BRP BOMBARDIER DS250 2006 Shop Manual Download

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CY CMY

2006-2019

Summary of Contents for BOMBARDIER DS250 2006

Page 1: ...C M Y CM MY CY CMY K 2006 2019 ...

Page 2: ...2006 2019 Shop Manual DS 250 ...

Page 3: ......

Page 4: ...OCEDURES 7 FUEL SYSTEM 7 ENGINE 7 ELECTRICAL SYSTEM 7 COOLING SYSTEM 7 CVT TRANSMISSION 8 VEHICLE 8 04 SPECIAL PROCEDURES 11 ATV IMMERSION 11 02 TROUBLESHOOTING 01 TROUBLESHOOTING CHART 13 COOLING SYSTEM 13 ELECTRICAL SYSTEM 13 LUBRICATION SYSTEM 14 CYLINDER HEAD 15 CRANKSHAFT 16 GEARBOX 16 CVT 17 ENGINE GENERAL 19 STARTING SYSTEM 21 03 ENGINE 01 ENGINE REMOVAL AND INSTALLATION 23 GENERAL 23 REMOV...

Page 5: ...ER DRIVE 61 GENERAL 62 PROCEDURES 62 MAGNETO COVER 62 TRIGGER COIL 64 STATOR 64 CRANKSHAFT END BEARING 64 FLYWHEEL 65 STARTER REDUCTION GEAR 66 STARTING CLUTCH GEAR 67 08 CYLINDER HEAD 69 GENERAL 70 VALVE CLEARANCE ADJUSTMENT 70 CYLINDER HEAD REMOVAL 71 CYLINDER HEAD DISASSEMBLY 74 CLEANING 75 PARTS INSPECTION 75 CYLINDER HEAD ASSEMBLY 79 CYLINDER HEAD INSTALLATION 80 09 PISTON AND CYLINDER 83 GEN...

Page 6: ...9 GENERAL 129 TROUBLESHOOTING 130 REPAIR PROCEDURES 130 FUSES 131 SPARK PLUG 131 BATTERY 132 IGNITION SWITCH 132 ENGINE STOP SWITCH 134 TRIGGER COIL 134 IGNITION COIL 136 IGNITION MODULE 137 SHIFT GEAR CONTROL MODULE 139 OVERRIDE SWITCH 140 ADJUSTMENT 141 IGNITION TIMING 141 03 STARTING SYSTEM 143 GENERAL 143 TESTING PROCEDURES 144 FUSES 144 BATTERY 144 IGNITION SWITCH 144 ENGINE STOP SWITCH 144 S...

Page 7: ...EDURES 181 HANDLEBAR GRIP 181 MULTIFUNCTION SWITCH 181 AUXILIARY MULTIFUNCTION SWITCH 182 THROTTLE LEVER 183 MASTER CYLINDER 184 HANDLEBAR 184 TIE ROD 185 STEERING COLUMN 186 STEERING COLUMN BEARING 187 FRONT WHEEL HUB 188 WHEEL BEARING 188 KNUCKLE 189 SHOCK ABSORBER AND SPRING 189 LOWER A ARM 190 UPPER A ARM 192 ADJUSTMENT 193 STEERING ALIGNMENT 193 08 REAR SUSPENSION AND AXLE 01 REAR SUSPENSION ...

Page 8: ...DURES 226 PARKING BRAKE CABLE AND LEVER 226 CALIPERS 227 BRAKE PADS 228 MASTER CYLINDERS OF BRAKE LEVERS 230 REAR BRAKE PEDAL 231 MASTER CYLINDER OF REAR BRAKE PEDAL 232 FRONT BRAKE PRESSURE CONTROL VALVE 232 REAR BRAKE PRESSURE CONTROL VALVE 233 BRAKE DISCS 233 BRAKE HOSES 234 BRAKE LIGHT SWITCHES 234 10 BODY FRAME 01 BODY 237 PARTS REPLACEMENT 239 DECAL 239 SEAT 239 SEAT LATCH 239 FUEL TANK COVE...

Page 9: ...E OF CONTENTS REAR FRAME EXTENSION 250 FRONT FENDER SUPPORT 251 REAR FENDER SUPPORT 251 11 TECHNICAL SPECIFICATIONS 01 DS 250 253 12 WIRING DIAGRAMS 01 WIRING DIAGRAMS 261 WIRE COLORS 261 CONNECTORS 261 VI ...

Page 10: ... 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 and ...

Page 11: ...s or equipment without incurring obligation VEHICLE SERIAL NUMBER LOCATION 1 2 vmo2006 014 004_a 1 V I N Vehicle Identification Number 2 Model number ENGINE SERIAL NUMBER LOCATION vmo2006 014 005_a E I N ENGINE IDENTIFICATION NUMBER ARRANGEMENT OF THE MANUAL ILLUSTRATIONS AND PROCEDURES The manual is divided into many major sections as you can see in the main table of contents at the beginning of ...

Page 12: ...king any task you read and thoroughly understand the en tire section or subsection concerning the proce dure A number of procedures throughout the book re quire the use of special tools Before starting any procedure be sure that you have on hand all re quired tools or approved equivalents vmr2006 060 IX ...

Page 13: ...rt Tightening torque nearby fastener In this case nut must be torqued to 10 N m or 89 lbf in This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog Exploded view assists you in identifying parts and related positions TYPICAL PAGE V00A2NS Illustration number for publishing process Subsection title indicates beginning of the subsection Drop represents...

Page 14: ...ator with trigger coil no 13 1 Stator 2 Stator screws 3 Trigger coil 4 Trigger coil screws Inspection Check stator and trigger coil condition If damaged replace the faulty part For electrical inspection refer to CHARGING SYS TEM for the stator and IGNITION SYSTEM for the trigger coil TYPICAL PAGE Title indicates main procedure to be carried out Bold face number following part name refers to explod...

Page 15: ...r strength Loctite threadlocker Fit bolt in the hole Apply a few drops of threadlocker at proposed tightened nut engagement area Position nut and tighten as required Blind Holes A00A3MA 1 2 1 On threads 2 On threads and at the bottom of hole Clean threads bolt and hole with solvent Apply Loctite Primer N P N 293 800 041 on threads bolt and nut and allow to dry for 30 seconds Choose proper strength...

Page 16: ...o readjust heat screw with a soldering iron 232 C 450 F Stripped Thread Repair A00A3QA 5 8 6 7 1 2 3 4 1 Release agent 2 Stripped threads 3 Form A Thread 4 Tapes 5 Cleaned bolt 6 Plate 7 New threads 8 Threadlocker Standard Thread Repair Follow instructions on Loctite FORM A THREAD 81668 package if a plate is used to align bolt a Apply release agent on mating surfaces b Put waxed paper or similar f...

Page 17: ... the hole and on threads Tighten If holes are sunken apply proper strength Loctite on bolt threads Tighten as usual Mounting on Shaft Mounting with a Press A00A3UA 1 2 3 1 Bearing 2 Proper strength Loctite 3 Shaft Clean shaft external part and element internal part Apply a strip of proper strength Loctite on shaft circumference at insert or engagement point NOTE Retaining compound is always forced...

Page 18: ...ormal strength and gap are required Install according to standard procedure Wipe off surplus Allow it to cure for 30 minutes NOTE Normally used on worn out housings to prevent leaking or sliding It is generally not necessary to remove gasket compound applied on outer gasket diameter vmr2006 060 XV ...

Page 19: ...he nut Torque to the recommended torque value NOTE 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 10 10 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 22 2...

Page 20: ...control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoper ative by any person Among those acts presumed to constitute tampering are the acts listed below 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts re moval of engine ...

Page 21: ...gine oil R R Engine oil strainer C LUBRICATION Gearbox oil I R GEARBOX Valve adjustment T T CYLINDER HEAD Condition of engine seals I I ENGINE Engine mount fasteners I I ENGINE REMOVAL AND INSTALLATION Engine air filter 1 I C R Air injection valve filter 1 I C R AIR INTAKE SYSTEM Exhaust system I I Spark arrester except on CE models C EXHAUST SYSTEM Coolant I I 2 R Radiator cap cooling system pres...

Page 22: ...RIABLE TRANSMISSION CVT DRIVE TRAIN Drive chain adjustment and lubrication 4 4 4 4 4 Drive chain slider condition 4 4 4 4 4 Drive chain sprockets I I Wheel bearings I Wheel nuts studs I I Tire wear and pressure 4 4 4 4 4 Front and rear differentials oil level seals and vents I I R STEERING AND FRONT SUSPENSION REAR SUSPENSION AND AXLE STEERING AND FRONT SUSPENSION Handlebar fastener I I Steering s...

Page 23: ...ECT L LUBRICATE R REPLACE T PROCEED WITH TASK EVERY 200 HOURS OR 4000 KM 2485 mi OR 2 YEAR PART TASK REFER TO BODY FRAME Frame fastener I Hitch trailer ball condition if installed 4 4 4 4 4 Seat fasteners 4 4 4 4 4 Frame I Engine and vehicle cleaning and protection 4 4 4 4 4 BODY AND FRAME 1 More often under severe use such as dusty area sand snow wet or muddy conditions 2 Every 100 hours check co...

Page 24: ...n indicated EVERY 100 HOURS OR 2000 KM 1250 mi OR 1 YEAR vmr2006 062 001_aen 1 Use this column Furthermore proceed with the following Vehicles Prepared as per Storage Procedure Remove rags from CVT inlet and outlet hoses engine air intake and muffler Clean drive and driven pulleys with pulley flange cleaner P N 413 711 809 and install the drive belt Start vehicle and allow it to run at idle speed ...

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Page 26: ...hes its operating tempera ture Stop the engine Change engine oil and clean engine oil strainer Refer to LUBRICATION SYSTEM Remove air filter housing cover and air filter to spray storage oil P N 413 711 600 into carbu retor NOTE For USA use storage oil P N 413 711 900 only Restart engine and run at idle speed Inject storage oil until the engine stalls or until a sufficient quantity of oil has ente...

Page 27: ... clean plastic parts with strong detergent degreasing agent paint thinner acetone prod ucts containing chlorine etc To clean the entire vehicle including metallic parts use BRP Cleaner P N 293 110 001 Inspect the vehicle and repair any damage Touch up all metal spots where paint has been scratched off Spray all metal parts with XP S Lube P N 293 600 016 Rags Installation Using cleans rags block th...

Page 28: ...VEHICLE Protection Protect the vehicle with a cover to prevent dust accumulation during storage CAUTION The vehicle has to be stored in a cool and dry place and covered with an opaque tarpaulin This will prevent sun rays and grime from affecting plastic components and vehicle finish vmr2006 063 9 ...

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Page 30: ...ctions Drain engine oil Drain air filter housing then clean and dry air filter Look for water in fuel tank in doubt flush fuel tank and refill with new gas Remove the drain tube underneath CVT cover to drain water Remove the CVT cover then clean and check all parts of CVT Refer to CVT vmr2006 064 001_a 1 CVT cover drain tube 2 CVT cover 3 LH footrest Lubricate all cables Check if the cables operat...

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Page 32: ... on cylinder head Thermostat defective does not open when engine gets hot Replace thermostat 7 Check thermo switch for electrical mechanical failure Thermo switch defective Replace 8 Check leak indicator hole under magneto cover if coolant leaks Coolant leaking from leak indicator hole means a damaged oil seal and or O ring on water pump cover Replace both oil seals and O rings refer to COOLING SY...

Page 33: ...econnect Harness electrical failure and or other damages Replace wire harness Grounded BLUE YELLOW wire between ignition module and shift gear module Replace defec tive parts LUBRICATION SYSTEM Symptom LOW OR NO OIL PRESSURE HIGH OIL CONSUMPTION 1 Check oil level and search for leakage on crankcase and or defective sealing ports Crankcase is leaking due to damage Rebuild engine with new crankcase ...

Page 34: ... recommended oil and or coolant refer to COOLING SYSTEM 2 Check cylinder head and or cylinder base gasket Gasket damaged or leaking Retighten cylinder head with recommended torque and or replace gasket 3 Check screws for torque Screws not fixed Retighten screws with recommended torque and or replace oil 4 Check oil for particles may indicate possible damages inside the engine Oil contamination due...

Page 35: ...earing s do es not move freely Replace bearing s 3 Check for whistling noise inside gearbox Countershaft and intermediate shaft are noisy Replace countershaft and intermediate shaft the same time 4 Check for gear noise Teeth of gears are damaged and or worn Replace respective gears Symptom FAILURE OF INDICATOR LAMPS TRANSMISSION LEVER POSITION 1 Check contact switches gearbox for damage and or wea...

Page 36: ...g installed and or otherwise damaged refer to CONTINUOUSLY VARIABLE TRANSMISSION Replace all rollers at the same time roller kit 4 Check function of sprag clutch on driven pulley Sprag clutch is clogged and or worn out refer to CONTINUOUSLY VARIABLE TRANSMISSION Replace sprag clutch together with ball bearing and oil seal refer to CONTINUOUSLY VARIABLE TRANSMISSION Symptom ENGINE MAXIMUM RPM IS TO...

Page 37: ...tch turned by 180 Symptom PULLEYS DO NOT DOWN SHIFT PROPERLY 1 Refer to VIBRATIONS COMING FROM DRIVEN PULLEY and check items listed 2 Check drive pulley bushings cleanliness wear etc Bushings stick to fixed sheave pulley shaft Clean or replace 3 Check driven pulley spring tension Spring tension is too weak Replace Symptom BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE 1 Check if drive pulley a...

Page 38: ...ective part s 2 Check leakage on intake manifold Air leak on intake system Retighten screws and or replace intake manifold 3 Check exhaust air leaking Exhaust gasket is leaking Retighten screws and or replace exhaust gasket 4 Check intake valve s for leaking Intake valve s is are leaking Repair or replace valve s 5 Check if fuel supply is to less at high RPM Fuel line is contaminated and or bent e...

Page 39: ...sand through engine intake Replace defective part s and use new air filter 8 Check connecting rod crankshaft rocker arm rollers movement Connecting rod failure due to leak of oil Repair and replace defective parts and use a high quality oil Crankshaft failure due to leak of oil Repair and replace defective parts and use a high quality oil Oil contamination due to clogged oil filter Replace oil fil...

Page 40: ...ion Replace defective part s e g piston ring s etc Valve seat worn and or otherwise damaged Repair by performing valve guide procedure refer to CYLINDER HEAD Readjust valve clearance Symptom MELTED AIR INJECTION VALVE HOSE 1 Check reed valve Faulty reed valve of air injection system Repair or replace Symptom HIGH ENGINE OPERATING TEMPERATURE 1 Check if cooling system shows any failure see COOLING ...

Page 41: ...c components are good Check engine Symptom STARTER TURNS BUT DOES NOT CRANK THE ENGINE 1 Weak battery Recharge or replace battery 2 Poor contact of battery terminal s Clean and tighten terminal s 3 Poor battery ground cable connection Clean and tighten 4 Burnt or poor contact of solenoid switch contact disc Replace starting solenoid 5 Broken or worn starter reduction gear Check and replace gear if...

Page 42: ...ice products as in the exploded views WARNING Torque wrench tightening specifications must strictly be adhered to 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 re newed REMOVAL Turn fuel valve to OFF Drain engine oil Refer to LUBRICATION...

Page 43: ...cover coolant Dis pose coolant as per environmental laws vmr2006 066 002_a Disconnect coolant inlet hose vmr2006 066 002_b Disconnect engine temperature sensor bypass hose and coolant outlet hose vmr2006 066 003_a Disconnect engine vent tube vmr2006 066 014_a Remove engine sprocket Refer to REAR SUS PENSION AND AXLE Remove shift lever bolt then pull out lever vmr2006 066 004_a 24 vmr2006 066 ...

Page 44: ...exhaust pipe Refer to EX HAUST SYSTEM Disconnect vacuum tube and air supply hose from air injection valve vmr2006 066 007_a Remove carburetor from intake manifold and from air intake hose vmr2006 066 008_a Temporarily attach carburetor to body for engine removal Disconnect inlet and outlet air hoses from CVT cover vmr2006 066 009_a Remove speedometer cable from crankcase if so equipped vmr2006 066...

Page 45: ...vmr2006 066 010_a Turn steering on RH side to make room Install engine removal hook P N 529 035 829 in engine hook and lift tool to support engine weight 529 035 829 vmr2006 066 011 Remove engine mount bolts Remove LH and RH front engine supports vmr2006 066 012_a Carefully pull out engine from left side 26 vmr2006 066 ...

Page 46: ...n is the reverse procedure of removal However pay attention to the following Align shift lever dot with flat surface on shift shaft vmr2006 066 015_a 1 Dot 2 Flat surface Reconnect battery cables vmr2006 069 006_b Step 1 Positive first Step 2 Negative last Refill cooling system Refer to COOLING SYS TEM Refill engine with oil Refer to LUBRICATION SYSTEM Check throttle and choke cables adjustment Re...

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Page 48: ...ter pump cover means damaged gasket s and or loosened screws refer to COOLING SYSTEM NOTE For all the checkpoints mentioned above see the appropriate engine section to diagnose and repair the engine PROCEDURES Preparation CAUTION Perform leak down testing with the engine cold Introducing cold air into a hot en gine can warp or fracture valves and or other engine parts Disconnect battery Refer to C...

Page 49: ...ft gear as shown Otherwise continue turning drive pulley until crankshaft and camshaft marks are properly positioned mmr2006 073 008_a How to Lock Piston at TDC compression To maintain the piston at TDC position install the camshaft locking tool P N 529 036 055 vmr2006 067 001 Leak Test Thread the correct adaptor hose of the leak down tester P N 529 035 661 into the spark plug hole Do not connect ...

Page 50: ...fected 41 and higher Poor condition diagnose and repair engine Diagnosis Listen for air leaks air escaping from intake side means leaking in take valve s air escaping from exhaust side means leaking exhaust valve s air bubbles out of radiator means leaking cylin der head gasket air oil escaping from crankcase means dam aged gasket and or loosened screws air coolant escaping from cylinder head mean...

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Page 52: ...INTAKE SYSTEM AIR INTAKE SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 5150 silicone sealant 293 800 086 35 Loctite 5150 silicone sealant 12 N m 106 lbf in 12 N m 106 lbf in 4 N m 35 lbf in vmr2006 068 001_a vmr2006 068 33 ...

Page 53: ...ilters at the same time Remove seat Release clamps and remove air filter housing cov er vmo2006 014 045_a 1 Air filter housing cover Loosen clamp and remove retaining screw then remove air filter vmo2006 014 046_a 1 Clamp 2 Retaining screw CAUTION Engine performance degradation or severe damages can occur if the air filter is not properly maintained and or if it not well oiled Cleaning Pour cleani...

Page 54: ... Carburetor Unscrew air intake duct clamp from air filter hous ing vmr2006 068 003_a 1 Air intake duct 2 Air filter housing 3 Exhaust shield Remove air filter see procedure above Unscrew bolts holding air filter housing to frame then slide air intake hose inside air filter housing vmr2006 068 004_a 1 Air filter housing bolts 2 Air intake hose Remove air filter housing Installation Properly reinsta...

Page 55: ...14 073_a 1 Air injection valve filters Cleaning Pour cleaning solution P N 219 700 341 or an equivalent into a bucket Put filters in to soak While filters soak clean inside of air injection valve Rinse filters with warm water until all cleaning so lution disappears NOTE If filters are still dirty replace them with new ones Then let filters dry completely Installation Properly reinstall removed par...

Page 56: ...Section 03 ENGINE Subsection 04 EXHAUST SYSTEM EXHAUST SYSTEM vmr2006 069 001 vmr2006 069 37 ...

Page 57: ...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 re newed PROCEDURES MUFFLER Removal Remove screws and pull out heat shield vmr2006 069 001_a Loosen muffler clamp vmr2006 069 002_a Remove screws then pull out muffler vmr2006 069 004_a Inspection Check part for cracks rust or any ...

Page 58: ... arrester must be periodically purged of accumulated carbon WARNING Never perform this operation immediately af ter the engine has been run because exhaust system is very hot Wear eye protection and gloves Respect all applicable laws and reg ulations Removal Remove the spark arrester from the muffler vmo2006 014 042_a 1 Remove muffler end 2 Muffler vmo2006 013 006_a 1 Spark arrester Cleaning Remov...

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Page 60: ...Section 03 ENGINE Subsection 05 LUBRICATION SYSTEM LUBRICATION SYSTEM 15 N m 133 lbf in 20 N m 15 lbf ft vmr2006 070 001_a vmr2006 070 41 ...

Page 61: ...E Subsection 05 LUBRICATION SYSTEM 3 5 6 4 1 1 2 7 5 vmr2006 070 002_a ENGINE LUBRICATION 1 Oil strainer 2 Oil pump 3 Lubrication outlet 4 Connecting rod 5 Lubrication spray 6 Camshaft 7 Valve rocker arm 42 vmr2006 070 ...

Page 62: ...r it must contains at least one of the above standards Oil Viscosity SAE 5W30 is recommended for all seasons However during the hottest days of the summer the BRP XP S 10W40 mineral oil P N 219 700 346 can be used NOTE For improved overall performance and all season applications use XP S 5W40 synthetic oil P N 293 600 039 XP S 5W40 Synthetic Oil P N 293 600 039 SAE 0W30 SAE 5W30 SAE 10W30 XP S 10W...

Page 63: ...be very hot Wait until en gine oil is warm Ensure vehicle is on a level surface Remove dipstick Clean the drain plug area Place a drain pan under the engine drain plug area Unscrew drain plug vmo2006 014 035_a LH SIDE UNDERNEATH CVT COVER 1 Oil drain plug Unscrew the oil strainer cover Allow enough time for oil to flow out of oil strainer hole vmo2006 014 036_a RH SIDE OF ENGINE 1 Oil strainer cov...

Page 64: ...aches rocker arms CAUTION Do not race engine with valve cover removed If oil properly flows everything is correct Other wise verify strainer oil pressure relief valve and oil pump ENGINE OIL PRESSURE RELIEF VALVE The oil pressure relief valve opens when the oil pressure exceeds a predefined amount This al lows oil pressure to drop Oil flows out of relief valve by the side hole vmr2006 070 003_a 1 ...

Page 65: ...t Remove oil pump shaft roller and shaft vmr2006 070 007_a Inspection Inspect and clean oil passages Check inner rotor and oil pump housing for pitting scratches or other damage Check side contact surface of rotor and friction plate vmr2006 070 011_b Check clearance between oil pump housing and outer rotor vmr2006 070 008 OIL PUMP HOUSING AND OUTER ROTOR CLEARANCE NEW 0 15 0 20 mm 006 008 in SERVI...

Page 66: ... 0 09 mm 002 004 in SERVICE LIMIT 0 12 mm 005 in Assembly Assembly is the reverse procedure of disassem bly However pay attention to the following Align indent on driving shaft with that of inner ro tor Install pump shaft and roller Install pump housing and align pins properly vmr2006 070 011_a vmr2006 070 012_a Properly torque screws vmr2006 070 006_a Make sure oil pump shaft can be turned freely...

Page 67: ...on 05 LUBRICATION SYSTEM Reinstall magneto flywheel and cover Refer to MAGNETO AND STARTER DRIVE Refill engine with the recommended oil Verify if lubrication system is working properly Refer to ENGINE OIL PRESSURE 48 vmr2006 070 ...

Page 68: ...YSTEM SERVICE TOOLS Description Part Number Page special radiator cap 529 035 991 52 water pump oil seal installer 529 036 052 57 SERVICE PRODUCTS Description Part Number Page Loctite 5910 293 800 081 57 Loctite 592 pipe sealant 293 800 018 55 vmr2006 071 49 ...

Page 69: ...Section 03 ENGINE Subsection 06 COOLING SYSTEM WATER PUMP 12 N m 106 lbf in vmr2006 071 001_a 50 vmr2006 071 ...

Page 70: ...Section 03 ENGINE Subsection 06 COOLING SYSTEM COOLING SYSTEM Loctite 592 vmr2006 071 002_a vmr2006 071 51 ...

Page 71: ...f 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 re newed COOLING SYSTEM INSPECTION LEAK INDICATOR HOLE Check the leak indicator hole if there is oil and or coolant and replace oil seals in water pump cover if necessary refer to WATER PUMP NOTE Coolant leakage indicates a faulty seal on impel...

Page 72: ...hould be between MIN and MAX level marks of coolant reservoir vmo2006 014 022_a NOTE When checking level at temperature low er than 20 C 68 F it may be slightly lower than MIN mark Add recommended coolant up to MAX mark if required Use a funnel to avoid spillage Do not overfill Reinstall and tighten filler cap Reinstall front cover If coolant is added in the coolant reservoir check also level in r...

Page 73: ...efill radiator as necessary Reinstall radiator cap Adjust coolant level in coolant reservoir RADIATOR CAP Test Use a suitable pressure tester and check radiator cap It should stand a pressure of 76 103 kPa 11 15 PSI and release pressure above that val ue THERMOSTAT Removal Drain cooling system Remove thermostat retaining screws vmr2006 071 013_a Pull thermostat out vmr2006 071 014 Test Visually in...

Page 74: ...switch no con tinuity It controls cooling fan When coolant temperature reaches 92 C 198 F switch closes continuity Cooling fan turns on When coolant temperature cools down to 87 C 189 F switch reopens Cooling fan turns off To test put thermo switch in a container filled with coolant and heat container The end of the switch should not touch container Use a suitable ther mometer to measure coolant t...

Page 75: ...r radial play must be detected during inspection Replace bearings if defective or suspicious with new ones Remove bearing circlip vmr2006 071 017 Push out impeller shaft vmr2006 071 018 Remove inner bearing Use a claw type hammer puller and pull bearing out from inner race F01J0ZA vmr2006 071 019_a Push out mechanical seal using an appropriate pusher CAUTION Do not remove seal needlessly Re moval ...

Page 76: ...1 on mating surface of seal with its bore Use water pump oil seal installer P N 529 036 052 to properly install mechanical seal CAUTION Using an inappropriate pusher may damage seal or may install seal inadequately vmr2006 071 021 vmr2006 071 022 Install inner seal using an appropriate pusher vmr2006 071 020 Install inner bearing using an appropriate pusher CAUTION Install a new bearing only vmr20...

Page 77: ...Ensure to position the ceramic side on shaft side vmr2006 071 026_a 1 Ceramic side here Install impeller and properly torque vmr2006 071 027 Install dowel pin and gasket Install pump cover vmr2006 071 028 Install magneto cover Refer to MAGNETO AND STARTER DRIVE Refill cooling system Ensure there is no leak COOLING FAN MOTOR Test Turn ignition switch on Unplug connector from thermo switch 58 vmr200...

Page 78: ... it If it turns check its fuse and wiring Reconnect all connectors Replacement Refer to RADIATOR RADIATOR Removal Drain cooling system Remove radiator shield Refer to BODY Clean radiator with low pressure water and com pressed air as necessary CAUTION Be careful with compressed air as it could damage radiator fins Drain cooling system Remove radiator retaining screws vmr2006 071 006_a Disconnect t...

Page 79: ...ir passage for clogging or damage Remove insects mud or other obstructions with compressed air or low pressure water Check for any coolant leakage from radiator and hoses Check fan for bending cracks or other damage Assembly Assembly is the reverse procedure of disassem bly Installation Installation is the reverse procedure of removal However pay attention to the following Refill and bleed cooling...

Page 80: ...STARTER DRIVE MAGNETO AND STARTER DRIVE SERVICE TOOLS Description Part Number Page crankshaft protector 529 036 051 66 magneto puller 529 036 049 66 55 N m 41 lbf ft Loctite 243 10 N m 89 lbf in 12 N m 106 lbf in vmr2006 072 001_a vmr2006 072 61 ...

Page 81: ...tic 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 re newed PROCEDURES MAGNETO COVER Removal Drain engine oil Refer to LUBRICATION SYS TEM Drain engine coolant Refer to COOLING SYS TEM Disconnect coolant hoses vmr2006 066 002_c Remove magneto cover vmr2006 072 003_a Remove dowe...

Page 82: ...lignment of water pump shaft will cause damage to engine components Do not force cover at installation Position bracket as shown vmr2006 072 021_a Properly torque cover screws Reinstall water pump cover with a new gasket vmr2006 072 003_a vmr2006 066 002_c Reinstall coolant hoses Refill engine with the recommended oil Refer to LUBRICATION SYSTEM Refill engine with the recommended coolant Re fer to...

Page 83: ...HARGING SYSTEM for the stator test Removal Remove magneto cover Remove trigger coil Remove stator screws and pull stator out vmr2006 072 004_b Installation Install stator in magneto cover Position wiring harness in recess of crankcase CAUTION Ensure to route wiring harness un der trigger coil vmr2006 072 018_a CRANKSHAFT END BEARING Inspection Remove magneto cover Bearing must turn smoothly and fr...

Page 84: ...stallation Use an appropriate pusher to install magneto cov er bearing CAUTION Always support cover properly when installing bearing Never use a hammer to install bearing Use a press only Always heat cover housing up to 100 C 212 F before installing bearing Use a heat gun WARNING Clean oil outside and inside from housing before heating Oil is inflammable Place new bearing in freezer for 10 minutes...

Page 85: ...crankshaft and flywheel vmr2006 075 025_b Installation CAUTION Before installing flywheel ensure taper is clean and free of grease NOTE Make sure starter reduction gear is in stalled first Install flywheel and align its keyway with woodruff key on crankshaft vmr2006 072 017_a Properly torque flywheel nut CAUTION Ensure flywheel is well locked to ad equately apply tightening torque STARTER REDUCTIO...

Page 86: ...ise Gear must not turn vmr2006 072 015_b Firmly hold flywheel while turning starting clutch gear counterclockwise Gear must turn freely vmr2006 072 015_a Check outside diameter for hammered surface deformation or scratches Measure diameters as follows STARTING CLUTCH GEAR CONDITION INNER DIAMETER OUTER DIAMETER New 25 026 25 045 mm 9853 9860 in 42 192 42 208 mm 1 6611 1 6617 in Service limit 25 05...

Page 87: ...g clutch from flywheel Remove screws then pull out one way clutch vmr2006 072 012_a 1 Retaining screws 2 One way clutch 3 Starting clutch Installation Install one way clutch on flywheel Properly torque screws vmr2006 072 011_a Install gear on one way clutch Turn gear counter clockwise to ease installation vmr2006 072 015 68 vmr2006 072 ...

Page 88: ...e valve spring compressor clamp 529 035 724 74 80 valve spring compressor cup 529 035 764 74 80 38 N m 28 lbf ft 12 N m 106 lbf in 26 N m 19 lbf ft 12 N m 106 lbf in 12 N m 106 lbf in 12 N m 106 lbf in 9 N m 80 lbf in 12 N m 106 lbf in 11 N m 97 lbf in 11 N m 97 lbf in vmr2006 073 001_a vmr2006 073 69 ...

Page 89: ...roup of parts for example if you find a worn valve guide a bent spring could be the cause it will be easier to know which one of the springs is the cause and to replace it Besides since parts are matched together it is a good practice to reinstall parts in the same position Intake port air filter contaminated clogged with dirt sand etc leads to worn valves piston rings and finally to loss of power...

Page 90: ...d adjusting screw while loosening locking nut vmr2006 073 032_a 1 Adjusting screw 2 Lock nut Turn adjustment screw as required When adjustment is appropriate hold adjusting screw while tightening locking nut Recheck adjustment Reinstall cylinder head side cover NOTE It is a good opportunity to check the engine lubrication system See ENGINE OIL PRESSURE in the LUBRICATION SYSTEM section Reinstall r...

Page 91: ...n system pipe and spark plug mmr2006 073 003_a Remove valve cover mmr2006 073 007_a Remove cylinder head side cover mmr2006 073 004_a Remove magneto access plug mmr2006 073 005_a Remove CVT cover Turn drive pulley clockwise to bring piston at TDC Align TDC mark as shown 72 vmr2006 073 ...

Page 92: ...perly positioned mmr2006 073 008_a Remove camshaft gear bolts Detach gear from chain mmr2006 073 009_a NOTE Attach timing chain to prevent it from falling Remove camshaft locking plate Screw in a M5 x 0 8 x 75 screw in rocker arm shaft end then pull it out Remove both shafts NOTE The throttle idle stop screw can be used mmr2006 073 010_a Remove camshaft Use a suitable puller or care fully pry out ...

Page 93: ...pins and chain guide vmr2006 073 012_a CYLINDER HEAD DISASSEMBLY Valve Use valve spring compressor clamp P N 529 035 724 and valve spring compressor cup P N 529 035 764 529 035 724 529 035 764 Compress spring valve and remove valve cotters WARNING Always wear safety glasses when disassem bling valve springs Be careful when unlock ing valves Components could fly away be cause of the strong spring p...

Page 94: ...ove valve stem seals with valve stem seal pliers Snap on YA 8230 R610motr125A vmr2006 073 018_a CLEANING Clean gasket residues off the contact surfaces CAUTION Pay attention not to damage con tact surface of the gasket It is better to moist en the gasket residue for easy scraping Take care so that no residue falls into crankcase or oil coolant passages Clean carbon deposits in combustion chamber C...

Page 95: ... scuffing cracks or other signs of wear Manually turn each bearing to see if it turns freely smoothly and noiselessly Check for radial and axial play vmr2006 0 73 021_a 1 Bearing 2 Lobe 3 Bearing Measure cam lobe with a micrometer vmr2006 073 021_b CAMSHAFT LOBE DESCRIPTION INTAKE EXHAUST New 34 880 mm 1 3732 in 34 740 mm 1 3677 in Service limit 34 860 mm 1 3724 in min 34 725 mm 1 367 in min If an...

Page 96: ...4711 4718 in Service limit 11 936 mm 4699 in max Valve Spring Check valve spring for visible damages Check also for free length and straightness R610motr122A A A Valve spring free length VALVE SPRING FREE LENGTH DESCRIPTION INNER OUTER New 38 70 mm 1 523 in 40 40 mm 1 591 in Service limit 35 20 mm 1 386 in 36 90 mm 1 453 in Valve Inspect valve surface check for abnormal stem wear burning cracking ...

Page 97: ... 3 Valve face contact surface to valve seat Measure valve face contact width NOTE The location of contact area should be in center of valve seat Measure valve seat width using a caliper VALVE SEAT CONTACT WIDTH Service limit 1 60 mm 063 in If valve seat contact width is too wide or has dark spots replace cylinder head V01C1HA B A A Valve face contact width B Valve seat contact width Valve Guide Cl...

Page 98: ...m as a set crank shaft camshaft gear and chain Refer to CRANK SHAFT AND CRANKCASE for procedures Chain Tensioner Check tensioner notches for damage Install spring and screw Tensioner pusher should go out Try to push in pusher It must not go in Other wise replace it vmr2006 073 026_a CYLINDER HEAD ASSEMBLY Assembly is essentially the reverse procedure of disassembly However pay attention to the fol...

Page 99: ...and closes a few times vmr2006 073 028 CYLINDER HEAD INSTALLATION Install chain guide dowel pins and a new cylinder head gasket onto the cylinder CAUTION Prior to inserting chain guide en sure to pull up chain to recover all slack so that chain is completely meshed with crank shaft gear Hold chain tight then insert guide This operation is critical so that chain remains in position for further asse...

Page 100: ...ft at TDC Align TDC mark as shown mmr2006 073 006_a TDC MARK BESIDES THE T ALIGNED CAUTION Crankshaft must be placed at TDC position to set camshaft sprocket at the prop er position Otherwise serious engine damage might occur CAUTION Ensure timing chain is properly meshed with crankshaft gear Align camshaft mark with cylinder head Hold in this position vmr2006 073 034_a 1 Marks aligned Install tim...

Page 101: ...nsioner end in its body then install it in cylinder as shown vmr2006 073 036 Torque tensioner screws Install tensioner spring and tighten adjuster screw vmr2006 073 037 Recheck camshaft timing marks NOTE Ensure crankshaft is still at the proper po sition Install remaining components except valve cover and air injection pipe and spark plug Perform valve adjustment 82 vmr2006 073 ...

Page 102: ...ction 03 ENGINE Subsection 09 PISTON AND CYLINDER PISTON AND CYLINDER SERVICE TOOLS Description Part Number Page piston circlip installer 529 036 048 88 12 N m 106 lbf in vmr2006 074 001_a vmr2006 074 83 ...

Page 103: ...he parts of the same assembly as a group If you find a defective component it will be much easier to find the cause of the failure among its group of parts for example if you found a worn valve guide a bent spring could be the cause it will be easy to know which one of the springs is the cause and to replace it Besides since parts are matched together it is a good practice to rein stall parts in t...

Page 104: ...to crankcase or oil coolant passages Remove piston rings vmr2006 074 013 Clean piston grooves NOTE A broken ring works well Clean piston from carbon deposits INSPECTION Cylinder Check cylinder for cracks scoring and wear ridges on the top and bottom of the cylinder If found replace cylinder Measure cylinder bore at 3 positions top center and bottom Measure along X and Y axis vmr2006 074 008_a 1 To...

Page 105: ...er one at a time for measure ment Position ring at 20 mm 787 in from top of cylinder NOTE In order to correctly position ring in cylin der use piston as a pusher Using a feeler gauge check ring end gap vmr2006 074 050_a A 20 mm 787 in from top RING END GAP Top ring 0 15 0 30 mm 006 012 in 2nd ring 0 30 0 45 mm 006 018 in Nominal new Oil ring 0 20 0 70 mm 008 028 in Top ring 0 50 mm 020 in 2nd ring...

Page 106: ...ON CYLINDER WALL CLEARANCE Nominal new 0 010 0 040 mm 0004 0016 in Service limit 0 10 mm 0039 in If clearance exceeds specified tolerance replace worn part Piston Pin Inspect piston pin for scoring cracking or other damages Using a micrometer measure piston pin diameter vmr2006 074 010 PISTON PIN Nominal new 16 994 17 000 mm 6691 6693 in Service limit 16 960 mm 6677 in Replace piston pin if out of...

Page 107: ... to break rings at in stallation Dots on rings must be positioned on top Ensure rings can move freely after instal lation Position piston with the IN letters on dome to wards intake side Coat piston pin with engine oil and install it vmr2006 074 003_a Install new circlips Use piston circlip installer P N 529 036 048 CAUTION Always install new circlips 529036048 Place circlip in sleeve as shown R17...

Page 108: ...is ton cutout vmr2006 074 005_a CORRECT POSITION 1 Circlip opening 2 Cutout Install dowel pins and a new gasket vmr2006 074 006_a Coat cylinder piston and rings with engine oil Use a suitable ring compressor to compress and hold rings while inserting cylinder Carefully insert cylinder over piston CAUTION Do not force cylinder to enter piston This would damage ring s vmr2006 074 007 TYPICAL Install...

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Page 110: ...0 CRANKSHAFT AND CRANKCASE CRANKSHAFT AND CRANKCASE SERVICE PRODUCTS Description Part Number Page synthetic grease 293 550 014 92 39 N m 29 lbf ft 12 N m 106 lbf in 10 N m 89 lbf in 10 N m 89 lbf in vmr2006 075 020_a vmr2006 075 91 ...

Page 111: ... shaft during removal of oil seal V06C2LA 1 2 TYPICAL 1 Oil seal in its housing 2 Awl or pick Check shaft surface around oil seal friction area for grooves and replace if necessary crankcase disassembly is required Apply synthetic grease P N 293 550 014 inside oil seal lips Install new seal using an appropriate seal pusher 2 R175motr114A 1 TYPICAL 1 Oil seal 2 Seal pusher Preparation for Crankcase...

Page 112: ...ssary to remove oil pump cov er Remove bolts on the left half crankcase vmr2006 075 003_a Place crankcase as shown vmr2006 075 004 Hold up crankcase so that it does not touch the working table and tap the left half crankcase with a plastic hammer to remove it CAUTION Care should be taken not to damage the contact surfaces Remove balance shaft from right half crankcase vmr2006 075 93 ...

Page 113: ...on not to damage contact surface of the gasket It is better to moisten the gasket residue for easy scraping Drive out left half crankcase oil seal vmr2006 075 008 INSPECTION Crankshaft NOTE Crankshaft axial play is took up by a wave washer If washer is worn replace with a new one Use a feeler gauge and measure axial clearance of connecting rod big end vmr2006 075 009_a AXIAL CLEARANCE New 0 10 0 4...

Page 114: ...5 025_a Timing Chain Gear Mesh chain in gear and check for excessive radial play If gear is worn or damaged replace as a set crankshaft camshaft gear and chain NOTE Refer to CYLINDER HEAD for timing chain inspection Balance Shaft Gear Check gear condition on crankshaft and balance shaft If any gear is worn or damaged replace crankshaft and balance shaft as a set Ensure gear is tight and cannot mov...

Page 115: ...e bearing puller to remove bearings from balance shaft CRANKCASE ASSEMBLY Install wave washer into right half crankshaft bear ing seat vmr2006 075 014_a Install crankshaft in the right half crankcase Align connecting rod in opening vmr2006 075 015 Align the position dot on the balance shaft drive gear with dot of driven gear Then install balance shaft into right half crankcase vmr2006 075 016_a In...

Page 116: ...003_a Properly torque bolts on the right half crankcase vmr2006 075 002_a Clean the crankshaft Apply a layer of grease on the lip of oil seal Put seal on crankshaft vmr2006 075 018 Using an suitable pusher install the oil seal in the left half crankcase with care not to damage the lip of the oil seal vmr2006 075 019 Install the chain guide and tighten the pivot bolt Properly torque bolt Install th...

Page 117: ...Section 03 ENGINE Subsection 10 CRANKSHAFT AND CRANKCASE vmr2006 075 001_a 1 Locking plate 2 Chain guide 98 vmr2006 075 ...

Page 118: ...Subsection 11 GEARBOX GEARBOX SERVICE TOOLS Description Part Number Page countershaft needle bearing installer 529 036 053 105 SERVICE PRODUCTS Description Part Number Page synthetic grease 293 550 014 103 vmr2006 076 99 ...

Page 119: ...Section 03 ENGINE Subsection 11 GEARBOX 40 N m 30 lbf ft 10 N m 89 lbf in 28 N m 21 lbf ft vmr2006 076 001_a 100 vmr2006 076 ...

Page 120: ...move gearbox fill plug Place a drain pan under the gearbox drain plug area then remove plug vmo2006 014 039_a 1 Gearbox drain plug 2 Gearbox fill plug NOTE To completely drain the gearbox place a jack under the left footpeg and tilt the vehicle to ward the right side Inspection Oil condition gives information about the teeth condition inside the gearbox See TROU BLESHOOTING section Clean the drain...

Page 121: ...Any other position Infinite 0L vmr2006 076 050_a If any test fail check wiring and if good replace gearbox switch Remove driven pulley to have access to switch Refer to CONTINUOUS VARI ABLE TRANSMISSION NOTE Also pay attention to shift drum contact pin condition vmr2006 076 051_a OIL SEAL REPLACEMENT NOTE Oil seals can be replaced when engine is installed in vehicle Remove required component s Usi...

Page 122: ...all new seal using an appropriate seal pusher 2 R175motr114A 1 TYPICAL 1 Oil seal 2 Seal pusher GEARBOX DISASSEMBLY Drain gearbox oil Remove drive and driven pulleys Refer to CON TINUOUSLY VARIABLE TRANSMISSION CVT Remove engine sprocket Refer to REAR SUS PENSION AND AXLE Remove shift lever bolt then pull out lever vmr2006 066 004_a Remove gearbox cover screws then cover vmr2006 076 005_a Remove s...

Page 123: ...case vmr2006 076 010 Remove gasket and dowel pins Bearings All bearings must turn smoothly and freely No excessive axial or radial play must be detected during inspection Replace a defective or suspicious bearing with a new one Always heat bearing bore up to 100 C 212 F be fore removing its bearing Use a heat gun WARNING Clean oil outside and inside from case be fore heating Oil is inflammable CAU...

Page 124: ...y Always heat crankcase housing up to 100 C 212 F before installing bearing Use a heat gun WARNING Clean oil outside and inside from housing before heating Oil is inflammable Place new bearing in freezer for 10 minutes before installation Push against outer race to install a bearing in its bore vmr2006 076 004_a Push against inner race to install a bearing on its shaft To install countershaft need...

Page 125: ...asure as shown Replace if damaged or out of specifications vmr2006 076 020_a TYPICAL A Claw thickness B Bore diameter SHIFT FORK CONDITION CLAW THICKNESS BORE DIAMETER New 5 93 6 00 mm 233 236 in 12 016 12 043 mm 4731 4741 in Service limit 5 73 mm 226 in min 12 01 mm 473 in max Check also wear at shifting pin vmr2006 076 023_a Check shift fork shaft for bending wear or other damage Measure diamete...

Page 126: ...t for wear or damage vmr2006 076 026_a Check output shaft for wear or damage vmr2006 076 027_a GEARBOX ASSEMBLY Assembly is essentially the reverse procedure of disassembly However pay attention to the fol lowing Apply grease on seal lip of output shaft seal vmr2006 076 011_a Hold reverse shaft and countershaft together Pay attention that spacer is in place on end of counter shaft vmr2006 076 012_...

Page 127: ...2006 076 014_a Insert shaft in fork then in gearbox vmr2006 076 015_a Ensure drum shift catch ball is removed under neath gearbox Slightly move fork to allow insertion in drum shaft Properly mesh fork pin in drum shaft vmr2006 076 016_a Install catch ball underneath gearbox 108 vmr2006 076 ...

Page 128: ...ure to align dots as shown vmr2006 076 017_a 1 Align dots Install dowel pins and a new gasket vmr2006 076 018_a Install gearbox cover Install bracket where shown vmr2006 076 005_b 1 Bracket here Properly torque screws Install remaining parts Refill gearbox with the recommended oil See OIL CHANGE vmr2006 076 109 ...

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Page 130: ...CE TOOLS Description Part Number Page cable luber 529 035 738 120 121 digital inductive tachometer 529 014 500 117 float level gauge 529 035 520 116 small hose pincher 295 000 076 114 115 117 118 SERVICE PRODUCTS Description Part Number Page cable lubricant 293 600 041 120 121 vmr2006 077 111 ...

Page 131: ...Section 04 FUEL SYSTEM Subsection 01 CARBURETOR AND FUEL TANK FUEL TANK FUEL VALVE AND FUEL FILTER 12 N m 106 lbf in 12 N m 106 lbf in 4 N m 35 lbf in vmr2006 077 001_a 112 vmr2006 077 ...

Page 132: ...Section 04 FUEL SYSTEM Subsection 01 CARBURETOR AND FUEL TANK CARBURETOR vmr2006 077 002_a vmr2006 077 113 ...

Page 133: ...ing 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 re newed Fuel Lines WARNING Whenever working on fuel system always verify for water or dust infiltration in reser voir Replace any damaged leaking or dete riorated fuel lines When replacing fuel lines be sure to us...

Page 134: ...ngs etc Therefore it is recom mended to remove those parts prior to clean ing Carburetor body and jets should be cleaned in a carburetor cleaner following manufacturer s instructions WARNING Solvent with a low flash point such as gaso line naphtha benzol etc should not be used as they are flammable and explosive Installation For installation reverse the removal procedure but pay attention to the f...

Page 135: ...nd in line with main jet hole Ensure that both float level gauge tips are properly positioned on carburetor body and that L arm is leaning on float while compressing valve spring Refer to following photos for proper float level gauge positioning vmr2006 077 009_a TYPICAL 1 Gauge tips 2 L arm A Height vmr2006 077 010 GAUGE ALIGNED WITH MAIN JET To adjust height bend the contact tab of float arm unt...

Page 136: ...com mended values when engine speed is stable If idle speed and CO values are fluctuating repeat the adjustment procedures as described above FUEL FILTER Removal Turn fuel valve to OFF position Install a small hose pincher P N 295 000 076 on fuel line then disconnect the fuel line from carbu retor vmr2006 077 006_a 1 Small hose pincher 2 Fuel line Unplug fuel line between filter and valve from fue...

Page 137: ...r2006 077 012_b 1 Main fuel line 2 Reserve fuel line 3 Fuel valve screws Installation For installation reverse the removal procedure FUEL TANK Removal Remove front fender Refer to BODY Turn fuel valve to OFF position Unplug fuel line between filter and valve from fuel valve vmr2006 077 012_a 1 Fuel valve 2 Fuel filter Unscrew fuel valve from frame Unscrew bolts retaining the front of fuel tank to ...

Page 138: ... housing cover screws Move back rubber cap vmr2006 083 007 Tighten adjustment screw to its maximum Using long nose pliers disconnect throttle cable from throttle lever vmr2006 083 008_a 1 Throttle cable barrel 2 Throttle lever Unscrew throttle adjustment screw completely and remove cable vmr2006 083 009 Carburetor Side Unscrew carburetor cover from the carburetor Compress the carburetor spring to ...

Page 139: ...able Place the cable in a vertical position during approx imately 15 minutes or until no lubricant flows out of cable Reinstall and adjust cable see below Installation For installation reverse the removal procedure Adjustment WARNING Ensure the key is turned OFF prior to perform the throttle cable adjustment Slide rubber protector back to expose throttle ca ble adjuster Loosen lock nut then turn t...

Page 140: ...cable lu bricant P N 293 600 041 or an equivalent WARNING Always use a silicone based lubricant Us ing another lubricant like a water based lu bricant could cause the throttle lever cable sticking or stiffness To lubricate the choke cable remove cable from multifunction switch and from carburetor Install the cable luber P N 529 035 738 on cable Insert the needle of lubricant can on cable luber hol...

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Page 142: ...ves the AC volt age and rectifies converts it into DC The voltage is also regulated to a predefined voltage DC Battery The battery supplies with electric current the elec tric starter and the entire vehicle So only DC cur rent is used in the entire electrical system PROCEDURES For best results use the multimeter Fluke 111 P N 529 035 868 529 035 868 If the battery is regularly discharged check cur...

Page 143: ...rt engine Connect multimeter to battery posts vmr2006 078 005_a Read voltage TEST ENGINE SPEED VOLTAGE 1500 RPM Max 13 5 15 Vdc If voltage is above specification replace voltage regulator rectifier If voltage is below specification check wiring and connections Properly secure battery positive terminal boot NOTE If the battery will not stay charged the problem can be any of the charging system com ...

Page 144: ...olyte container that comes with the battery Sealed VRLA battery electrolyte is a higher con centration of sulfuric acid All sealed VRLA bat tery electrolyte containers are not the same Each contains the proper amount of electrolyte for its specific battery CAUTION Never remove the sealing strip after charging is completed Refer to battery manufacturer s instructions for proper filling activation a...

Page 145: ...ble WARNING Always respect this order for disassembly disconnect BLACK cable first Remove the retaining screws than bracket vmr2006 078 001_a 1 Positive cable RED 2 Negative cable BLACK 3 Retaining screws Remove battery from vehicle Cleaning Clean the battery tray cables and battery posts using a solution of baking soda and water Remove oxidation if so from battery cable ter minals and battery pos...

Page 146: ...NG Ensure to store battery in a safe place out of reach for children Installation Reinstall battery in vehicle Properly secure retaining bracket Reconnect battery cables WARNING Connect RED cable first then BLACK ca ble Always connect RED cable first vmr2006 078 127 ...

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Page 148: ...s engine RPM so that vehicle speed does not exceed approximately 15 km h 9 MPH when gearbox is in reverse It allows full engine RPM in Reverse when over ride switch is used For override switch testing refer to IGNITION SYSTEM European Models It stops engine when moving transmission lever when engine RPM is too high It requires that ignition key is turned ON to al low turning ON or OFF hazard light...

Page 149: ...t problems there is no easy diagnosis For example problems that occur only at cold engine temperature have to be tested under similar conditions In most cases of temperature and or vibration fail ure only parts replacement might solve the prob lem as most of these failures return to normal when engine is not running Multiple Problems There is always the possibility of more than one faulty part If ...

Page 150: ...e to a loss of compression Other possible causes are pro longed idling or low speed riding or running on a too rich mixture due to abuse of choke a clogged air filter a faulty carburetor adjustment incorrect fuel defective ignition system incorrect ignition timing incorrect spark plug gap lubricating oil en tering the combustion chamber or too cold spark plug The plug face of a fouled spark plug h...

Page 151: ...if ignition key works prop erly turn switch ON If tail light turns on assuming bulb is good ignition switch is good European Models As a quick test to check if ignition key works prop erly turn it ON Press horn button If horn sounds assuming it is good ignition switch is good All Models If test failed perform the following tests Remove front cover Refer to BODY Disconnect ignition switch connector...

Page 152: ...and BLACK wires 0 4 max Replace switch if defective If switch is good continue the other tests Removal Remove front cover Refer to BODY Disconnect ignition switch connector Remove steering cover Refer to STEERING AND FRONT SUSPENSION Disconnect ignition switch with RED wire vmr2006 079 004_a Push tabs of switch and while holding them squeezed push switch out vmr2006 079 011_a Installation Properly...

Page 153: ...multimeter and set it to Measure the resistance as follows vmr2006 079 012_a ENGINE STOP SWITCH POSITION WIRE RESISTANCE OFF Infinite 0L RUN BLUE YELLOW and BLUE YELLOW 0 4 max Replace switch if defective If switch is good continue the other tests TRIGGER COIL vmr2006 079 007_a TRIGGER COIL INSIDE MAGNETO COVER NOTE The trigger coil is not adjustable Static Test Continuity Check resistance with a ...

Page 154: ...Set engine stop switch to RUN 4 Press START button NOTE On European models set transmission to Neutral and press any brake while starting 5 Read voltage as follows vmr2006 079 014_b TRIGGER COIL WIRE RESISTANCE BLUE YELLOW and GREEN WHITE 0 4 and 0 7 Vac 6 Repeat test 3 times 7 Reconnect connectors NOTE Check wires condition and particularly where they go out of magneto cover 8 If trigger coil is ...

Page 155: ...on coil vmr2006 079 015 Use a multimeter and set it to Read resistance as follows vmr2006 079 015_a IGNITION COIL TERMINALS RESISTANCE 20 C 68 F 1 and 2 0 19 23 If not within specification replace ignition coil Power Supply to Primary Winding If primary winding tests good check power supply from electronic module as follows Turn ignition key ON and set engine stop switch to RUN Use a multimeter an...

Page 156: ...may leak through its insulation to a nearby metallic part If resistance is good continue tests Otherwise replace ignition coil Secondary Winding Dynamic Test The output voltage should not be less than 12 kV An ignition coil tester available from aftermarket tool equipment suppliers can be used CAUTION Do NOT use coil tester on metal work bench Follow manufacturer instruc tions If the ignition coil...

Page 157: ...K WHITE Battery ground Battery voltage If voltage is now adequate repair ground wire of ignition module vmr2006 079 019_a BATTERY AND IGNITION MODULE GROUNDS CLOSE TO REAR BRAKE MASTER CYLINDER If there is still no voltage check shift gear sup ply voltage it provides power to ignition module See SHIFT GEAR CONTROL MODULE below When every other components above have been tested and are good ignitio...

Page 158: ...r2006 079 021_a Use a multimeter and set it to Vdc Read voltage as follows vmr2006 079 022_a SHIFT GEAR CONTROL MODULE WIRES VOLTAGE WHITE BLACK and GREEN Battery voltage If there is no voltage recheck as follows vmr2006 079 022_b SHIFT GEAR CONTROL MODULE WIRES VOLTAGE WHITE BLACK and battery ground Battery voltage If there is voltage check module ground wire If there is no voltage wiring harness...

Page 159: ...e and disconnect the single connector with the GREEN wire vmr2006 079 009_b Using a multimeter check switch as follows vmr2006 076 052_a WIRE OVERRIDE SWITCH POSITION RESISTANCE Pressed and held 0 5 max WHITE BLUE with GREEN wire Released Infinite 0L If test failed check wiring harness going to switch and if good replace switch If test succeeded recheck switch as follows vmr2006 076 053_a WIRE OVE...

Page 160: ...cess plug mmr2006 073 005_a Use a timing light and the digital inductive type tachometer P N 529 014 500 F01B1GA Start engine Bring engine speed to 1600 RPM and ensure the line besides F properly aligns using the timing light vmr2006 079 001_a Increase engine speed to 6000 RPM to ensure ignition timing advances If marks are aligned and timing advanced as de scribed ignition timing is adequate Othe...

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Page 162: ...e multimeter Fluke 111 P N 529 035 868 529 035 868 Engine Starting The following conditions must be met to allow en gine cranking ALL MODELS EXCEPT EUROPEAN MODELS Ignition switch turned ON Engine stop switch in RUN position Transmission in Neutral position NOTE Engine can be cranked in P or R if any brake lever is held when pressing start button Start button is pressed and held EUROPEAN MODELS Ig...

Page 163: ...ain fuse and 15 A fuse supplying ignition module and shift gear control module are in good condition If fuses test good continue with next tests vmr2006 078 001_b 1 Fuses NOTE Starting solenoid may be the cause of a burnt fuse If solenoid tests good an accessory may be defective BATTERY To check battery condition refer to CHARGING SYSTEM If it tests good continue with the next tests IGNITION SWITC...

Page 164: ...esistance as follows vmr2006 080 012_a START SWITCH POSITION WIRE RESISTANCE Switch released Infinite 0L Switch depressed and held YELLOW RED and YELLOW BLACK 0 6 max Replace switch if defective If switch tests good check starting solenoid winding See below If winding tests good check power supply to shift gear control module Refer to IGNITION SYSTEM Reconnect switch connector STARTING SOLENOID In...

Page 165: ...CONNECTIONS Check all connections cables and wires Tight en any loose connections Replace any chafed wires cables If wiring and connectors are good check the elec tric starter See below ELECTRIC STARTER Using booster cables carefully supply current from the battery directly to the starter Connect the RED cable first Then connect the remain ing jumper cable from the battery then to the starter If s...

Page 166: ...aces are free of debris Serious problem may arise if the starter is not properly aligned Tighten starter screws Connect the RED cable to the starter and tight en nut Apply dielectric grease P N 293 550 004 on terminal and nut First connect RED cable to battery then con nect the BLACK cable WARNING Always connect RED cable first then BLACK cable last Whenever connecting the RED cable to the starter...

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Page 168: ...d replace it with a known good component IMPORTANT When solving an electrical problem the first thing to do is to check battery condition as well as its cables and connections Also en sure the ignition switch is turned on and engine run stop switch is set to RUN Check solidity and related circuit fuse condition with an ohmmeter visual inspection could lead to false results Also visually examine ha...

Page 169: ...RES FUSES vmr2006 078 001_b 1 Fuses Check if filament is melted 1 2 A15E0KA TYPICAL 1 Fuse 2 Check if melted If a fuse is damaged replace it with one of the same rating CAUTION Do not use a higher rated fuse as this can cause severe damage HEADLAMP NOTE Assuming headlamps are good failure of both LO or HI beam headlamps may be caused by their respective relay All lights failure may be caused by fu...

Page 170: ...UE Battery ground Battery voltage If voltage is good check headlamp ground wire If voltage is not good continue testing LO Beam Relay Disconnect LO beam relay connector vmr2006 081 003_a Using a jumper wire connect wires as follows vmr2006 081 006_a RELAY CONNECTOR WIRES RED WHITE WHITE Battery voltage should appear to headlamp termi nals If so replace relay Otherwise check wire between relay and ...

Page 171: ...headlamps If they do not work continue testing Headlamp Switch Remove front cover Refer to BODY Disconnect headlamp switch connector with the WHITE BLACK and BLUE wires coming from headlamp switch vmr2006 079 009_a Turn on ignition switch Use a multimeter and set it to Vdc Read switch supply voltage from main harness as follows vmr2006 081 007_b SWITCH SUPPLY VOLTAGE WIRE COLOR VOLTAGE WHITE BLACK...

Page 172: ...ge test failed check ground wire If it is good continue testing Use a multimeter and set it to Measure relay winding resistance as follows vmr2006 081 009_a WHITE TERMINALS RELAY WINDING RESISTANCE WHITE TERMINALS RESISTANCE 1 2 Approximately 110 If out of specification replace relay Reconnect relay connector Disconnect HI beam relay connector vmr2006 081 003_a Turn ignition switch on Select HI be...

Page 173: ...gers it shortens its operating life If glass is touched clean it with isopropyl alcohol which will not leave a film on the bulb All Models except Europe To unplug connector release locking tab then pull on connector using a wiggle movement vmo2006 013 007_a 1 Release locking tab 2 Pull on connector using a wiggle movement Unlock bulb holder by turning it counterclockwise Replace bulb Properly rein...

Page 174: ...ience or as per your local regulations Adjust both headlamps evenly All Models except Europe vmo2006 013 007_b 1 Beam height adjustment European Models vmo2006 014 058_a 1 Headlamp housing 2 Beam height adjustment TURN SIGNAL LIGHTS European Models Tests Check fuses Refer to FUSES above NOTE When turn signal switch or hazard switch is turned on and turn signal lights do not flash check hazard cont...

Page 175: ...to Check switch as follows vmr2006 081 012_a TURN SIGNAL SWITCH SWITCH POSITION WIRE COLOR RESISTANCE PINK OFF BLACK BROWN WHITE Infinity 0L Left turn PINK Right turn BLACK BROWN WHITE Close to 0 If switch is out of specifications replace multi function switch See STEERING AND FRONT SUSPENSION If switch is good continue testing Reconnect connectors Hazard Control Module vmr2006 081 013_a 1 LH head...

Page 176: ...r and set it to Vdc Turn ignition switch on Read voltage as follows vmr2006 081 014_a HAZARD CONTROL MODULE SUPPLY VOLTAGE WIRE COLOR VOLTAGE BLACK GREEN Battery voltage If there is no voltage recheck as follows vmr2006 081 014_b HAZARD CONTROL MODULE SUPPLY VOLTAGE WIRE COLOR VOLTAGE BLACK Battery ground Battery voltage If there is now voltage check ground wire If there is no voltage check wire f...

Page 177: ... ignition switch on Activate turn signal switch and read voltage as fol lows Disconnect 2 pin connector Use a multimeter and set it to Vdc Turn ignition switch on Activate turn signal switch and read voltage as fol lows vmr2006 081 015_a HAZARD CONTROL MODULE OUTPUTS TURN SIGNAL SWITCH WIRE COLOR VOLTAGE Left turn ORANGE Right turn LIGHT BLUE Battery ground Pulsating battery voltage If there is no...

Page 178: ...e If everything works check hazard switch Hazard Switch Disconnect connector with GREY and GREEN wires coming from switch Use a multimeter and set it to Check switch as follows vmr2006 081 016_a HAZARD SWITCH SWITCH POSITION WIRE COLOR RESISTANCE OFF Infinity 0L ON GREY GREEN Close to 0 If switch test failed replace the auxiliary multi function switch See STEERING AND FRONT SUSPENSION Front Turn S...

Page 179: ...cover Refer to STEERING AND FRONT SUSPENSION Remove socket from position light Turn ignition switch on Turn headlamp switch either LO or HI Use a multimeter and set it to Vdc Read voltage as follows vmr2006 081 018_a POSITION LIGHT SOCKET WIRES VOLTAGE BROWN GREEN Battery voltage There should be battery voltage If so replace bulb If there is no voltage measure voltage between BROWN wire and batter...

Page 180: ...at socket ter minals Battery voltage should be read vmr2006 081 019_b If so replace bulb Otherwise follow appropriate procedure below Gearbox Position Lamps Measure voltage at lamp socket between sus pected supply wire and battery ground vmr2006 081 019_a If there is no voltage check wire from battery to lamp socket If battery voltage is present continue the follow ing tests Check gearbox switch R...

Page 181: ...ONTROL MODULE vmr2006 081 019 PILOT LAMP If wire test failed repair replace wire as neces sary If wire tests good try a new shift gear control module Engine Overheat Lamp When engine overheat sensor reaches a resis tance of 17 equivalent to coolant temperature of 123 C 253 F engine overheat lamp module turns on pilot lamp Drain cooling system Refer to COOLING SYS TEM Disconnect and remove sensor f...

Page 182: ...ule vmr2006 081 020_a Apply directly 12 Vdc on GREEN BLACK wire and connect battery ground to the other wire Measure voltage at lamp socket Battery voltage should be read vmr2006 081 020_c If there is no voltage check supply wire going to lamp socket If good check ground wire of lamp socket If good continue testing Measure voltage between WHITE BLACK and GREEN wires going to module You should read...

Page 183: ... Reinstall removed parts Turn signal Lamp European models Use a multimeter and set it to Vdc Measure voltage at lamp socket as follows vmr2006 081 019_c TURN SIGNAL LIGHT SOCKET TURN SIGNAL SWITCH POSITION WIRES VOLTAGE Left ORANGE Right LIGHT BLUE Battery ground Pulsating battery voltage If battery voltage is present check socket ground wire If there is no voltage check supply wire of socket from...

Page 184: ...in and hold while turning counterclock wise to release Install the new bulb by first pushing in while turn ing clockwise Reinstall lens HORN European Models Horn Switch Remove front cover Refer to BODY Disconnect horn switch connector 4 pin connec tor with WHITE BLACK and LIGHT GREEN wires Use a multimeter and set it to Check switch as follows vmr2006 081 022_a HORN SWITCH POSITION WIRE RESISTANCE...

Page 185: ...ge as follows vmr2006 081 023_a HORN TERMINALS HORN SWITCH POSITION WIRE VOLTAGE Pressed and held LIGHT GREEN and GREEN wires Battery voltage If voltage is adequate replace horn Otherwise recheck voltage as follows vmr2006 081 023_b HORN TERMINALS HORN SWITCH POSITION WIRE VOLTAGE Pressed and held LIGHT GREEN and battery ground Battery voltage If there is now voltage check ground wire If there is ...

Page 186: ..._a OUTLET CONNECTORS VOLTAGE 1 2 Battery voltage No voltage Check fuses and wiring condition Voltage is good Change power outlet Reconnect terminals Removal Unplug the connectors of the power outlet Unscrew the retaining nut Installation Reverse the removal procedure vmr2006 081 167 ...

Page 187: ......

Page 188: ...mber Page blind hole puller kit 529 036 056 172 driven pulley holding support 529 035 864 176 driven pulley support 529 035 863 176 driven pulley support tab kit 529 036 047 176 pulley holder 529 036 054 172 175 176 SERVICE PRODUCTS Description Part Number Page Isoflex grease 293 550 021 178 pulley flange cleaner 413 711 809 174 176 vmr2006 082 169 ...

Page 189: ... VARIABLE TRANSMISSION CVT Isoflex grease Isoflex grease Isoflex grease 95 N m 70 lbf ft 4 N m 35 lbf in 9 N m 80 lbf in 55 N m 41 lbf ft 4 N m 35 lbf in 9 N m 80 lbf in 9 N m 80 lbf in Isoflex grease 55 N m 41 lbf ft vmr2006 082 001_a 170 vmr2006 082 ...

Page 190: ... proce dures detailed WARNING Never touch CVT while engine is running Never drive vehicle when CVT cover is re moved CAUTION These pulleys have metric threads Do not use imperial threads puller Always tighten puller by hand to ensure that the drive pulley has the same type of threads prior to fully tightening PROCEDURES DRIVE BELT Removal Remove CVT cover refer to CVT COVER further To remove the d...

Page 191: ...o not force the CVT cover to install it Install the center top screw of cover in first Install the other screws then torque them in a crisscross sequence Install CVT cooling hoses then torque clamps CVT COVER BEARING Inspection Check if the CVT cover bearing turns smoothly and freely Otherwise replace it Removal Remove CVT cover from engine Remove both screws retaining the bearing plate to CVT cov...

Page 192: ...ing sheave ramp plate and pull vmr2006 082 008_a 1 Drive pulley spacer 2 Sliding sheave of drive pulley Disassembly of Drive Pulley Sliding Sheave Lift ramp plate with sliding shoes Withdraw spacer R175motr37A 1 2 3 TYPICAL 1 Ramp plate 2 Sliding shoes 3 Spacer vmr2006 082 009_a 1 Roller 2 Contact surface to sliding shoes 3 Ramp for the rollers Cleaning of Drive Pulley Clean pulley faces and shaft...

Page 193: ...oller diameter Measure the roller diameter If a roller is out of specification replace as required ROLLER DIAMETER SERVICE LIMIT 19 0 mm 748 in Spacer Check if the outer surface of spacer is worn or damaged Replace as required Measure the sliding sheave spacer If the exter nal diameter is out of specification replace as re quired vmr2006 082 011_a 1 Spacer A External diameter of spacer SLIDING SHE...

Page 194: ... details When installing rollers place them in accordance with the following illustration 1 2 1 1 1 1 1 1 vmr2006 082 012_a 1 Closed faces 2 Open faces Insert slider shoes into ramp plate to properly slide in guides of drive pulley sliding sheave Installation of Drive Pulley For installation reverse the removal procedure Pay attention to the following details WARNING Do not apply antiseize or any ...

Page 195: ...n pulley support tab kit P N 529 036 047 Mount the holding support on driven pulley and unscrew the centrifugal clutch nut vmr2006 082 014_a 1 Driven pulley holding support 2 Centrifugal clutch nut WARNING Centrifugal clutch is spring loaded Never un screw centrifugal clutch nut without special tool Remove the holding support then remove cen trifugal clutch from driven pulley Remove the seal colla...

Page 196: ...n creases in accordance with lining thickness wear 4 R175motr50A 3 1 2 1 Lining thickness next to lever fixation 2 Lining thickness on lever end 3 Direction of lever movement 4 Centrifugal clutch LINING THICKNESS SERVICE LIMIT 3 00 mm 118 in If lining thickness is out of specifications replace centrifugal clutch Driven Pulley Spring Measure spring free length Replace if the spring is out of specif...

Page 197: ...t vmr2006 082 020_a A Outside diameter FIXED SHEAVE OUTSIDE DIAMETER SERVICE LIMIT 40 93 mm 1 611 in If the outside diameter of shaft is out of specifica tion change driven pulley Assembly of Driven Pulley For assembly reverse the removal procedure Pay attention to following details Lubricate the inner of sliding sheave with Isoflex grease P N 293 550 021 Install guide pins in sliding sheave groov...

Page 198: ...cription Part Number Page shock spring remover 529 036 007 190 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page Smoothflow tapered tip 16 ga 511 rtt b 181 SERVICE PRODUCTS Description Part Number Page Loctite 406 glue 293 800 100 181 pulley flange cleaner 413 711 809 181 synthetic grease XP S 293 550 010 187 vmr2006 083 179 ...

Page 199: ...f ft 33 N m 24 lbf ft 20 N m 15 lbf ft 45 N m 33 lbf ft 45 N m 33 lbf ft 35 N m 26 lbf ft 45 N m 33 lbf ft 90 N m 66 lbf ft 45 N m 33 lbf ft 65 N m 48 lbf ft 35 N m 26 lbf ft 65 N m 48 lbf ft 49 N m 36 lbf ft 35 N m 26 lbf ft Synthetic grease XP S 49 N m 36 lbf ft vmr2006 083 001_a 180 vmr2006 083 ...

Page 200: ...stall handlebar grip by blowing compressed air between 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 the glue about 4 spots per side NOTE The Loctite 406 dries quickly Do not apply it before installing grip Apply pressure on the grip for approximately ...

Page 201: ...able from the switch Refer to CARBURETOR AND FUEL TANK Installation For installation reverse the removal procedure When installing multifunction switch position the switch by inserting the switch pin in the handlebar hole vmr2006 083 004_a TYPICAL 1 Multifunction switch pin 2 Handlebar hole AUXILIARY MULTIFUNCTION SWITCH European Models Only Replacement Remove front cover vmr2006 083 035_a Remove ...

Page 202: ...ew throttle clamp V06i1CA 1 TYPICAL 1 Throttle clamp screws Put throttle lever aside Procedure for Throttle Lever Replacement Remove throttle housing cover vmr2006 083 006_a 1 Throttle housing cover screws Move back rubber cap vmr2006 083 007 Tighten adjustment screw to its maximum Using long nose pliers disconnect throttle cable from throttle lever vmr2006 083 008_a 1 Throttle cable barrel 2 Thro...

Page 203: ...er Refer to CARBURETOR AND FUEL TANK for throttle cable adjustment procedure MASTER CYLINDER Refer to BRAKING SYSTEM HANDLEBAR Removal Procedure if Handlebar is not Replaced All Models except Europe Remove steering cover by unscrewing both retain ing screws vmr2006 083 011_a Remove handlebar bolts steering cover support and steering clamps vmr2006 083 013_a 1 Handlebar bolt 2 Steering clamps 3 Ste...

Page 204: ...ehicle Inspection Inspect the handlebar for damage cracks or bend ing Replace if any problem is detected Installation For the installation reverse the removal proce dure NOTE When torquing the gap between lower and upper steering clamps must be equal on both sides and between rear and front TIE ROD Removal Place the vehicle on jack stands and remove ap propriate front wheel Remove cotter pin nut a...

Page 205: ...Steering bolt Remove steering bolt locking tabs plate holder half housings bushings and seals vmr2006 083 028_a 1 Steering bolt 2 Locking tabs plate 3 Holder 4 Half housings Remove tie rods from steering column Using a hoist lift the front of vehicle Close fuel valve before lifting Remove cotter pin and nut at the bottom of steer ing column Discard cotter pin vmr2006 083 029 Move steering column u...

Page 206: ...e from front fender Move all wires and hoses out of holder vmr2006 083 026_a 1 Holder Unlock locking tabs from steering bolts vmr2006 083 027_a 1 Locking tabs 2 Steering bolt Loosen steering bolts Separate tie rods from steering column Remove cotter pin and steering nut Lift up the steering column until it is free from bearing Remove seal vmr2006 083 031 Remove circlip vmr2006 083 032 Using a suit...

Page 207: ...stalling a new hub install new bearings and new seals Never reuse bearings Torque castle nut and further tighten until one of its grooves is aligned with a cotter pin hole Install a new cotter pin Both ends of cotter pin must be folded WHEEL BEARING Inspection To verify the wheel bearings the wheel hub re moval is necessary Turn each bearing with a finger The bearings must turn smoothly and freely...

Page 208: ...installation is the reverse of the removal pro cedure Torque castle nut and further tighten until one of its grooves is aligned with a cotter pin hole Install a new cotter pin Both ends of cotter pin must be folded SHOCK ABSORBER AND SPRING Adjustment Rear spring preload can be changed by setting the adjusting nut up or down Shorten the spring to decrease preload or lengthen the spring to in creas...

Page 209: ...ravel Seizing or binding conditions except at extreme end of either stroke A gurgling noise after completing one full com pression and extension stroke Replace shock if any of these conditions are found Assembly and Installation For assembly and installation reverse the disas sembly and removal procedures LOWER A ARM Inspection Before removing A arm do the following Move A arm from side to side Th...

Page 210: ... to frame vmr2006 083 040_a 1 Lower A arm 2 Bolts and nuts 3 Upper A arm Remove A arm from vehicle Installation NOTE Install all bolts before torquing them Position A arm on frame then install bolts and nuts Insert ball joint end into knuckle and install ball joint nut Install shock absorber bolt Torque all bolts TORQUE A arm bolts 49 N m 36 lbf ft Shock absorber bolt 45 N m 33 lbf ft Ball joint n...

Page 211: ...A arm if necessary Removal NOTE Use the same procedure to remove RH or LH A arm Lift front of vehicle and place jack stands under frame Remove appropriate wheel Detach tie rod from knuckle vmr2006 083 015_a KNUCKLE SIDE 1 Cotter pin 2 Nut 3 Knuckle Remove upper ball joint nut vmr2006 083 041 Remove bolts retaining A arm to frame vmr2006 083 042_a 1 Upper A arm 2 Bolts Detach upper ball joint from ...

Page 212: ...acers on rear rims These spacers will prevent the rope from touching tire vmr2006 083 044_a TYPICAL 1 Rear rim 2 Spacers NOTE Different items can be used as spacers like magnets recommended The rope must be placed at the center of the wheels Do not place rope on tire threads vmr2006 083 045 From the front of vehicle near the front of rim move rope so that the rope does not touch the first spacer v...

Page 213: ... STEERING AND FRONT SUSPENSION Subsection 01 STEERING AND FRONT SUSPENSION vmr2006 083 049 REAR DISTANCE The perfect front toe in adjustment is 3 mm 118 in each side Adjust alignment with tie rod 194 vmr2006 083 ...

Page 214: ...iption Part Number Page crankcase support sleeve tool 529 036 031 205 rear axle key 529 036 046 201 shock spring remover 529 036 007 197 SERVICE PRODUCTS Description Part Number Page Loctite 271 red 293 800 005 203 Loctite 277 green 293 800 073 203 suspension synthetic grease 293 550 033 201 203 205 207 vmr2006 084 195 ...

Page 215: ...ynthetic grease Suspension synthetic grease Suspension synthetic grease Loctite 271 Loctite 271 40 N m 30 lbf ft 29 N m 21 lbf ft 140 N m 103 lbf ft 27 N m 20 lbf ft 50 N m 37 lbf ft 27 N m 20 lbf ft 130 N m 96 lbf ft 45 N m 33 lbf ft 12 N m 106 lbf in 12 N m 106 lbf in Suspension synthetic grease Loctite 277 vmr2006 084 001_a 196 vmr2006 084 ...

Page 216: ...ment Preload can be changed by setting the adjusting nut to compress the spring to different lengths Shortening the spring will increase the preload or lengthening the spring will decrease the preload Removal Lift rear of vehicle until rear shock absorber is fully extended Install jack stands under the frame to support the vehicle Remove bolts holding shock absorber vmr2006 084 002_a 1 Upper bolt ...

Page 217: ...leting one full com pression and extension stroke Replace shock if any of these conditions are found Assembly and Installation For assembly and installation reverse the disas sembly and removal procedures DRIVE CHAIN Adjustment NOTE Never adjust drive chain with the driver seated on the vehicle Remove all load on vehicle Select a level surface and set transmission to NEUTRAL Loosen chain tensioner...

Page 218: ... or gasoline Damage to the O ring will result causing premature wear and drive chain failure Clean the side surfaces of the chain with a dry cloth NOTE Do not brush chain Lubricate only with an approved O ring chain lubri cant Other commercial chain lubricants may con tain solvent which could damage the O rings Removal Lift the rear of vehicle and install jack stands under frame to support the rea...

Page 219: ...gine sprocket for distortion exces sive wear or other damages V02H02A 1 2 1 Good 2 Replace CAUTION Replace chain and sprockets togeth er to prevent premature wear of these compo nents Installation The installation is the reverse of the removal pro cedure AXLE SPROCKET Removal Lift the rear of vehicle and install jack stands under frame to support the rear of vehicle off the ground Remove RH rear w...

Page 220: ...tter pin vmr2006 084 010_a 1 Cotter pin 2 Castle nut 3 Wheel hub Remove castle nut and washer Pull hub to remove it Inspection Check hub for cracks or other damages Replace if necessary Check hub splines for wear or damages Replace hub if necessary Installation The installation is the reverse of the removal pro cedure Pay attention to the following Apply suspension synthetic grease P N 293 550 033...

Page 221: ...cle off the ground Remove both wheel hubs Refer to WHEEL HUB above in this section Loosen drive chain and remove chain from axle sprocket vmr2006 084 014 Remove brake disc hub Refer to BRAKE DISC HUB above Slide out the rear axle from the right side of chain tensioner If the bearings are defective parts around the bearing area may be damaged It is possible that the axle will not slide out easily i...

Page 222: ...damages If splines are defective change hub Check hub branches for straightness If a branch is bent or distorted replace hub Check if the O ring inside sprocket hub spacer is brittle hard or damaged Replace if necessary vmr2006 084 031_a 1 Sprocket hub spacer 2 O ring Installation The installation is the reverse of the removal pro cedure Pay attention to the following Apply Loctite 271 red P N 293...

Page 223: ...nspection The rear axle should turn smoothly and freely in side chain tensioner Replace bearings if a prob lem is detected If a bearing is seized on the axle this axle must be replaced Bearings must be slide fit on the axle otherwise it will result in a faulty reassembly and a failure may occur Bearing mating surface on the axle must be in good condition Check chain tensioner for cracks or wear Re...

Page 224: ...er Do not forget the inner sleeve when installing the second bearing vmr2006 084 032_a 1 Crankcase support tool 2 Bearing 3 Chain tensioner Install new seals On the side without adjusting holes position spacer before installing the seal Put suspension synthetic grease P N 293 550 033 inside seals before installing them Too much grease inside LH seal could cause pop out of it when installing the ch...

Page 225: ...ove drive chain from engine sprocket Remove swing arm bolt Pull back rear drive train assembly to detach swing arm assembly with drive chain from the frame Procedure With Rear Axle Removed NOTE The rear axle must be removed only if the swing arm is replaced Remove the lower bolt of shock absorber vmr2006 084 003_a 1 Lower bolt Unscrew bolt that attach brake hose bracket to swing arm brake hose and...

Page 226: ...t cracks bend or other damages Change if necessary Check bushings and shaft for wear or damages Replace defective parts Check if the seals are brittle hard or otherwise damaged Assembly Press new bushings into swing arm Insert swing arm shaft Install new seals on both ends of swing arm Installation For installation reverse the removal procedure Position drive chain on the front part of swing arm t...

Page 227: ......

Page 228: ...BRAKES FRONT AND REAR BRAKES SERVICE TOOLS Description Part Number Page vacuum pressure pump 529 021 800 226 SERVICE PRODUCTS Description Part Number Page GTLMA brake fluid 293 600 062 212 225 suspension synthetic grease 293 550 033 219 232 vmr2006 085 209 ...

Page 229: ... ALL MODELS EXCEPT EUROPEAN MODELS FRONT BRAKES 35 N m 26 lbf ft 9 N m 80 lbf in 5 N m 44 lbf in 9 N m 80 lbf in 5 N m 44 lbf in 27 N m 20 lbf ft 35 N m 26 lbf ft 27 N m 20 lbf ft 9 N m 80 lbf in 35 N m 26 lbf ft 9 N m 80 lbf in vmr2006 085 001_a 210 vmr2006 085 ...

Page 230: ...T AND REAR BRAKES REAR BRAKE 35 N m 26 lbf ft 9 N m 80 lbf in 35 N m 26 lbf ft 35 N m 26 lbf ft 9 N m 80 lbf in 15 N m 133 lbf in 5 N m 44 lbf in 9 N m 80 lbf in 5 N m 44 lbf in 27 N m 20 lbf ft 27 N m 20 lbf ft vmr2006 085 002_a vmr2006 085 211 ...

Page 231: ...ake fluid from a sealed container Do not use brake fluid taken from old or already opened containers nor mix different fluids for topping off CAUTION Sealing washers must be discarded and replaced with new proper ones every time a Banjo fitting is unscrewed MAINTENANCE BRAKE FLUID The brake fluid must be changed in accordance with the maintenance chart Recommended Fluid Use brake fluid meeting the...

Page 232: ...gm are removed Connect a clear hose to RH caliper and loosen bleeding screw Place the other end of hose in a container vmr2006 085 007_a Using a big syringe push brake fluid into the LH caliper vmr2006 085 008_a When brake fluid freely flows out of RH caliper without bubbles close the bleeding screw Continue to push brake fluid until reservoir is half full Close bleeding screw on LH caliper Fill r...

Page 233: ... screw Fill reservoir NOTE The reservoir is full when the fluid reaches the top of window Squeeze brake lever It should be firm If yes install diaphragm and cover on reservoir If not bleed rear brake lever circuit as per pro cedure in BRAKE SYSTEM BLEEDING Rear Brake Pedal Circuit To drain and fill the rear brake pedal circuit use the following procedure Remove master cylinder reservoir cover of t...

Page 234: ...ragm and cover on reservoir Rear Brake Lever Circuit Pump up circuit pressure with brake lever until lever resistance is felt Squeeze brake lever open bleeding screw and then close it NOTE Do not release brake lever until bleeding screw has been closed Release brake lever slowly Repeat the procedure until no more air bubbles appear in hose and lever is firm NOTE Check fluid level often to prevent ...

Page 235: ...iper Check brake pads Refer to BRAKE PAD further in this section Installation For the installation reverse the removal proce dure pay attention to the following details Use new sealing washers when installing Banjo fitting retaining brake hose to caliper Torque Ban jo fitting to 35 N m 26 lbf ft Install caliper in its original position Torque caliper bolt to 27 N m 20 lbf ft Refill and bleed the b...

Page 236: ...re the brakes operate normally before driving MASTER CYLINDERS OF BRAKE LEVERS Removal Master Cylinder of LH Rear Brake Lever Drain the rear brake lever circuit Refer to BRAKE FLUID REPLACEMENT in this section Remove banjo fitting and the sealing washers Unplug brake light switch connectors Note posi tion of wires for reinstallation vmr2006 085 020_a 1 Brake fluid reservoir 2 Brake light switch co...

Page 237: ... of LH Rear Brake Lever Refill rear brake lever circuit Bleed rear brake system WARNING Bleed rear brake lever and rear brake pedal circuits before riding vehicle Master Cylinder of RH Front Brake Lever Refill and bleed front brake circuit WARNING Bleed front brake circuit before riding vehicle REAR BRAKE PEDAL Inspection Check rear brake pedal for cracks or distortion Replace if necessary Check b...

Page 238: ...etic grease P N 293 550 033 on shaft before installing rear brake pedal MASTER CYLINDER OF REAR BRAKE PEDAL Removal Drain rear brake pedal circuit Refer to BRAKE FLUID REPLACEMENT in this section Remove E clip holding yoke to the end of brake pedal vmr2006 085 024_a Then remove pin to separate yoke and brake ped al vmr2006 085 025_a Unplug brake fluid reservoir hose from master cylinder Remove Ban...

Page 239: ...riding vehicle BRAKE DISCS Inspection Brake discs can be inspected without removing them from the vehicle NOTE To verify the front brake discs raise vehicle and support it securely Remove wheels Visually inspect disc surfaces for scratches or grooves Make sure to check both sides of disc Measure thickness of the disc DISC MINIMUM THICKNESS Front and rear 2 mm 5 64 in Replace disc if not within spe...

Page 240: ...ll necessary parts to reach the hoses Thoroughly clean the area around the joints that will be disconnected Place a drain pan under the joint that will be dis connected Disconnect any retaining clips or brackets holding the hoses Installation Install the new hose Make sure the piece will not rub against any other part When there is a Banjo fitting securing the hoses to the calipers pressure contro...

Page 241: ...pins Infinite 0L Firmly pushed 0 2 max RH front brake lever Released BLACK GREEN YELLOW Infinite 0L Removal Front and Rear Brake Levers The brake light switches on brake levers are not available in spare parts Replace brake levers Rear Brake Pedal The brake pedal switch is located over brake ped al vmr2006 085 033_a 1 Brake pedal switch 2 Brake pedal The brake pedal switch cannot be adjusted Disco...

Page 242: ... EUROPEAN MODELS FRONT BRAKES 35 N m 26 lbf ft 9 N m 80 lbf in Dielectric grease 5 N m 44 lbf in 9 N m 80 lbf in 9 N m 80 lbf in 35 N m 26 lbf ft 27 N m 20 lbf ft 9 N m 80 lbf in 27 N m 20 lbf ft 5 N m 44 lbf in 35 N m 26 lbf ft vmr2006 085 036_a vmr2006 085 223 ...

Page 243: ... 01 FRONT AND REAR BRAKES REAR BRAKE 35 N m 26 lbf ft 9 N m 80 lbf in 35 N m 26 lbf ft 35 N m 26 lbf ft 9 N m 80 lbf in 35 N m 26 lbf ft 27 N m 20 lbf ft 27 N m 20 lbf ft 5 N m 44 lbf in 15 N m 133 lbf in vmr2006 085 037_a 224 vmr2006 085 ...

Page 244: ...e fluid from a sealed container Do not use brake fluid taken from old or already opened containers nor mix different fluids for topping off CAUTION Sealing washers must be discarded and replaced with new proper ones every time a Banjo fitting is unscrewed MAINTENANCE BRAKE FLUID The brake fluid must be changed in accordance with the maintenance chart Recommended Fluid Use brake fluid meeting the s...

Page 245: ... The front and the rear brakes must be bled at the same time Close bleeding screw and operate brake lever or brake pedal If it still feels spongy bleed circuit again Repeat the procedures until air bubbles do not appear in hose and lever or pedal is firm Fill reservoirs to the upper level with brake fluid Install diaphragms and covers on reservoirs Without a vacuum pump If vacuum pump is not avail...

Page 246: ...rking brake lever 4 RH handle brake lever Disconnect cable from rear caliper vmr2006 085 042 Detach cable from swing arm and frame Unscrew socket screws under lever Remove lever plate and parking brake lever vmr2006 085 041_a 1 Socket screws 2 Lever plate 3 Parking brake lever 4 Cable adjuster Detach the end of cable from lever Unscrew adjuster completely and remove cable from lever housing Remove...

Page 247: ...t remove Banjo fitting and its sealing washers Re move parking brake cable from caliper and un screw caliper bolts Remove the caliper from the vehicle and discard sealing washers vmr2006 085 043_a 1 Parking brake cable 2 Caliper 3 Caliper bolts Inspection Check piston for scratches rust or other damages If so replace caliper Check brake pads Refer to BRAKE PAD further in this section Installation ...

Page 248: ...n lining is 2 mm 5 64 in thick or less or if the wear groove on lining pad is no longer visible vmr2006 085 018_a 1 Wear groove on pad lining BRAKE PAD MINIMUM THICKNESS 2 mm 5 64 in Installation Clean the visible portion of piston with clean brake fluid Make sure that pad spring is in position vmr2006 085 019_a 1 Pad spring Install new brake pads and pad pins Torque pad pins to 18 N m 159 lbf in ...

Page 249: ...nder of rear brake lever Master Cylinder of RH Front Brake Lever Drain the front brake circuit Refer to BRAKE FLUID REPLACEMENT in this section Remove banjo fitting and the sealing washers Unplug brake light switch connectors The con nectors are located under front cover Note posi tion of wires for reinstallation vmr2006 085 032_a 1 Brake light switch connectors Unscrew master cylinder holder bolt...

Page 250: ...or distortion Replace if necessary Check brake pedal spring for distortion Replace if necessary Removal Remove the RH footrest Refer to BODY Detach brake pedal spring and brake pedal switch spring vmr2006 085 023_a 1 Brake pedal spring 2 Brake pedal switch spring Remove E clip holding yoke to the end of rear brake pedal vmr2006 085 024_a Then remove pin to separate yoke and rear brake pedal vmr200...

Page 251: ...of master cylinder Discard sealing washers and catch spilled fluid with a rag Remove bolts securing master cylinder to frame vmr2006 085 028_a 1 Brake fluid reservoir hose 2 Banjo fitting 3 Brake hose 4 Master cylinder bolts Installation For installation reverse the removal procedure Refill and bleed the rear brake pedal circuit WARNING Bleed rear brake pedal circuit before riding vehicle FRONT BR...

Page 252: ...everse of the removal pro cedure Refill and bleed braking system WARNING Bleed braking system before riding vehicle BRAKE DISCS Inspection Brake discs can be inspected without removing them from the vehicle NOTE To verify the front brake discs raise vehicle and support it securely Remove wheels Visually inspect disc surfaces for scratches or grooves Make sure to check both sides of disc Measure th...

Page 253: ...Before removing any hoses drain the ap propriate brake circuit Remove all necessary parts to reach the hoses Thoroughly clean the area around the joints that will be disconnected Place a drain pan under the joint that will be dis connected Disconnect any retaining clips or brackets holding the hose and remove the defective part s Installation Install the new hose Make sure the piece will not rub a...

Page 254: ...ver Released BLACK GREEN YELLOW Infinite 0L If brake pedal switch is defective replace with a new one If a brake lever switch is defective replace brake lever Removal Front and Rear Brake Levers The brake light switches on brake levers are not available in spare parts Replace brake levers Rear Brake Pedal The brake pedal switch is located over brake ped al vmr2006 085 033_a 1 Brake pedal switch 2 ...

Page 255: ......

Page 256: ...Section 10 BODY FRAME Subsection 01 BODY BODY BODY 4 N m 35 lbf in 4 N m 35 lbf in 4 N m 35 lbf in vmr2006 086 001_a vmr2006 086 237 ...

Page 257: ...Section 10 BODY FRAME Subsection 01 BODY SEAT 10 N m 89 lbf in 4 N m 35 lbf in 4 N m 35 lbf in vmr2006 086 002_a 238 vmr2006 086 ...

Page 258: ...a SEAT Removal Unlock seat using latch lever located underneath the rear fender vmo2006 014 016_a TYPICAL Gently lift rear of seat while pulling rearward to release Installation Insert seat tab into frame hook vmo2006 014 018_a 1 Tab 2 Hook When seat rests in its position firmly push seat down to latch NOTE A distinctive snap will be felt Double check that the seat is secure by giving it a tug to ...

Page 259: ...emove fuel tank cap vmr2006 086 005 Lift the front of cover vmr2006 086 006_a Lift until cover is over the fuel tank neck vmr2006 086 007 Move the fuel tank cover rearward to unlock the tabs vmr2006 086 008_a 1 Fuel tank cover tab Remove fuel tank cover and install fuel tank cap Installation The installation is the reverse of removal proce dure FRONT COVER Removal Pull the top of front cover Pull ...

Page 260: ... cap vmr2006 086 010 Unscrew bolts and screws securing front fender to frame and fender support left side only vmr2006 086 012_a Remove screws at the bottom of front fender left side only vmr2006 086 013_a Remove screw joining front and rear side panels left side only vmr2006 086 017 Remove screws at the bottom of radiator shield vmr2006 086 011_a Remove screws from radiator shield vmr2006 071 003...

Page 261: ...oval Remove front cover seat and fuel tank cover See procedures above Unscrew bolt near radiator cap vmr2006 086 010 Remove screws at the bottom of radiator shield vmr2006 086 011_a Unscrew bolt and screw securing front fender to frame and fender support one on each side vmr2006 086 012_a Remove screws at the bottom of front fender same on both sides vmr2006 086 013_a Remove screws that attach fro...

Page 262: ...ear side panels one on each side vmr2006 086 017 Using a flat screwdriver unlock and separate front fender and rear fender vmr2006 086 018 Remove CVT air inlet hose from the front fender vmr2006 086 019_a 1 CVT air inlet hose 2 Radiator cap Lift front fender and disconnect the power outlet connectors vmr2006 086 020_a 1 Power outlet Lift the front fender over shifter shaft vmr2006 086 243 ...

Page 263: ...s above Remove screws at the bottom of rear fender one on each side vmr2006 086 023_a Remove screws that attach front fender and rear fender vmr2006 086 014_a Unscrew bolts holding front fender and rear fender to frame vmr2006 086 015_a Remove screws under front fender side panels vmr2006 086 017 Using a flat screwdriver unlock and separate front fender and rear fender vmr2006 086 018 Disconnect i...

Page 264: ...wire from the solenoid vmr2006 086 027_a 1 Starting solenoid connectors 2 BLACK wire on solenoid Remove starting solenoid from vehicle Unlatch the fuse box from fender Slide fuse box and wires through the fender open ing Disconnect rear light Lift rear fender and remove it Installation The installation is the reverse of removal proce dure FOOTREST Removal Remove screws retaining footrest to its su...

Page 265: ...directly on decals CAUTION The following products must not be used to clean or wax any of the plastic compo nents used on the vehicles gasoline brake fluid kerosene diesel fuel lighter fluid varsol naphtha acetone strong detergents abrasive cleaners waxes containing an abrasive or a cleaning agent in their formula Apply wax without abrasive agent on glossy finish only Protect the vehicle with a co...

Page 266: ...PRODUCTS Description Part Number Page XP S Lube 293 600 016 249 27 N m 20 lbf ft 12 N m 106 lbf in 12 N m 106 lbf in 12 N m 106 lbf in 12 N m 106 lbf in 12 N m 106 lbf in 27 N m 20 lbf ft 12 N m 106 lbf in 12 N m 106 lbf in vmr2006 087 014_a vmr2006 087 247 ...

Page 267: ...Y FRAME Subsection 02 FRAME 27 N m 20 lbf ft 4 N m 35 lbf in 4 N m 35 lbf in 12 N m 106 lbf in 27 N m 20 lbf ft 12 N m 106 lbf in 27 N m 20 lbf ft 12 N m 106 lbf in 27 N m 20 lbf ft vmr2006 087 015_a 248 vmr2006 087 ...

Page 268: ...safety related such as steering footrests suspension etc electric welding amperage 70 110 A voltage 20 24 V rod E 7014 3 32 in CAUTION Before performing electrical weld ing anywhere on the vehicle unplug the electronic module connector Also unplug the BLACK cable from the battery and the volt age regulator This will protect the electronic module and battery against damage caused by flowing current...

Page 269: ...st 2 Bottom screw of rear fender Installation The installation is the reverse of the removal pro cedure REAR FRAME EXTENSION Removal Remove protective box bolt vmr2006 087 006_a Detach the CVT air outlet hose from its attach ment then cut the locking tie vmr2006 087 007_a 1 Detach hose here 2 Cut locking tie Remove the rear fender Refer to BODY Remove muffler Refer to EXHAUST SYSTEM Unplug and rem...

Page 270: ...09_a LH SIDE OF FRONT FENDER SHOWN Remove the headlamp Refer to LIGHTS AND AC CESSORIES Remove screw and bolt attaching the top of fend er to the support and frame vmr2006 087 010_a 1 Retaining screw 2 Retaining bolt Remove nuts retaining the support to the frame vmr2006 087 011_a vmr2006 087 012_a Remove all components attached on the support Installation Reverse the removal procedure REAR FENDER...

Page 271: ...Section 10 BODY FRAME Subsection 02 FRAME vmr2006 087 013_a Installation The installation is the reverse of the removal pro cedure 252 vmr2006 087 ...

Page 272: ...4 990 1968 to 1973 Intake Service limit mm in 4 900 1980 New mm in 4 950 to 4 975 1968 to 1973 Valve stem outer diameter Exhaust Service limit mm in 4 900 1980 New mm in 5 00 to 5 012 1968 to 1973 Valve guide internal diameter Service limit mm in 5 030 1980 New mm in 0 010 to 0 050 0004 to 0015 Intake Wear limit mm in 0 080 0032 New mm in 0 025 to 0 062 0010 to 0024 Clearance between valve stem an...

Page 273: ...0020 Piston ring groove clearance Wear limit mm in 0 090 0035 New mm in 11 982 to 12 000 4717 to 4724 Rocker arm bore diameter Wear limit mm in 12 080 4756 New mm in 11 966 to 11 984 4711 to 4718 Rocker arm shaft diameter Wear limit mm in 11 936 4699 Cylinder head warpage Wear limit mm in 0 050 002 Cylinder warpage Wear limit mm in 0 050 002 New mm in 70 995 to 71 015 2 7951 to 2 7959 Cylinder bor...

Page 274: ...0 RPM Ignition system type CDI Capacitor Discharge Ignition Ignition timing Not adjustable Quantity 1 Make and type NGK CR8E Spark plug Gap mm in 0 8 03 Trigger coil 445 5 to 544 5 Battery charging coil 0 315 to 0 385 Primary 0 189 to 0 231 20 C 68 F Ignition coil Secondary k 6 54 to 9 66 20 C 68 F with spark plug cap 2 79 to 3 41 20 C 68 F without spark plug cap Forward 8450 1500 Engine RPM limit...

Page 275: ...pe Forced circulation and splashing Oil filter No oil filter on this engine New mm in 0 15 006 Clearance between inner and outer rotors Wear limit mm in 0 20 008 New mm in 0 15 to 0 20 006 to 008 Clearance between outer rotor and pump body Wear limit mm in 0 25 0098 New mm in 0 04 to 0 09 0016 to 0035 Clearance between inner rotor side face and pump body Wear limit mm in 0 12 0047 TRANSMISSION Tra...

Page 276: ...45 450 5 7264 New mm in 102 400 4 0315 Spring free length Wear limit mm in 97 400 3 8346 New mm in 40 950 to 40 990 1 6122 to 1 6138 Fixed sheave shaft outside diameter Wear limit mm in 40 930 1 6114 New mm in 41 000 to 41 050 1 6142 to 1 6161 Sliding sheave inside diameter Wear limit mm in 41 070 1 6169 COOLING Coolant BRP premixed coolant or ethyl glycol water mix 50 coolant 50 distilled water U...

Page 277: ...2 2 Rear preload adjustment 5 settings BRAKES Qty 2 discs Front brake Type Hydraulic Qty 1 disc Rear brake Type Hydraulic Parking brake Brake lever lock on RH brake lever Separate RH lock lever on handlebar Caliper Floating Lining material Organic Minimum pad thickness mm in 2 0 0787 New mm in 3 5 1378 Minimum brake disk thickness Wear limit mm in 2 0 0787 Maximum brake disk warpage mm in 0 1 0039...

Page 278: ...900 mL 30 4 U S oz Gearbox Recommended XP S chaincase oil P N 413 801 900 or XP S synthetic chaincase oil P N 413 803 300 or 85W 140 Cooling system 1 2 L 1 27 U S quarts BODY Total vehicle load allowed 150 kg 330 lb includes operator all other loads and added accessories DIMENSIONS Dry weight kg lb 219 483 Overall length m in 1 890 74 4 Overall width m in 1 055 41 5 Overall height m in 1 115 43 9 ...

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Page 280: ...while the second color is the tracer color XX XX XX XX vmr2006 089 001 Example YL BK is a YELLOW wire with a BLACK stripe CONNECTORS To release and disconnect a connector proceed as follows vmr2006 089 002_a Step 1 Lift tab and hold Step 2 Pull connector apart Before reconnecting connector apply dielectric grease P N 293 550 004 on terminals WARNING Ensure all terminals are properly crimped on the...

Page 281: ......

Page 282: ...16 17 18 19 i i i_ri i il ii RPL REVERSE PILOT LAMP NPL NEUTRAL PILOT LAMP i irl ME ENGINE OVER HEAT LAMP MODULE m al al m al iii 1 REVERSE NEUTRAL OUT OUT REVERSE FOWARD NEUTRAL IN IN IN GND iii iii REVERSE IN 1 ___ z I ci JT GN WH iii t iii iii iii t iii iii iii iii t iii iii iii I t l JSPK1 I I SPARK 9 PLUG PRN GEAR BOX SWITCH iii 15 16 17 i t iii 1li i t 1li i a al j PR m l TAIL LAMP i l 18 TP...

Page 283: ... _ J OVER HEAD LAMP 1 1 1 e l LO PILOT i 1 e HI LAMP MODULE OFF R1 R2 I HEAD LAMP HEAD LAMP ii _ RELAY il ii RELAY HI LO i RIGHl OFF I LEFT 1 e IC FLASHER SWITCH LEFT RIGHT POWER IOFF I I IO N I I il il il BU ii I se HAZARD ON IN IN MG 4 5 0 MULTIFUNCTION SWITCH HEAD LAMP FOWARD REVERSE NEUTRAL OUT OUT Ol T REVERSE FOWARD NEUTRAL IN IN IN GND JT WH I le HAZARD HZ HAZARD OFF SWITCH _ v 10 i H BP L ...

Page 284: ...C M Y CM MY CY CMY K ...

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