TABLE OF CONTENTS 0. Section 04 ENGINE TRAXTER Subsection 01 (TABLE OF CONTENTS)

Transcription

1 Subsection 0 (TABLE OF CONTENTS) TABLE OF CONTENTS 0 TROUBLESHOOTING COOLING SYSTEM MAGNETO SYSTEM LUBRICATION CYLINDER AND HEAD CRANKSHAFT AND BALANCER SHAFT GEARBOX REWIND STARTER ENGINE - GENERAL LEAK TEST VERIFICATION LEAK TEST PROCEDURE PREPARATION AND TEST DIAGNOSE INSTALLATION REMOVAL AND INSTALLATION ENGINE REMOVAL ENGINE INSTALLATION ANTI-VIBRATION SYSTEM EXHAUST SYSTEM SHIFTING SYSTEM COOLING SYSTEM VEHICLE SIDE ENGINE SIDE GENERAL COOLANT LEVEL COOLING SYSTEM LEAK TEST INSPECTION DRAINING THE SYSTEM COOLANT REPLACEMENT RADIATOR CAP RADIATOR THERMOSTAT COOLANT TANK FAN AND OUTLET DEFLECTOR TEMPERATURE SENDER WATER PUMP HOUSING WATER PUMP IMPELLER VMR2004_079_04_0ATOC.FM 04-0-

2 Subsection 0 (TABLE OF CONTENTS) WATER PUMP SHAFT WATER PUMP CERAMIC SEAL WATER PUMP BEARINGS REWIND STARTER REWIND STARTER STARTING PULLEY MAGNETO SYSTEM GENERAL MAGNETO HOUSING COVER STATOR AND TRIGGER COIL ROTOR SPRAG CLUTCH LUBRICATION SYSTEM GENERAL ENGINE PRESSURE TEST OIL CHANGE AND OIL FILTER REPLACEMENT OIL STRAINER ENGINE OIL PRESSURE REGULATOR OIL PUMP MAIN OIL PRESSURE REGULATOR CYLINDER AND CYLINDER HEAD GENERAL VALVE COVER CYLINDER HEAD PUSH ROD ROCKER ARM VALVE SPRING VALVE VALVE STEM SEAL CYLINDER LIFTER PISTON PISTON RINGS CRANKSHAFT/BALANCER SHAFT GENERAL TO LOCK THE CRANKSHAFT CAMSHAFT BALANCER SHAFT CRANKSHAFT RECENTRE CRANKSHAFT VMR2004_079_04_0ATOC.FM

3 Subsection 0 (TABLE OF CONTENTS) CLUTCH CLUTCH DRUM, CLUTCH WEIGHT AND SPRAG CLUTCH FRICTION DRIVE PLATE, STEEL DRIVEN PLATE AND CLUTCH BASKET TRANSMISSION GEAR SHIFT SYSTEM TRANSMISSION GEAR SHIFT MECHANISM TRANSMISSION VMR2004_079_04_0ATOC.FM

4 Section 04 Subsection 02 ENGINE TRAXTER (TROUBLESHOOTING) TROUBLESHOOTING 0 The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. This section pertains to engine mechanical components only. Some related problems can come from other systems such as ignition system, fuel system etc. and have an impact on the engine. Ensure to check the other systems prior to concluding that the engine is in fault. COOLING SYSTEM SYMPTOM CONDITION Test/Inspection HIGH ENGINE OPERATING TEMPERATURE. NORMAL USE.. Check coolant level. a. Coolant less than recommended level. Refill. 2. Check temperature sensor for electrical/mechanical failure. a. Temperature sensor defective. Replace. b. Wiring harness or connectors defectives. Check and repair or change de defective part(s). 3. Check thermostat (located on cylinder head). a. Thermostat defective (does not open when engine gets hot). Replace thermostat. 4. Check the leak indicator hole (on magneto cover) if coolant leaks. a. Coolant leaking from leak indicator hole means a damaged water pump rotary seal. Replace rotary seal (refer to COOLING SYSTEM and MAGNETO COVER). 5. Check coolant bleeding screw on water pump housing. a. Screw looses and/or gasket ring is missing. Retighten screw and/or place gasket ring. 6. Check condition of hoses and hose clamps fixation. a. Hoses are brittle and/or hard. Replace. b. Hose clamps are loose. Retighten clamps. 7. Check condition of impeller located on the water pump shaft. a. Impeller wings broken and/or impeller thread is damaged. Replace. 8. Check gasket on water pump housing. a. Gasket on water pump housing leaks. Retighten screws and/or replace gasket. VMR2004_049_04_02A.FM

5 Subsection 02 (TROUBLESHOOTING) SYMPTOM CONDITION Test/Inspection HIGH ENGINE OPERATING TEMPERATURE. NORMAL USE. 9. Check cylinder head and/or cylinder base gasket. a. Worn out gasket(s) is(are) causing water leakage. Replace. 0. Check radiator condition. a. Radiator dirty or air ducts obstructed. Clean radiator fins and/or air ducts.. Check radiator fan. a. Fan does not work properly. Check and/or replace VMR2004_049_04_02A.FM

6 Section 04 Subsection 02 ENGINE TRAXTER (TROUBLESHOOTING) MAGNETO SYSTEM SYMPTOM CONDITION Test/Inspection NO SPARK. NORMAL USE.. Check spark plug electrode condition. a. Incorrect gap. Readjust gap (refer to TECHNICAL DATA). b. Spark plug electrode is damaged. Replace by Bombardier s recommended spark plug (refer to TECHNICAL DATA). c. Spark plugs wet with fuel. Dry or replace. 2. Check ignition coil for damage and/or electrical failure. a. Ignition coil damaged. Replace ignition coil. b. Connector is corroded or ignition coil shows electrical failure. Clean spark plug area and replace ignition coil. c. Wire harness is brittle or hard (no connection). Replace. 3. Check wire harness for cracks or other damages. a. Harness shows electrical failure and/or other damages. Replace wire harness. 4. Check trigger coil for damage and/or electrical failure. a. Windings of stator have electrical failure. Replace magneto. b. Connector on trigger coil is damaged and/or has electrical failure. Repair and clean contacts of connector. 5. Check electronic module. a. Module shows electrical failure or violent damages. Replace electronic module. b. AMP connectors are corroded or they are not inserted or crimped correctly. Clean, insert or crimp correctly and reconnect. 6. Check spark plug cables. a. Defective spark plug cables. Replace spark plug cables. b. Poor contact between spark plug cable cap and the cable. Replace spark plug cables. VMR2004_049_04_02A.FM

7 Subsection 02 (TROUBLESHOOTING) LUBRICATION SYMPTOM CONDITION Test/Inspection LOW OR NO OIL PRESSURE. NORMAL USE.. Check oil level and look for leakage on crankcase and/or defective gaskets. a. Crankcase is leaking due to damage. Rebuild engine with new crankcase and gasket parts. Use Bombardier s recommended oil (refer to TECHNICAL DATA). b. Crankcase is leaking due to loose screws. Retighten screws with recommended torque. c. Sealing rings, O-rings and/or gaskets are brittle and/or hard or damaged. Replace damaged parts. 2. Check oil drain plug on engine bottom. a. Plug is loosed and/or gasket ring is missing. Retighten the plug and/or place gasket ring. 3. Check oil strainer cover on engine bottom. a. Screw(s) is(are) loose and/or gasket is damaged, brittle or hard. Retighten screws and/or replace gasket. 4. Check the leak indicator hole if oil leaks (on magneto cover). a. Oil leaking from leak indicator hole means a damaged oil seal on water pump shaft. Replace oil seal (refer to COOLING SYSTEM and MAGNETO COVER). 5. Check oil pressure switch function. a. Oil pressure switch damaged. Replace oil pressure switch. b. Check wiring harness or connectors. Check and repair or change de defective part(s). 6. Check piston rings for heavy wear, breaking or incorrect installation. a. Piston rings worn out (blue colored engine exhaust emission). Replace piston rings (refer to CYLINDER AND HEAD). b. Piston rings are broken (low compression). Replace piston rings (refer to CYLINDER AND HEAD). 7. Check valve stem seal for leakage. a. Valve stem seal damaged and/or sealing lip is hard and/or brittle. Replace all valve stem seals. 8. Check oil orifice(s) on the oil pump suction side. a. Oil orifice(s) is(are) clogged. Clean from contamination. Replace oil and oil filter if necessary (refer to MAINTENANCE or LUBRICATION) VMR2004_049_04_02A.FM

8 Section 04 Subsection 02 ENGINE TRAXTER (TROUBLESHOOTING) SYMPTOM CONDITION Test/Inspection LOW OR NO OIL PRESSURE. NORMAL USE. 9. Check oil pump function. a. Oil pump rotor is out of wear limit. Replace oil pump shaft (refer to LUBRICATION). b. Oil pump seized due to oil leakage and/or air inclusion. Replace oil pump (refer to LUBRICATION). c. Gears driving oil pump are broken or otherwise damaged. Replace gears. d. Incorrect oil being used. Use Bombardier s recommend oil (refer to TECHNICAL DATA). 0. Check oil pressure regulator valve (spring) function. a. Valve spring damaged (valve always open). Replace spring. b. Valve piston is stuck in oil pump housing. Repair valve piston. SYMPTOM CONDITION Test/Inspection OIL CONTAMINATION (white appearance). NORMAL USE.. Check if the dipstick is in place. a. Disptick or O-ring missing. Reinstall dipstick and/or O-ring. 2. Check the leak indicator hole (on magneto cover) if water and oil leaks. a. Leakage of oil/water mixture from leak indicator hole means damaged water pump seal ring and rotary seal. Replace sealing ring, rotary seal and refill with recommended oil and/or coolant (refer to COOLING SYSTEM and MAGNETO COVER). 3. Check cylinder head and/or cylinder base gasket. a. Gasket damaged or leaking. Retighten cylinder head with recommended torque and/or replace gasket. Perform a leak test. 4. Check screws for torque. a. Screws not fixed. Retighten screws with recommended torque and/or replace oil. 5. Check oil for particles (may indicate possible damages inside the engine). a. Oil contamination due to metal or plastic particles. Replace possibly damaged parts. Use Bombardier s recommended oil (refer to TECHNICAL DATA). VMR2004_049_04_02A.FM

9 Subsection 02 (TROUBLESHOOTING) CYLINDER AND HEAD SYMPTOM CONDITION Test/Inspection UNUSUAL ENGINE NOISE AND/OR VIBRATION. NORMAL USE.. Check noise coming from cylinder head area. a. Hydraulic lifters are worn out. Replace hydraulic lifters. b. Rocker arm shaft worn out. Replace rocker arm shaft and/or rocker arms. c. Faulty push rods. Replace push rods. d. Piston rings or grooves worn or broken. Replace defective part(s). e. Piston or cylinder worn. Replace the defective part(s). SYMPTOM CONDITION Test/Inspection OIL CONTAMINATION ON CYLINDER AND/OR HEAD. NORMAL USE.. Check if the dipstick is in place. a. Disptick or O-ring missing. Reinstall dipstick and/or O-ring. 2. Check screws for torque. a. Loose screws. Retighten screws with recommended torque. b. Gaskets are brittle, hard, worn out or otherwise damaged. Replace damaged gaskets, O-rings or the V-ring on breather. CRANKSHAFT AND BALANCER SHAFT SYMPTOM CONDITION Test/Inspection UNUSUAL ENGINE NOISE AND/OR VIBRATIONS. NORMAL USE.. Check ball bearings on balancer shaft ends. a. Ball bearing(s) do(es) not move freely. Replace bearing(s). 2. Check if mark on balancer shaft corresponds with crankshaft position mark. a. Marks on balancer shaft and crankshaft are not aligned. Readjust position of balancer shaft and crankshaft. 3. Check thrust washer on crankshaft MAG side. a. Thrust washer is missing. Fit thrust washer. 4. Check shim on crankshaft PTO side. a. Shim is missing or wrong thickness. Fit shim or replace it by the right thickness VMR2004_049_04_02A.FM

10 Section 04 Subsection 02 ENGINE TRAXTER (TROUBLESHOOTING) GEARBOX SYMPTOM CONDITION Test/Inspection UNUSUAL ENGINE NOISE AND/OR VIBRATIONS. NORMAL USE.. Check bearings in the gearbox for free movement. a. Bearing(s) do(es) not move freely. Replace bearing(s). 2. Check gears and shafts for damage and/or wear. a. Gear(s) and/or shaft(s) worn or broken. Replace defective part(s). SYMPTOM CONDITION Test/Inspection GEAR INDICATION FAILS. NORMAL USE.. Check Gear Box Position Sensor (GBPS) for damage and/or wear. a. Sensor is worn and/or otherwise damaged. Replace sensor. b. Wire harness has broken cables. Replace wire harness. c. Sensor setting is out of range. Calibrate the sensor. 2. Check connector condition and/or electronic module. a. Connector contact(s) is (are) corroded and/or otherwise damaged. Clean connector(s) and/or replace wire harness if damaged. b. Electric module failed and/or otherwise damaged. Repair and/or replace damaged part(s). VMR2004_049_04_02A.FM

11 Subsection 02 (TROUBLESHOOTING) SYMPTOM CONDITION Test/Inspection GEAR(S) IS (ARE) HARD TO SHIFT. NORMAL USE.. Check shift drum and/or shift forks for wear and/or damages. a. Shift drum has worn out and/or damaged tracks. Replace shift drum. b. Shift fork(s) is (are) worn out and/or engagement pins are damaged. Replace shift fork(s). c. Shift fork(s) is (are) worn out and/or fork(s) is (are) damaged. Replace shift fork(s). d. Shift gear(s) is (are) worn out. Replace shift gear(s). e. Shift shaft teeth do not correspond with shift drum position. Readjust shift shaft (refer to GEARBOX). 2. Check engine idle speed (choke in use). a. Idle speed is to high. Adjust idle speed. b. Choke is in use and increases the engine RPM. Release choke. 3. Check shifter tie-rods a. Shifter tie-rods are not adjusted correctly. Adjust shifter tie-rods. REWIND STARTER SYMPTOM CONDITION Test/Inspection REWIND STARTER ROPE DOES NOT REWIND. NORMAL USE.. Check rewind spring. a. Broken spring. Replace spring. 2. Check internal parts for damaged. a. Broken parts. Replace defective parts. SYMPTOM CONDITION Test/Inspection REWIND STARTER PAWL DOES NOT ENGAGE. NORMAL USE.. Check stop spring. a. Broken stop spring. Replace. 2. Check pawl and pawl lock. a. Pawl and pawl lock are stuck together because of heat. Replace. 3. Check pawl and rope sheaves. a. Pawl and rope sheaves are stuck together because of heat. Replace VMR2004_049_04_02A.FM

12 Section 04 Subsection 02 ENGINE TRAXTER (TROUBLESHOOTING) ENGINE - GENERAL SYMPTOM CONDITION Test/Inspection ENGINE BACKFIRES. NORMAL USE.. Check spark plugs and/or electrical system. a. Carbon accumulation caused by defective spark plugs. Clean carbon accumulation and replace spark plugs. b. Electrical system has failure. Replace defective part(s). 2. Check leakage on intake manifold. a. Air leak on intake system. Retighten screws and/or replace intake manifold. 3. Check exhaust air leaking. a. Exhaust gasket is leaking. Retighten screws and/or replace exhaust gasket. b. Exhaust spring area is leaking. Reinstall or change exhaust springs. 4. Check valve(s) for leaking. a. Valve(s) is(are) leaking. Perform a leak down test then repair or replace valve(s). 5. Check if fuel supply is to less at high RPM. a. Fuel line is contaminated and/or bent (engine gets lean). Clean and/or replace defective part(s). b. Gas tank cap is plugged. Clean and/or change tank cap. c. Check if carburetor is dirty. Clean carburetor parts. 6. Check carburetor. a. Fualty idle screw and/or pilot screw adjustment. Adjust the carburetor. VMR2004_049_04_02A.FM

13 Subsection 02 (TROUBLESHOOTING) SYMPTOM CONDITION Test/Inspection ENGINE SUDDENLY TURNS OFF. NORMAL USE.. Check the ignition system. a. Spark plug(s) folded or otherwise damaged. Install new spark plug(s). b. Spark plug cable(s) disconnected. Connect spark plug cable(s). c. Battery or fuses or electronic module faulty. Charge and/or change the defective part(s). 2. Perform engine leak test. Refer to ENGINE LEAK TEST procedure. Check for possible piston seizure. a. Damaged head gasket and/or seal and/or leaking inlet/exhaust valve(s). Replace and/or repair defective parts. 3. Check crankshaft, rocker arms movement. a. Oil pump failure due to leak of oil. Repair and replace defective parts and use Bombardier s recommended oil. b. Oil contamination due to clogged oil filter/oil strainer. Oil passes through bypass valve. Replace oil, replace defective part(s) (refer to MAINTENANCE CHART). 4. Check valve springs exhaust/inlet. a. Broken valve spring damages the cylinder head, valve(s), rocker arm(s)/piston/ piston rings and connecting rod. Replace defective part(s). 5. Check if fuel supply is to low at high RPM. a. Fuel line is contaminated and/or bent. Clean and/or replace defective part(s). b. Gas tank vent clogged. Clean and/or replace defective part VMR2004_049_04_02A.FM

14 Section 04 Subsection 02 ENGINE TRAXTER (TROUBLESHOOTING) SYMPTOM CONDITION Test/Inspection ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH MAXIMUM OPERATING RPM. NORMAL USE.. Check spark plugs condition and/or gap. a. Fouled spark plugs or wrong spark plug gap. Readjust gap and clean spark plugs or replace. 2. Check spark plug type. a. Improper spark plug heat range. Install recommended spark plug (refer to TECHNICAL DATA). 3. Perform engine leak test. Refer to ENGINE LEAK TEST procedure. Check for possible piston seizure. a. Damaged head gasket and/or seal and/or leaking inlet/exhaust valve(s). Replace and/or repair defective parts. 4. Check for water in fuel (wrong fuel). a. There is water in fuel or wrong fuel. Drain fuel system, search for leakage and refill it with appropriate fuel. 5. Check engine compression. a. Worn piston(s) and/or piston ring(s). Replace (refer to CYLINDER AND HEAD). 6. Check carburetor. a. Diaphragm is installed wrongly. Install diaphragm correctly. b. Dirty carburetor. Clean carburetor. 7. Check throttle cable adjustment. a. Worn throttle cable adjustment. Adjust throttle cable. 8. Check fuel pump. a. Worn fuel pump. Inspect, repair or replace fuel pump. 9. Check air intake parts. a. Leaking between carburetor and engine. Install the grommet correctly. b. Parts installed improperly. Install parts correctly. VMR2004_049_04_02A.FM

15 Subsection 02 (TROUBLESHOOTING) SYMPTOM CONDITION Test/Inspection ENGINE TURNS OVER BUT FAILS TO START. NORMAL USE.. Check if ignition coil fits on spark plug (refer to ENGINE DOES NOT START - NO SPARK AT SPARK PLUGS). 2. Check spark plugs. a. Define spark plugs (no spark) or wrong spark plug gap. Readjust gap and clean spark plugs or replace. 3. Check for fuel on spark plugs. a. Flooded engine (spark plugs wet when removed). Do not overchoke. Remove spark plugs and crank engine several times. Install clean dry spark plugs. Start engine following usual starting procedure. 4. Check engine compression. a. Insufficient engine compression. Perform a leak down test and replace defective part(s) (ex.:piston, ring(s), etc.). 5. In cold weathers, check engine decompressor. a. Centrifugal weight spring is not engaged and/or damaged. Readjust spring or replace centrifugal weight if damaged. SYMPTOM CONDITION Test/Inspection HIGH ENGINE OPERATING TEMPERATURE. NORMAL USE.. Check if cooling system shows any failure (see COOLING SYSTEM). a. System is leaking. Repair and/or replace damaged part(s). 2. Check operation of lubrication system (see LUBRICATION). a. Lubrication is not done properly. Repair and/or replace damaged part(s). 3. Check air leakage on engine intake/exhaust. a. Leaks. Repair or replace. 4. Check condition and heat range of spark plugs. a. Melted spark plug tip or inadequate heat range. Replace. 5. Check carburetor. a. Dirty carburetor. Clean. 6. Check cooling fan. a. Fan does not turn. Check and/or replace VMR2004_049_04_02A.FM

16 Section 04 Subsection 02 ENGINE TRAXTER (TROUBLESHOOTING) SYMPTOM CONDITION Test/Inspection STARTER TURNS, BUT ENGINE DOES NOT CRANK. NORMAL USE.. Check starter. a. Teeth damaged. Replace starter. 2. Check ring gear. a. Excessively worn ring gear. Replace ring gear. 3. Check one way bearing on magneto. a. Improper one way bearing. Replace one way bearing. SYMPTOM CONDITION Test/Inspection ENGINE DOES NOT START - NO SPARK AT SPARK PLUGS (see magneto system). AT ENGINE CRANKING.. Verify spark plugs condition. a. Defective, improperly set, worn out, fouled. Identify source of problem and correct. Replace spark plugs. 2. Verify ignition coil resistance with an ohmmeter. a. Defective part. Replace ignition coil. 3. Verify trigger coil resistance with an ohmmeter and connector condition. a. Defective coil. Corroded connector terminal. Replace magneto. Clean terminals and apply silicone dielectric grease. 4. Verify condition of ignition coil. a. Mechanically damaged part. Vibration problem. Electrically damaged part. Replace ignition coil. 5. Verify condition of trigger coil. a. Mechanically damaged part. Vibration problem. Electrically damaged part. Replace trigger coil and/or tighten mounting screw(s). 6. Verify wiring harness. a. Defective harness or connector(s). Repair or replace defective part(s). 7. Verify electronic module. a. Poor connections or faulty module. Repair or replace defective part(s). VMR2004_049_04_02A.FM

17 Subsection 03 (LEAK TEST) LEAK TEST 0 VERIFICATION Before performing the cylinder leak test, verify the following: clamp(s) tightness radiator and hoses condition oily contamination on leak indicator hole (under water pump cover) means a damaged oil seal on water pump shaft LEAK TEST PROCEDURE PREPARATION AND TEST NOTE: The following procedures should be done with a cold engine. Disconnect battery. WARNING Always respect this order for disassembly; disconnect BLACK (-) cable first. Electrolyte or fuel vapors can be present in engine compartment and a spark may ignite them and possibly cause personal injuries. V0C2RA 2. Leak indicator hole 2. Water pump cover coolant out of leak indicator hole means a damaged seal on water pump shaft (refer to COOL- ING SYSTEM) coolant escaping from water pump housing means damaged gasket(s) and/or loosened screws (refer to COOLING SYSTEM). NOTE: For all the check mentioned above see the appropriate engine section to diagnose and repair the engine. Remove: vehicle seat radiator cap valve cover. Unplug and remove one spark plug only. Crank engine with the rewind starter until piston is at TDC, compression stroke. NOTE: The pressure on valve springs will be released when the piston is at TDC (compression stroke). Remove the rocker arm shaft (refer to CYLINDER AND HEAD). Connect leak tester to adequate air supply. Set needle of measuring gauge to zero. NOTE: Each tester will have specific instruction on the gauge operation and required pressure. Install gauge adapter into previously cleaned spark plug hole. VMR2004_050_04_03A.FM

18 Subsection 03 (LEAK TEST) Supply combustion chamber with air pressure. 3 V0C2SA. Leak tester 2. Adequate adapter for spark plug hole 3. Air supply hose 4. Rocker arm shaft Note the amount of leaking or percentage (depending on tester). LEAKAGE PERCENTAGE ENGINE CONDITION 0% to 7% Excellent condition 8% to 5% 6% to 30% 30% and higher 4 Fair condition; proceed with tuned up or adjustment Poor condition; engine will run and performance might be down in some cases Very poor condition; diagnose and repair engine 2 DIAGNOSE Listen for air leaks: air escaping from spark plug means poor spark plug tightness or defective spark plug gasket air escaping on intake port/carburetor means leaking intake valve air escaping on exhaust port means leaking exhaust valve air bubbles out of radiator means leaking cylinder head gasket air escaping into crankcase area means excessively worn cylinder and/or broken piston rings air/oil escaping from crankcase means damaged gasket and/or loosened screws (refer to CRANKSHAFT/BALANCER SHAFT) air/coolant escaping from cylinder/head means damaged gasket(s) and/or loosened screws. (refer to CYLINDER AND HEAD). NOTE: For all the check mentioned above see the appropriate engine section to diagnose and repair the engine. INSTALLATION NOTE: At reassembly, use the torque values and Loctite products from the exploded views (refer to particular engine sections). For installation, reverse the preparation procedure. NOTE: Replace the piston at the TDC position to reinstall the rocker arm shaft. NOTE: During this leak test, the piston is at bottom of cylinder. Cylinder inspection is recommended if the engine has oil consumption, even if the leak test indicates a good engine condition VMR2004_050_04_03A.FM

19 Subsection 04 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION 0 All Models except XL 22 7 N m (62 lbf in) Synthetic grease N m (6 lbf ft) 5 22 N m (6 lbf ft) 2 23 N m (7 lbf ft) 48 N m (35 lbf ft) N m (97 lbf in) N m (35 lbf ft) 7 2 Synthetic grease N m (7 lbf ft) N m (7 lbf ft) Synthetic grease 8 48 N m (35 lbf ft) 5 23 N m (7 lbf ft) N m 4 (89 lbf in) 0 N m (89 lbf in) N m (7 lbf ft) N m 4 (89 lbf in) N m (7 lbf ft) Loctite V0C2TS 0 N m (89 lbf in) N m (89 lbf in) VMR2004_05_04_04A.FM

20 Subsection 04 (REMOVAL AND INSTALLATION) XL Models 22 6 N m (53 lbf in) 22 0 N m (89 lbf in) N m (53 lbf in) Synthetic grease 5 22 N m (6 lbf ft) N m (7 lbf ft) N m (35 lbf ft) N m (35 lbf ft) N m (89 lbf in) Synthetic grease N m (7 lbf ft) Synthetic grease 5 23 N m (7 lbf ft) N m 4 (89 lbf in) 0 N m (89 lbf in) N m (97 lbf in) 23 N m (7 lbf ft) N m (7 lbf ft) 34 0 N m (89 lbf in) 35 Loctite 243 V0C3TS 0 N m (89 lbf in) N m (89 lbf in) VMR2004_05_04_04A.FM

21 Subsection 04 (REMOVAL AND INSTALLATION) ENGINE REMOVAL Vehicle Preparation Place the vehicle on jack stands and place the shifter no. on NEUTRAL position. Remove seat then remove battery. Disconnect BLACK (-) cable from battery, then RED (+) cable. WARNING Always disconnect battery or starter cables exactly in the specified order, BLACK (-) cable first. It is recommended to disconnect electrical connections prior to disconnecting fuel lines. Drain engine oil and engine coolant by removing drain plugs. All Models Remove solenoid(s) connector. Remove sub-transmission position sensor. NOTE: Do not unplug only, remove sensor completely. Remove shifting rod no. 2. Refer to SHIFTING ROD REMOVAL section. Unplug vehicle speed sensor. Engine Preparation Unplug spark plug cables. Unplug oil pressure sensor. Remove exhaust pipe no. 3. Refer to EXHAUST SYS- TEM section. Remove radiator inlet hose. Disconnect breather hose. Unplug temperature sensor. All Models except XL Disconnect TPS connector. V0C3SB 2 UNDER ENGINE. Engine oil plug 2. Engine coolant plug All Models except MAX and MAX XT Remove fuel tank cover. All Models Remove footrests, inner fenders and skid plate. Refer to BODY. Front Part Preparation All Models except MAX and MAX XT Remove seat pivot bar. V0C2VA Spark plug cable 2. Exhaust pipe 3. Radiator inlet hose 4. Breather hose 5. Temperature sensor 6. TPS connector VMR2004_05_04_04A.FM

22 Subsection 04 (REMOVAL AND INSTALLATION) All Models Remove carburetor no. 4. Refer to CARBURETOR AND FUEL PUMP. Remove engine impulse line. V0J0WA 2 V0C0FA. Engine impulse line Remove fuse box. Remove shifting valve. Refer to ELECTRIC SHIFT SYSTEM. Remove brake pedal, rear master cylinder and brake switch. Refer to HYDRAULIC BRAKES. Rear Part Preparation Unplug gear box position sensor. Remove: RH rear wheel rear brake caliper lower bolts retaining rear shocks. Reinstall rear wheel. On LH side, remove swing arm pivot jam nut and the pivot bolt.. Pivot bolt jam nut 2. LH pivot bolt On RH side, remove the other pivot bolt. V0J0XA TYPICAL. RH pivot bolt Pull out swing arm. Unplug magneto/trigger wiring harness connector. Remove radiator outlet hose. Remove starter VMR2004_05_04_04A.FM

23 Subsection 04 (REMOVAL AND INSTALLATION) On RH side, remove the 3 bolts no. 5 retaining engine bracket no. 6 to frame. V0C2ZA V0C2WA. Engine bracket bolts Remove the rear engine mounting nut no. 7, do not remove bolt no. 8 yet. TYPICAL Check if exhaust gasket no. 3 is removed. Install engine lifting tool (P/N ) then install a hoist. Remove front propeller shaft bolt. V0C2XA Unscrew front mounting bolt no. 9. On LH side, remove engine mounting nut no. 0, do not remove bolt no. yet. V0C30A TYPICAL Place rewind starter handle in frame. V0C2YA TYPICAL Remove engine bracket bolts no. 2. V0C3A TYPICAL VMR2004_05_04_04A.FM

24 Subsection 04 (REMOVAL AND INSTALLATION) Remove bolts from engine supports. Raise engine enough to pull out front propeller shaft. Pull down engine lifting tool arm and lift engine. V0C33A Install the 3 bolts no. 5 retaining engine supports no. 6 to frame. Torque all engine supports. V0C0HA TYPICAL ENGINE INSTALLATION Apply anti-seize lubricant on swing arm pivot bolts and on propeller shaft splines, as well as on shift rod spline and brake lever pivot. Lower engine in frame. Install front drive shaft on engine splines. Slide bolt no. in LH engine support. Do not tighten. Install LH engine bracket bolts no. 2. Do not tighten. BOLT M8 M0 TORQUE 23 N m (7 lbf ft) 48 N m (35 lbf ft) Remove the engine lifting tool. Relocate rewind starter handle. Install shifting valve, clean contact surfaces before installation (shifting valve body and engine). Install breather hose. Connect temperature sensor. Install shifting rod no. 2 and the sub-transmission position sensor. Plug gearbox position sensor to harness then install it on engine. Plug magneto harness. Install fuel valve. Install the impulse line. V0C32A Install rear engine support bolt no. 8 on RH side. Do not tighten. V0C34A VMR2004_05_04_04A.FM

25 Subsection 04 (REMOVAL AND INSTALLATION) Install lower coolant inlet hose. Connect VSS, clutch/pressure solenoid and oil pressure connectors. Install front propeller shaft bolt and torque to 34 N m (25 lbf ft). Apply Loctite 27 on threads. Install seat pivot bar. NOTE: At the time of seat pivot bar installation, it is possible that the frame is too wide or too restricted. According to your needs, close or widen the frame slightly. Install carburetor then connect fuel line to carburetor. Install choke cable and reconnect TPS connector. Connect breather hose to carburetor. Install fuse box. Install starter and connect wires. WARNING Connect RED (+) cable first then BLACK (-) cable. Always connect RED positive cable first. Install LH pivot bolt and torque it to N m (97 lbf in). Move the swing arm up and down several times and retighten LH pivot bolt. Retorque LH pivot bolt to N m (97 lbf in). Torque RH pivot bolt to 47 N m (08 lbf ft). Install jam nut and torque to 47 N m (08 lbf ft) while holding pivot bolt. WARNING The LH pivot bolt must have more than 2 threads out of jam nut. Reinstall master cylinder. Check brake pedal adjustment. Refer to HYDRAULIC BRAKES for complete adjustment procedure. Fasten rear brake caliper. Route brake hose and secure to the brackets. Reinstall shock absorber bolts. Reattach cables, hoses, harness wiring, etc. Pack cone bearing cavities with synthetic grease (P/N ). Apply grease (P/N ) to splines before inserting the end of the propeller shaft into differential. Push swing arm toward engine to engage propeller shaft splines and position the swing arm in the frame. NOTE: Do not forget to route brake line over the swing arm. Line up cone bearing and install RH pivot bolt. 2 V0C7A Before starting the engine, remove spark plugs no. 5 and ground them on engine or frame. Run starter about thirty seconds. This operation activates the oil pump. Reinstall spark plugs and check if engine runs correctly. Let the engine idle for one minute to ensure full charge of hydraulic valve lifters. Calibrate STPS, GBPS and TPS (AUTOSHIFT model). Refer to ELECTRIC SHIFT SYSTEM. V0J0AA. RH pivot bolt 2. Pivot bearing VMR2004_05_04_04A.FM

26 Subsection 04 (REMOVAL AND INSTALLATION) ANTI-VIBRATION SYSTEM Anti-Vibration System Removal Remove flanged bolt no. 8, 9 or, elastic nut no. 7, 0 or 6 and engine brackets no. 6 or 4. RH Anti-Vibration System Remove anti-vibration bushing no. 7, push out with a punch. Insert a punch in hole of anti-vibration bushing no. 7 and push other anti-vibration bushing out housing. Use punch to remove the other bushing. CAUTION: Do not use a screwdriver to removing anti-vibration bushing. LH Anti-Vibration System Insert a punch in hole of anti-vibration bushing no. 9 and push support bushing no. 20 and antivibration bushing out the housing. Use punch to remove the other bushing. Anti-Vibration System Installation Insert support bushing in engine support. Before inserting support bushing, spray BOMBARDIER LUBE (P/N ) in support. Install a new O-ring no. 2 in anti-vibration bushing grooves. Apply grease on anti-vibration bushings and insert in engine support, one on each side. For installation, use a 52 mm (6 in) bolt for LH side and 02 mm (4 in) for RH side, three washers and a nut. Refer to the following illustration V0C0TA. Bolt 2. Washers (3) 3. Nut EXHAUST SYSTEM WARNING Never touch exhaust system components immediately after the engine has been run because these components are very hot. Heat Shield Removal All Models except XL Remove the rear fender. Refer to BODY. Remove screws no. 22 retaining heat shield no. 23. V0C0SA VMR2004_05_04_04A.FM

27 Subsection 04 (REMOVAL AND INSTALLATION) XL Model Heat Shield Pipe Tip up the rear cargo box. Remove screws no. 22 retaining heat shields no. 24 to muffler no. 26. All Models except XL First, install bottom screw then rear screw, do not tighten yet. Install the screws on top of heat shield. Torque all screws to 7 N m (62 lbf in) V0C8A V03C0A Step Step Step : Bottom screw 2 : Rear screw 3 : Screws on top Exhaust Pipe Removal Remove the exhaust pipe nuts no Heat shield pipe 2. Heat shield screws Heat Shield Remove: muffler no. 26, see below NOTE: Remove the muffler with the heat shields pipe installed. screws retaining heat shield no. 25 to rear extension frame. Heat Shield Installation For installation, reverse the removal procedure. V0C0JA Remove screw no. 28 from exhaust pipe bracket. VMR2004_05_04_04A.FM

28 Subsection 04 (REMOVAL AND INSTALLATION) Remove springs no. 29 retaining exhaust pipe and muffler no. 26. V0C9A With muffler secured in its rubber mounts, fit exhaust pipe, securing it loosely at its flange and on engine. Tighten flange nuts, making sure exhaust pipe is properly aligned inside muffler ball socket then install retaining springs after pushing muffler forward in exhaust pipe. Tighten exhaust pipe support bolt. Muffler Removal All Models except XL Remove heat shield no. 23 and exhaust pipe no. 3. Pull muffler no. 26 forward, pull out retaining rod from supports and remove muffler. TYPICAL TRAXTER SHOWN. Retaining springs Pull exhaust pipe forward. Exhaust Pipe Installation For installation, reverse the removal procedure, paying attention to the following details. Use a new exhaust pipe gasket no. 3 and make sure that it is properly installed. V0CMA 2. Muffler 2. Retaining rod XL Model Remove the retaining springs then pull out muffler with heat shields. Muffler Installation For the installation, reverse the removal procedure. NOTE: Check rubber bushings no. 30 for cracks or other damages, change if necessary. SHIFTING SYSTEM NOTE: Always set the NEUTRAL position before remove any parts from shifting system. V0C0LA TYPICAL. Exhaust pipe gasket VMR2004_05_04_04A.FM

29 Subsection 04 (REMOVAL AND INSTALLATION) Shifter Tie-Rod Removal Remove fuel tank. Refer to FUEL CIRCUIT. NOTE: Separate fuel tank from frame only, do not remove tank completely. Do not remove fuel lines. Remove shifter tie-rod nuts no. 3, one on LH ball joint and one on RH ball joint. Shifter Tie-Rod Installation For installation, reverse the removal procedure, pay attention to the following details. Pre-adjust shifter tie-rod no. 32 to 50 mm (5-29/32 in). NOTE: Shifter tie-rod must have 20 mm (25/32 in) maximum between center of ball joint and jam nut. See the following illustration. A B V0I0JA LEVER SPRING INSTALLATION Shifter Column Removal Remove shifter lever no.. Remove shifter tie-rod no. 32. Shifter Column Installation For installation, reverse the removal procedure. Shift Rod Removal Remove fuel tank. Refer to FUEL CIRCUIT. NOTE: Separate fuel tank from frame, do not remove tank completely. Separate shifting rod no. 2 from engine shift rod. Unscrew bolt no. 39 and pull shift rod forward. V0I0IA 3. Shifter tie-rod 2. Jam nut 3. Ball joint A. Shifter tie-rod length 50 mm (5-29/32 in) B. Ball joint length 20 mm (25/32 in) maximum Install shifter tie-rod. Lever Removal Remove fuel tank. Refer to FUEL CIRCUIT. Remove upper and lower retaining clamps no. 33 and half rings no. 34. Unscrew lever button no. 35. Remove shifter lever no. from shifter guide. Unscrew lever retaining bolt no. 36 and pull lever. Lever Installation For installation, reverse the removal procedure, paying attention to the following details. Place nylon bushing no. 37 in shifter lever. Place lever spring no. 38 properly. 2 V0I0KA. Shifting rod Unscrew elastic nuts from RH ball joint. Remove retaining clamp no. 40 and half rings no. 4. Shift Rod Installation For installation, reverse the removal procedure. VMR2004_05_04_04A.FM

30 Subsection 05 (COOLING SYSTEM) COOLING SYSTEM 0 VEHICLE SIDE N m (80 lbf in) 4 3 N m (97 lbf in) N m (40 lbf in) V0C3US VMR2004_052_04_05A.FM

31 Subsection 05 (COOLING SYSTEM) ENGINE SIDE Molykote Engine oil N m (80 lbf in) 26 Engine oil N m (22 lbf in) N m (80 lbf in) 9 N m (80 lbf in) 9 N m (80 lbf in) 2 V0C3VS VMR2004_052_04_05A.FM

32 Subsection 05 (COOLING SYSTEM) GENERAL During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE AP- PLICATION at the beginning of this manual for complete procedure. 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 renewed. WARNING To avoid potential burns, do not remove the radiator cap or loosen the cooling drain plug if the engine is hot. COOLANT LEVEL Place the vehicle on a level surface and check the coolant in the coolant tank no.. The coolant level should be between MIN. and MAX. level marks of the coolant tank. NOTE: When checking level at temperature lower than 20 C (68 F), it may be slightly lower than MIN. mark. If the level in the tank is lower than the MIN. mark, remove the coolant tank cap no. 2 and add coolant up to MAX. mark. Reinstall the tank cap then check the level in the radiator no. 3. Add coolant if necessary. NOTE: A cooling system that frequently requires coolant is the indication of leaks or engine problems. Perform a cooling system leak test and inspect the components of cooling system. COOLING SYSTEM LEAK TEST To perform the leak test on the cooling system, remove the protective cap on the rear fender or tilt the cargo box to allow an access to the radiator cap no. 4. Install the special radiator plug (P/N ) instead of the radiator cap then pinch the overflow hose no. 5 with a small hose pincher (P/N ). V04B0VA 2. Special radiator plug 2. Small hose pincher Using the pump (P/N ), pressurize all system to 03 kpa (5 PSI). V0C09A NOTE: The rear fender removal is not necessary. The fender has been removed for a better comprehension. VMR2004_052_04_05A.FM

33 Subsection 05 (COOLING SYSTEM) INSPECTION Check all hoses, radiator no. 3 and cylinder/base for coolant leaks. Spray a soap/water solution and look for air bubbles. Check general condition of hoses and clamp tightness. Check the leak indicator hole if there is oil or coolant. This hole is located on the magneto housing no. 6 near the meeting point with the water pump housing no. 7. When cooling system is drained completely, screw cooling drain plug and torque it to 7 N m (62 lbf in). COOLANT REPLACEMENT Recommended Coolant Use Bombardier Premixed Coolant (P/N ) or a blend of 50% antifreeze with 50% distilled water. CAUTION: To prevent rust formation or freezing condition, always replenish the system with the Bombardier Premixed Coolant or with 50% antifreeze and 50% distilled water. Pure antifreeze without water thickens and does not have the same efficacy. Always use ethylene glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines. System Capacity Refer to TECHNICAL DATA. V0C37A. Leak indicator hole If engine oil trickles by the leak indicator hole, that means the oil seal no. 8 in the magneto housing is defective. If coolant trickles by the leak indicator hole, the ceramic seal no. 9 must be replaced by a new one. Replacement Procedure Drain system completely. Lift the rear of vehicle, about 2 or 3 inches, then pinch engine outlet hose no. 0 between radiator and thermostat housing with a large hose pincher (P/N ). DRAINING THE SYSTEM To drain cooling system, unscrew plug under engine and remove the radiator cap no. 4. V0C3SA. Cooling plug V03C03A VMR2004_052_04_05A.FM

34 Subsection 05 (COOLING SYSTEM) Unscrew bleeding screw on top of thermostat housing. Removal Drain cooling system. Remove rear fender. Refer to BODY. Remove engine outlet no. 0 and inlet no. hoses. V0C0BB. Bleeding screw Refill the radiator no. 3. When the coolant comes out by the thermostat housing hole, reinstall the bleeding screw and remove the hose pincher. Install the radiator cap. NOTE: Do not forget gasket ring when bleeding screw is installed. Torque bleeding screw to 4.5 N m (40 lbf in). Refill coolant tank no. up to cold level mark. Install the coolant tank cap. Run engine until thermostat opens then stop engine. When engine has completely cooled down, recheck coolant level in radiator no. 3 and coolant tank no. and top up if necessary. Every 00 hours or once a year, check coolant concentration (freezing point) with proper tester. RADIATOR CAP Using a suitable tester, check if the radiator cap no. 4 pressurizes the system. If not, install a new 0 kpa (6 PSI) cap (do not exceed the pressure specified on the old cap). RADIATOR Inspection Check radiator fins 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. V0C0AA TYPICAL. Engine outlet hose 2. Engine inlet hose Remove overflow hose no. 5. Remove upper mounting bolts no. 2. Unplug temperature sender no. 3. Pull the radiator upwards. Installation For installation, reverse the removal procedure. Pay attention to the following detail. Install the rubber cushion no. 4 between radiator and frame. Replace any defective cushions. Install the metal sleeves no. 5 into the rubber grommet no. 6 on the top of the radiator. Replace any defective grommets. Fill up radiator. Refer to COOLANT REPLACE- MENT, above in this section. 2 VMR2004_052_04_05A.FM

35 Subsection 05 (COOLING SYSTEM) THERMOSTAT The thermostat is a single action type and it is located on the top of engine, to the right of cylinder head. Removal When the engine is cooled, remove the bleeding screw on the top of thermostat housing. Remove thermostat housing screws and pull thermostat cover with hose. COOLANT TANK The coolant expands as the temperature (up to 00-0 C ( F)) and pressure rise in the system. If the limiting system working radiator cap is reached 0 kpa (6 PSI), the pressure relief valve in the radiator cap is lifted from its seat and allows coolant to flow through the overflow hose into the overflow coolant tank. Removal Remove overflow hose no. 5. Pull coolant tank no. upward. Empty coolant tank. Installation The installation is the reverse of the removal procedure. FAN AND OUTLET DEFLECTOR V0C0BA. Remove screws NOTE: Install a rag around thermostat housing to catch any spillage. Remove thermostat with gasket out of hole. Discard gasket. Test Unplug temperature sender connector. Install a jumper wire end in connector. Replace fan no. 7 if it does not work when the system is jumped. Test To check thermostat, put in water and heat water. Thermostat should begin to open when water temperature reaches 75 C (67 F). Installation For installation, reverse the removal procedure. Pay attention to the following details. Clean all residue from the old gasket on the cylinder head. Install thermostat with a new gasket. Install the thermostat cover then torque screws to 9 N m (80 lbf in). Check coolant level in radiator and coolant tank and top up if necessary. R60dvrs0A VMR2004_052_04_05A.FM

36 Subsection 05 (COOLING SYSTEM) Fan Removal Remove rear fender. Refer to BODY. Remove bolts no. 8 and fan supports no Outlet Deflector Installation The installation is the reverse of the removal procedure. TEMPERATURE SENDER Test Remove temperature sender no. 3, see below for procedure. Put sender in water and heat water. Using a multimeter, check the resistance from temperature sender. Temperature sender should close when water temperature reaches the following degree. WATER TEMPERATURE 90 C to 95 C (94 F to 203 F) V0G0AA TYPICAL. Remove bolts 2. Fan supports Unplug fan connector. 2 Change temperature sender if the resistance does not change when the water temperature is equal or over specification. Removal Unplug temperature sender connectors. V0G0BA TYPICAL. Fan connector Remove fan. Fan Installation For the installation, reverse the removal procedure. Outlet Deflector Removal Remove fan no. 7. Remove radiator. Pull outlet deflector no. 20 upward. R60motr40A 2 TYPICAL. Temperature sender connector 2. Engine inlet hose Unscrew temperature sender no. 3. Installation The installation is the reverse of the removal procedure. Pay attention to the following details. Check O-ring and change if necessary. CAUTION: Do not apply any product on the threads or on the O-ring. VMR2004_052_04_05A.FM

37 Subsection 05 (COOLING SYSTEM) WATER PUMP HOUSING Removal Drain cooling system. Remove: engine inlet hose no. formed tube no. 2 between fitting inlet no. 22 and water pump housing no. 7 water pump housing screws no. 23 water pump housing no. 7 with rubber ring no. 24. Inspection Check housing for cracks or spots of corrosion. Change housing if necessary. Check if the rubber ring is brittle, hard or damaged. If so, replace by a new one. Installation The installation is the opposite of the removal procedure. CAUTION: To prevent leaking, make sure that the rubber ring is exactly in its groove when reinstalling the water pump housing. WATER PUMP IMPELLER Removal Remove the water pump housing no. 7. Unscrew the water pump impeller no. 25. Turn clockwise. Inspection Check impeller for cracks or other damages. Change the impeller if necessary. Installation The installation is the opposite of the removal procedure. WATER PUMP SHAFT The water pump shaft no. 26 should be removed only if the ceramic seal no. 27 is defective or if its end is scratched by a faulty bearing no. 28. Removal Remove: magneto housing no. 6 water pump impeller no. 25 needle pin no. 29 and distance sleeve no. 30. Extract the water pump shaft no. 26. Remove bearings no. 28 and oil seal no. 3. Discard oil seal. Installation For installation, reverse the removal procedure. Install a new oil seal no. 3. This seal must be replaced each time the shaft is removed. NOTE: The ceramic seal must be installed into water pump housing before inserting the shaft in its final position. WATER PUMP CERAMIC SEAL Inspection To determine if the ceramic seal no. 27 is still good, check if coolant trickles by the leak indicator hole. If so, replace the ceramic seal. Removal Drain cooling system. Remove: magneto housing from engine water pump housing no. 7 impeller no. 25. Remove the water pump shaft no. 26 and discard the oil seal no. 3. Using two screwdrivers, remove the ceramic seal. NOTE: Place two thin pieces of wood on magneto housing to avoid damaging the surface VMR2004_052_04_05A.FM

38 Subsection 05 (COOLING SYSTEM) Installation To insert the ceramic seal in place, use the water pump ceramic seal installer (P/N ). V0B0YA CAUTION: Never use a hammer for the ceramic seal installation. Only use a press to avoid damaging the ceramic component. WATER PUMP BEARINGS Inspection Water pump bearings no. 28 must turn smoothly and freely. If not, change the bearings. NOTE: Change both bearings at the same time. Removal Remove water pump shaft no. 26. Using a suitable puller, remove bearings no. 28. Installation For installation, reverse the removal procedure. VMR2004_052_04_05A.FM

39 Subsection 06 (REWIND STARTER) REWIND STARTER 0 5 N m (44 lbf in) 5 Loctite 243 Molykote PG N m (5 lbf ft) Loctite V0CBU VMR2004_053_04_06A.FM

40 Subsection 06 (REWIND STARTER) REWIND STARTER Removal Remove seat, fuel tank cover and engine skid plate. Refer to BODY. Remove seat pivot bar and unplug VSS connector then clutching and clutch modulator valve connector. Remove rewind starter mounting bolts no. 5 and pull rewind starter. Disassembly To remove rope no. 5 from rewind starter mechanism: First remove flat washer no. 0 and screw no., locking spring no. 9, locking spring washer no. 8, pawl lock no. 7 and pawl no. 6. Remove sheave no. 3 from starter housing no.. Disengage key no. 4 and pull out rope no. 5. V0C0WA TYPICAL. Outer end into guide notch NOTE: Due to dust accumulation, rewind starter must be periodically cleaned, inspected and relubricated. CAUTION: It is of the utmost importance that the rewind starter spring(s) be lubricated periodically using specific lubricants. Otherwise, rewind starter component life will be shortened and/or rewind starter will not operate properly under very cold temperatures. Lubricate spring assembly with Molykote PG 54 (P/N ) and position into starter housing as illustrated. CAUTION: This lubricant must NOT be used on rewind starter locking spring as it does not stay on under vibration. A0C2A TYPICAL GENTLY TAP ON KEY Assembly At assembly, position spring no. 2 outer end into spring guide notch then wind the spring clockwise into guide. WARNING Since the spring is tightly wound inside the guide it may fly out when rewind is handled. Always handle with care. V0C0XA TYPICAL. Apply Molykote PG 54 inside spring guide VMR2004_053_04_06A.FM

41 Subsection 06 (REWIND STARTER) CAUTION: The use of standard multi-purpose grease could result in rewind starter malfunction. To install a new rope no. 5, insert rope into sheave orifice and lock it with the key no. 4 as illustrated. V0C0ZA V0C0A TYPICAL. Locking spring Install locking ring. TYPICAL. Push to lock To adjust rope tension: Wind rope on sheave and place rope sheave into starter housing making sure that the sheave hub notch engages in the rewind spring hook. Rotate the sheave counterclockwise until rope end is accessible through starter housing orifice. Pull the rope out of the starter housing and temporarily make a knot to hold it. One turn preload will give 7 turns of tension when fully extended. Installation Thread starter rope no. 5 through rope guide when applicable. Reinstall rewind starter assembly on engine. NOTE: Before torque mounting bolts no. 5, apply Loctite 243 on threads. Prior to installing starter grip on new rope, it is first necessary to fuse the rope end with a lit match. Pass rope through starter grip and tie a knot in the rope end. Fuse the knot with a lit match then insert rope end down and pull the starter grip over the knot. V0C0YA TYPICAL Position pawl no. 6, pawl lock no. 7 and locking spring washer no. 8. Install locking spring no. 9. A0C8A TYPICAL VMR2004_053_04_06A.FM

42 Subsection 06 (REWIND STARTER) STARTING PULLEY Removal Remove rewind starter. Remove screw no. 2 and O-ring no. 3 retaining starting pulley no. 4 to crankshaft. Installation For installation, reverse the removal procedure. Paying attention to the following detail. Check O-ring for damage and change if necessary. Apply Loctite 243 on threads and torque the screw to 2 N m (5 lbf ft) VMR2004_053_04_06A.FM

43 Section 04 Subsection 07 ENGINE TRAXTER (MAGNETO SYSTEM) MAGNETO SYSTEM Engine oil 6 8 Loctite N m (80 lbf in) 7 N m 50 N m (62 lbf in) ( lbf ft) Loctite Loctite N m (7 lbf ft) Loctite N m (80 lbf in) 5 7 N m (62 lbf in) 2 V0C38S 9 N m (80 lbf in) VMR2004_054_04_07A.FM

44 Subsection 07 (MAGNETO SYSTEM) GENERAL To reach any parts of the magneto system, the engine removal is not necessary. During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE AP- PLICATION at the beginning of this manual for complete procedure. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed. MAGNETO HOUSING COVER Removal Place the vehicle on jack stands and place the shifter on NEUTRAL position. Remove seat then remove battery. Disconnect BLACK (-) cable from battery, then RED (+) cable. WARNING Always disconnect battery or starter cables exactly in the specified order, BLACK (-) cable first. Drain engine oil and engine coolant by removing drain plugs. Remove: rear swing arm and rear propeller shaft (refer to REAR AXLE) water pump housing (refer to COOLING SYSTEM) GBPS (Gear Box Position Sensor) V0C2IA. Gear Box Position Sensor all bolts retaining ignition cover ignition cover no. gasket no. 2. Inspection Check magneto housing cover for cracks or other damages. Change it if necessary. Installation For installation, reverse the removal procedure. Pay attention to the following details. Clean the mating surfaces then install a new gasket on ignition cover. NOTE: Clean all metal component in a non-ferrous metal cleaner. Use Bombardier gasket remover (P/N ) or suitable equivalent. Place hydraulic piston properly before installing ignition cover. Piston can move in its bore; the cover can be torqued down and the shifting system locked. V0C3SB 2 UNDER ENGINE. Engine oil plug 2. Engine coolant plug VMR2004_054_04_07A.FM

45 Section 04 Subsection 07 ENGINE TRAXTER (MAGNETO SYSTEM) If it has a space between ignition cover and crankcase, remove ignition cover and re-align the hydraulic piston. V0C39A 2 3 V0D0JA. Hydraulic piston STATOR AND TRIGGER COIL Removal Remove the ignition cover. Inside ignition cover, unscrew bolts no. 5 and the wire support no. 4. Unscrew bolts no. 3 and no. 3 retaining stator no. 4 and trigger coil no. 6. Remove connector from magneto housing cover. Inspection Check stator and trigger coil condition. If damaged, replace by a new part. For electrical inspection, refer to CHARGING SYS- TEM for the stator and IGNITION SYSTEM for the trigger coil. Installation For installation, reverse the removal procedure. ROTOR Removal Remove: magneto housing cover no. pawl no. 5. Install a strap wrench around rotor.. Strap wrench 2. Rotor 3. Nut NOTE: The strap wrench is available at automotive parts retailer. Unscrew nut no. 7 retaining rotor no. 8. NOTE: The rotor nut is a left-hand thread. Turn clockwise to remove it and counterclockwise to torque. Remove serrated washer no. 9. Install magneto puller (P/N ) and crankshaft protector (P/N ) then remove rotor. Installation For installation, reverse the removal procedure. Paying attention to the following details. Insert ring gear in sprag clutch no. 0. Install nut on crankshaft end. Apply Loctite 243 on threads. Torque to 50 N m ( lbf ft). SPRAG CLUTCH Removal Remove rotor no. 8. Unscrew all socket screws no. retaining rotor and sprag clutch housing no. 2. Remove sprag clutch from sprag clutch housing. Installation For installation, reverse the removal procedure. NOTE: Apply engine oil on sprag clutch. Install sprag clutch with the arrow on the top. VMR2004_054_04_07A.FM

46 Subsection 08 (LUBRICATION SYSTEM) LUBRICATION SYSTEM 0 0 N m (89 lbf in) Engine oil Engine oil N m (42 lbf in) Loctite Loctite N m (89 lbf in) V0C2CS Engine oil 2 N m (5 lbf ft) VMR2004_055_04_08A.FM

47 Subsection 08 (LUBRICATION SYSTEM) GENERAL During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE AP- PLICATION at the beginning of this manual for complete procedure. 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 renewed. ENGINE PRESSURE TEST NOTE: The engine pressure test should be done with a warm engine and with the recommended oil at the proper level. Remove the oil pressure switch under oil filter and install the oil pressure gauge (P/N ) with the adapter (P/N ). 3 2 When the hydraulic shifter is used, the engine oil pressure must increase up to about 80 kpa (8 PSI) at 3500 RPM. NOTE: Since gear change happen very quickly, making the to 5 LEDS flashing by upshifting and downshifting many times rapidly will make the pressure go high for long enough so it can be read. If the engine oil pressure is out of specifications, refer to TROUBLESHOOTING section. NOTE: Use also annexes and 2 at the end of manual to diagnose. OIL CHANGE AND OIL FILTER REPLACEMENT Oil and filter are to be replaced at the same time. Oil change should be done with a warm engine. WARNING The engine oil can be very hot. Wait until engine oil is warm. Ensure vehicle is on a level surface. Clean the drain plug area. Remove dipstick. Place a drain pan under the engine drain plug area. Unscrew drain plug. V0C3HA. Oil pressure gauge 2. Adapter 3. Oil filter The engine oil pressure should be between 0 kpa (4.7 PSI) and 608 kpa (88 PSI) at the idle. V0C3SC. Oil drain plug Wait a while to allow oil to flow out of oil filter. Carefully unscrew oil filter and as soon as it can be removed from the engine, turn it upright. Discard filter. NOTE: Be sure that the old filter rubber gasket is removed VMR2004_055_04_08A.FM

48 Subsection 08 (LUBRICATION SYSTEM) CAUTION: Only use Bombardier high pressure filter or suitable equivalent. The Bombardier filter is specifically designed for this engine. This filter does not operate at the same pressure as other brands. Using a non-recommended filter may cause serious engine/transmission damage. Lubricate the rubber gasket on the filter with engine oil. Install the new filter then screw one full turn after rubber gasket makes contact. Wipe out any oil spillage on engine. Change gasket on drain plug. Clean gasket area on engine and drain plug then reinstall plug. Refill engine at the proper level with the recommended oil. Refer to TECHNICAL DATA for capacity. Start engine and let idle for a few minutes. Ensure oil filter area and drain plug areas are not leaking. Stop engine. Wait a while to allow oil to flow down to crankcase then check oil level. Refill as necessary. Dispose of oil as per your local environmental regulations. OIL STRAINER Removal Ensure vehicle is on a level surface. Remove: skid plate under vehicle engine oil screws no. retaining oil strainer cover no. 2 oil collector no. 3 and O-ring no. 4 oil strainer no. 5. Cleaning and Inspection Clean oil strainer with parts cleaner then use an air gun to dry it. Inspect O-ring and oil strainer gasket no. 6 for damage. Change if necessary. Engine internal inspection is recommended if some metal particles bigger than 2 mm are found. Installation For installation, reverse the removal procedure. ENGINE OIL PRESSURE REGULATOR The engine oil pressure regulator is located near exhaust pipe bracket. It controls engine oil pressure when not shifting. V0CUA. Engine oil pressure regulator The pressure should be between 0 kpa (4.7 PSI) and 500 kpa (72.5 PSI). Removal Remove the plug screw no. 7, sealing ring no. 8, compression spring no. 9 and piston no. 0. Inspection Inspect piston for scoring or other damages. Check compression spring for free length, squareness or other damage. COMPRESSION SPRING FREE LENGTH NOMINAL (new) 43.5 mm (.7 in) SERVICE LIMIT 42 mm (.65 in) Installation For installation, reverse the removal procedure. Pay attention to the following details. Always install a new sealing ring when the oil pressure regulator is removed. When the repair is done. Perform an oil pressure test then test drive to confirm all is working well. VMR2004_055_04_08A.FM

49 Subsection 08 (LUBRICATION SYSTEM) OIL PUMP The oil pump is located on the clutch side of the crankcase housing. Removal Place the vehicle on jack stands and place the shifter on NEUTRAL position. Remove seat then remove battery. Disconnect BLACK (-) cable from battery, then RED (+) cable. WARNING Always disconnect battery or starter cables exactly in the specified order, BLACK (-) cable first. It is recommended to disconnect electrical connections prior to disconnecting fuel lines. Drain engine oil and engine coolant by removing drain plugs. starting pulley clutch cover and clutch drum (refer to CLUTCH) NOTE: To remove clutch drum, the crankshaft must be locked. To lock the crankshaft, refer to CRANKSHAFT AND BALANCER SHAFT section. snap ring no. oil pump gear no. 2 needle pin no. 3 thrust washer no. 4 oil pump cover no. 5 oil pump shaft no. 6 oil pump outer rotor no. 8 oil pump inner rotor no. 7 oil pump housing no. 9 rubber ring no. 20. Inspection Inspect oil pump for marks or other damages. Using a feeler gauge, measure the clearance between oil pump outer rotor and oil pump inner rotor. 2 A V0C3SB 2 UNDER ENGINE. Engine oil plug 2. Engine coolant plug Remove: fuel tank cover and fuel tank inner fenders engine skid plate seat pivot bar. Unplug the solenoid connectors. Remove or unplug: sub transmission position sensor NOTE: Do not unplug only, remove sensor completely. shifting rod vehicle speed sensor (unplug only) rewind starter V0CVA. Oil pump rotor 2. Inner rotor OIL PUMP ROTOR AND INNER ROTOR CLEARANCE SERVICE LIMIT A B 0.25 mm (.009 in) C Measure oil pump rotor thickness and oil pump rotor bore depth. C B VMR2004_055_04_08A.FM

50 Subsection 08 (LUBRICATION SYSTEM) Difference between measurements should not exceed 0.2 mm (.007 in). If so, replace oil pump rotors and/or oil pump housing and/or oil pump cover. Check the inside of oil pump housing for scoring or other damages. If so, change the ring housing. Check rubber ring for damage. Change if necessary. Installation For installation, reverse the removal procedure. NOTE: When the repair is done. Perform an oil pressure test then test drive to confirm all is working well. MAIN OIL PRESSURE REGULATOR The regulator works when shifting. The pressure should be between 600 kpa (87 PSI) and 800 kpa (6 PSI). Removal Remove water pump and magneto cover. Refer to MAGNETO SYSTEM. Unscrew plug no. 2. Remove compression spring no. 22, valve piston no. 23 and valve seat sleeve no. 24. Inspection Inspect piston for scoring or other damages. Check if the O-ring no. 25 is brittle, hard or other damaged. Change if necessary. Check compression spring for free length, squareness or other damage. COMPRESSION SPRING FREE LENGTH NOMINAL (new) 6.5 mm (2.42 in) SERVICE LIMIT 59.5 mm (2.34 in) Installation For installation, reverse the removal procedure. NOTE: When the repair is done. Test drive to confirm all is working well. VMR2004_055_04_08A.FM

51 Subsection 09 (CYLINDER AND CYLINDER HEAD) CYLINDER AND CYLINDER HEAD 0 0 N m (89 lbf in) 3 2 Antiseize lubricant N m (89 lbf in) Engine oil N m (37 lbf ft) 0 N m (89 lbf in) 8 Engine oil 6 22 N m (6 lbf ft) Engine oil 22 Engine oil 8 24 Engine oil Engine oil V0CCT VMR2004_056_04_09A.FM

52 Subsection 09 (CYLINDER AND CYLINDER HEAD) GENERAL To remove any parts of the cylinder head or cylinder, the engine removal is not necessary. During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE AP- PLICATION at the beginning of this manual for complete procedure. 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 renewed. NOTE: For a better understanding, the following illustrations are taken with engine out of vehicle. To perform the following instructions, it is not necessary to remove engine from vehicle. Always disconnect the negative wire from the battery before working the engine. Even if the removal of many parts is not necessary to reach another part, it is recommended to remove these parts in order to check them. When disassembling parts that are duplicated in the engine, (eg: valves, springs, etc.), it is strongly recommended to note their position (PTO, MAG side) and to keep the 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 (eg: you found a worn valve guide. A bent spring could be the cause; it will be easy to know which one of the springs is the cause and to replace it if you grouped the parts of the same assembly at disassembly). Besides, since used parts have matched together during the engine operation, they will keep their matched fit when you reassemble them together within their group. When the repair is done, test drive to confirm all is working well. If the test drive is good, perform a change of engine oil to catch all metal chips or other debris in the engine coming from the repair. VALVE COVER Removal Remove seat then disconnect battery. First, disconnect BLACK (-) cable from battery, then RED (+) cable. WARNING Always disconnect battery or starter cables exactly in the specified order, BLACK (-) cable first. Unscrew valve cover bolts no.. Unplug the crankcase vent from the valve cover nipple. Remove valve cover no. 2 and valve cover gasket no. 3. Inspection Check valve cover for cracks or other damages. Replace it if necessary. Check if the valve cover gasket is brittle, hard or damaged. Replace if necessary. Installation For installation, reverse the removal procedure. CYLINDER HEAD NOTE: When diagnosing an engine problem, always perform a cylinder leak test. This will help pin-point a problem. Refer to the instructions included with your leak tester, for procedure. Removal Drain engine coolant by removing drain plug. V0C3SA UNDER ENGINE. Engine coolant plug VMR2004_056_04_09A.FM

53 Subsection 09 (CYLINDER AND CYLINDER HEAD) Remove valve cover. Disconnect temperature sensor. Unplug radiator inlet hose. Remove screws retaining air box. Unscrew the clamp retaining carburetor adaptor to engine. Pull back the air box with carburetor assembly. Remove: exhaust pipe (refer to REMOVAL AND INSTALLATION) valve cover no. 2 and its gasket no. 3 flanged bolts no. 4 retaining cylinder head no. 5 to cylinder no. 6 flanged nuts no. 7 retaining cylinder head to the engine. Installation For installation, reverse the removal procedure. Install a new gasket no. 8 between cylinder head and cylinder no. 6. Install the flanged nuts no. 7 in first then flanged bolts no. 4. PUSH ROD Removal Remove cylinder head no. 5. Pull the push rods no. 9 out of cylinder no. 6. Inspection Check push rod end for wear or damage. Check push rod for bends by placing the rod on a flat metal plate. Rotate rod and measure the deflection with a dial indicator. If the rod is bent, it should be replaced. PUSH ROD BEND SERVICE LIMIT 0.2 mm (.008 in) Installation For installation, reverse the removal procedure. NOTE: Apply engine oil on push rod end, on the hydraulic lifter side only. On the rocker arm side, apply anti-seize lubricant. V0CDA. Flanged nuts Pull up cylinder head. Inspection Check for crack between valve seats, if so, replace cylinder head. ROCKER ARM Removal Remove: cylinder head no. 5 holding strip no. 0. Extract rocker arm shaft no. using a M8 x 53.5 screw. NOTE: Use a flanged bolt no. 4 retaining cylinder head to cylinder. VMR2004_056_04_09A.FM

54 Subsection 09 (CYLINDER AND CYLINDER HEAD) Measure of shaft diameter. ROCKER ARM SHAFT DIAMETER MINIMUM (new) MAXIMUM (new) SERVICE LIMIT mm (.5386 in) mm (.539 in) 3.67 mm (.5382 in) Any area worn excessively will require part replacement. V0CEA. Rocker arm shaft 2. Flanged bolt 3. Rocker arm Inspection Rocker Arm Inspect each rocker arm for cracks and scored friction surfaces. If so, replace parts. Measure rocker bore diameter. If diameter is out of specification, change the rocker arm. V0CFA A. Rocker arm bore diameter 3 A 2 Installation For installation, reverse the removal procedure. NOTE: Apply anti-seize lubricant on rocker arm shaft. VALVE SPRING Removal Remove: cylinder head no. 5 rocker arm no. 2. Compress valve spring no. 3. Use valve spring compressor clamp (P/N ) and valve spring compressor cup (P/N ). Remove valve cotters no. 4. Remove spring compressor clamp, valve spring retainer no. 5 and valve spring. Inspection Check valve spring for rust or corrosion, free length and squareness. ROCKER ARM BORE DIAMETER MINIMUM (new) MAXIMUM (new) SERVICE LIMIT 3.75 mm (.540 in) mm (.54 in) mm (.542 in) Rocker Arm Shaft Check for scored friction surfaces, if so, replace parts. Insert shaft in rocker arm and check for excessive play. R60motr22A A A. Valve spring length VMR2004_056_04_09A.FM

55 Subsection 09 (CYLINDER AND CYLINDER HEAD) Installation For installation, reverse the removal procedure. Pay attention to the following details. Colored area of the valve spring must be placed on top. NOTE: Valve cotters must be properly engaged in valve stem grooves. VALVE Removal Remove valve spring no. 3. Push the valve stem then pull valve no. 6 out of valve guide. Inspection VALVE SPRING FREE LENGTH SERVICE LIMIT 39 mm (-/2 in) VALVE SPRING MAXIMUM SQUARENESS SERVICE LIMIT. mm (.043 in) Valve Inspect valve surface, check for abnormal stem wear and bending. If so, replace. Valve Stem and Valve Guide Clearance Check valve stem and valve guide for wear or friction surfaces, if so, replace parts. Measure valve stem and valve guide in three places, using a micrometer and a small hole gauge. NOTE: Clean valve guide to remove carbon deposits before measuring. Change valve if valve stem is out of specification. Valve Face and Seat Check valve face and seat for burning, pitting, and other signs of damage. Apply some lapping compound to valve face and work valve on its seat with a lapping tool. Measure valve face contact width. NOTE: The location of contact area should be in center of valve face. Measure valve seat width, using a caliper. If valve seat contact width is too wide, too narrow or has spots, the seat must be ground or cylinder head replaced. A VALVE SEAT CONTACT WIDTH Exhaust Intake Exhaust Intake NEW SERVICE LIMIT.25 to.55 mm (.049 to.06 in).45 to.75 mm (.057 to.069 in) 2 mm (.078 in).8 mm (.07 in) B VALVE STEM DIAMETER SERVICE LIMIT Exhaust Intake 6.95 mm (.274 in) V0CHA VALVE GUIDE CLEARANCE SERVICE LIMIT Exhaust 0.3 mm (.005 in) Intake A. Valve face contact width B. Valve seat contact width Installation For installation, reverse the removal procedure. NOTE: Apply engine oil on valve stem. VMR2004_056_04_09A.FM

56 Subsection 09 (CYLINDER AND CYLINDER HEAD) VALVE STEM SEAL Removal Remove valve(s). Remove circlip on the bottom of valve stem seal no. 7. Inspection Cylinder Check cylinder for cracks, scoring, rust and wear ridges on the top and bottom of the cylinder. Cylinder Taper Measure cylinder diameter 6 mm (5/8 in) from top of cylinder then half-way through and finally at 3 mm (/2 in) from bottom. 2 V0CIA. Circlip 2. Valve stem seal Inspection Inspection of valve stem seals is not needed as new seals should always be installed whenever a cylinder head is diassembled. Installation For installation, reverse the removal procedure. CYLINDER Removal Remove: cylinder head no. 5 water cooling hose from cylinder no. 9 push rods no. 9 all flanged screws no. 8 retaining cylinder no. 6 to the crankcase housing. Pull cylinder. V0CJA. Measure at three points MAXIMUM (new) SERVICE LIMIT CYLINDER TAPER mm (.00 in) mm (.004 in) Cylinder Out-of-Round Measure cylinder diameter in piston axis direction from top of cylinder. Take an other measurement 90 from first one and compare VMR2004_056_04_09A.FM

57 Subsection 09 (CYLINDER AND CYLINDER HEAD) A B Inspection Check for excessive clearance between lifter and its bore or straightness. A telescoping gauge and micrometer are used to check the lifter bore clearance. Subtract lifter diameter from lifter bore diameter to determine clearance. LIFTER AND LIFTER BORE SERVICE LIMIT Lifter Lifter bore 22.9 mm (.874 in) mm (.876 in) V0CKA A. Perpendicular to crankshaft axis B. Parallel to crankshaft axis Installation For installation, reverse the removal procedure. Pay attention to the following details. Apply engine oil in cylinder bore. Install a new gasket no. 20 between cylinder and crankcase. Using a ring compressor, slide piston no. 2 into cylinder. Install bolts no. 8 first, then flanged bolts no. 4, then flanged nuts no. 7. LIFTER Removal CYLINDER OUT-OF-ROUND MAXIMUM (new) SERVICE LIMIT mm (.0002 in) 0.05 mm (.006 in) Remove cylinder no. 6. Pull hydraulic lifters no. 22 out of crankcase. If the clearance is out of specified tolerance change lifter and/or crankcase. Installation For installation, reverse the removal procedure. PISTON Removal Remove cylinder no. 6. Remove both piston pin circlips no. 23 then push piston pin no. 24 out of piston no. 2. Detach piston from connecting rod. Inspection LIFTER BORE CLEARANCE SERVICE LIMIT 0.08 mm (.003 in) Inspect piston for scoring, cracking or other damages. Using a micrometer, measure piston at 6 mm (5/8 in) perpendicularly (90 ) to piston pin axis. VMR2004_056_04_09A.FM

58 Subsection 09 (CYLINDER AND CYLINDER HEAD) With the micrometer set to the dimension, adjust a cylinder bore gauge to the micrometer dimension and set the indicator to 0 (zero). A 2 V0C3KA TYPICAL. Measuring perpendicularly (90 ) to piston pin axis A. 6 mm (5/8 in) The measured dimension should be as described in the previous table. If not, replace piston. PISTON MEASUREMENT F00B09A. Use the micrometer to set the cylinder bore gauge 2. Dial bore gauge SERVICE LIMIT 88.9 mm (3.5 in) Piston/Cylinder Clearance PISTON/CYLINDER CLEARANCE NEW 0.06 to mm (.0006 to.002 in) SERVICE LIMIT mm (.004 in) NOTE: Make sure used piston is not worn. See PISTON MEASUREMENT TABLE above. Adjust and lock a micrometer to the piston dimension. F00B08A F00B0AA TYPICAL. Indicator set to 0 (zero) Position the dial bore gauge at 6 mm (5/8 in) below cylinder top edge, measuring perpendicularly (90 ) to piston pin axis. Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. If clearance exceeds specified tolerance, replace cylinder or rebore. See previous table. NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the micrometer, otherwise the reading will be false.. Micrometer set to the piston dimension VMR2004_056_04_09A.FM

59 Subsection 09 (CYLINDER AND CYLINDER HEAD) Installation For installation, reverse the removal procedure. Paying attention to the following details. Apply engine oil on the piston pin. Insert piston pin into piston and connecting rod. Secure piston pin with both piston pin circlips. NOTE: Do not align the end gap of the piston pin circlips with the cutout in the piston bore. A PISTON RINGS Removal Remove piston. To remove piston ring no. 25, it is recommended to use ring expanders. This special plier is available at automotive parts retailers. Inspection Ring/Piston Groove Clearance Using a feeler gauge measure each ring/piston groove clearance. If the clearance is too large, the piston should be replaced. RING/PISTON GROOVE CLEARANCE MINIMUM (new) Upper compression ring 0.03 mm (.00 in) Lower compression ring 0.03 mm (.00 in) Oil scraper ring 0.02 mm (.0008 in) MAXIMUM (new) Upper compression ring mm (.0024 in) Lower compression ring mm (.0024 in) Oil scraper ring mm (.0022 in) SERVICE LIMIT All 0.5 mm (.006 in) V0CLA A. Measure here Ring End Gap Upper compression ring Lower compression ring Oil scraper ring Upper compression ring Lower compression ring Oil scraper ring All RING END GAP MINIMUM (new) MAXIMUM (new) SERVICE LIMIT 0.5 mm (.006 in) 0.5 mm (.006 in) 0.5 mm (.006 in) 0.35 mm (.04 in) 0.40 mm (.06 in) 0.35 mm (.04 in).5 mm (.06 in) Position ring 6 mm (5/8 in) from top of cylinder. NOTE: In order to correctly position the ring in the cylinder, use piston as a pusher. Using a feeler gauge, check ring end gap. Replace ring, if gap exceeds specified tolerance. See above table. VMR2004_056_04_09A.FM

60 Subsection 09 (CYLINDER AND CYLINDER HEAD) Installation For installation, reverse the removal procedure. Paying attention to the following details. Install the oil ring first, then the middle ring with the word TOP facing up, then the top ring with the dot facing up. 2 3 A3C2NA. Upper compression (black/gray color) 2. Lower compression ring (chrome/stainless steel looking ring) 3. Oil ring or oil scraper ring CAUTION: Ensure that top and second rings are not interchanged. NOTE: Use a ring expander to prevent breakage during installation. The oil ring must be installed by hand. Check that rings rotate smoothly after installation. Space the piston ring end gaps 20 apart and do not align the gaps with the piston pin bore or the thrust side axis. A A A 2 A3C2OA. DO NOT align ring gap with piston thrust side axis 2. DO NOT align ring gap with piston pin bore axis A VMR2004_056_04_09A.FM

61 Subsection 0 (CRANKSHAFT/BALANCER SHAFT) CRANKSHAFT/BALANCER SHAFT N m (70 lbf ft) 4 Loctite N m (6 lbf ft) N m ( lbf ft) Loctite Engine oil Anti-seize lubricant Loctite Anti-seize lubricant 3 0 Engine oil Anti-seize lubricant Anti-seize lubricant Anti-seize lubricant V0C2DT VMR2004_057_04_0A.FM 04-0-

62 Subsection 0 (CRANKSHAFT/BALANCER SHAFT) GENERAL To remove camshaft, the engine removal is not necessary. But, for removal of balancer shaft or crankshaft, engine removal is necessary. During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE AP- PLICATION at the beginning of this manual for complete procedure. 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 renewed. When the repair is done. Test drive to confirm all is working well. TO LOCK THE CRANKSHAFT The following procedures can be perform with the engine in the vehicle or on the workbench. The crankshaft is locked with the crankshaft locking bolt (P/N ). First, remove one spark plug. Then, remove the rewind starter and the clutch cover. Refer to the specific sections for the procedure. The hole for the crankshaft locking bolt is located under clutch drum. V0C3IA 2. Clutch drum 2. Hole for the crankshaft locking bolt Look in the hole and, with the help of the clutch drum, turn the crankshaft until the locking notch on the crankshaft is aligned with the hole. Using a 6 mm socket (short), an universal joint and an extension, place the crankshaft locking bolt in the threaded hole and screw bolt in place to lock the crankshaft V0C3JA. Crankshaft locking bolt 2. 6 mm socket 3. Universal joint 4. Extension NOTE: Do not forget to remove crankshaft locking bolt before installing the clutch cover VMR2004_057_04_0A.FM

63 Subsection 0 (CRANKSHAFT/BALANCER SHAFT) CAMSHAFT Removal To remove camshaft no., do the following procedure. Place the vehicle on jack stands and place the shifter on NEUTRAL position. Remove seat then remove battery. Disconnect BLACK (-) cable from battery, then RED (+) cable. WARNING Always disconnect battery or starter cables exactly in the specified order, BLACK (-) cable first. It is recommended to disconnect electrical connections prior to disconnecting fuel lines. Remove or unplug: cylinder head, cylinder and hydraulic lifters (refer to CYLINDER AND HEAD) sub transmission position sensor NOTE: Do not unplug only, remove sensor completely. shifting rod vehicle speed sensor (unplug only) rewind starter (refer to REWIND STARTER) clutch cover and clutch drum (refer to CLUTCH) bolt no. 6, lock washer no. 7 and washer no. 8 retaining cam shaft gear no. 9 with centrifugal weight no. 0. Drain engine oil and engine coolant by removing drain plugs. V0CXA V0C3SB UNDER ENGINE. Engine oil plug 2. Engine coolant plug 2 Remove: fuel tank cover inner fenders engine skid plate seat pivot bar. Unplug the solenoid connectors. Unscrew all bolts retaining fuel tank then remove fuel tank.. Crankshaft gear nut 2. Crankshaft gear 3. Cam shaft gear 4. Control gear 5. Balancing shaft gear 6. Oil pump gear Unscrew the screws retaining the camshaft housing then remove the housing. Remove camshaft. VMR2004_057_04_0A.FM

64 Subsection 0 (CRANKSHAFT/BALANCER SHAFT) Inspection Check each lobe for scoring, scuffing, cracks, or other sign of wear. Measure each end of camshaft. V0CZA CAMSHAFT ENDS mm (in) SERVICE LIMIT Clutch side 3.95 (.258) Magneto side 7.96 (.707). Measure here Measure the camshaft bore in both housing. NOTE: To measure camshaft bores, it is necessary to remove engine from vehicle and split the crankcase. Subtract the camshaft end diameter from the proper bore diameter to find clearance. If necessary, change camshaft and/or camshaft housing and/or crankcase. Installation CAMSHAFT BORE mm (in) SERVICE LIMIT Clutch housing (.26) Magneto housing (.7) CAMSHAFT END CLEARANCE mm (in) SERVICE LIMIT Clutch side (.0034) Magneto side (.0029) For installation reverse the removal procedure. Paying attention to the following details. Align the dot on the camshaft gear with the dot on the control gear. Always install new housing gasket(s). BALANCER SHAFT Removal To reach and remove the balancer shaft no. 2, perform the following procedure. Remove: engine from the vehicle (refer to REMOVAL AND INSTALLATION) cylinder head, cylinder, piston, clutch cover, the first section of shifting system, clutch drum, clutch housing, clutch basket and camshaft no. crankshaft gear nut no. 4, use 46 mm socket (P/N ), then remove crankshaft gear no. 5 NOTE: Do not forget. The crankshaft must be locked to remove clutch drum and all nuts. nut no. and lock washer no. 2 retaining control gear no. 3 and balancing shaft gear. Remove both gears oil pump gear holding strip retaining oil pipe the second section of shifting system (refer to TRANSMISSION) starter, water pump, magneto and ring gear (refer to MAGNETO SYSTEM) all bolts and socket screws retaining crankcase. Separate crankcase housings. Remove balancer shaft. Inspection Check balancer shaft bearing in the front and rear housing for excessive play and smooth operation. Replace if necessary. Installation For installation, reverse the removal procedure. Do not forget, to align the camshaft gear dot with the control gear dot as well as the dot on crankshaft gear with the balancing shaft gear dot VMR2004_057_04_0A.FM

65 Subsection 0 (CRANKSHAFT/BALANCER SHAFT) CRANKSHAFT Removal Use the same removal procedure as balancer shaft. Remove crankshaft no. 3 and adjusting washer no. 4. Inspection Crankshaft Deflection Crankshaft deflection is measured with a dial indicator. Check crankshaft deflection on V blocks. If deflection exceeds the specified tolerance, change it. CRANKSHAFT DEFLECTION mm (in) SERVICE LIMIT Clutch side 0.08 (.003) Magneto side 0.05 (.002) Connecting Rod/Piston Pin Clearance Measure piston pin. Compare to inside diameter of connecting rod. CONNECTING ROD SMALL END DIAMETER SERVICE LIMIT mm (.869 in) PISTON PIN DIAMETER SERVICE LIMIT 2.99 mm (.866 in) PISTON PIN BORE CLEARANCE SERVICE LIMIT 0.08 mm (.003 in) Installation For installation, reverse the removal procedure. Do not forget, align the camshaft gear dot with the control gear dot as well as the dot of crankshaft gear with the balancing shaft gear dot. NOTE: Recentre the crankshaft in the crankcase if the crankshaft or the crankcase are replaced. RECENTRE CRANKSHAFT NOTE: Only fit spacer on the magneto end. Place crankshaft into rear crankcase housing (magneto side). Do not install spacer on clutch side at this time. Using depth gauge, measure distance between crank web and housing edge. This is the dimension B. V0C2EA. Measure here Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. If the distance exceeds specified tolerance, replace the crankshaft. CONNECTING ROD BIG END mm (in) SERVICE LIMIT Axial play.3 (.05) Radial play 0.08 (.003) V0C2FA VMR2004_057_04_0A.FM

66 Subsection 0 (CRANKSHAFT/BALANCER SHAFT) Determine dimension between case and inner ring of bearing. Place a compressed gasket on front crankcase housing (clutch side). This is the dimension A. V0C2GA Subtract dimension B from dimension A, the result is the end float of crankshaft plus spacer thickness. Select suitable spacer to ensure the correct end float is obtained. END FLOAT OF CRANKSHAFT 0. to 0.4 mm (.004 to.06 in) THICKNESS ADJUSTING SPACERS AVAILABLE.3 mm (.05 in).5 mm (.060 in).8 mm (.07 in) VMR2004_057_04_0A.FM

67 Subsection (CLUTCH) CLUTCH N m (99 lbf ft) Loctite Engine oil 2 Engine oil 3 5 Engine oil N m ( lbf ft) Loctite Engine oil Engine oil N m (62 lbf in) Engine oil 3 Engine oil V0D0PS VMR2004_058_04_A.FM 04--

68 Subsection (CLUTCH) CLUTCH DRUM, CLUTCH WEIGHT AND SPRAG CLUTCH Disassembly Remove: engine oil and coolant rewind starter drive shaft (refer to FRONT DRIVE) clutch cover. Install the crankshaft locking bolt (P/N ). Sparg Clutch Hold clutch drum and rotate clutch weight. The clutch weight should only turn counterclockwise. If it rotates in both directions, replace the sprag clutch. Inspect sparg clutch no. 5 for smooth operation and roller for excessive wear. Change sparg clutch if necessary. Weight Lining Remove E-clips, washer, clutch spring and washer. Remove clutch weights. Measure weight lining thickness. The weight lining thickness must be at least 2.0 mm (5/64 in). A V0D02A. Crankshaft locking bolt Unscrew nut no. retaining clutch weight assembly no. 4 to crankshaft. Pull clutch drum no. 2 out of housing and remove thrust washer no. 3. Separate clutch weight assembly from clutch drum. Inspection Clutch Drum Check inside of drum clutch for excessive wear or scratches.change if necessary. Measure the inside diameter of clutch drum. If the I.D. is over to 40.4 mm (5-7/32 in), change clutch drum. V0D03A A. Weight lining If weight lining thickness is out of specification, replace the clutch weight assembly. Weight Spring Remove E-clips, washer, clutch spring and washer. Remove clutch weights and weight springs from plate VMR2004_058_04_A.FM

69 Subsection (CLUTCH) Measure length of weight springs. If they are longer than 2.6 mm (.85 in), change the clutch weight assembly. V0D0EA A. 2.6 mm (.85 in) Check weight springs for wear or other damage. Replace the clutch weight assembly if necessary. Assembly A For installation, reverse the removal procedure. Pay attention to the following details. Install weight springs with the open ends down. Install sparg clutch in clutch drum with its OUT SIDE mark facing out. Apply engine oil on sprag clutch. FRICTION DRIVE PLATE, STEEL DRIVEN PLATE AND CLUTCH BASKET Disassembly Remove: engine oil and coolant rewind starter clutch cover front output shaft collar sleeve helical spring parking locking lever shaft tension spring indicator shaft actuating lever and thrust washer circlip output gear V0D04A. Out side mark V0D05A Front output shaft 2. Collar sleeve 3. Helical spring 4. Parking locking lever 5. Shaft 6. Tension spring 7. Indicator shaft 8. Actuating lever 9. Circlip 0. Output gear clutch housing. VMR2004_058_04_A.FM 04--3

70 Subsection (CLUTCH) Install the crankshaft locking bolt (P/N ). FRICTION DRIVE PLATE MINIMUM THICKNESS 2.8 mm (. in) V0D06A 2 3. Crankshaft locking bolt 2. Clutch drum 3. Oil pump gear Remove clutch drum no. 2 and thrust washer no. 3. Remove clutch bolts no. 6, pressure plate no. 7 and clutch spring no. 8. Unlock the tab washer no. 9 then install spanner tool for clutch basket (P/N ). Unscrew the clutch lock nut no. 0 then remove tab washer. Remove: clutch hub no. friction drive plates no. 2 steel driven plates no. 3 inner plate no. 4 thrust washer no. 5 O-ring no. 2 clutch basket no. 6 needle bearings no. 8 and no. 9 large thrust washer no. 7. Inspection Friction Drive Plate Measure each friction drive plate thickness. Friction drive plates must be replaced when lining is 2.8 mm (. in) thick or less. V0D07A Steel Driven Plate Using a feeler gauge, check each steel driven plate for warpage on a flat surface. Change if the warpage is over to 0.25 mm (.0 in) or if they show signs of discoloration. V0D08A STEEL DRIVEN PLATE MAXIMUM WARPAGE 0.25 mm (.0 in) VMR2004_058_04_A.FM

71 Subsection (CLUTCH) Clutch Basket Check slots of clutch basket for damage or wear caused by friction drive plates. Change if necessary. V0D0BA V0D09A Clutch Hub Check grooves of clutch hub for damage or wear caused by steel driven plates.. Retaining plate bearing Clutch Spring Measure each clutch springs free length. CLUTCH SPRING MINIMUM LENGTH 32.5 mm (.28 in) V0D0CA V0D0AA Pressure Plate Bearing Check the pressure plate bearing no. 20. Turn the bearing with your finger. The bearing should turn smoothly and not have excessive play. Replace if necessary. Assembly For assembly, reverse the disassembly procedure. Pay attention to the following details. Install large thrust washer no. 7, the wide needle bearing no. 9 then the narrow needle bearing no. 8. Assemble friction drive plates, steel driven plates, inner plate and clutch hub in clutch basket. Apply engine oil on each friction drive plate. VMR2004_058_04_A.FM 04--5

72 Subsection (CLUTCH) NOTE: Place the last friction drive plate in short slots of clutch basket. 2 3 V0D0DA. Last friction drive plate 2. Retaining plate 3. Clutch basket Install a new tab washer and clutch lock nut. Fold up tab washer on nut. CAUTION: Do not use clutch lock nut to install clutch hub in clutch basket. V0D0IA VMR2004_058_04_A.FM

73 Subsection 2 (TRANSMISSION) TRANSMISSION 0 GEAR SHIFT SYSTEM Engine oil 0 N m (89 lbf in) Engine oil 2 0 N m (89 lbf in) Engine oil Engine oil Engine oil 23 5 Engine oil Engine oil Loctite 243 Engine oil 20 Engine oil N m (89 lbf in) 4 0 N m (89 lbf in) V0E0LS VMR2004_059_04_2A.FM 04-2-

74 Subsection 2 (TRANSMISSION) TRANSMISSION Loctite 243 Anti-seize lubricant 8 7 Anti-seize lubricant Anti-seize lubricant Anti-seize lubricant Molykote G-n Loctite N m (89 lbf in) Anti-seize lubricant 5 23 Anti-seize lubricant V0E0MS Anti-seize lubricant Anti-seize lubricant VMR2004_059_04_2A.FM

75 Subsection 2 (TRANSMISSION) GEAR SHIFT MECHANISM Disassembly Front Side Remove: engine from vehicle (refer to REMOVAL AND INSTALLATION) rewind starter (refer to REWIND STARTER) clutch (refer to CLUTCH) shift shaft no. Rear Side Remove: water pump and magneto cover nut no. 8 retaining shift drum gear 2 Callout V0E0QA 3 V0E0OA. Shift shaft socket screw no. 2 and lock washer retaining index gear no. 3. Shift drum gear nut 2. Lock washer 3. Index gear screw no. 9, washer no. 0, index lever no. and index spring no V0E0PA. Index gear NOTE: Insert a flat screw driver in the index lever slot and twist the screw driver clockwise then pull index gear. socket screw no. 4, washer no. 5, index lever no. 6 and index spring no. 7. V0E0RA. Screw 2. Washer 3. Index lever 4. Index spring VMR2004_059_04_2A.FM

76 Subsection 2 (TRANSMISSION) Remove the tension spring no. 3 then pull shift shaft with pawl no. 4 out of housing. V0E0FA 2 3 V0E0SA 2. Tension spring 2. Shift shaft with pawl Assembly Clutch Side Reassemble in the reverse order of disassembly. Pay attention to the following detail. Align mark on index gear with mark on shift shaft.. Indicator shaft 2. Shift shaft 3. Transmission actuating lever Magneto Side Reassemble in the reverse order of disassembly. TRANSMISSION Disassembly Remove gear shift mechanism. Separate both housing of crankcase. Remove the shift fork shafts no. 5, no. 6 and no. 7. Remove shift fork no. 8 then pull shift drum no. 9. Pull all gears and shafts, at the same time. V0E0EA 2. Index gear 2. Shift shaft After clutch housing installation, align mark on shift shaft with mark on indicator shaft. V0E0GA VMR2004_059_04_2A.FM

77 Subsection 2 (TRANSMISSION) Inspection Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Replace if necessary. During and after transmission disassembly, inspect the condition of each parts closely. In particular, check for: gear teeth damage worn or scored bearing surfaces worn or scored shifting fork worn or scored shift fork shaft rounded engagement dogs and slots bent shift forks bent shift fork shaft worn shift fork engagement pins worn tracks on shift drum worn splines on shafts and gears. Change any defective part. Assembly Reassemble in the reverse order of disassembly. Pay attention to the following details. NOTE: Install all shafts and gears together. Place the shift forks no. 20, no. 2, no. 22 and no. 23 in the proper shift drum tracks before install the transmission in half housing. Place the last shift fork no. 8 in after transmission is installed in housing half. Install the shift drum. NOTE: Verify shaft pin is properly installed in drum slot before installing housing. V0E0IA. Shaft pin 2. Shift drum Install the shift fork shafts. NOTE: Make sure all of the shift fork pins are aligned with the grooves in the shift drum. Install the index gear on end of shift drum. At the same time, turn the sub-transmission shaft no. 24 and the index gear no. 3. The transmission should turn smoothly. 2 VMR2004_059_04_2A.FM