedure 28 vmr2008 010 ...

Page 49: ...M EXHAUST SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 271 red 293 800 005 32 25 N m 18 lbf ft Loctite 271 5 N m 44 lbf in 25 N m 18 lbf ft 25 N m 18 lbf ft 25 N m 18 lbf ft NEW NEW 11 N m 97 lbf in vmr2008 011 001_a vmr2008 011 29 ...

Page 50: ...ctly adhered to Locking devices e g locking tabs elastic stop nuts cotter pin etc must be replaced with new ones PROCEDURES MUFFLER Muffler Removal Loosen muffler clamp vmr2008 011 002_a 1 Exhaust pipe 2 Muffler clamp Over the LH foot protector remove screw secur ing muffler pipe to frame vmr2008 011 008_a 1 Muffler pipe screw 2 LH foot protector Remove muffler screw vmr2008 011 003_a 1 Muffler 2 ...

Page 51: ...008 011 005_a 1 Exhaust pipe nut 2 other nuts not shown Loosen muffler clamp vmr2008 011 002_a 1 Exhaust pipe 2 Muffler clamp Pull exhaust pipe forward to remove it Discard the muffler gasket and the exhaust gas ket vmr2008 011 006_a 1 Muffler gasket 2 Exhaust pipe 3 Exhaust gasket If necessary remove heat shield from the exhaust pipe NOTE Heat screws to break the threadlocker vmr2008 011 007_a 1 ...

Page 52: ... of muffler vmo2008 011 068_a 1 Spark arrester Spark Arrester Cleaning Remove carbon deposits from the spark arrester using a brush NOTE Use a soft brush and be careful to avoid damaging spark arrester vmo2008 011 069_a 1 Clean this portion Replace spark arrester if it is damaged Spark Arrester Installation For installation reverse the removal procedure HEAT SHIELD Heat Shield Removal Apply heat o...

Page 53: ...ICE TOOLS Description Part Number Page adapter hose 529 035 652 40 pressure gauge 529 035 709 40 timing chain tensioner adapter 529 036 079 40 SERVICE PRODUCTS Description Part Number Page XP S 5W 40 synthetic oil 293 600 039 36 Loctite 243 blue 293 800 060 39 vmr2008 012 33 ...

Page 54: ...Section 03 ENGINE Subsection 04 LUBRICATION SYSTEM 10 N m 89 lbf in 7 N m 62 lbf in NEW Loctite 243 NEW Engine oil 34 N m 25 lbf ft vmr2008 012 100_a 34 vmr2008 012 ...

Page 55: ...SYSTEM 39 N m 28 lbf ft Engine oil 9 N m 80 lbf in Loctite 243 Engine oil Engine oil Engine oil 23 N m 17 lbf ft 9 N m 80 lbf in 9 N m 80 lbf in 9 N m 80 lbf in NEW NEW 19 N m 168 lbf in NEW NEW 19 N m 168 lbf in vmr2008 012 001_a vmr2008 012 35 ...

Page 56: ...e market for the moment If a high quality equivalent were available it could be used Engine Oil Level Verification Use the oil tank dipstick to check the oil level in the engine The engine oil tank is located in front of engine CAUTION Check level frequently and refill if necessary Do not overfill Operating the engine with an improper level may severely damage engine and transmission Wipe off any ...

Page 57: ...all NEW sealing washers on drain plugs CAUTION Never use a sealing washer a sec ond time Always replace with a new one Install and tighten drain plugs Replace OIL FILTER see procedure further in this section In accordance with the maintenance chart clean the OIL TANK STRAINER See further in this sec tion for the procedure Wipe out any oil spillage Refill oil tank at the proper level with the recom...

Page 58: ... outlet orifice to the engine lubrication system 3 Clutch cover Install a NEW O ring on oil filter cover Apply engine oil on filter and on filter cover O ring vmr2008 012 038_a 1 Apply oil Install cover using proper screw length as shown vmo2008 011 042_a 1 Oil filter cover 2 Screw 25 mm 3 Screw 55 mm Replace engine oil Refer to ENGINE OIL RE PLACEMENT OIL TANK STRAINER Oil Tank Strainer Removal D...

Page 59: ...ngine oil on O ring Apply Loctite 243 blue P N 293 800 060 on out let fitting screws Carefully reinstall all previously removed parts CAUTION Take care not to damage O ring while inserting outlet fitting into oil tank vmo2008 011 100_a TYPICAL OIL OUTLET ASSEMBLY 1 Outlet fitting screw 2 Washer 3 Insert 4 Outlet fitting 5 O ring 6 Strainer INSPECTION ENGINE OIL PRESSURE From LH side of vehicle rem...

Page 60: ... engine The engine oil pressure should be within the fol lowing specification with the recommended oil at the proper level and with a warm engine mini mum oil temperature of 80 C 176 F OIL PRESSURE AT IDLE 5000 RPM Minimum 80 kPa 12 PSI 200 kPa 29 PSI If the engine pressure is out of specifications check the points described in TROUBLESHOOT ING section Remove engine oil pressure test tools Using a...

Page 61: ...ame vmr2008 012 043_a 1 Oil tank bolts Withdraw oil tank from frame Oil Tank Installation The installation is the reverse of the removal pro cedure Refill oil tank with recommended oil and at the proper level Refer to ENGINE OIL REPLACE MENT at the beginning of this section OIL HOSE CONNECTOR The oil hose connector is located on the crankcase clutch side vmr2008 012 005_a 1 Oil hose connector 2 Cr...

Page 62: ...removal procedure Pay attention to the following details Install a NEW connector gasket Install hoses to connector vmr2008 012 005_b 1 Connect oil tank LOWER hose to this fitting 2 Connect oil tank UPPER hose to this fitting Reinstall plastic protector on LH side of engine ENGINE OIL PRESSURE REGULATOR The engine oil pressure regulator is located in the crankcase on the magneto side vmr2008 012 03...

Page 63: ...allation For installation reverse the removal procedure Pay attention to the following details Before installing the plug screw press on pres sure regulator housing a few times to check if the oil pressure regulator works properly Install a NEW gasket ring on plug screw Ensure gasket ring is installed properly to allow the open ing of the oil pressure regulator at the proper oil pressure OIL PRESS...

Page 64: ...pection Inspect oil pump for marks or other damages Check for scratches in crankcase between outer rotor and oil pump bore If so replace damaged parts vmr2008 012 015_b 1 Outer rotor 2 Inner rotor 3 Needle pin 4 Oil pump bore Check inner rotor for corrosion pin holes or other damages If so replace oil pressure pump inner and outer rotor vmr2008 012 016_a 1 Pitting on the teeth Using a feeler gauge...

Page 65: ...mr2008 012 018 OIL PUMP AXIAL CLEARANCE MEASUREMENT Check oil pump cover for damages and for surface straightness with a straight edge Difference between measurements should not exceed 0 2 mm 008 in If damaged or out of tolerance replace the com plete oil pump assembly NOTE When the axial clearance of the oil pump assembly increases the oil pressure decreases Oil Pressure Pump Installation For ins...

Page 66: ... on the clutch side vmr2008 012 020_a 1 Oil strainer cover 2 Crankcase clutch side Engine Oil Strainer Removal Split crankcase Refer to CRANKCASE CRANK SHAFT section Unscrew the bolts retaining the oil strainer cover vmr2008 012 021_a 1 Screws 2 Oil strainer cover Remove snap ring retaining the oil strainer Remove the oil collector with the O ring Remove the strainer vmr2008 012 022_a 1 Snap ring ...

Page 67: ... see procedure above in this section Split crankcase Refer to CRANKCASE CRANK SHAFT section Remove ENGINE OIL STRAINER COVER see pro cedure above in this section Remove outer and inner rotors Remove the needle pin Pull out the oil pump shaft vmr2008 012 025_a 1 Outer rotor 2 Inner rotor 3 Needle pin 4 Oil pump shaft Oil Suction Pump Inspection Inspect oil pump for marks or other damages Check for ...

Page 68: ...il nozzle Oil Nozzle Removal Split crankcase Refer to CRANKCASE CRANK SHAFT section Remove screw retaining the oil nozzle to crankcase Oil Nozzle Cleaning Clean oil nozzle with a parts cleaner then use an air gun and dry the parts Oil Nozzle Installation CAUTION At assembly make sure the contact surface of the oil nozzle is well fitted onto the crankcase If this is not ensured the oil spray direct...

Page 69: ...thin the scope of repair work take this opportunity to clean the oil tube Oil Tube Removal Split crankcase Refer to CRANKCASE CRANK SHAFT section Oil Tube Inspection Clean oil tube with a parts cleaner then use an air gun and dry the parts Oil Tube Installation For installation reverse the removal procedure vmr2008 012 49 ...

Page 70: ......

Page 71: ... vacuum pressure pump kit 529 021 800 54 large hose pincher 529 032 500 57 oil seal pusher 529 035 757 64 suction pump 529 035 880 57 test cap 529 035 991 54 water pump seal installer 529 036 077 64 bearing installer 529 036 078 63 SERVICE PRODUCTS Description Part Number Page BRP premixed coolant 219 700 362 55 Loctite 243 blue 293 800 060 64 Dow Corning 111 413 707 000 64 vmr2008 013 51 ...

Page 72: ... COOLING SYSTEM Engine oil 19 N m 168 lbf in Loctite 648 15 N m 133 lbf in Loctite 243 4 N m 35 lbf in Loctite 243 17 N m 150 lbf in 10 N m 89 lbf in Dow Corning 111 Engine oil NEW NEW NEW Loctite 243 vmr2008 013 001_a 52 vmr2008 013 ...

Page 73: ...STEM 4 N m 35 lbf in 10 N m 89 lbf in 5 N m 44 lbf in NEW 10 N m 89 lbf in NEW NEW 2 N m 18 lbf in NEW NEW 1 5 N m 13 lbf in 3 N m 27 lbf in 1 5 N m 13 lbf in 2 N m 18 lbf in 2 N m 18 lbf in NEW 2 N m 18 lbf in vmr2008 013 100_a vmr2008 013 53 ...

Page 74: ... ties removed during a pro cedure must be replaced and installed at the same location Oetiker Clamp Replacement To secure or cut Oetiker clamps use Oetiker pliers P N 295 000 070 F01B03A 1 1 Cutting clamp F01B04A 1 1 Securing clamp F01B05A 1 1 Securing clamp in limited access INSPECTION COOLING SYSTEM LEAK TEST WARNING In order to avoid getting burned do not re move the coolant tank cap or loosen ...

Page 75: ...sen the cooling drain plug if the engine is hot Recommended Coolant Use BRP premixed coolant P N 219 700 362 or a blend of 50 antifreeze with 50 water To prevent antifreeze deterioration always use the same brand Never mix different brands unless cooling system is completely flushed and refilled CAUTION To prevent rust formation or freez ing condition always replenish the system with the BRP premi...

Page 76: ...08 013 003_a 1 Drain plug 2 Gasket ring 3 Water pump cover Refilling the System Ensure vehicle is on a flat surface and engine is cold Fill tank until coolant reaches level marks small ribs vmo2008 011 107_a 1 Level marks Install coolant tank cap Run engine until thermostat opens then stop en gine Let engine cool down Recheck coolant level and top up if necessary NOTE Check coolant concentration f...

Page 77: ...ssembly Refer to BODY section Remove screw securing the front of coolant tank vmr2008 013 030_a 1 Coolant tank front screw Lift coolant tank and install a small hose pincher P N 295 000 076 on coolant tank inlet hose 295 000 076 vmr2008 013 031_a 1 Inlet hose from radiator and cylinder head Install a large hose pincher P N 529 032 500 on coolant tank outlet hose 529 032 500 vmr2008 013 032_a 1 Out...

Page 78: ...THE SYSTEM above in this section Remove the front body assembly Refer to BODY section Remove both radiator mouldings vmr2008 013 033_a 1 LH radiator moulding screw 2 LH radiator moulding Disconnect the bottom hose from radiator vmr2008 013 034_a 1 Radiator outlet hose Disconnect the bleeding hose from the top of ra diator vmr2008 013 035_a 1 Radiator bleeding hose Disconnect upper radiator hose vm...

Page 79: ...t temperature sensor CTS If the cooling fan does not work check the 20 A fuse If fuse is good check the cooling fan relay Cooling Fan Relay Test Remove the front body assembly Refer to BODY section Remove the cooling fan relay vmr2008 013 043_a 1 Fan relay Install a jumper wire end between pins 3 and 5 vmr2008 013 044_a 1 Pin 3 2 Pin 5 If the fan works correctly replace the relay If the fan does n...

Page 80: ...vmr2008 013 101_a Partially drain coolant until approximately 1 L 1 quart flowed out Refer to COOLANT RE PLACEMENT Cut Oetiker clamps vmr2008 013 101_b Pull out thermostat housing Catch spilled coolant Thermostat Test To check thermostat put housing in water and heat water Thermostat should begin to open when water temperature reaches 75 C 167 F If the thermostat is defective always replace it wit...

Page 81: ...cooling system Refer to COOLANT RE PLACEMENT in this section Remove radiator outlet hose from water pump housing Remove screws retaining water pump housing vmr2008 013 003_b 1 Cooling drain plug 2 Sealing ring 3 Screws 4 Water pump cover Water Pump Housing Inspection Check if gasket is brittle hard or damaged and replace as necessary vmr2008 013 005_a 1 Gasket Water Pump Housing Installation The i...

Page 82: ...en installed CAUTION Be careful not to damage impeller wings during installation WATER PUMP SHAFT BEARING AND SEALS Water Pump Shaft Removal Drain engine oil Refer to LUBRICATION SYSTEM section Drain cooling system Refer to COOLANT RE PLACEMENT in this section Remove water pump cover and impeller Remove clutch cover retaining screws and pull clutch cover vmr2008 013 007_a 1 Water pump shaft 2 Clut...

Page 83: ...ump Bearing and Seals Removal To remove bearing and seals push them out of clutch cover using a 10 mm socket vmr2008 013 019_a 1 Extractor 10 mm socket 2 Clutch cover 3 Support 36 mm socket Check if leak indicator orifice in clutch cover is free If necessary use a parts cleaner then use an air gun to dry it vmr2008 013 010_a 1 Leak indicator orifice 2 Clutch cover Water Pump Bearing Installation U...

Page 84: ...29 035 757 420 877 650 vmr2008 013 021_a 1 Inner oil seal 2 Oil seal pusher 3 Handle Water Pump Outer Seal Installation Apply Loctite 243 blue P N 293 800 060 on the outer diameter of oil seal vmr2008 013 023_a 1 Apply Loctite 243 on this surface Use press machine only to install outer oil seal Install outer oil seal with a press and the water pump seal installer P N 529 036 077 529036139 vmr2008 ...

Page 85: ...utch cover has been installed Place thrust washer on water pump shaft and fit clutch cover on crankcase vmr2008 013 018_a 1 Thrust washer 2 Water pump shaft Take care that the pin in the water pump shaft engages in the slot of the intermediate gear vmr2008 013 014_a 1 Pin in water pump shaft 2 Slot in intermediate gear If a gap is visible between clutch cover and hous ing do not force the cover Re...

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Page 87: ...neto harness adapter 529 036 016 72 crankshaft locking tool 529 036 107 76 SERVICE PRODUCTS Description Part Number Page dielectric grease 293 550 004 83 Super Lube grease 293 550 030 82 Loctite 243 blue 293 800 060 75 Loctite 5910 293 800 081 70 76 pulley flange cleaner 413 701 809 77 Bombardier gasket remover 413 708 500 70 Loctite 648 green 413 711 400 77 79 vmr2008 015 67 ...

Page 88: ...RTER 40 N m 30 lbf ft Loctite 243 14 N m 124 lbf in 10 N m 89 lbf in Loctite 648 Engine oil Loctite 5910 Antiseize lubricant 10 N m 89 lbf in Loctite 243 10 N m 89 lbf in Loctite 243 10 N m 89 lbf in Loctite 5910 vmr2008 014 001_a 68 vmr2008 015 ...

Page 89: ... Locking devices ex locking tabs elastic stop nuts self locking fasteners cotter pin etc must be installed or replaced with new ones where specified If the efficiency of a locking device is impaired it must be renewed PROCEDURES MAGNETO COVER Magneto Cover Removal Remove seat Refer to BODY Disconnect stator connector vmr2008 025 010_a RIGHT SIDE VIEW 1 Air inlet silencer 2 Brake fluid reservoir 3 ...

Page 90: ...f necessary Clean all metal component in a non ferrous met al cleaner Use Bombardier gasket remover P N 413 708 500 or suitable equivalent WARNING Wear safety glasses and work in a well ventilated area when working with strong chemical products Also wear suitable non absorbent gloves to protect your hands Magneto Cover Installation For installation reverse the removal procedure However pay attenti...

Page 91: ...er to ELECTRONIC FUEL INJECTION CPS Replacement CPS is replaced with the stator Refer to STATOR for the procedure STATOR Stator Continuity Test Test at Voltage Regulator Rectifier Connector Disconnect the voltage regulator connector vmr2008 025 008_a 1 Disconnect voltage regulator rectifier Set multimeter to Connect multimeter between each pair of YEL LOW wires vmr2008 025 009_a STATOR CONTINUITY ...

Page 92: ...ir vmr2008 025 010_a RIGHT SIDE VIEW 1 Air inlet silencer 2 Brake fluid reservoir 3 Stator connector Reach in from behind the vehicle and remove the connector from its support vmr2008 025 014_a STATOR CONNECTOR Disconnect the stator connector and connect the magneto harness adapter P N 529 036 016 to the stator side only not to the rear main harness side vmr2008 025 015_a 1 Adapter connected to st...

Page 93: ... voltage regulator rectifier connector Set multimeter to Connect multimeter between any YELLOW wire and chassis ground vmr2008 025 009_b STATOR INSULATION TEST AT VOLTAGE REGULATOR RECTIFIER CONNECTOR Read resistance STATOR INSULATION TEST AT VOLTAGE REGULATOR RECTIFIER PROBE POSITIONS RESISTANCE 20 C 69 F Any YELLOW wire and chassis ground Infinity open circuit If there is a resistance or continu...

Page 94: ...ector Disconnect the voltage regulator connector vmr2008 025 008_a 1 Disconnect voltage regulator rectifier connector Set multimeter to Vac scale Start engine Connect multimeter between each pair of YEL LOW wires vmr2008 025 009_c STATOR OUTPUT VOLTAGE TEST AT VOLTAGE REGULATOR RECTIFIER CONNECTOR Read voltage STATOR OUTPUT VOLTAGE TEST AT VOLTAGE REGULATOR RECTIFIER TEST ENGINE SPEED TERMINAL VOL...

Page 95: ...ace wiring connector or stator as required Install removed connectors Stator Removal Remove the magneto cover Refer to MAGNETO COVER above Remove gasket Remove retaining screws of stator Pull out stator and CPS vmr2008 014 005_a 1 Stator 2 Stator retaining screws 3 CPS 4 CPS retaining screws Stator Inspection Check stator and CPS condition If damaged re place it Check if stator and CPS wires are b...

Page 96: ...ning screw vmr2008 014 009_a 1 Screw M8 2 Washer 3 Rotor Use the screw from the magneto puller P N 529 035 748 vmr2006 041 008 Install the puller screw in rotor NOTE Apply grease on screw threads and screw tip to prevent damage to the threads during re moval Tighten puller screw to remove rotor The rotor is mounted with Loctite 648 and will be stuck on the crankshaft Proceed as follows to release ...

Page 97: ...Rotor Installation For installation reverse the removal procedure Pay attention to the following details Clean crankshaft taper and rotor with pulley flange cleaner P N 413 701 809 CAUTION Taper on crankshaft and rotor must be free of grease Apply a light coat of Loctite 648 green P N 413 711 400 to taper on rotor Apply engine oil on sprag clutch and sprag clutch gear needle bearing vmr2008 014 01...

Page 98: ...ve sprag clutch housing Remove sprag clutch from sprag clutch housing vmr2008 014 015_a 1 Sprag clutch housing screws 2 Rotor 3 Sprag clutch 4 Sprag clutch housing Sprag Clutch Inspection Inspect sprag clutch and sprag clutch housing for wear and damage Check the bushing of the sprag clutch gear Perform a functional test of the sprag clutch as follows Hold sprag clutch and rotate gear clockwise Ge...

Page 99: ...Rotor 2 Sprag clutch gear 3 Friction clutch Pull sprag clutch gear from the rotor vmr2008 014 012_b 1 Rotor 2 Sprag clutch gear Sprag Clutch Gear Inspection Inspect gear especially teeth and sprag clutch bushing for wear and other damage Check needle bearing condition Replace sprag clutch gear if necessary vmr2008 014 017_a 1 Teeth 2 Bushing 3 Needle bearing Sprag Clutch Gear Installation The inst...

Page 100: ...le Remove PF1 fuse holder cover Remove the 15 A injector and ignition fuse to pre vent engine from starting vmr2008 026 002_c 1 Fuse cover 2 PF1 fuse holder 3 Injector ignition fuse NOTE Check engine light will flash when power is turned ON Starter will crank engine but with an initial delay of 1 or 2 seconds Locate the starter on the LH side of the engine Pull back RED rubber protector from start...

Page 101: ...TY TEST Starter Cable Continuity Test Disconnect and remove battery from vehicle for access to starter solenoid refer to CHARGING SYSTEM section Carry out a continuity test of the starter cable as per following table NOTE An abnormally high resistance may be at tributable to loose dirty or corroded connections STARTER CABLE CONTINUITY TEST RED PROBE BLACK PROBE MEASUREMENT Starter terminal Solenoi...

Page 102: ...proce dure However pay particular attention to the fol lowing Ensure starter and engine mating surfaces are free of debris Serious problems may arise if the starter is not properly aligned vmr2008 139 013_a Apply Super Lube grease P N 293 550 030 to the starter O ring seal vmr2008 139 014_a TYPICAL Insert starter in crankcase and install both mount ing screws and engine ground loosely Install star...

Page 103: ...08 026 004_d 1 Torque starter mounting screws 2 Apply dielectric grease Connect the BLACK battery cable WARNING Always connect the RED starter cable first then the BLACK battery cable last When ever connecting the RED cable to the starter motor always make sure the BLACK battery cable is disconnected to prevent electric shock Test starter operation vmr2008 015 83 ...

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Page 105: ...9 036 074 106 valve guide installer 529 036 075 107 circlip installer 529 036 083 110 camshaft timing device 529 036 084 96 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page Snap on piston ring compressor tool RC 980 101 Snap on valve holder VL2 105 Snap on valve stem seal pliers YA 8230 104 SERVICE PRODUCTS Description Part Number Page Loctite 243 blue 293 800 060 96 Loctite 5910 293 800 ...

Page 106: ...on 07 CYLINDER HEAD CYLINDER 11 N m 97 lbf in 11 N m 97 lbf in 39 N m 29 lbf ft 19 N m 168 lbf in 100 N m 74 lbf ft Loctite 243 Loctite 243 Loctite 648 Engine oil Engine oil Engine oil Engine oil vmr2008 015 002_a 86 vmr2008 015 ...

Page 107: ...e Ghy 133n Engine oil Engine oil Engine oil Engine oil Engine oil Loctite 574 Loctite 648 Loctite 648 Loctite 243 11 N m 97 lbf in Petamo grease Ghy 133n 15 N m 133 lbf in 58 N m 43 lbf ft 19 N m 168 lbf in 17 N m 150 lbf in 4 N m 35 lbf in 9 N m 80 lbf in NEW NEW NEW vmr2008 015 001_a vmr2008 015 87 ...

Page 108: ...Section 03 ENGINE Subsection 07 CYLINDER HEAD CYLINDER Engine oil 30 N m 22 lbf ft Engine oil Engine oil NEW NEW NEW vmr2008 015 003_a 88 vmr2008 015 ...

Page 109: ...be replaced with new ones Hoses or cables removed or disconnected must be installed and routed at the same place CAUTION Locking ties removed during a pro cedure must be replaced and installed at the same location When disassembling parts that are duplicated in the engine e g valves springs etc it is strongly recommended to note their position and to keep the parts of the same assembly as a group ...

Page 110: ...the engine at normal operating temper ature WARNING Prevent burning yourself due to handling on the hot engine Preparation Remove the bottom spark plug Refer to IGNI TION SYSTEM section Remove VALVE COVER See procedure in this section Bring the piston to TDC of compression stroke Refer to CRANKSHAFT LOCKING PROCEDURE in the CRANKCASE CRANKSHAFT section Leak Test Install a gauge adaptor of the engi...

Page 111: ...aged gasket and or loosened screws refer to CRANKCASE CRANKSHAFT section Repair Tips Blue exhaust gas means damaged worn piston rings or valve stem seals White exhaust gas means damaged cylinder head gasket Radiator cap opening without overheat means damaged cylinder head gasket Assembly Reverse the preparation procedure PROCEDURES VALVE COVER Valve Cover Removal Engine in Vehicle Remove seat Use ...

Page 112: ...gine harness connectors and ECM connector Refer to ELECTRICAL FUEL INJECTI ION EFI section vmr2008 015 103_a Move crankcase vent hose away to free valve cov er area vmr2008 015 105_a vmr2008 015 106 Disconnect fuel rail quick connector vmr2008 015 107_a Move headlight power regulator away toward ECM Move engine harness away toward seat area 92 vmr2008 015 ...

Page 113: ... Engine Removed Unscrew cover retaining screws Remove the cover with the gasket vmr2008 015 007_a 1 Retaining screws 2 Valve cover 3 Valve cover gasket Valve Cover Inspection Check the valve cover for cracks or other dam ages Check if the gasket is brittle hard or otherwise damaged Replace all defective parts Valve Cover Installation For installation reverse the removal procedure Take care that th...

Page 114: ...r for scoring Compress chain tensioner and check if it works properly Timing Chain Tensioner Installation For installation reverse the removal procedure CAMSHAFT TIMING GEAR Camshaft Timing Gear Removal Remove VALVE COVER See procedure in this section Lock crankshaft to TDC of compression stroke Refer to CRANKSHAFT LOCKING PROCEDURE in the CRANKCASE CRANKSHAFT section Loosen camshaft timing gear s...

Page 115: ...pay attention to the following NOTE Make sure that crankshaft is locked to TDC Install timing gears on camshafts so that marks IN on intake and EX on exhaust camshaft are aligned vmr2008 015 004_a 1 Marks on timing gears Install the TIMING CHAIN TENSIONER See pro cedure in this section Recheck timing gears alignment after the installa tion of timing chain tensioner Camshaft Timing Gear Installatio...

Page 116: ...e timing device vmr2008 016 007_a 1 Intake timing gear 2 Mark IN 3 Mark on camshaft timing device Apply Loctite 243 blue P N 293 800 060 on threads of camshaft timing gear screws NOTE Temporarily hand tighten screws Do NOT tighten yet Install timing chain guide and timing chain tension er refer to TIMING CHAIN AND TENSION GUIDE Apply Loctite 243 blue P N 293 800 060 on con trol gear screw and torq...

Page 117: ...efer to CRANKSHAFT LOCKING PROCEDURE in the CRANKCASE CRANKSHAFT section Remove Timing chain tensioner Upper chain guide Timing chain guide Camshaft timing gears Secure timing chain with a retaining wire Remove camshaft holder vmr2008 015 016_a 1 Retaining screws 2 Washers 3 Camshaft holder Remove exhaust and intake camshafts vmr2008 015 017_a 1 Exhaust camshaft 2 Decompressor 3 Intake camshaft Ca...

Page 118: ...omotive parts retailer Place the camshaft in the cylinder head and apply a plastic gauge on the camshaft bearing journal vmr2008 016 066_a 1 Plastic gauge 2 Camshaft bearing journal Install camshaft holder in the proper position and tighten bearing cover screws to specified torque Unfasten camshaft holder Measure the maximum width of the pressed plastic gauge with the corresponding graduated scale...

Page 119: ...CE NOTE After bearing cover installation check if camshafts turn easily Check VALVE CLEARANCE See procedure in this section VALVE LIFTER BUCKET Valve Lifter Bucket Removal Remove CAMSHAFT see procedure in this sec tion Use a magnet and lift valve lifter bucket CAUTION Adjustment shim could be stuck in valve lifter bucket Take care not to lose adjust ment shim vmr2008 016 021_a 1 Valve lifter bucke...

Page 120: ...ON section Referring at this section remove the following Valve cover Chain tensioner Camshafts First remove M6 cylinder head screws Then remove M10 cylinder head nuts vmr2008 015 024_a 1 Cylinder head screws M6 2 Cylinder head nuts M10 Pull cylinder head with cylinder from crankcase Remove cylinder screws M8 vmr2008 015 025_a 1 Cylinder screws M8 Separate cylinder head from cylinder Remove cylind...

Page 121: ...installation reverse the removal procedure Pay attention to the following details Assemble cylinder and cylinder head using a NEW gasket Install cylinder screws M8 and pre tighten them to 15 N m 133 lbf in according to following tight ening sequence vmr2008 015 025_b Apply Loctite 5910 P N 293 800 081 on crankcase sealing surface in the areas crankcase gasket cylinder base gasket chain duct and co...

Page 122: ...ng sequence vmr2008 015 072_a Finally tighten cylinder head screws M6 in cylinder head vmr2008 015 073_a 1 Cylinder head screws M6 VALVE SPRINGS Valve Springs Removal NOTE Whenever valves are removed it is recom mended to replace valve stem seal at the same time Remove Cylinder head Camshafts Valve lifter buckets and adjustment shims Compress valve spring use the spring compres sor P N 529 035 724...

Page 123: ...ust be placed on top vmr2008 016 031_b 1 Colored area of the valve spring To ease installation of cotters apply some oil or grease on them so that they remain in place while releasing the spring Install valve cotters Make sure valve cotters are properly engaged into valve stem grooves CAUTION Improperly locked valve springs will cause engine damage vmr2008 016 032_a 1 Valve cotters vmr2008 015 032...

Page 124: ...m Measure valve stem in three places using a mi crometer R400motr83A A A Valves stem diameter VALVE STEM DIAMETER INTAKE VALVE NEW 5 961 to 5 975 mm 2347 to 2352 in SERVICE LIMIT 5 950 mm 2343 in EXHAUST VALVE NEW 5 946 to 5 960 mm 2341 to 2346 in SERVICE LIMIT 5 935 mm 2337 in Change valve if valve stem is out of specification or has other damages such as wear or friction sur face Measure valve g...

Page 125: ...0 to 1 40 mm 0394 to 0551 in SERVICE LIMIT 1 60 mm 0630 in EXHAUST VALVE NEW 1 25 to 1 55 mm 0492 to 0610 in SERVICE LIMIT 1 80 mm 0709 in If valve seat contact width is too wide too narrow or has dark spots replace the cylinder head Valve Installation For installation reverse the removal procedure Pay attention to the following details Install valve spring shim Install a NEW valve stem seal whene...

Page 126: ...friction surface replace it Valve Guide Removal The sharp edge near the top of the valve guide must be removed using a special reamer Other wise the sharp edge will foul the valve guide hole in the head and destroy the head when removing the valve guide vmr2008 016 037_a 1 Reamer 2 Valve guide sharp edge Clean valve guide area from contamination before removing valve guide Using the valve guide re...

Page 127: ...7 to 5315 in Valve has guide to be adjusted in diameter by us ing a reamer NOTE Ensure to turn reamer in the right direc tion Use cutting oil and make brakes to clean reamer valve guide from metal shavings vmr2008 016 042_b A Valve guide diameter VALVE GUIDE DIAMETER INTAKE AND EXHAUST VALVE NEW 6 006 to 6 018 mm 2365 to 2369 in NOTE After valve guide installation ensure valve seats properly again...

Page 128: ...axis CYLINDER OUT OF ROUND MAXIMUM NEW 0 015 mm 0006 in SERVICE LIMIT 0 020 mm 0008 in Chain Tensioner Hole Ensure that chain tensioner and hole in the cylin der are in perfect condition Cylinder Installation For cylinder installation refer to CYLINDER HEAD INSTALLATION in this section NOTE If cylinder replacement is necessary al ways replace cylinder and piston at the same time Refer to PISTON to...

Page 129: ...T 96 910 mm 3 8153 in SIZE 2 B NEW 96 940 to 96 970 mm 3 8165 to 3 8177 in SERVICE LIMIT 96 920 mm 3 8157 in vmr2008 015 050_a 1 Size code 1 or 2 of piston NOTE If the wear limit is exceeded a new piston must be used or the cylinder complete with pis ton has to be replaced Piston Cylinder Clearance Adjust and lock a micrometer to the piston dimen sion Make sure piston is within specification F00B0...

Page 130: ...der size B The cylinder size code A or B is stamped on the lower side of the cylinder vmr2008 016 051_a 1 Size code A or B of cylinder Apply engine oil on the piston pin Insert piston pin into piston and connecting rod CAUTION Take care that piston will be in stalled with the punched arrow on piston top direction to exhaust valves vmr2008 015 052_a 1 Arrow on piston must show to exhaust side of cy...

Page 131: ... 0028 in SERVICE LIMIT 0 120 mm 0047 in OIL SCRAPER RING NEW 0 015 to 0 060 mm 0006 to 0024 in SERVICE LIMIT 0 100 mm 0039 in Measure ring end gap RING END GAP UPPER COMPRESSION RING NEW 0 15 to 0 40 mm 0059 to 0157 in SERVICE LIMIT 1 00 mm 0394 in LOWER COMPRESSION RING NEW 0 15 to 0 40 mm 0059 to 0157 in SERVICE LIMIT 1 00 mm 0394 in OIL SCRAPER RING NEW 0 15 to 0 35 mm 0059 to 0138 in SERVICE L...

Page 132: ...ston Pin Removal For piston pin removal see PISTON above Piston Pin Inspection Using synthetic abrasive woven clean piston pin from deposits Inspect piston pin for scoring cracking or other damages Measure piston pin See the following illustration for the proper measurement positions A R400motr30A A Piston pin diameter PISTON PIN DIAMETER NEW 19 996 to 20 000 mm 7872 to 7874 in SERVICE LIMIT 19 99...

Page 133: ... Piston Pin Installation For installation reverse the removal procedure Pay attention to the following details NOTE Take care that the hook of the piston circlip is positioned properly vmr2008 016 054 CORRECT POSITION OF THE PISTON CIRCLIP vmr2008 015 113 ...

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Page 135: ... 120 oil seal installer 529 035 854 117 bearing heater 529 035 969 125 protection sleeve 529 036 068 117 oil seal installer 529 036 069 124 crankshaft locking tool 529 036 107 128 blind hole bearing puller set 529 036 117 123 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page bearing splitter 1123 124 SERVICE PRODUCTS Description Part Number Page pulley flange cleaner 413 701 809 118 121 vm...

Page 136: ...be grease Super Lube grease Loctite 5910 2 N m 18 lbf in 9 N m 80 lbf in 9 N m 80 lbf in 5 3 9 1 11 8 6 11 N m 97 lbf in Loctite 243 Loctite 243 Engine oil Loctite 648 Loctite 648 Loctite 648 Spray nozzle 4 2 10 40 N m 30 lbf ft 100 N m 74 lbf ft 100 N m 74 lbf ft 11 N m 97 lbf in 19 N m 168 lbf in 19 N m 168 lbf in vmr2008 016 001_a 116 vmr2008 016 ...

Page 137: ...efer to FRONT SPROCKET in the DRIVE SYSTEM section Remove oil seal NOTE A small flat screw driver can be used to remove oil seal CAUTION Be careful not to score main shaft and or seat of oil seal in crankcase vmr2008 032 050_b 1 Oil seal 2 Main shaft Main Shaft and Bearing Inspection Check if running surface of main shaft is grooved Replace if necessary refer to GEARBOX Check bearing behind oil se...

Page 138: ... removal pro cedure Pay attention to the following details Lock crankshaft at TDC see CRANKSHAFT LOCK ING PROCEDURE in CRANKSHAFT below Clean tapers of crankshaft and primary drive gear with pulley flange cleaner P N 413 701 809 be fore installation vmr2008 016 013_a 1 Crankshaft shaft taper 2 Primary drive gear taper Properly install gear and nut TIMING CHAIN AND CHAIN TENSIONER GUIDE Timing Chai...

Page 139: ...in tensioner guide for wear cracks or other damage Replace if necessary Timing Chain and Chain Tensioner Guide Installation The installation is the reverse of the removal pro cedure However pay attention to the following To adjust the camshaft timing correctly refer to TIMING CHAIN DRIVE GEARS INSTALLATION in this section CAUTION Improperly adjusted valve timing will damage engine components TIMIN...

Page 140: ...eces sary to tap on screw head to release control gear from its taper Timing Chain Drive Gears Inspection Bearing Pin Check bearing pin surface for wear or scoring Re place if necessary vmr2008 016 019_a 1 Bearing pin surface Intermediate Gear Inspect the intermediate gear for chipped worn or broken gear teeth Check intermediate gear for worn or scoured bear ing surface If timing chain teeth of in...

Page 141: ...gear Install camshaft timing gears prior to finalize tim ing chain drive gears installation Refer to CYLIN DER HEAD CYLINDER section CRANKCASE Crankcase Disassembly Drain lubrication system refer to LUBRICATION SYSTEM Drain cooling system refer to COOLING SYSTEM Remove Engine from vehicle refer to ENGINE REMOVAL INSTALLATION Front sprocket refer to DRIVE SYSTEM Cylinder head and cylinder refer to ...

Page 142: ... GEARBOX Withdraw crankshaft and balancer shaft Crankcase Inspection Clean crankcase halves from contaminations us ing a parts cleaner and dry them with compressed air Clean oil passages with compressed air to make sure that they are not clogged WARNING Wear safety goggles to avoid eye injuries vmr2008 016 124_a CRANKCASE HALF CLUTCH SIDE 1 Check oil supply holes vmr2008 016 125_a CRANKCASE HALF C...

Page 143: ...f necessary Crankshaft Main Bearings Check crankshaft roller bearings no 3 and no 4 for excessive play and smooth operation Replace if necessary Inspect inner rings of crankshaft roller bearings for wear or scoring Replace if necessary NOTE Always replace inner ring and roller bearing at the same time vmr2008 016 130_a 1 Inner rings of crankshaft roller bearings Balancer Shaft Oil Seal Check oil s...

Page 144: ...ove ball bearing no 1 to get access to the balancer shaft oil seal Use a screwdriver to remove oil seal from crankcase CAUTION Take care not to damage oil seal area Balancer Shaft Oil Seal Installation To install the oil seal no 9 use oil seal installer P N 529 036 069 and handle P N 420 877 650 529036069 vmr2008 016 131_a 1 Oil seal 2 Oil seal installer Crankshaft Main Bearings Removal Use a suit...

Page 145: ...6557 Use a press and press out inner ring Heat inner ring again if necessary vmr2008 016 203_a PARTIAL CRANKSHAFT SHOWN 1 Crankshaft protector 2 Press WARNING Always wear heat resistant safety gloves when handling hot parts to avoid burning yourself Crankshaft Main Bearings Installation Unless otherwise instructed never use a hammer to install bearings Use a press only Use a suitable installer for...

Page 146: ...se Assembly The assembly of the crankcase is essentially the reverse of the disassembly procedure However pay attention to following details Install a new crankcase gasket CAUTION Temporarily secure connecting rod to the front of crankcase Otherwise connect ing rod will crush the oil spray nozzle no 10 vmr2008 016 204_a 1 Oil spray nozzle 2 Secure connecting rod here For installation of balancer s...

Page 147: ...ess screw vmr2008 015 117_a Use a screwdriver to feel the groove when the crankshaft is aligned with the hole vmr2008 016 009_a 1 Screwdriver Turning Crankshaft from Magneto Cover Remove magneto cover Refer to MAGNETO STARTER Use a 13 mm nut and turn crankshaft CAUTION Turn only clockwise to avoid loosen ing of magneto flywheel screw Turning Crankshaft using Rear Wheels Alternately crankshaft can ...

Page 148: ...ome oil came out of access hole Crankshaft Removal Refer to CRANKCASE Crankshaft Inspection For crankshaft main bearing inspection and re placement refer to CRANKCASE above Crankshaft Gear Inspect the crankshaft gear for chipped worn or broken teeth Replace if necessary refer to CRANKSHAFT GEAR REPLACEMENT PROCE DURE below NOTE If any imperfection is detected replace also the balance shaft gear re...

Page 149: ...If crankshaft gear was removed once replace it by a new one Remove crankshaft main bearing and the inner ring on PTO side Use two M8 bolts to extract crankshaft gear Partly tighten M8 bolts to create a pulling force on crankshaft gear Do not overtighten Use a propane torch and heat crankshaft gear to unstick it from crankshaft CAUTION Do not use a welding torch to heat crankshaft gear Too much hea...

Page 150: ...o the front of crankcase Otherwise connect ing rod will crush the oil spray nozzle no 10 vmr2008 016 204_a 1 Oil spray nozzle 2 Secure connecting rod here For installation refer to BALANCER SHAFT instal lation CAUTION Marks on balance shaft gear and crankshaft gear must be aligned 130 vmr2008 016 ...

Page 151: ... 141 144 oil seal installer 529 036 070 146 protection sleeve 529 036 071 146 clutch adjustment wrench 529 036 076 135 SERVICE PRODUCTS Description Part Number Page Super Lube grease 293 550 030 138 Loctite 518 293 800 038 138 145 146 Loctite 243 blue 293 800 060 138 Loctite 648 green 413 711 400 143 vmr2008 017 131 ...

Page 152: ...erLube grease 9 N m 80 lbf in NEW NEW Loctite 518 9 N m 80 lbf in 4 N m 35 lbf in 9 N m 80 lbf in Loctite 243 Super Lube grease Loctite 243 9 N m 80 lbf in Engine oil Tighten fingertight Engine oil Loctite 518 Vmr2008 017 001_a 132 vmr2008 017 ...

Page 153: ...Section 03 ENGINE Subsection 09 CLUTCH 100 N m 74 lbf ft 6 N m 53 lbf in NEW NEW Engine oil Engine oil Engine oil Loctite 648 Vmr2008 017 002_a vmr2008 017 133 ...

Page 154: ...ame place CAUTION Locking ties removed during a pro cedure must be replaced and installed at the same location MAINTENANCE CLUTCH ADJUSTMENT NOTE The X package model is equipped with a quick cable adjuster therefore there is no lock nut with this type of adjuster Procedure for the clutch cable are the same for both types except that details regarding the lock nut must be ignore The clutch lever no...

Page 155: ...t is strongly recommended to take a few minutes to inspect clutch plates condition Fully unscrew cable adjustment lock nut vmr2008 017 100_a Fully screw and tighten clutch cable adjuster to provide maximum free play Loosen cable adjuster lock nut Remove clutch cover access plug vmo2008 011 042_c LH SIDE OF ENGINE 1 Access plug Install the clutch adjustment wrench P N 529 036 076 onto lock nut 5290...

Page 156: ...wrench To confirm proper adjustment gently push on ad justment screw using a finger a small play should be felt if not perform adjustment again CAUTION A premature clutch disk wear may occur if adjustment is too tight Apply engine oil on access plug O ring Reinstall access plug CAUTION Do not over torque vmo2008 011 042_c 1 Access plug Properly adjust clutch lever Refer to ADJUST MENT AT CLUTCH LE...

Page 157: ... clutch release cover re move the following Leaf spring Thrust washer Clutch release cam Adjustment screw Locking nut Balls vmr2008 017 008_a 1 Screw 2 Leaf spring 3 Thrust washer 4 Clutch release cam 5 Balls 6 Adjustment screw 7 Locking nut Clutch Release Cover Inspection Clutch Release Cover Check ramps for wear vmr2008 017 009_a 1 Ramps Clutch Release Cam Check ramps and cable engagement areas ...

Page 158: ...pring screw When fitting the release cam make sure that the end of the leaf spring rests neatly on the thrust washer and does not touch the adjustment screw vmr2008 017 102_a LEAF SPRING NOT TOUCHING ADJUSTMENT SCREW Check clutch release cam for easy movement Clutch Release Cover Installation Apply a proper amount of Loctite 518 P N 293 800 038 in the groove of the clutch release cover to retain t...

Page 159: ...r dimension is ob tained vmo2008 011 063_b 1 Cable adjuster Detach clutch cable end from clutch lever Cut all locking ties securing the clutch cable Remove the cable from the vehicle noting its cor rect routing Clutch Cable Installation The installation is the reverse of the removal pro cedure Proceed with the clutch cable adjustment CLUTCH LEVER Clutch Lever Removal NOTE If the clutch lever is no...

Page 160: ...er has been replaced perform a clutch cable adjustment See procedure above in this section RETAINING PLATE AND CLUTCH SPRING Retaining Plate and Clutch Spring Removal Remove CLUTCH RELEASE COVER see proce dure above in this section Unfasten screws crosswise and remove retaining plate and clutch spring vmr2008 017 014_a 1 Screws 2 Retaining plate 3 Clutch springs Retaining Plate and Clutch Spring I...

Page 161: ...dure Perform the CLUTCH ADJUSTMENT see proce dure at the beginning of this section CLUTCH Clutch Removal Remove RETAINING PLATE AND CLUTCH SPRINGS see procedure above in this section Using the clutch spanner P N 529 035 647 and a 27 mm socket remove clutch hub nut and spring washer 529 035 647 vmr2008 017 017_a 1 Clutch spanner 2 Clutch hub nut 3 Spring washer Install a clutch spring using a retai...

Page 162: ...or other damage vmr2008 017 019_a 1 Splines 2 Flat surface Friction Plate Measure friction plate thickness Even if one friction plate is worn out replace all friction plates FRICTION PLATE THICKNESS NEW 2 52 to 2 68 mm 100 to 106 in SERVICE LIMIT 2 45 mm 096 in vmr2008 017 021 Using a feeler gauge check friction plate warpage Place friction plate on a flat surface and tip with a finger on plate to...

Page 163: ...the friction and clutch plates togeth er with the inner plate onto the clutch hub Align the tabs of the friction plates and secure the clutch assembly in place with a clutch spring NOTE Take care that the inner splines of the inner plate slip into the outer splines of the clutch hub vmr2008 017 024_a 1 Clutch hub 2 Inner plate 3 Friction plates tabs 4 Clutch spring flat washer and retaining plate ...

Page 164: ... RELEASE COVER see proce dure above in this section Remove oil filter cover and filter refer to LUBRI CATION SYSTEM section Remove water pump cover Refer to COOLING SYSTEM section Remove clutch cover screws Discard sealing washer vmr2008 017 054_a 1 Clutch cover screws 2 Sealing washer Remove clutch cover and discard the gasket vmr2008 017 055_a 1 Clutch cover 2 Gasket CAUTION When removing the cl...

Page 165: ... Bearing Sleeve for Crankshaft Check if bearing sleeve is in proper position vmr2008 017 058_a 1 Bearing sleeve 2 Water pump shaft A Minimum 2 6 mm 102 in Shift Shaft Oil Seal Check if shift shaft oil seal is brittle hard or dam aged Replace if necessary The shift shaft oil seal can be removed without clutch cover removal Use a small flat screwdriver for removal CAUTION Avoid scoring clutch cover ...

Page 166: ...E Install new sealing washer on screw vmr2008 017 054_a 1 Clutch cover screws 2 Sealing washer Shift Shaft Oil Seal Put the protection sleeve P N 529 036 071 on shift shaft and position oil seal on shaft 529036071 vmr2008 017 039_a 1 Protection sleeve 2 Oil seal 3 Shift shaft Use oil seal installer P N 529 036 070 for instal lation of the oil seal 529036070 vmr2008 017 041_a 1 Oil seal installer 2...

Page 167: ...eck if O ring on clutch shaft is Brittle Hard Otherwise damaged vmr2008 017 035_b 1 O ring 2 Clutch shaft Replace as required Check slots of clutch basket for steps damage or wear caused by friction plates vmr2008 017 036_a 1 Clutch basket slots Replace the clutch hub if one of slots is damaged Inspect primary drive gear and oil pump drive gear for Chipped teeth Worm teeth Broken teeth vmr2008 017...

Page 168: ...017 062_a 1 Locking tabs Insert the NEW oil pump gear on clutch hub Align oil pump drive gear dowels with clutch hub holes vmr2008 017 063_a 1 Dowels 2 Clutch hub holes Press down the gears until locking tabs are snapped into clutch hub groove vmr2008 017 064_a 1 Clutch hub groove 2 Gear locking tab Clutch Drum Installation For installation reverse the removal procedure 148 vmr2008 017 ...

Page 169: ... 10 GEARBOX GEARBOX SERVICE TOOLS Description Part Number Page oil seal protection sleeve 529 036 068 160 SERVICE PRODUCTS Description Part Number Page Loctite 243 blue 293 800 060 155 Loctite 5910 293 800 081 152 vmr2008 018 149 ...

Page 170: ... Subsection 10 GEARBOX 9 N m 80 lbf in NEW 9 N m 80 lbf in 9 N m 80 lbf in Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Loctite 243 NEW Engine oil 15 N m 133 lbf in vmr2008 018 001_a 150 vmr2008 018 ...

Page 171: ...Section 03 ENGINE Subsection 10 GEARBOX NEW NEW NEW NEW NEW Engine oil Engine oil Engine oil Clutch shaft Main shaft Engine oil Engine oil vmr2008 018 002_a vmr2008 018 151 ...

Page 172: ...stance from the indicator switch to the engine ground If the resistance is infinite OL replace the indi cator switch Neutral Indicator Switch Removal Remove screw retaining indicator switch wire Unscrew indicator switch Neutral Indicator Switch Installation For installation reverse the removal procedure However pay attention to the following Apply carefully some Loctite 5910 P N 293 800 081 on ind...

Page 173: ...Pawl springs are loaded and will pop outside of tooth segment if pawls are not held during tooth segment removal vmr2008 018 023_a 1 Tooth segment 2 Pawls Unscrew and remove bearing pin vmr2008 018 024_a 1 Bearing pin Insert a flat screwdriver in the slot of index lever Turn screwdriver counterclockwise and remove in dex washer vmr2008 018 025_a 1 Index lever 2 Index washer Remove Index lever scre...

Page 174: ...uared edges of pawl Check springs for squareness or bending vmr2008 018 034_a A 90 Index Washer Check engagement slots of index washer for wear or other damages vmr2008 018 032_a 1 Engagement slots Index Lever Index lever and roller of index lever must move freely Replace if necessary Shifting Mechanism Installation The installation is the reverse of the removal pro cedure However pay attention to...

Page 175: ...e in this section Remove cylinder with cylinder head refer to CYLINDER HEAD CYLINDER section Split the crankcase Refer to CRANKCASE CRANKSHAFT section Remove both shift fork shafts from shift forks vmr2008 018 027_a 1 Long shift fork shaft with a retaining ring 2 Short shift fork shaft 3 Shift forks Disengage shift forks from shift drum Remove shift drum and bearing vmr2008 018 028_a 1 Shift drum ...

Page 176: ...Soft hammer Gearbox Disassembly NOTE Snap rings should be removed using retain ing ring pliers only These pliers avoid to damage other parts around snap rings Main Shaft Remove Snap ring discard Thrust washer Free pinion vmr2008 018 009_a 1 Snap ring 2 Thrust washer 3 Free pinion 4 Main shaft assembly Remove Free pinion Both needle bearings Angular ring vmr2008 018 010_a 1 Free pinion 2 Needle bea...

Page 177: ...ng 4 Thrust washer 5 Shifting gear 6 Clutch shaft assembly Remove from clutch shaft Snap ring discard Thrust washer Free pinion Needle bearing vmr2008 018 014_a 1 Snap ring 2 Thrust washer 3 Free pinion 4 Needle bearing 5 Clutch shaft Gearbox Inspection Always verify for the following when inspecting gearbox components Gear teeth damage Worn or scoured bearing surfaces Rounded engagement dogs and ...

Page 178: ...Shift Fork Check shift fork engagement pins for wear Re place as required Check shift forks for visible damage wear scratches or bent shift fork claws Measure the shift fork claw thickness vmr2006 022 075_a 1 Micrometer A Shift fork claw thickness SHIFT FORK CLAW THICKNESS NEW 3 54 to 3 60 mm 1394 to 1417 in SERVICE LIMIT 3 40 mm 134 in Shift Fork shaft Check shift shaft for Bending Wear Other dam...

Page 179: ... in SERVICE LIMIT 25 025 mm 9852 in Main Shaft Check main shaft for wear Check taper grooves and annular grooves of shafts Annular grooves must have sharp edges Check splines for wear and or damages vmr2008 018 019_a 1 Grooves 2 Splines A Magneto side journal B Free pinion bearing C Clutch side journal MAIN SHAFT MAGNETO SIDE JOURNAL NEW 24 991 to 25 000 mm 9839 to 9843 in SERVICE LIMIT 24 970 mm ...

Page 180: ...with the correspond ing meshing gears Ball Bearings When gearbox is removed check gearbox ball bearings for contamination and or metal shavings Check if bearings turn freely and smoothly Re place if necessary refer to CRANKCASE CRANK SHAFT section Gearbox Assembly For assembly reverse the disassembly proce dures Pay attention to the following details Apply engine oil on moving parts when assem bli...

Page 181: ...oil TPS CPS Injector Neutral switch CTS Ignition coil AAPTS AAPTS Ambient Air Pressure and Temperature Sensor CPS Crankshaft Position Sensor CTS Coolant Temperature Sensor IACV Idle Air Control Valve MAPS Manifold Absolute Pressure Sensor TPS Throttle Position Sensor outputs inputs ECM ECM vmr2008 019 001_aen vmr2008 019 161 ...

Page 182: ...ghts Starter solenoid Cooling fan Fuel pump relay Fuel pump Ignition coils 2 Fuel injector Diagnostic connector EMS sensors and actuators Inj ign fuse ECM ECM fuse Ignition switch Engine stop switch Check engine lamp Low fuel lamp Main fuse Main relay ECM signal Start switch Cooling fan relay ECM signal ECM signal vmr2008 019 004_aen 162 vmr2008 019 ...

Page 183: ...APS CTS CPS IDLE AIR CONTROL VALVE CLUTCH SWITCH NEUTRAL SWITCH BE GN BE Diagnostic connector BAT ECM FUEL LEVEL SENSOR NEUTRAL SWITCH AAPTS Ambient Air Pressure and Temperature Sensor CPS Crankshaft Position Sensor CTS Coolant Temperature Sensor IACV Idle Air Control Valve MAPS Manifold Absolute Pressure Sensor TPS Throttle Position Sensor Pilot lamps cluster LIGHTS vmr2008 019 005_aen ECM Inputs...

Page 184: ...ION Engine RPM Limiter The ECM will limit the maximum engine speed when vehicle shifter is in Forward position Neutral position The ECM uses the CPS and the neutral switch for this function Drowned Mode Flooded Engine If engine is fuel flooded and does not start this special mode can be activated to prevent fuel in jection and ignition while cranking Proceed as fol lows to activate it With ignitio...

Page 185: ... section for more information POWER DISTRIBUTION Three relays are used to distribute power to differ ent components Main relay Fuel pump relay Cooling fan relay Relays are located under the front fascia vmr2008 019 007_a The ECM provides the trigger signal to activate each relay individually When ignition key is turned ON and engine stop switch is in RUN position the main relay and the fuel pump r...

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Page 187: ...able on BOSSWeb MPI 2 P N 529 036 018 Optional extension cable P N 529 035 697 Diagnostic cable P N 710 000 851 MPI 2 Power Supply The MPI 2 uses the PC computer USB port for for its power supply Connections with Vehicle WARNING If the computer you are using is connected to the power outlet there is a potential risk of electrocution when working in contact with water Be careful not to touch water ...

Page 188: ...e B U D S software use its help which contains de tailed information on its functions Ensure the appropriate connections are done for B U D S Ensure to use the latest B U D S version compat ible with the DS 450 available on BOSSWeb Turn ignition switch ON and set engine stop switch to RUN to activate the communication Start B U D S Select the protocol Kw2000 500K vmr2008 133 003 Ensure the status ...

Page 189: ...M Anytime a change is brought in ECM through B U D S there will be an EMS Tracking mes sage that will say Remove key from vehicle When this occurs remove the key from ignition switch and wait until the message disappears it lasts approximately 30 seconds after key re moval Communication Problems If an X is shown this means there is no commu nication between the MPI and the ECM mmr2009 020 001 The ...

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Page 191: ...y if the check engine pilot lamp is ON or blinks If so use the B U D S software and look for fault codes to diagnose the trouble The following components or functions are moni tored COMPONENT EMS TPS CPS AAPTS MAPS CTS IACV neutral switch ignition coil and fuel injector Battery voltage Engine RPM CAN ECM Starter solenoid Fuel pump Cooling fan Relays FAULT CODES The fault codes recorded in the ECM ...

Page 192: ...d and TPS closed position not reset Reset Closed Throttle and Idle Actuator Throttle body has been replaced and TPS closed position not reset Reset Closed Throttle and Idle Actuator ECM has been replaced and TPS closed position not reset Reset Closed Throttle and Idle Actuator Throttle cable too tight Tighten and reset Closed Throttle and Idle Actuator Sensor is loose Tighten and reset Closed Thro...

Page 193: ...nsor for approximately 2511 ohms at 20 C Replace the sensor if necessary Check circuits between sensor pin 2 and ECM pin F3 between C3 1 and between A1 3 114 Air intake silencer pressure and temperature sensor signal switched intermittent fault Faulty AAPTS sensor partially disconnected connector faulty terminals cut wires incoherent change in temperature reading Check for disconnected air tempera...

Page 194: ...d or terminals wires from the ECM to the relay shorted to a GND Check for damaged or disconnected fuel pump relay damaged circuit wires damaged connectors or damaged ECM output pins Check circuit from relay pin 1 to ECM pin J1 232 Fuel pump relay signal pin shorted to battery 12 V Faulty relay faulty terminal under the relay or at engine connector Dirt stuck on relay blades and or terminals wires ...

Page 195: ... 95 V Check CPS wires Check if CPS is dirty with metal particle Check encoder wheel 351 Ignition coil signal shorted to battery 12 V Faulty primary ignition coil wire shorted to battery 12 V Check for 1 0 5 ohm between ignition coil pins Check circuit between ignition coil and ECM pin M1 and M2 if shorted to 12 V 480 Engine cooling fan relay disconnected Faulty relay faulty terminal under the rela...

Page 196: ...rter solenoid not connected Faulty solenoid faulty terminal at solenoid or at engine connector Dirt stuck on solenoid blades and or terminals wires from the ECM to the solenoid cut Check cooling fan and acc fuse Look for damaged or disconnected starter solenoid damaged circuit wires damaged connectors or damaged ECM output pins Check circuit from solenoid ORANGE BROWN wire to ECM pin L3 616 Starte...

Page 197: ...pin 1 and ECM L4 if open 1335 RPM signal too high 12000 Damaged encoder wheel damaged CPS metal dirt stuck on CPS CPS wires damaged and or shorted to the engine or frame squeezed CPS wires between the magneto cover and engine tampered engine Check circuit between CPS and ECM pin E1 and D1 Check CPS coil resistor value approx 260 ohm Check CPS AC voltage value approx 1 V Check CPS wires Check if CP...

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Page 199: ...n sensor The ECM is the central point of the engine man agement system It reads the signals from differ ent sensors which indicate engine operating con ditions at micro second intervals The ECM reads the inputs from the sensors makes computations uses pre determined pa rameters and activates the outputs to the injector Signals from sensors are used by the ECM to de termine the injection parameters...

Page 200: ... rail ensures all the time that enough fuel can be delivered to the fuel injector The fuel rail is fed by the fuel pump with the properly regulated fuel pressure Fuel Injector One fuel injector is used to inject fuel into the in take port of the cylinder head GENERAL RECOMMENDATIONS Engine problems are not necessarily related to the electronic fuel injection system It is important to ensure the en...

Page 201: ...spection could lead to false results After a problem has been solved ensure to clear the fault code s in the ECM using the B U D S software Refer to MONITORING SYSTEM FAULT CODES subsection WARNING Some EMS components are continuously powered by the battery when ignition key is turned on and engine stop switch is set in RUN position The ECM switches the cir cuit to the ground to complete the elect...

Page 202: ...trol valve will determine the basic parameters for the idle speed control of the engine Closed throttle and idle actuator reset must be done if TPS is loosened removed or replaced Throttle body is replaced IACV is replaced ECM is replaced CAUTION An improperly set TPS or idle air control valve may lead to poor engine perfor mance and emission compliance could possi bly be affected In addition impr...

Page 203: ...r2008 019 002_A ECM LOCATION NOTE Prior to replacing an ECM ensure to con duct all testing procedures ECM Connector Removal To reach ECM connector remove front body ass y Refer to BODY Push and hold the locking tab vmr2008 022 013_a Rotate connector lock until it stops vmr2008 022 014_a Pull out connector vmr2008 022 015_A ECM Connector Installation Fully open connector lock vmr2008 022 015_b Inst...

Page 204: ...eate intermittent or permanent contact problems Power Supply to ECM Battery Main fuse ECM fuse ECM Power Signal B A Wake up A4 L1 K1 Main relay Engine stop switch Ignition switch E 2 3 5 1 Injection ignition fuse C D Switched power M3 M4 3 1 C F B4 G1 D vmr2008 022_004_aen When engine stop switch is set to STOP or igni tion key is turned OFF ECM will turn off after ap proximately 30 seconds All th...

Page 205: ...29 035 868 and select Check continuity of ground connections as fol lows ECM CONNECTOR PIN BATTERY MEASUREMENT G1 M3 M4 Battery ground post Close to 0 continuity vmr2008 022 100_a If test succeeded ECM grounds are adequate If test failed ensure wiring and connectors are good and repair or replace as necessary If wiring and connectors are good check the following grounds TEST PROBES CONTINUITY TEST...

Page 206: ...115 multimeter P N 529 035 868 and select Vdc 529035868_a Check voltage as follows ECM CONNECTOR PIN MEASUREMENT B4 G1 Battery voltage vmr2008 022 005_b If voltage is out of specification check wiring and connectors from battery to ECM If voltage is as per specification carry out the ECM WAKE UP CIRCUIT TEST ECM Wake Up Circuit Test Turn ignition key to ON Set engine stop switch to RUN Use the Flu...

Page 207: ...g and connectors from main fuse through the relay socket to ECM Check power circuit wiring and connectors from main fuse through the relay socket and through the injector ignition fuse to ECM If faulty repair or replace wiring and connectors If everything tested good but ECM does not work try a new ECM Refer to ECM REPLACEMENT ECM Removal NOTE If ECM is removed for replacement refer first to ECM R...

Page 208: ... the PC computer as long as B U DS is running Remove the faulty ECM Install and connect the new ECM From B U D S choose ECM Replace under Module mmr2009 023 077 B U D S will automatically write the data from the PC computer into the new ECM Go to the Setting tab Reset the Closed Throttle and Idle Actuator Refer to CLOSED THROTTLE RESET In B U D S click the Write Data button to save the information...

Page 209: ...ersion_V I N _date read yyyymmdd _hour read hhmmss mpem Example P2 3 18 3_2BPSMJ9A59V000262_20080201_142322 mpem B U D S version P2 3 18 3 V I N 2BPSMJ9A59V000262 Date file was read 2008 02 01 Hour file was read 14h 23m 22s Go to the Vehicle tab and record the following information Vehicle V I N number Engine number without the leading M Model number Customer vmr2008 022 008 Enter data into ECM as...

Page 210: ...ailed in ENTERING THE COLLECTED INFORMATION INTO THE ECM be low Entering the Collected Information into the ECM Use B U D S to enter the recorded data into the new ECM In B U D S click the Read Data button to read the new empty ECM vmr2006 012 100_aen Go to the Vehicle tab and enter the information you recorded previously Vehicle V I N number Engine number NOTE Do not enter the leading M Model num...

Page 211: ...est Disconnect the connector from the injector NOTE If connector is hard to unlock gently use a screwdriver to release connector vmr2006 014 001_a Use the Fluke 115 multimeter P N 529 035 868 and select Vdc Read voltage NOTE It is not necessary to activate the injector since it is continuously powered TEST PROBES MEASUREMENT VIOLET BLUE wire injector connector Battery ground Battery voltage vmr200...

Page 212: ...2006 014 075_c If control circuit is faulty repair or replace wiring and connectors Injector Resistance Test Reconnect the injector connector Disconnect the ECM connector Install ECM adapter P N 529 036 085 on ECM connector Using the Fluke 115 multimeter P N 529 035 868 check resistance value between terminals as fol lows RELAY SOCKET ECM ADAPTER RESISTANCE 20 C 68 F Pin 5 Pin L4 Approximately 12 ...

Page 213: ...5 Manifold O ring Injector Installation For the installation reverse the removal proce dure Pay attention to the following details Install new O rings Apply a thin film of engine oil to O rings to ease insertion in rail Position the manifold O ring as shown on injector vmr2006 014 071_a Carefully insert injector in manifold paying atten tion to the manifold O ring Gently push in evenly all around ...

Page 214: ...r to disconnecting the quick fitting en sure engine and exhaust system are not hot Wrap a rag around the inlet hose and release the quick fitting vmr2008 022 039_A Unplug injector connector NOTE If connector is hard to unlock gently use a screwdriver to release connector vmr2006 014 001_a Unscrew rail retaining screws vmr2008 022 038_a NOTE To reach the RH screw a 1 4 drive 8 mm hexagonal socket w...

Page 215: ... pressure test and ensure that there is no leak Refer to FUEL TANK FUEL PUMP Run engine and check for leaks THROTTLE BODY vmr2008 022 010_a 1 Throttle body 2 Throttle cable attachment 3 Throttle plate 4 TPS 5 Idle air bypass channel 6 Idle air control valve Mechanical Inspection Check that the throttle plate moves freely and smoothly when depressing throttle lever Check if the throttle body idle s...

Page 216: ...m Remove seat guide vmr2008 022 042_a Remove air deflector vmr2008 022 043_a Unplug TPS IACV and diagnostic connectors Loosen throttle body clamps vmr2008 022 044_a Pull air intake silencer adaptor from throttle body vmr2008 022 045 Pull out throttle body vmr2008 022 046 Remove throttle body cover 196 vmr2008 022 ...

Page 217: ...ttle cable Throttle Body Installation Installation of the throttle body is the reverse of the removal procedure Pay attention for the fol lowing details Properly install cable barrel to throttle cable end vmr2006 014 063_a Hook cable to throttle lever vmr2006 014 064_a Do not reinstall cover yet Install throttle body on intake manifold Ensure to index throttle body tab with boot notch vmr2006 014 ...

Page 218: ...for more information TPS Wear Test While engine is not running activate throttle and pay attention for smooth operation without physi cal stops of the cable Using the B U D S software use the Throttle Opening display under Monitoring vmr2006 014 083_aen Slowly and regularly depress the throttle Ob serve the needle movement It must change gradually and regularly as you move the throt tle If the nee...

Page 219: ...od replace TPS Reconnect ECM connector TPS Voltage Test Check the ECM voltage output to the TPS as fol lows Disconnect connector from TPS vmr2008 022 016_a Turn ignition key ON and set engine stop switch to RUN Use the Fluke 115 multimeter P N 529 035 868 and select Vdc Check the voltage readings from harness connec tor as follows CONNECTOR PIN VOLTAGE 1 2 5 0 Vdc 2 3 0 Vdc 1 3 4 75 5 Vdc BAT Vdc ...

Page 220: ...h is not de tectable without measuring the air flow Replac ing the idle air control valve may be necessary as a test If an erratic engine idle is experienced clean the idle air bypass in throttle body IACV Resistance Test Disconnect idle air control valve connector vmr2008 022 016_c Using the Fluke 115 multimeter P N 529 035 868 and select Check the resistance in both windings NOTE It is easier to...

Page 221: ...n it is dismount ed Also do not move the piston by hand The drive screw is very sensitive and may be dam aged Use a throttle body cleaner such as Gunk Intake Medic or the equivalent WARNING Only use an appropriate throttle body cleaner that will not damage O rings MAPS sensor and idle control valve Clean idle air bypass in throttle body from contam ination then use an air gun to dry it WARNING Alw...

Page 222: ...voltage TEST PROBES MEASUREMENT Pin 1 Pin 2 Approximately 1 Vac vmr2008 022 020_b If test succeeded CPS is good If test failed perform the resistance test CPS Resistance Test Use the Fluke 115 multimeter P N 529 035 868 and select Probe terminals as shown TEST PROBES RESISTANCE 20 C 68 F Pin 1 Pin 2 Approximately 260 vmr2008 022 020_a RH SIDE OF VEHICLE If resistance is not within specifications r...

Page 223: ...ated and should not be tem pered with Otherwise improper engine calibra tion could occur MAPS Test with B U D S Start engine Using B U D S software read the manifold abso lute pressure Click on Monitoring tab then on ECM tab Needle should move as you throttle the engine Otherwise perform the voltage and continuity tests vmr2008 022 023 MAPS Input Voltage Test Check voltage output from ECM to manif...

Page 224: ... multimeter P N 529 035 868 and select Check the continuity of the MAPS circuits MAPS CIRCUIT MEASUREMENT MAPS PIN ECM PIN RESISTANCE 20 C 68 F 2 G2 3 F2 Close to 0 vmr2008 022 024_c If continuity is not good repair or replace the wiring and connectors between ECM connector and the MAPS If everything tested good replace MAPS sensor MAPS Removal Remove seat Refer to BODY Remove the 3 rear screws of...

Page 225: ...MPERATURE SENSOR AAPTS The sensor continuously measures the intake air pressure and temperature vmr2008 022 021_b Remove seat Refer to BODY AAPTS Resistance Test Temperature Function Detach AAPTS sensor from air filter housing Re fer to AAPTS REMOVAL Disconnect AAPTS connector vmr2008 022 026_b Use the Fluke 115 multimeter P N 529 035 868 and select Check the resistance of the sensor itself as sho...

Page 226: ...ove front body assembly Refer to BODY Disconnect the ECM connector Install ECM adapter P N 529 036 085 on ECM connector vmr2008 022 005 Measure resistance as follows TEST PROBES RESISTANCE 20 C 68 F Pin C3 Pin F3 Refer to table above vmr2008 022 005_a If resistance is not good check continuity of wiring between ECM and AAPTS AAPTS Circuit Continuity Test Temperature Function Disconnect the ECM con...

Page 227: ...AAPTS connector vmr2008 022 026_b Use the Fluke 115 multimeter P N 529 035 868 and select Vdc Check voltage as follows TEST PROBES MEASUREMENT Pin 3 AAPTS connector Battery ground 5 Vdc vmr200 022 200_b If voltage test failed check wiring and connectors from this wire to the ECM If voltage test succeeded test continuity of the remaining wires AAPTS Circuit Continuity Test Pressure Function Disconn...

Page 228: ...sted good replace AAPTS sensor AAPTS Removal Remove seat Refer to BODY Remove the 3 rear screws of RH side panel vmr2008 022 048_a Pull panel to make room Remove AAPTS retaining screw NOTE A 1 4 drive Torx driver works well vmr2008 022 049 Pull out sensor and unplug connector AAPTS Installation Reverse operations for the installation NOTE To ease installation of sensor connector safely lift rear o...

Page 229: ...sistance on the ECM adapter Com pare result with sensor temperature table ECM ADAPTER Pin C3 Pin F4 SENSOR TEMPERATURE TABLE TEMPERATURE RESISTANCE OHMS C F CTS 40 40 45000 30 22 28000 20 4 15000 0 32 5750 20 68 2600 40 104 1200 60 140 600 80 176 320 100 212 180 130 266 90 vmr2008 022 005_b If resistance value is incorrect check wiring har ness and connectors between ECM connector and the CTS If t...

Page 230: ... ELECTRONIC FUEL INJECTION EFI vmr2008 022 028_c CTS Installation Install the new CTS Torque CTS to 17 N m 150 lbf in Reinstall remaining removed parts Refill and bleed the cooling system Refer to COOLING SYSTEM subsection 210 vmr2008 022 ...

Page 231: ...UEL PUMP SERVICE TOOLS Description Part Number Page Oetiker pliers 295 000 070 216 vacuum pressure pump 529 021 800 213 pressure gauge 529 035 709 215 Fluke 115 multimeter 529 035 868 217 220 fuel hose adapter 529 036 023 215 ECM adapter 529 036 085 219 vmr2008 023 211 ...

Page 232: ...Section 05 FUEL SYSTEM Subsection 02 FUEL TANK FUEL PUMP 1 25 N m 18 lbf ft 10 N m 89 lbf in 1 N m 9 lbf in 2 N m 18 lbf in 2 vmr2008 023 001_a 212 vmr2008 023 ...

Page 233: ...el line connection with an absorbent shop rag Slowly disconnect the fuel hose to minimize spilling Wipe off any fuel spillage WARNING Do not allow fuel to spill on hot engine parts or electrical connectors The evaporating fuel on the hot components or on the electrical connectors produce highly inflammable fuel vapors that can easily be ignited by the heat a spark electrostatic discharge or stray ...

Page 234: ...r the fuel pump and tests for leaks in the system NOTE See also the diagnostic flow chart in the TROUBLESHOOTING section to help diagnose a fuel system related problem Before proceeding with the pressure test ensure the battery is fully charged Battery voltage must be over 12 volts WARNING If engine has been recently running always allow engine and exhaust system time to cool before disconnecting ...

Page 235: ...N and observe fuel pressure Turn ignition key OFF then back ON Repeat the test FUEL PRESSURE 350 kPa 51 PSI A rapid pressure drop indicates leakage either from the fuel rail or from the fuel pump check valve Check fuel rail for leaks If it is not leaking replace fuel pump A slow pressure drop indicates leakage either from the fuel injector or from the fuel pressure regulator Check fuel injector fo...

Page 236: ... pump operation NOTE Fuel pump will come ON for a few seconds and stop This is to pressurize the fuel injector system prior to engine start If the fuel pump came on for a few seconds and shut off the fuel pump ECM and associated cir cuits are functioning normally However this does not validate fuel pump pressure If fuel pump did not come on first check in B U D S for applicable fault codes Refer t...

Page 237: ... vmr2008 023 017_a FUEL PUMP CONNECTOR RH VIEW 1 Fuel tank 2 Coolant hose T fitting 3 Fuel pump connector 4 Locking tab vmr2008 023 018_a FUEL PUMP CONNECTOR DISCONNECTED 1 Fuel pump 2 Fuel pump connector 3 Coolant hose T fitting Remove the red plastic pin lock from the connec tor vmr2008 023 012_a PLASTIC PIN LOCK TABS Set Fluke 115 multimeter P N 529 035 868 to Vdc Connect multimeter between pin...

Page 238: ...y test If battery voltage is not read between pins 3 and 4 of the fuel pump connector but is good to chassis ground test for continuity of the fuel pump ground circuit wire fuel pump connector pin 4 to chassis ground Repair or replace wiring as required If battery voltage is not read to chassis ground carry out the following Fuel pump relay test Fuel pump relay input voltage test Fuel pump circuit...

Page 239: ... Relay Input Voltage Test Remove fuel pump relay vmr2008 023 013_a FUEL PUMP RELAY REMOVED Test for fuel pump relay input voltage as per fol lowing table vmr2008 023 013_b FUEL PUMP RELAY INPUT VOLTAGE TEST PROBES VOLTAGE READING Relay socket pin 2 Relay socket pin 3 Chassis ground Battery voltage If you do not read any voltage test the injector and ignition fuse If battery voltage is read carry o...

Page 240: ... all tools Reinstall the red plastic pin lock on the connector prior to installing it on the fuel pump Reinstall all removed components and connec tors If all tests were carried out good test ECM Refer to ELECTRONIC FUEL INJECTION section Fuel Pump Removal Remove front body section refer to theBODY sec tion Disconnect the electrical connector from the fuel pump vmr2008 027 005_a 1 Fuel pump connec...

Page 241: ...vel sensor forward end of pump and fuel filter bottom of pump to avoid deforming them Any deformation of the fuel level sensor thermistor will require fuel pump replacement Fuel Pump Installation For installation reverse the removal process but pay attention to the following Install a new gasket Pay attention to pump orientation vmr2008 023 015_b 1 Fuel line at top 2 Connector at bottom CAUTION Wh...

Page 242: ...G SYSTEM section Remove seat refer to the BODY section Remove front body assembly refer to the BODY section Drain fuel tank refer to the FUEL TANK DRAINING procedure Disconnect and remove the ECM refer to the ELECTRONIC FUEL INJECTION section vmr2008 026 011_a Disconnect the electrical connector from the fuel pump vmr2008 027 005_a 1 Fuel pump connector 2 Fuel tank Remove the fuel tank mounting sc...

Page 243: ...W Carefully lower the fuel tank until the filler neck clears the frame top plate then pull it out the RH side Fuel Tank Inspection Inspect fuel tank for any damages or cracks which may result in fuel leaks Inspect tank attachment points for damage WARNING If cracks and other damages which may re sult in fuel leaks or tank not being secure are found replace fuel tank Fuel Tank Installation Reverse ...

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Page 245: ... piston in the cylinder is produced and sent to the ECM The ECM uses this signal as well as engine RPM to establish the exact moment at which the ignition spark is required It then provides the ground to the primary winding of the ignition coils With the ground provided by the ECM current flows through the primary coil winding which in duces a higher current potential in the secondary winding This...

Page 246: ... 002_e PF1 FUSE HOLDER 1 20 A cooling fan fuse Ignition switch Engine STOP switch Main relay refer to ELECTRONIC FUEL INJEC TION EFI section ECM refer to ELECTRONIC FUEL INJECTION EFI section Headlights and Taillight Turn ON If the headlights if selected and taillight turn ON the ignition switch engine shut off switch and the main relay are functioning normally Test the following items in the indi...

Page 247: ...lic object IGNITION SWITCH Ignition Switch Operation The ignition switch is a three position switch OFF ON with headlights ON without headlights vmr2008 137 002_a TYPICAL 1 OFF 2 ON with headlights 3 ON without headlights The primary function of the ignition switch is to provide a signal to the ECM of the intent to start wake up signal and run the engine The ignition switch receives 12 Vdc directl...

Page 248: ...nd Battery voltage vmr2008 137 001_b IGNITION SWITCH INPUT VOLTAGE TEST If you do not obtain battery voltage test the fol lowing 20 A main fuse vmr2008 026 001_a 1 20 A main fuse 5 A ECM fuse vmr2008 026 002_a 1 5 A ECM fuse Wiring harness If the ignition switch input voltage is good carry out an ignition switch continuity test Ignition Switch Continuity Test Set the Fluke 115 multimeter P N 529 0...

Page 249: ...e stop switch Ignition Switch Removal Remove the front body assembly refer to the BODY section Disconnect the ignition switch connector 1 V07G1BA TYPICAL 1 Disconnect ignition switch connector While holding switch with one hand unscrew the ignition switch retaining nut with the other vmr2008 137 002_b TYPICAL 1 Remove retaining nut Ignition Switch Installation For installation of the ignition swit...

Page 250: ... Remove the front body assembly refer to the BODY section Disconnect the multifunction switch connectors MG1 and MG2 vmr2008 026 003_d MULTIFUNCTION SWITCH CONNECTORS 1 Disconnect MG1 2 Disconnect MG2 Set the Fluke 115 multimeter P N 529 035 868 to Measure the resistance through the stop switch steering harness side as per following table ENGINE STOP SWITCH CONTINUITY TEST POSITION CONNECTOR RESIS...

Page 251: ...CM adapter tool P N 529 036 085 vmr2008 139 016_a TYPICAL ECM ADAPTER TOOL INSTALLATION 1 ECM connector 2 Adapter tool Carry out the following continuity tests ENGINE STOP SWITCH WIRING TEST TEST PROBES RESISTANCE MG1 pin 3 VIOLET BEIGE vehicle harness side HIC1 pin B VIOLET BEIGE to steering harness side HIC1 pin B to ECM ECM pin A4 Close to 0 vmr2008 026 012_a CONNECTOR MG1 PIN OUT vmr2008 024 2...

Page 252: ...wered as follows Remove front body assembly Refer to the BODY section Locate the two small primary winding connectors on each ignition coil Pull back each plastic connector housing enough to access the metal connectors vmr2008 024 013_a 1 Front ignition coil 2 VIOLET BLUE connector housing 3 BROWN ORANGE connector housing vmr2008 024 005_a 1 Rear ignition coil 2 VIOLET BLUE connector housing 3 BRO...

Page 253: ...t for continuity of the ignition coil ground circuit Ignition Coil Ground Circuit Continuity Test Disconnect ECM connector vmr2008 022 015_A Install the ECM connector onto the ECM adapter tool P N 529 036 085 vmr2008 139 016_a TYPICAL ECM ADAPTER TOOL INSTALLATION 1 ECM connector 2 Adapter tool Pull back the plastic connector housing on the BROWN ORANGE wire of each coil enough to ac cess the meta...

Page 254: ...IL PRIMARY WINDING RESISTANCE TEST If the primary winding resistance is not within specification replace the ignition coil If the primary winding tests good test the sec ondary winding resistance Secondary Winding Resistance Test Disconnect both spark plug cables from its spark plug vmr2008 024 006_a 1 Outer spark plug cable to front coil 2 Inner spark plug cable to rear coil Measure the secondary...

Page 255: ...move the two ignition coil mounting screws and relocate the coil outside of the frame to pro vide access to the two small input connectors vmr2008 024 005_b REAR IGNITION COIL VIEW FROM LEFT SIDE 1 Rear ignition coil 2 VIOLET BLUE wire terminal 3 BROWN ORANGE wire terminal 4 Locking tie 5 Mounting screws Pull back the plastic connector housings from both coil input connectors As you hold the top i...

Page 256: ...he start button is pressed refer to the STARTING SYSTEM section If the starter rotates the engine and there is no spark indicated by the tester follow the ignition system troubleshooting sequence as indicated If the inductive spark tester indicates ignition to the spark plug install a new spark plug If a known good spark plug does not solve the problem continue testing the other system com ponents...

Page 257: ...erheated light grey white 2 Normal light brown brown 3 Fouled black wet or dry dark deposits grey melted coating The plug face reveals the condition of the engine operating condition method of driving and fuel mixture For this reason it is advisable to inspect the spark plug at prescribed intervals examining the plug face i e the part of the plug projecting into the combustion chamber Spark Plug I...

Page 258: ...Section 06 ELECTRICAL SYSTEM Subsection 01 IGNITION SYSTEM Apply Super Lube P N 293 550 030 to the elec trical contact inside the spark plug cap before in stalling it on the spark plug 238 vmr2008 024 ...

Page 259: ... For an overview of the vehicle electrical system refer to ENGINE MANAGEMENT SYS TEM section Magneto The magneto is the primary source of electrical energy It transforms a magnetic field into electric current AC The alternating current is regulated and trans formed into direct current DC by the voltage regulator rectifier and normally powers all of the vehicles systems and accessories The magneto ...

Page 260: ...on the load requirements of the vehicles systems It pro vides its total output voltage to the vehicle through a 20 A charging system fuse If the battery is regularly discharged test the charging system fuse If the fuse is blown the vehicle runs on battery power only The voltage regulator rectifier could be the cause of a blown fuse To test this possibility simply disconnect the voltage regulator r...

Page 261: ... regulator Repair or replace as required Install all removed parts and connectors Voltage Test With a Multimeter Proceed as follows Remove seat Measure battery voltage at the battery terminals vmr2008 025 002_a BATTERY VOLTAGE TEST Start the engine Install a digital inductive tachometer P N 529 014 500 or equivalent to measure engine speed Fol low manufacturers instructions NOTE Vehicle RPM may al...

Page 262: ...reading will not be accurate vmr2008 025 005_a 1 Turn ON the inductive ammeter 2 Select 40 Adc 3 Zero set the ammeter Install the inductive ammeter clamp over the RED YELLOW wire connected to the fuse holder vmr2008 025 006_a 1 Clamp inductive ammeter over RED YELLOW wire Install a digital inductive tachometer P N 529 014 500 to measure engine speed Follow manufac turers instructions NOTE Vehicle ...

Page 263: ...ring connections Faulty voltage regulator rectifier Faulty stator Rectify any problem identified recharge battery as per manufacturers instructions and carry out a battery load test to confirm the condition of the battery Battery Voltage Test No Load NOTE A battery voltage test without a load ap plied is carried out on a battery without discharg ing current It is the simplest and most common ly us...

Page 264: ...ectrolyte or fuel vapors can be present and a spark may ignite them possibly causing an explosion which could result in equipment damage severe personal injuries or death Disconnect BLACK battery cable vmr2008 025 002_b 1 Disconnect BLACK battery cable Pull back the red rubber protector from the posi tive battery terminal Disconnect the RED battery cable vmr2008 025 011_a 1 Pull out protective boo...

Page 265: ...lean battery battery support compartment and connections as required refer to BATTERY CLEANING in this section For other recommendations during storage refer to battery manufacturers instructions WARNING Ensure battery is stored in a safe place out of reach for children New Battery Activation Refer to the instructions provided with the battery Battery Charging WARNING Always wear safety glasses an...

Page 266: ... RED battery cable 2 Connect BLACK battery cable 3 Apply dielectric grease 4 Install red rubber protector over positive battery post Install the seat ELECTRICAL SYSTEM MAIN GROUNDS The main electrical system chassis ground is lo cated on the LH side of the vehicle attached to the inside of the oblique frame member The engine ground is attached to one of the starter mounting screws See following il...

Page 267: ...ht Turn ON If the Engine cranking conditions are met and the starter will not crank the engine pull in the clutch lever and press the start button If the starter cranks the engine test the neutral switch If the starter will not crank the engine with the clutch pulled in try manually rotating the engine To manually rotate the engine carry out the fol lowing Set the ignition switch to the OFF positi...

Page 268: ... mounting screw vmr2008 026 005_a Disconnect the small terminal wires from the so lenoid vmr2008 026 007_a 1 Small solenoid coil wires 2 Small solenoid coil terminals Set multimeter to Measure solenoid coil resistance as follows CAUTION Battery must remain disconnected for the following continuity tests or multimeter damage may occur vmr2008 026 008_a SOLENOID COIL CONTINUITY TEST MEASUREMENT SOLE...

Page 269: ...INUITY TEST PROBE POSITIONS MEASUREMENT Red battery cable terminal Starter solenoid battery post Close to 0 If you do not obtain a resistance reading near 0 and cable connection to solenoid is clean and tight replace solenoid battery cable NOTE A reading other than almost 0 indicates a bad crimp on a terminal or corrosion within the crimped terminal leading to a high resistance and a voltage drop ...

Page 270: ...y polarity when connecting battery cables Connecting battery in reverse polarity could result in equip ment damage Always connect the RED bat tery cable first and the BLACK battery cable last Set parking brake Set transmission to Neutral N WARNING Before starting engine ensure parking brake is set and transmission is selected to neutral N Failure to comply with this procedure may result in severe ...

Page 271: ...t voltage test refer to START BUTTON in this sec tion Solenoid Dynamic Test Remove the injection and ignition fuse to prevent engine from starting NOTE Check engine light will flash starter will crank engine but with an initial delay of 1 or 2 sec onds vmr2008 026 002_c REMOVE INJECTION IGNITION FUSE 1 PF1 fuse holder cover 2 Fuse holder 3 Injection ignition fuse Set parking brake Set transmission...

Page 272: ...fer to BODY section Locate ECM on LH side of fuel tank vmr2008 026 011_a ECM LOCATION To remove ECM connector push and hold the con nector locking tab vmr2008 022 013_a Rotate connector lock until it stops vmr2008 022 014_a Pull out connector vmr2008 022 015_A Install the ECM connector onto the ECM adapter tool P N 529 036 085 vmr2008 139 016_a TYPICAL 1 ECM connector 2 ECM adapter tool Set multim...

Page 273: ...L INJECTION EFI section START BUTTON Start Button Input Voltage Test Remove the front body assembly refer to BODY section Disconnect the LH multifunction switch connector MG1 vmr2008 026 003_b DISCONNECT MG1 Set parking brake Set transmission to neutral N position Set engine stop switch to RUN Turn ignition switch ON Set multimeter to Vdc and measure the start but ton input voltage as follows STAR...

Page 274: ...nnector MG1 Test start button switch continuity as follows vmr2008 026 012_b START BUTTON CONTINUITY TEST START BUTTON MULTIFUNCTION SWITCH CONNECTOR MG1 RESISTANCE Released Infinite OL Depressed and held Pin 6 RED VIOLET and pin 1 YELLOW BLUE 0 6 max If start switch does not test as specified replace the multifunction switch assembly If start switch tests as specified remove the 20 A cooling fan ...

Page 275: ...nked in gear with the clutch engaged Refer to the CLUTCH section for lever free play adjustment Clutch Switch Continuity Test Remove front body assembly refer to BODY sec tion Disconnect the two clutch switch connectors vmr2008 026 003_c Set multimeter to selection Connect the multimeter between the two clutch switch connectors steering side and measure the resistance as follows CLUTCH SWITCH CONT...

Page 276: ...h alignment keys in a vertical position Push switch into housing until the locking tab snaps into position vmr2008 026 014_a CLUTCH SWITCH 1 Alignment key 2 Locking tab Gently pull on the switch to ensure that it is se cure Route the wiring as noted before removal Carry out a continuity test to ensure it functions properly with the clutch lever Reconnect the two switch connectors to the wiring har...

Page 277: ...power drain such as when the en gine is at idle or not running the electrical system voltage will drop The headlight power regulator detects this voltage drop and cycles its output to the lights to reduce the electrical system load The main purpose of the headlight power regulator is to prevent battery power drainage saving pow er for the essential engine systems The low fu el and check engine ind...

Page 278: ...engine WARNING Before starting engine ensure parking brake is set and transmission is selected to neutral N Failure to comply with this procedure may result in severe injury and possible loss of life Measure charging system voltage at battery ter minals refer to CHARGING SYSTEM section Again measure taillight brake light input voltage vmr2008 027 006_a TAILLIGHT INPUT VOLTAGE TEST PIN 2 If the tai...

Page 279: ... the headlight power regulator connector to the taillight brake light connector pin 2 vmr2008 027 002_d 1 Headlight voltage regulator connector 2 Taillight brake light connector If all items tested as specified and lights remain dim or will not come on replace the headlight power regulator HEADLIGHTS Headlight Input Voltage Test Pull back the rubber protector from the headlight connector Disconnec...

Page 280: ...d the ignition switch for continuity Re fer to the IGNITION SECTION for ignition switch testing procedures If voltage test is good in one headlight switch po sition but not in the other refer to the HEADLIGHT SWITCH CONTINUITY TEST If there is no voltage present at both headlight con nectors but the taillight brake light is functioning test the headlight switch and wiring Headlight Bulb Replacemen...

Page 281: ...both headlights evenly vmo2008 011 074_a 1 Headlight 2 Adjusting screw HEADLIGHT SWITCH vmo2008 011 008_a HEADLIGHT SWITCH FUNCTIONS 1 Headlight switch 2 Low beam 3 High beam Headlight Switch Continuity Test Remove the front body assembly refer to the BODY section Disconnect the multifunction switch connector MG1 vmr2008 026 003_b MG1 CONNECTOR Using the Fluke 115 multimeter P N 529 035 868 measur...

Page 282: ...make ensure both switches can turn on the brake light Taillight Brake Light Circuit Test No Taillight or Brake Light If neither taillight or brake light come on discon nect the taillight brake light connector secured to the inside of the LH rear frame extension next to the battery compartment vmr2008 027 001_a 1 Taillight brake light connector 2 Rear frame extension Set engine stop switch to RUN S...

Page 283: ...he tail light and brake light functions NEUTRAL INDICATOR LIGHT GREEN Neutral Indicator Light Operation The neutral N indicator light is an LED that comes on only when the vehicle is powered and the transmission is in neutral It is mounted in a cluster dashboard just ahead of the fuel cap and has no light test function vmo2008 011 028_b 1 Neutral N indicator light 2 Check engine indicator light 3 ...

Page 284: ... 004_a NEUTRAL INDICATOR LIGHT LED TESTING If you do not obtain readings as per table replace the LED indicator light If the LED tested good carry out the following tests With the transmission set to neutral measure the ground circuit continuity from the WHITE GREEN wire connector to ground vmr2008 027 007_a CONTINUITY TEST 1 WHITE GREEN wire connector to ground If the ground circuit was good set ...

Page 285: ...dicator light is an LED that will come on flashing momentarily when the power is first applied to the vehicle light test function It is mounted in a cluster dashboard just ahead of the fuel cap vmo2008 011 028_b 1 Neutral N indicator light 2 Check engine indicator light 3 Low fuel level indicator light The light receives power from the cooling fan and accessories fuse When power is first turned on...

Page 286: ...o the ECM adapter tool P N 529 036 085 vmr2008 139 016_a TYPICAL 1 ECM connector 2 ECM adapter tool Test for continuity of the PINK ORANGE wire from the LED terminal to the ECM adapter tool pin K4 vmr2008 027 008_b CONTINUITY TEST OF CHECK ENGINE INDICATOR LIGHT 1 PINK ORANGE wire to K4 If you do not obtain continuity repair or replace the wiring connectors Install all removed components and conne...

Page 287: ...nt flow increases Low Fuel Level Indicator Light Dynamic Test To test the low fuel level indicator light operation remove the fuel cap and syphon the fuel out of the tank until it is just below the fuel pump Install the fuel cap Set the engine stop switch to RUN Set ignition switch to ON As the thermistor heats up with power applied the low fuel level light should come on If the light does not com...

Page 288: ...o the BODY section Disconnect the fuel pump connector vmr2008 027 005_a 1 Fuel pump connector 2 Fuel tank Measure for continuity through the low fuel level sensor at the pump and the ground circuit wiring as per following table GROUND CIRCUIT CONTINUITY TEST LOW FUEL LEVEL SENSOR PROBE POSITIONS RESISTANCE AT 20 C 68 F Fuel pump connector pin 1 Fuel pump connector pin 2 1000 150 BROWN PINK wire te...

Page 289: ... wiring connectors Reinstall the red pin lock on the connector and reconnect the fuel pump connector as required If wiring and sensor tested good carry out the LOW FUEL LEVEL LIGHT INPUT VOLTAGE TEST Input Voltage Test low fuel level indicator light Set the engine stop switch to RUN Set ignition switch to ON Measure voltage at the low fuel level light RED BLACK wire connector You should ob tain ba...

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Page 291: ...tion Part Number Page bearing remover installer tool 529 035 918 282 rear axle key 529 036 082 279 SERVICE PRODUCTS Description Part Number Page CV grease 293 550 019 279 281 Loctite 767 antiseize lubricant 293 800 070 282 Loctite 609 413 703 100 281 pulley flange cleaner 413 711 809 280 vmr2008 032 271 ...

Page 292: ...f ft 48 N m 35 lbf ft 48 N m 35 lbf ft 25 N m 18 lbf ft 61 N m 45 lbf ft CV grease 293 550 019 XP S synthetic grease 293 550 010 Loctite 609 XP S synthetic grease 293 550 010 CV grease 293 550 019 31 N m 23 lbf ft 10 N m 89 lbf in CV grease 293 550 019 NEW vmr2008 032 001_a 272 vmr2008 032 ...

Page 293: ... or equivalent weight seated on the vehicle Check drive chain free play midway between sprockets on upper run of drive chain V06H06A Drive chain free play should allow the following vertical movement by hand DRIVE CHAIN FREE PLAY 22 mm 7 8 in Check drive chain free play at several points along the chain The free play should remain constant Otherwise inspect drive chain NOTE A drive chain with unev...

Page 294: ...ce as re quired Drive Chain Cleaning CAUTION Never wash the chain with a high pressure washer or gasoline Damage to the O rings 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 Drive Chain Lubrication Lubricate only with an approved O ring chain lubri cant Other commercial chain lubricant may con tain solvent w...

Page 295: ... hose to swing arm vmr2008 032 006_a Remove front sprocket protector vmr2008 032 007_a 1 Protector screws 2 Brake pedal Remove chain guard vmr2008 032 008_a 1 Chain guard Remove drive chain from front sprocket Remove swing arm bolt vmr2008 032 009_a 1 Swing arm bolt Move swing arm backward Support swing arm to avoid damaging brake hose Remove drive chain from vehicle Drive Chain Installation Insta...

Page 296: ...osen drive chain Refer to DRIVE CHAIN RE MOVAL for the procedure Remove front sprocket protector vmr2008 032 007_a 1 Protector screws 2 Brake pedal Remove chain guard vmr2008 032 008_a 1 Chain guard Remove and discard circlip at the center of front sprocket vmr2008 032 034_a 1 Circlip Remove front sprocket and chain from engine out put shaft Remove front sprocket from chain Front Sprocket Inspecti...

Page 297: ...050_a 1 O ring 2 Main shaft splines Front Sprocket Installation The installation is the reverse of the removal pro cedure Install a NEW circlip REAR SPROCKET Rear Sprocket Removal Lift the rear of vehicle and install jack stands under the frame to support vehicle off the ground Remove the RH rear wheel Remove swing arm protector Loosen rear sprocket nuts vmr2008 032 013_a Loosen rear axle lock bol...

Page 298: ... over wheel hub vmr2008 032 016 Rear Sprocket Inspection Check rear sprocket for Distortion Excessive wear Other damages V02H02A 1 2 1 Good 2 Worn CAUTION Replace drive chain and sprockets together to prevent premature wear Rear Sprocket Installation The installation is the reverse of the removal pro cedure REAR AXLE Rear Axle Removal Select a level surface and set transmission to NEUTRAL Loosen w...

Page 299: ... vmr2008 032 031_a Rear Axle Inspection Check axle for Bending Torsion Rust indicates a possible damage to axle Bearing surfaces condition Replace rear axle as required Rear Axle Installation Insert rear axle into chain tensioner On LH side install the O ring Push it inside chain tensioner Install axle nut Using the rear axle key P N 529 036 082 tighten axle nut to 31 N m 23 lbf ft vmr2008 032 032...

Page 300: ...low hub displacement vmr2008 032 051_a 1 Rear sprocket hub 2 Steel tube used as a pusher 3 C clip Pull tube out and remove C clip WARNING Wear gloves to handle the parts to protect your hands from the heated parts Turn rear axle upside down Press the hub out of rear axle vmr2008 032 052_a 1 Steel tube used as a pusher Discard hub Remove and discard the O ring vmr2008 032 053_a 1 O ring Rear Sprock...

Page 301: ... fit on the axle Chain Tensioner Removal Remove rear axle Refer to REAR AXLE above for complete procedure Remove the circlip on the LH side of chain ten sioner vmr2008 032 035_a 1 Circlip 2 Caliper bracket Remove caliper bracket vmr2008 032 036_a 1 Pull off bracket Remove chain tensioner from the RH side Chain Tensioner Disassembly Remove and discard both seals Using a heat gun heat chain tensione...

Page 302: ...s can be installed with out tools Clean Loctite surplus Check if bearings turn smoothly and freely Install NEW seals Chain Tensioner Installation Apply Loctite 767 antiseize lubricant P N 293 800 070 on chain tensioner lobes Insert chain tensioner inside swing arm by the RH side vmr2008 032 041_a 1 Apply antiseize lubricant here Install caliper bracket Install the circlip Install all other removed...

Page 303: ...ERVICE PRODUCTS Description Part Number Page CV grease 293 550 019 287 288 52 N m 38 lbf ft 5 N m 44 lbf in NEW 250 N m 184 lbf ft 52 N m 38 lbf ft 48 N m 35 lbf ft NEW CV grease 293 550 019 NEW CV grease 293 550 019 REAR FRONT vmr2008 028 001_a vmr2008 028 283 ...

Page 304: ...SSURE WARNING Tire pressure greatly affects vehicle handling and stability Underpressure may cause tire to deflate and rotate on wheel Over pressure may burst the tire Always follow recommended pressure Since tires are low pressure types a manual pump should be used Check pressure when tires are COLD before using the vehicle Tire pressure changes with tempera ture and altitude Recheck pressure if ...

Page 305: ...ehicle Wheel Installation The installation is the reverse of the removal pro cedure However pay attention to the following Install wheel on vehicle NOTE Ensure that front brake disc protectors are properly installed vmr2008 028 005_a FRONT WHEELS 1 External protector Install flat washers Manually screw all lug nuts CAUTION Always use the recommended lug nuts P N 250 100 105 and flat washers P N 25...

Page 306: ...nscrew and remove the wheel hub screw vmr2008 028 009_a 1 Wheel hub screw 2 Locking washer 3 Retaining washer Remove the caliper Refer to BRAKES section vmr2008 028 010_a 1 Wheel hub 2 Caliper Remove the outer brake pad vmr2008 028 011_a 1 Outer brake pad Pull wheel hub vmr2008 028 012_a 1 Wheel hub Remove the small O ring the support ring and the large O ring 286 vmr2008 028 ...

Page 307: ...t ring Install the wheel hub Install brake pad and caliper Refer to BRAKES section Install locking washer tab into retaining washer hole Install washers by inserting the tab into the knuck le drilled hole vmr2008 028 016_a 1 Locking washer 2 Retaining washer 3 Locking washer tab 4 Knuckle drilled hole Install and tighten wheel hub screw Position the large O ring on the joint between hub and knuckl...

Page 308: ...move the conical washer vmr2008 028 023_a 1 Conical washer Rear Wheel Hub Installation Install conical washer with its flat side outward Apply CV grease P N 293 550 019 on drive axle splines Install wheel hub Align a wheel hub opening with a cotter pin hole vmr2008 028 024_a 1 Wheel hub opening 2 Cotter pin hole Install flat washer and nut Tighten wheel hub nut to 250 N m 184 lbf ft Further tighte...

Page 309: ...o feel wheel bearing play If there is any play replace wheel bearing Wheel Bearing Removal Remove FRONT WHEEL HUB see procedure in this section Remove circlip retaining wheel bearing into wheel hub vmr2008 028 018_a 1 Circlip 2 Wheel bearing Using a press and a proper extractor push the wheel bearing out of wheel hub Wheel Bearing Installation Place the NEW wheel bearing in a freezer for 30 minute...

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Page 311: ...OOLS OTHER SUPPLIER Description Part Number Page Smoothflow tapered tip 16 ga 511 rtt b 294 SERVICE PRODUCTS Description Part Number Page XP S synthetic grease 293 550 010 301 Loctite 406 glue 293 800 100 294 pulley flange cleaner 413 711 809 294 vmr2008 029 291 ...

Page 312: ... ft 25 N m 18 lbf ft XP S synthetic grease 293 550 010 Loctite 406 11 N m 97 lbf in 19 N m 168 lbf in NEW NEW NEW 25 N m 18 lbf ft NEW DS 450 X 28 N m 21 lbf ft 25 N m 18 lbf ft Loctite 406 25 N m 18 lbf ft XP S synthetic grease 293 550 010 vmr2008 029 001_a 292 vmr2008 029 ...

Page 313: ...must be replaced and installed at the same location ADJUSTMENT STEERING ALIGNMENT Place vehicle on level surface Position handlebar so that it is in straight ahead position by measuring from the extremities of the handlebar to a rear fixed point vmr2008 029 045_a A Same length NOTE The reference point must be the same to each side Tie handlebar to prevent movements during align ment Measure the di...

Page 314: ...ir between handlebar grip and handlebar Install a Smoothflow tapered tip P N 16 ga 511 rtt b from EFD Inc on a bottle of Loctite 406 glue P N 293 800 100 Lift a part of the grip using a small screwdriver and inject glue about 4 spots per side NOTE The glue dries quickly Do not apply it be fore installing grip Apply pressure on the grip for approximately 30 seconds to set the glue Install the handl...

Page 315: ...ter 3 Rubber protector Remove cable from the throttle lever vmr2008 029 011_a 1 Throttle cable end 2 Throttle lever Underneath throttle lever housing remove screws securing the housing clamp vmr2008 029 012_a 1 Housing clamp 2 Housing clamp screws Remove throttle lever housing from handlebar Throttle Lever Installation The installation is the reverse of the removal pro cedure Adjust throttle cable...

Page 316: ...djuster 3 Rubber protector Remove cable from the throttle lever vmr2008 029 011_a 1 Throttle cable end 2 Throttle lever At Throttle Body Remove front body assembly Refer to BODY section Remove the air intake hose deflector vmr2008 029 016_a 1 Deflector 2 Air intake hose Loosen throttle body clamps Turn the throttle body to reach the throttle body cover screw vmr2008 029 013_a 1 Throttle body cover...

Page 317: ...l pro cedure Proceed with throttle cable adjustment Throttle Cable Adjustment Slide rubber protector back to expose throttle ca ble adjuster vmr2008 029 009_a 1 Rubber protector Loosen lock nut then turn the adjuster to obtain correct throttle lever free play vmr2008 029 010_a 1 Lock nut 2 Throttle cable adjuster 3 Rubber protector NOTE Measure throttle free play at the tip of throttle lever vmo20...

Page 318: ...ghten lock nut Release throttle lever HANDLEBAR Handlebar Removal NOTE If the handlebar must be changed remove all components handlebar wind deflectors throt tle lever front master cylinder clutch lever and multifunction switch before removing it from ve hicle Remove the handlebar cover vmr2008 029 018_a DS 450 1 Rigid cover vmr2008 029 050_a DS 450 X 1 Leatherette cover with foam Remove the handl...

Page 319: ... Remove the front body assembly Refer to BODY section Remove front shock absorbers Refer to FRONT SUSPENSION section Remove the radiator Refer to COOLING SYSTEM section Remove HANDLEBAR see procedure in this sec tion Inside shock absorber upper attachments un screw bolts securing the front upper brace vmr2008 029 022_a 1 LH upper attachment 2 Upper brace bolt one each side Detach tie rods from ste...

Page 320: ... WARNING Never try to weld or modify the steering col umn Always replace the column with a new one Check if steering column half seals are Brittle Hard Otherwise damaged Replace them if necessary At the same time check steering column bearing condition It must turn smoothly and freely If not replace bearing Steering Column Bearing Replacement Remove and discard cotter pin Remove and discard the nu...

Page 321: ...low ing Install a NEW bearing nut Install a NEW cotter pin Both ends of cotter pins must be folded Steering Column Installation The installation is the reverse of the removal pro cedure However pay attention to the following Apply XP S synthetic grease P N 293 550 010 on half seals Install all other removed parts accordingly with their installation procedures TIE ROD Tie Rod Removal Place vehicle ...

Page 322: ... of tie rod vmr2008 029 039_a A Preliminary adjustment 439 mm 17 9 32 in B Unengaged threads 20 mm 25 32 in TIE ROD Preliminary length adjustment dimension A 439 mm 17 9 32 in Maximum unengaged threads dimension B 20 mm 25 32 in Dimension B to be approximately equal upon assembly Tighten tie rod lock nuts Install NEW cotter pins Both ends of cotter pins must be folded Perform steering alignment Re...

Page 323: ...ate lower ball joint from knuckle vmr2008 029 038_a 1 Knuckle 2 Cotter pin 3 Lower ball joint nut 4 Lower suspension arm Knuckle Installation The installation is the reverse of the removal pro cedure However pay attention to the following Install NEW cotter pins Both ends of cotter pins must be folded Verify steering alignment Refer to ADJUST MENT at the beginning of this section vmr2008 029 303 ...

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Page 325: ...SION SERVICE TOOLS Description Part Number Page ball joint remover 529 036 121 312 315 SERVICE PRODUCTS Description Part Number Page suspension grease 293 550 033 309 Loctite 609 413 703 100 313 315 Loctite Chisel gasket remover 413 708 500 312 315 vmr2008 030 305 ...

Page 326: ... N m 35 lbf ft 48 N m 35 lbf ft 48 N m 35 lbf ft 48 N m 35 lbf ft NEW 48 N m 35 lbf ft 3 N m 27 lbf in 3 N m 27 lbf in Suspension grease 293 550 033 Suspension grease 293 550 033 Loctite 609 Loctite 609 25 N m 18 lbf ft vmr2008 030 001_a 306 vmr2008 030 ...

Page 327: ...set up the suspension is to start from factory settings refer to SUSPENSION FACTORY SETTINGS then customize each ad justment one at a time Front and rear adjustments are interrelated It may be necessary to readjust the rear shock ab sorber after adjusting front shock absorbers for instance Test run the vehicle under the same conditions trail speed driver riding position etc Change one adjustment a...

Page 328: ...rough trail condition Lengthen the spring for a softer ride on smooth trail condition Lift the front of the vehicle Measure springs length NOTE Spring length must be measured without load on the wheels Loosen top locking rings Turn adjusting rings to position springs to appro priate length vmo2008 011 057_d 1 Locking ring 2 Adjusting ring vmo2008 011 056_a A Same length Shock Absorber Compression ...

Page 329: ...High speed compression adjuster Turning it clockwise H increases shock damping action stiffer Turning it counterclockwise S decreases shock damping action softer Rebound Use a flat screwdriver to adjust it vmo2008 011 075_a 1 Rebound adjuster Turning it clockwise H increases shock damping action stiffer Turning it counterclockwise S decreases shock damping action softer MAINTENANCE LUBRICATION Use...

Page 330: ... ring vmr2008 030 005_a 1 Locking ring 2 Adjusting ring At the bottom of shock absorber remove spring stopper and rod protector vmr2008 030 006_a 1 Spring stopper 2 Rod protector Remove spring Shock Absorber Inspection Inspect the spring for damage Replace if neces sary Inspect shock for oil leakage Extend and com press the piston several times over its entire stroke Check piston rod for excessive...

Page 331: ...e piston rod Install spring with the color code upward vmr2008 030 005_b 1 Color code area Install rod protector and spring stopper Install the adjusting ring Shock Absorber Installation Install the shock absorber with the rebound ad juster rearward Position bolt heads as follow SHOCK ABSORBER BOLT HEAD POSITION Upper shock absorber bolt Forward Lower shock absorber bolt Rearward Adjust SPRING PRE...

Page 332: ... Pivot bushings 5 Sleeves 6 Wear caps Lubricate grease fittings UPPER BALL JOINT Upper Ball Joint Inspection Inspect ball joint end for damage Ensure it s moving freely without play Replace ball joint as required Upper Ball Joint Removal Remove UPPER SUSPENSION ARM see proce dure above Remove circlip securing ball joint to suspension arm vmr2008 030 011_a 1 Circlip Apply localized heat to break ad...

Page 333: ...n Arm Inspection Check lower suspension arm for Bending Cracks Pitting Other damages Replace as required Move lower suspension arm from side to side and up and down There should be no noticeable play in bushings If necessary remove suspension arm and inspect pivot bushings and sleeves for wear or damages Replace bushings and or sleeves if necessary Lower Suspension Arm Removal Place vehicle on a l...

Page 334: ...leeves Install lower suspension arm on vehicle using the front suspension plate vmr2008 030 026_a 1 Front suspension plate 2 Lower suspension arm front bolt 3 Lower suspension arm CAUTION Do not omit this plate The struc tural solidity of the frame would be greatly af fected Lubricate grease fittings LOWER BALL JOINT Lower Ball Joint Inspection Inspect ball joint end for damage Ensure it s moving ...

Page 335: ... a thin layer of Loctite 609 P N 413 703 100 on ball joint head and inside the suspension arm bore vmr2008 030 025_a 1 Apply adhesive product on these surfaces Using a press a steel plate and the ball joint re mover P N 529 036 121 press ball joint into the lower suspension arm vmr2008 030 023_a 1 Ball joint installer 2 Steel plate 3 Press Wipe any excess of adhesive product Install the circlip In...

Page 336: ......

Page 337: ...ENSION REAR SUSPENSION SERVICE TOOLS Description Part Number Page needle bearing installer 529 036 109 324 SERVICE PRODUCTS Description Part Number Page dielectric grease 293 550 004 322 suspension grease 293 550 033 320 325 326 vmr2008 031 317 ...

Page 338: ...105 N m 77 lbf ft Suspension grease 293 550 033 Suspension grease 293 550 033 Suspension grease 293 550 033 Dielectric grease 48 N m 35 lbf ft NEW 3 N m 27 lbf in Suspension grease 293 550 033 135 N m 100 lbf ft 105 N m 77 lbf ft 48 N m 35 lbf ft NEW NEW NEW NEW vmr2008 031 001_a 318 vmr2008 031 ...

Page 339: ...o not disassemble reservoir or shock body ADJUSTMENTS Before performing any suspension adjustments it is always good practice to start from factory set tings then customize each adjustment one at a time FACTORY SETTINGS Spring Preload Lift the rear of the vehicle Spring length should be measured without load on the wheels vmo2008 011 079_a SPRING LENGTH A 262 mm 10 in Shock Absorber Compression Da...

Page 340: ... clockwise H increases shock damping action stiffer Turning the compression adjuster counterclock wise S decreases shock damping action softer vmo2008 011 060_a 1 Compression adjuster use a flat screwdriver Rebound Damping Turning the rebound adjuster clockwise H in creases shock damping action stiffer Turning the rebound adjuster counterclockwise S decreases shock damping action softer vmo2008 01...

Page 341: ...upport the vehicle Remove and discard cotter pin securing lower bolt of shock absorber Unscrew lower bolt vmr2008 031 002_a UNDERNEATH SWING ARM 1 Cotter pin 2 Lower bolt 3 Shock absorber 4 Bell crank lever Remove bolt securing bell crank lever to swing arm vmr2008 031 003_a 1 Bell crank lever 2 Swing arm 3 Bolt to be removed Lift both rear ends of fascia to reach the shock absorber upper bolt Rem...

Page 342: ... any fault is present Shock Absorber Installation For installation reverse removal procedures However pay attention to the following Before installing the shock absorber upper bolt check condition of O rings Replace as required vmr2008 031 022 Apply dielectric grease P N 293 550 004 on O rings SPRING Spring Removal WARNING Rear shock absorber is pressurized An explosion may occur if heated or punc...

Page 343: ...uring brake hose on swing arm vmr2008 031 010_a 1 Brake hose screws Remove the caliper screws then the caliper Hang the caliper with a piece of wire to take the weight off the brake hose CAUTION Do not let caliper hang by the hose and do not stretch or twist the hose vmr2008 031 011_a 1 Caliper screws Remove front sprocket Refer to FRONT SPROCKET in DRIVE TRAIN section for the procedure Remove bol...

Page 344: ...08 031 016_a 1 Dust cap 2 Outer seal Remove the flanged bushing Remove and discard inner seal vmr2008 031 017_a 1 Press fit flanged bushing 2 Inner seal Using the following tools remove and discard needle bearings from swing arm A long 19 mm socket A short 30 mm socket C clamp vmr2008 031 018_a 1 C clamp 2 19 mm socket 3 30 mm socket Swing Arm Assembly Using the needle bearing installer P N 529 03...

Page 345: ...ut to 135 N m 100 lbf ft Check if the swing arm moves freely Install all other removed parts BELL CRANK LEVER Bell Crank Lever Removal Lift rear of vehicle until rear shock absorber is fully extended Install a jack stand under the frame to support the vehicle Remove bolt securing pivot arm to bell crank lever vmr2008 031 014_a UNDERNEATH SWING ARM 1 Pivot arm 2 Bell crank lever 3 Remove bolt and n...

Page 346: ...talling the single needle bearing apply suspension grease P N 293 550 033 on its inner face Install seals WITH GREASE FITTING SEAL LIPS FACE OUTWARD WITHOUT GREASE FITTING SEALS LIPS TOWARD NEEDLE BEARINGS Insert bushing Bell Crank Lever Installation Position the longest radius of bell crank lever up ward This curved portion allows more space for shock absorber travel vmr2008 031 026_a 1 Longest r...

Page 347: ...31 033_a 1 Seal Remove and discard needle bearings by using the procedure described in SWING ARM DISASSEM BLY vmr2008 031 034_a 1 Needle bearings Pivot Arm Assembly To install NEW needle bearings properly use pro cedure described in SWING ARM ASSEMBLY Install seals with lips facing outward vmr2008 031 035 Insert bushing Pivot Arm Installation The installation is the reverse of the removal pro cedu...

Page 348: ......

Page 349: ... pressure pump 529 021 800 334 axle key 529 036 082 345 blind hole puller kit 529 036 117 343 SERVICE PRODUCTS Description Part Number Page CV grease 293 550 019 344 jet pump bearing grease 293 550 032 339 342 brake fluid GTLMA DOT 4 293 600 062 332 Loctite 243 blue 293 800 060 338 vmr2008 033 329 ...

Page 350: ...4 N m 35 lbf in 25 N m 18 lbf ft Loctite 243 10 N m 89 lbf in 28 N m 21 lbf ft 10 N m 89 lbf in 28 N m 21 lbf ft 5 N m 44 lbf in 22 N m 16 lbf ft Loctite 243 22 N m 16 lbf ft 5 N m 44 lbf in 1 5 N m 13 lbf in 4 N m 35 lbf in 11 N m 97 lbf in 4 N m 35 lbf in 11 N m 97 lbf in vmr2008 033 001_a 330 vmr2008 033 ...

Page 351: ...REAR BRAKE 25 N m 18 lbf ft 10 N m 89 lbf in 5 N m 44 lbf in NEW NEW 25 N m 18 lbf ft 25 N m 18 lbf ft 13 N m 115 lbf in 8 N m 71 lbf in 28 N m 21 lbf ft Loctite 243 22 N m 16 lbf ft NEW NEW 25 N m 18 lbf ft vmr2008 033 003_a vmr2008 033 331 ...

Page 352: ...pening or working near bleeders reservoir or fittings clean the part and its area to avoid system contamination NOTE Dispose brake fluid as per your local envi ronmental regulations SYSTEM DESCRIPTION The brake system consists of two separate cir cuits Each system has its own master cylinder and reservoir Both front and rear brakes are disc type WARNING Periodically check the brake hoses for dam a...

Page 353: ...eservoir to the appropriate lev el using recommended brake fluid only NOTE Master cylinder reservoir must be kept full to prevent air from being pumped into the system If a lack of fluid occurs start the procedure again Bleed system as per the following procedure Manual Bleeding Procedure Install a clear hose to bleeder Place the other end of the hose in a small con tainer partially filled with cl...

Page 354: ...in Top up the master cylinder reservoir to the appro priate level using recommended brake fluid only Install diaphragm and cover on reservoir NOTE Make sure rear reservoir diaphragm is cor rectly installed see the following illustrations to position it vmr2008 033 062_a 1 Good position 2 To avoid Check brakes operation carefully before riding the vehicle PROCEDURES CALIPER Caliper Removal Front Ca...

Page 355: ...ody half to slide it out of guide pins vmr2008 033 008_a 1 Guide pins Rear Caliper Park the vehicle on a firm level surface NOTE If the caliper is not replaced omit the next steps concerning the brake system draining and brake hose removal Drain brake fluid from brake system Remove the Banjo fitting and discard the sealing washers Detach brake hose from caliper and catch spilled fluid with a rag v...

Page 356: ...rakes operate normally before driving BRAKE PADS Brake Pads Inspection CAUTION Soiled brake pads must be replaced by new ones Measure brake pad lining thickness Brake pads must be replaced when lining is 1 mm 1 32 in thick Verify the groove on the pad lining vmr2008 033 016_a 1 Groove on pad lining A Brake pad minimum thickness 1 mm 1 32 in SERVICE LIMIT Brake pad thickness 1 mm 1 32 in CAUTION Br...

Page 357: ...id level in the front brake fluid reservoir and top up if necessary Check for leaks and make sure the brakes operate normally before driving The pads must rest flat on the disc Rear Brake Pads Loosen brake pad screws vmr2008 033 017_a 1 Brake pad screws Remove caliper screws vmr2008 033 018_a 1 Caliper screws Remove brake pad screws vmr2008 033 019_a 1 Brake pad screws Remove brake pads vmr2008 03...

Page 358: ...ace Loosen wheel nuts Raise vehicle and support it securely Remove wheels Raise vehicle and support it securely NOTE For rear brake disc the wheels removal is not necessary Visually inspect both brake disc surfaces for Scratches Grooves Other damages Replace brake disc as required Measure thickness of the disc BRAKE DISC THICKNESS Minimum thickness 3 5 mm 13 in CAUTION Brake discs should never be ...

Page 359: ...e circlip securing parking brake lever to in ner lever vmr2008 033 042_a 1 Inner lever 2 Circlip 3 Parking brake lever 4 Parking brake lever spring 5 Parking brake lever pivot Remove the adjustment cam from brake lever vmr2008 033 043_a 1 Adjustment cam 2 Brake lever 3 Spring washer 4 Shim 5 Snap ring Reverse the previous steps to reinstall all removed parts However pay attention to the following ...

Page 360: ...ng washers Unscrew master cylinder screws vmr2008 033 028_a 1 Master cylinder screws Remove BRAKE LEVER see procedure in this sec tion Front Master Cylinder Installation For the installation reverse the removal proce dure However pay attention to the following Install brake light switch with two NEW sealing washers Torque brake light switch to 25 N m 18 lbf ft Fill and bleed the brake system Refer...

Page 361: ..._a 1 Brake pedal spring Remove pin securing brake pedal to master cylin der rod hook Discard the cotter pin vmr2008 033 033_a 1 Cotter pin discard 2 Brake pedal 3 Retaining pin 4 Hook Disconnect reservoir hose from master cylinder Remove bolts retaining master cylinder to frame vmr2008 033 034_a 1 Master cylinder bolts 2 Master cylinder 3 Reservoir hose Rear Master Cylinder Disassembly Remove hook...

Page 362: ...s the jet pump bearing grease P N 293 550 032 on the end of master piston vmr2008 033 038_b 1 Apply brake fluid here 2 Apply grease here Position the hook as per the following illustration vmr2008 033 047_a A 92 6 mm 3 65 in Rear Master Cylinder Installation For the installation reverse the removal proce dure However pay attention to the following Install brake light switch with two NEW sealing wa...

Page 363: ...e pedal 2 Brake pedal screw 3 Washer 4 Shim Remove brake pedal Brake Pedal Bearing Replacement Using a punch drive bearings out of frame vmr2008 033 052_a NOTE If the inner bearing outer race stays inside the frame the swing arm removal is necessary Use a blind hole puller from the blind hole puller kit P N 529 036 117 to extract the outer race 529036117 vmr2008 033 053_a 1 Inner bearing outer rac...

Page 364: ...ose and do not stretch or twist the hose Unfold locking washer Remove brake hub screws vmr2008 032 027_a 1 Locking washer 2 Brake hub screws Remove and discard the locking washer Remove brake hub with the disc brake vmr2008 032 028 Brake Disc Hub Inspection Check brake hub for cracks or other damages Re place if necessary Check brake hub splines for wear or damages Replace brake hub and or rear ax...

Page 365: ...ght Switch Test Refer to BODY section to remove the front body assembly Unplug the brake light switch connector vmr2008 033 025_a 1 Brake light switch connector Check switch operation as follows BRAKE LIGHT SWITCH POSITION PIN RESISTANCE 20 C 68 F Firmly pushed 0 2 max Released 1 2 Infinite OL If switch is defective replace it with a new one If the switch tests good verify wire continuity be tween...

Page 366: ...es operate normally before driving REAR BRAKE LIGHT SWITCH Rear Brake Light Switch Test Refer to BODY section to remove the RH foot pro tector Unplug the brake light switch connector vmr2008 033 030_a 1 Brake light switch connector 2 Air filter housing Check switch operation as follows BRAKE LIGHT SWITCH POSITION PIN RESISTANCE 20 C 68 F Firmly pushed 0 2 max Released 1 2 Infinite OL If switch is ...

Page 367: ... BLEEDING in this section Check for leaks and make sure the brakes operate normally before driving FLEXIBLE BRAKE HOSE Flexible Brake Hose Removal Front Flexible Brake Hoses Place vehicle on a level surface Loosen wheel lug nuts Lift the front of vehicle Support vehicle securely on jack stands Remove front wheels Drain brake fluid see BRAKE FLUID DRAINING in this section Remove the front body asse...

Page 368: ...id from rear brake circuit See BRAKE FLUID DRAINING at the beginning of this section Unscrew brake light switch and discard the sealing washers Unscrew Banjo fitting on caliper and discard the sealing washers Remove screws securing brake hose retainers to swing arm vmr2008 033 060_a 1 Brake light switch 2 Banjo fitting 3 Brake cable retainers Remove brake hose from vehicle and note the routing Fle...

Page 369: ...hat the brake hose does not rub against wheel hub or suspen sion arm Also remove the shock absorbers and move the suspension up and down If brake hose rubs on any parts reroute brake hose correctly Fill and bleed the brake system Refer to BRAKE FLUID BLEEDING in this section Install all other removed parts Check for leaks and make sure the brakes operate normally before driving vmr2008 033 349 ...

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Page 371: ... m 58 lbf in 10 N m 89 lbf in Loctite 243 18 N m 159 lbf in 6 5 N m 58 lbf in 6 5 N m 58 lbf in 4 5 N m 40 lbf in 10 N m 89 lbf in Loctite 243 DS 450 X Loctite 243 25 N m 18 lbf ft 2 5 N m 22 lbf in 2 5 N m 22 lbf in 25 N m 18 lbf ft Loctite 243 2 N m 18 lbf in 4 5 N m 40 lbf in vmr2008 035 001_a vmr2008 035 351 ...

Page 372: ... lbf in 2 N m 18 lbf in Loctite 243 4 5 N m 40 lbf in Loctite 243 2 5 N m 22 lbf in 4 5 N m 40 lbf in 2 N m 18 lbf in 2 5 N m 22 lbf in 10 N m 89 lbf in 2 5 N m 22 lbf in 15 N m 133 lbf in Loctite 243 2 5 N m 22 lbf in 25 N m 18 lbf ft DS 450 DS 450 X 2 5 N m 22 lbf in 2 5 N m 22 lbf in vmr2008 035 002_a 352 vmr2008 035 ...

Page 373: ...Section 08 CHASSIS Subsection 06 BODY SEAT 25 N m 18 lbf ft 25 N m 18 lbf ft vmr2008 035 003_a vmr2008 035 353 ...

Page 374: ...part on this vehicle is repairable Change all defective parts PROCEDURES DECALS Decal Removal Using a heat gun low heat setting 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 seco...

Page 375: ...iving it a tug to confirm proper latching vmo2008 011 031_a 1 Upper slot 2 Middle tab WARNING Make sure seat is securely latched before rid ing Seat Cover Replacement Remove the old seat cover Check the foam and replace if necessary Install staples with an electric tacker such as Ar row tacker no ETN 50 or with a manual tacker such as Arrow tacker no T 50 NOTE For an easier installation it s highl...

Page 376: ... indicator lamps Remove console completely Console Installation Installation is the reverse order of removal FRONT BUMPER Front Bumper Removal Remove bolts securing front bumper to frame vmr2008 035 006_a TYPICAL 1 Front bumper 2 Front bumper bolts Pull front bumper to remove it Front Bumper Installation Installation is the reverse order of removal FRONT BODY ASSEMBLY To work on frame fuel tank or...

Page 377: ...035 010_a 1 Front fender bracket 2 Headlamp Unplug headlamp connector Remove screw retaining headlamp to front fender and side panel same on both sides vmr2008 035 011_a 1 Headlamp connector 2 Screw to remove Remove headlamp support screw vmr2008 035 012_a 1 Headlamp 2 Headlamp support screw 3 Shock absorber Remove screw at the bottom of front grille vmr2008 035 013_a Lift front body assembly to r...

Page 378: ... lower screw 2 Plastic rivet Remove front fender Front Fender Installation The installation is the reverse of removal proce dure FRONT GRILLE Front Grille Removal Remove the bottom screw of front grille Remove both screws holding front grille to side panels vmr2008 035 017_a Remove both top screws securing front grille to fascia vmr2008 035 018_a 1 Top screws underneath front fascia Remove front g...

Page 379: ...Screws to be removed Remove both screws securing footrest to footrest support vmr2008 035 021_a Remove footrest Footrest Installation Installation is the reverse order of removal NOTE Install all bolts before torquing FOOTREST SUPPORT Footrest Support Removal Remove footrest Unscrew bolts retaining footrest support to the frame and footpeg vmr2008 035 022_a Footrest Support Installation Installati...

Page 380: ... screws retaining rear bumper Rear Bumper Installation Installation is the reverse order of removal NOTE Install all bolts before torquing ENGINE SKID PLATE DS 450 X Skid Plate Inspection The skid plate protects the engine and the frame Check for damage cracks or looseness Change if skid plate is damaged or cracked Skid Plate Removal Underneath vehicle remove screws retaining skid plate to frame v...

Page 381: ...g nerf bar to footpeg vmr2008 035 029_a 1 Nerf bar 2 Nerf bar s bolts 3 Footpeg Nerf Bar Inspection Check nerf bar for cracks or bents Replace nerf bar as required Check net strap for wear Change or repair as re quired Nerf Bar Installation Installation is essentially the reverse of removal procedure but pay attention to the following After installing the net strap on the frame make sure to tight ...

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Page 383: ...Section 08 CHASSIS Subsection 07 FRAME FRAME NEW 25 N m 18 lbf ft 25 N m 18 lbf ft 25 N m 18 lbf ft 25 N m 18 lbf ft NEW vmr2008 036 100_a vmr2008 036 363 ...

Page 384: ...mponents can cause frame distortion or cracks However the following parts can be replaced sep arately vmr2008 036 002_a 1 Rear frame extension 2 Rear engine supports 3 Footpegs 4 Both side members 5 Lower suspension arm attachments Frame Cleaning Using a high pressure washer clean the frame thoroughly CAUTION Never direct high pressure water jet towards decals They will peel off Clean frame with a...

Page 385: ...TION Make sure do not use elastic stop nuts to secure rear frame extension bolts The plastic inside elastic stop nuts could melt due to the exhaust system heat and their efficiency could be reduced REAR ENGINE SUPPORTS Rear Engine Support Removal Remove the front body assembly Refer to BODY section Unscrew rear engine mounting bolt vmr2008 036 005_a 1 Engine mounting bolt 2 RH rear engine support ...

Page 386: ...ng do not remove them un necessarily Engine removal Valves adjustment Fuel tank removal Side Member Removal Remove the front shock absorber Refer to FRONT SUSPENSION section Remove the side member front bolt locates inside shock absorber upper bracket vmr2008 036 009_a 1 Side member front bolt 2 Shock absorber upper bracket Remove front fender support screw vmr2008 036 010_a 1 RH fender support sc...

Page 387: ...N section Unscrew attachment bolts Discard bolts and nuts Remove suspension arm attachments vmr2008 036 018_a 1 Suspension arm attachments 2 Discard these bolts 3 Washers 4 Discard these nuts Lower Suspension Arm Attachment Installation The installation is the reverse of the removal pro cedure However pay attention to the following Use NEW bolts when installing lower suspension arm attachment CAUT...

Page 388: ......

Page 389: ...hetic blend oil or additive in Can Am ATV wet clutch equipped vehicles Intake valve opening 12 BTDC Intake valve closing 48 ABDC Exhaust valve opening 64 BBDC Exhaust valve closing 15 ATDC Intake mm in 0 11 to 0 18 0043 to 0071 Valve clearance Exhaust mm in 0 22 to 0 29 0087 to 0114 New mm in 5 961 to 5 975 2347 to 2352 Intake Service limit mm in 5 950 2343 New mm in 5 946 to 5 960 2341 to 2346 Va...

Page 390: ...ompression ring rectangular Piston ring type 3rd Oil scraper ring Upper compression ring 0 15 to 0 40 006 to 016 Lower compression ring 0 15 to 0 40 006 to 016 Oil scraper ring New mm in 0 15 to 0 35 006 to 014 Ring end gap All Service limit mm in 1 00 0394 Upper compression ring 0 025 to 0 070 0010 to 0028 Lower compression ring 0 025 to 0 070 0010 to 0028 Oil scraper ring New mm in 0 015 to 0 06...

Page 391: ... mm in 0 050 0020 New mm in 0 317 to 0 643 0125 to 0253 Connecting rod big end axial play Service limit mm in 0 700 0276 New mm in 20 015 to 20 025 7880 to 7884 Connecting rod small end diameter Service limit mm in 20 040 7890 New mm in 19 996 to 20 000 7872 to 7874 Piston pin diameter Service limit mm in 19 990 7870 Connecting rod piston pin clearance radial play Service limit mm in 0 050 0020 CL...

Page 392: ...to 20 065 7848 to 7900 Free pinion bearing Service limit mm in 19 920 7843 New mm in 24 980 to 24 993 9835 to 9840 Clutch side Service limit mm in 24 960 9827 New mm in 20 935 to 21 065 8242 to 8293 Clutch shaft journal diameter Clutch drum Service limit mm in 20 920 8236 COOLING SYSTEM Type Liquid cooled single radiator with cooling fan Type Ethyl glycol water mix 50 coolant 50 water Use premixed...

Page 393: ...M 2 91 or higher Fuel Octane rating Outside North America RON 95 or higher Fuel tank capacity 11 5 L 3 0 U S gal Remaining fuel in fuel tank when display light turns ON 3 L 79 U S gal DRIVE SYSTEM Rear axle Chain driven solid axle Rear drive ratio 14 42 Drive chain Regina 135 ORC6 STEERING Turning radius Standard m ft 6 12 20 1 Total toe in vehicle on ground without loads mm in 0 to 6 35 0 to 1 4 ...

Page 394: ...3 Brake fluid Type DOT 4 Parking brake Hydraulic type RH brake lever includes a parking brake on front wheels Front Floating piston inverted Caliper Rear Floating Front Semi metallic Brake pad material Rear Semi metallic Minimum brake pad thickness mm in 1 04 Front mm in 3 5 138 Minimum brake disc thickness Rear mm in 3 5 138 Maximum brake disc warpage mm in 0 2 01 TIRES AND WHEELS TIRES Maximum 4...

Page 395: ...um Frame Color Gray and Black Material Aluminum Wheel Color Anodized aluminum Material Aluminum Front bumper Color Anodized aluminum Material High density polyethylene Front rear fender Color Yellow Material High density polyethylene Fuel tank Color Black Material High density polyethylene Leatherette foam Steering cover Color Black Material High density polyethylene Front grid Color Black Materia...

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Page 397: ...REA LOCATION 1 Steering area 2 ECM area 3 Front of vehicle 4 Engine area 5 Rear of vehicle Connector Identification Indicates the connector individually If there are many connectors in the same area this helps to identify which wire is in which connector 2 BF A XX XX BF BF vmr2008 038 003_a THE SHADED PART INDICATES A CONNECTOR IDENTIFICATION Terminal Location in Connector This is the terminal pos...

Page 398: ......

Page 399: ...NOTES ...

Page 400: ...NOTES ...

Page 401: ...vmr2008 038 100 2008 DS 450 GENERAL SYSTEM ...

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