Transcript
Section 04 ENGINE – TRAXTER Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
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TROUBLESHOOTING ............................................................................................................ COOLING SYSTEM ........................................................................................................... MAGNETO SYSTEM ......................................................................................................... LUBRICATION.................................................................................................................... CYLINDER AND HEAD ...................................................................................................... CRANKSHAFT AND BALANCER SHAFT.......................................................................... GEARBOX .......................................................................................................................... REWIND STARTER ............................................................................................................ ENGINE - GENERAL ..........................................................................................................
04-02-1 04-02-1 04-02-3 04-02-4 04-02-6 04-02-6 04-02-7 04-02-8 04-02-9
LEAK TEST............................................................................................................................. VERIFICATION ................................................................................................................... LEAK TEST PROCEDURE .................................................................................................. PREPARATION AND TEST................................................................................................ DIAGNOSE ......................................................................................................................... INSTALLATION..................................................................................................................
04-03-1 04-03-1 04-03-1 04-03-1 04-03-2 04-03-2
REMOVAL AND INSTALLATION .......................................................................................... 04-04-1 ENGINE REMOVAL ........................................................................................................... 04-04-3 ENGINE INSTALLATION ................................................................................................... 04-04-6 ANTI-VIBRATION SYSTEM............................................................................................... 04-04-8 EXHAUST SYSTEM .......................................................................................................... 04-04-8 SHIFTING SYSTEM............................................................................................................ 04-04-10 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_01ATOC.FM
04-05-1 04-05-1 04-05-2 04-05-3 04-05-3 04-05-3 04-05-4 04-05-4 04-05-4 04-05-5 04-05-5 04-05-6 04-05-6 04-05-6 04-05-7 04-05-8 04-05-8 04-01-1
Section 04 ENGINE – TRAXTER Subsection 01 (TABLE OF CONTENTS)
WATER PUMP SHAFT ....................................................................................................... 04-05-8 WATER PUMP CERAMIC SEAL......................................................................................... 04-05-8 WATER PUMP BEARINGS................................................................................................. 04-05-9 REWIND STARTER ................................................................................................................. 04-06-1 REWIND STARTER............................................................................................................. 04-06-2 STARTING PULLEY............................................................................................................ 04-06-4 MAGNETO SYSTEM .............................................................................................................. GENERAL............................................................................................................................ MAGNETO HOUSING COVER........................................................................................... STATOR AND TRIGGER COIL ........................................................................................... ROTOR ................................................................................................................................ SPRAG CLUTCH .................................................................................................................
04-07-1 04-07-2 04-07-2 04-07-3 04-07-3 04-07-3
LUBRICATION SYSTEM......................................................................................................... GENERAL............................................................................................................................ ENGINE PRESSURE TEST ................................................................................................. OIL CHANGE AND OIL FILTER REPLACEMENT .............................................................. OIL STRAINER .................................................................................................................... ENGINE OIL PRESSURE REGULATOR ............................................................................. OIL PUMP ........................................................................................................................... MAIN OIL PRESSURE REGULATOR .................................................................................
04-08-1 04-08-2 04-08-2 04-08-2 04-08-3 04-08-3 04-08-4 04-08-5
CYLINDER AND CYLINDER HEAD ........................................................................................ GENERAL............................................................................................................................ VALVE COVER .................................................................................................................... CYLINDER HEAD ................................................................................................................ PUSH ROD .......................................................................................................................... ROCKER ARM..................................................................................................................... VALVE SPRING................................................................................................................... VALVE ................................................................................................................................. VALVE STEM SEAL ............................................................................................................ CYLINDER ........................................................................................................................... LIFTER ................................................................................................................................. PISTON ............................................................................................................................... PISTON RINGS ...................................................................................................................
04-09-1 04-09-2 04-09-2 04-09-2 04-09-3 04-09-3 04-09-4 04-09-5 04-09-6 04-09-6 04-09-7 04-09-7 04-09-9
CRANKSHAFT/BALANCER SHAFT ....................................................................................... GENERAL............................................................................................................................ TO LOCK THE CRANKSHAFT ............................................................................................ CAMSHAFT......................................................................................................................... BALANCER SHAFT............................................................................................................. CRANKSHAFT .................................................................................................................... RECENTRE CRANKSHAFT.................................................................................................
04-10-1 04-10-2 04-10-2 04-10-3 04-10-4 04-10-5 04-10-5
04-01-2
VMR2004_079_04_01ATOC.FM
Section 04 ENGINE – TRAXTER Subsection 01 (TABLE OF CONTENTS)
CLUTCH.................................................................................................................................. CLUTCH DRUM, CLUTCH WEIGHT AND SPRAG CLUTCH ............................................ FRICTION DRIVE PLATE, STEEL DRIVEN PLATE AND CLUTCH BASKET.....................
04-11-1 04-11-2 04-11-3
TRANSMISSION.................................................................................................................... GEAR SHIFT SYSTEM ....................................................................................................... TRANSMISSION ................................................................................................................ GEAR SHIFT MECHANISM ............................................................................................... TRANSMISSION ................................................................................................................
04-12-1 04-12-1 04-12-2 04-12-3 04-12-4
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04-01-3
Section 04 ENGINE – TRAXTER Subsection 02 (TROUBLESHOOTING)
TROUBLESHOOTING
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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. 1. 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.
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Section 04 ENGINE – TRAXTER 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. 10. Check radiator condition. a. Radiator dirty or air ducts obstructed. Clean radiator fins and/or air ducts. 11. Check radiator fan. a. Fan does not work properly. Check and/or replace.
04-02-2
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Section 04 ENGINE – TRAXTER Subsection 02 (TROUBLESHOOTING)
MAGNETO SYSTEM SYMPTOM CONDITION Test/Inspection
NO SPARK. NORMAL USE. 1. 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.
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04-02-3
Section 04 ENGINE – TRAXTER Subsection 02 (TROUBLESHOOTING)
LUBRICATION SYMPTOM CONDITION Test/Inspection
LOW OR NO OIL PRESSURE. NORMAL USE. 1. 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).
04-02-4
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Section 04 ENGINE – TRAXTER Subsection 02 (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). 10. 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. 1. 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).
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Section 04 ENGINE – TRAXTER Subsection 02 (TROUBLESHOOTING)
CYLINDER AND HEAD SYMPTOM CONDITION Test/Inspection
UNUSUAL ENGINE NOISE AND/OR VIBRATION. NORMAL USE. 1. 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. 1. 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. 1. 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.
04-02-6
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Section 04 ENGINE – TRAXTER Subsection 02 (TROUBLESHOOTING)
GEARBOX SYMPTOM CONDITION Test/Inspection
UNUSUAL ENGINE NOISE AND/OR VIBRATIONS. NORMAL USE. 1. 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. 1. 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).
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04-02-7
Section 04 ENGINE – TRAXTER Subsection 02 (TROUBLESHOOTING)
SYMPTOM CONDITION Test/Inspection
GEAR(S) IS (ARE) HARD TO SHIFT. NORMAL USE. 1. 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. 1. 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. 1. 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.
04-02-8
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Section 04 ENGINE – TRAXTER Subsection 02 (TROUBLESHOOTING)
ENGINE - GENERAL SYMPTOM CONDITION Test/Inspection
ENGINE BACKFIRES. NORMAL USE. 1. 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.
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04-02-9
Section 04 ENGINE – TRAXTER Subsection 02 (TROUBLESHOOTING)
SYMPTOM CONDITION Test/Inspection
ENGINE SUDDENLY TURNS OFF. NORMAL USE. 1. 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.
04-02-10
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Section 04 ENGINE – TRAXTER Subsection 02 (TROUBLESHOOTING)
SYMPTOM CONDITION Test/Inspection
ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH MAXIMUM OPERATING RPM. NORMAL USE. 1. 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.
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04-02-11
Section 04 ENGINE – TRAXTER Subsection 02 (TROUBLESHOOTING)
SYMPTOM CONDITION Test/Inspection
ENGINE TURNS OVER BUT FAILS TO START. NORMAL USE. 1. 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. 1. 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.
04-02-12
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Section 04 ENGINE – TRAXTER Subsection 02 (TROUBLESHOOTING)
SYMPTOM CONDITION Test/Inspection
STARTER TURNS, BUT ENGINE DOES NOT CRANK. NORMAL USE. 1. 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. 1. 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).
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Section 04 ENGINE – TRAXTER Subsection 03 (LEAK TEST)
LEAK TEST
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VERIFICATION
LEAK TEST PROCEDURE
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
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.
V01C2RA
1
2
1. Leak indicator hole 2. Water pump cover
– coolant out of leak indicator hole means a damaged seal on water pump shaft (refer to COOLING 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.
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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.
04-03-1
Section 04 ENGINE – TRAXTER Subsection 03 (LEAK TEST)
Supply combustion chamber with air pressure. 1
2
3
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1. 2. 3. 4.
4
Leak tester Adequate adapter for spark plug hole Air supply hose Rocker arm shaft
Note the amount of leaking or percentage (depending on tester). LEAKAGE PERCENTAGE
ENGINE CONDITION
0% to 7%
Excellent condition
8% to 15%
Fair condition; proceed with tuned up or adjustment
16% to 30%
Poor condition; engine will run and performance might be down in some cases
30% and higher
Very poor condition; diagnose and repair engine
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.
04-03-2
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Section 04 ENGINE – TRAXTER Subsection 04 (REMOVAL AND INSTALLATION)
REMOVAL AND INSTALLATION
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All Models except XL 22 7 Nm (62 lbfin)
4
10
19
20
21 19
Synthetic grease
14
23
30
30
15 22 Nm (16 lbfft)
26
12 23 Nm (17 lbfft)
11 48 Nm (35 lbfft)
15 22 Nm (16 lbfft)
29 27 11 Nm (97 lbfin)
13 29 30
7 17
Synthetic grease
18
21
17
6
8 48 Nm 5 23 Nm (35 lbfft) (17 lbfft) 6
9 48 Nm (35 lbfft) 21
5 23 Nm (17 lbfft)
17
18
2 39 10 Nm 41 (89 lbfin)
Synthetic 5 23 Nm grease (17 lbfft) 16
17 6
3 28 23 Nm (17 lbfft) 40 10 Nm 31 (89 lbfin) 41 35
1
37 10 Nm (89 lbfin) 33
Loctite 243
38
34
36 23 Nm (17 lbfft)
34
32 10 Nm (89 lbfin) 33 V01C2TS
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34 34
10 Nm 31 (89 lbfin)
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Section 04 ENGINE – TRAXTER Subsection 04 (REMOVAL AND INSTALLATION)
XL Models 4
25
22 10 Nm (89 lbfin)
20 19
26
14 11 48 Nm (35 lbfft)
12 23 Nm (17 lbfft) 15 22 Nm (16 lbfft)
30 24
21
Synthetic grease
22 6 Nm (53 lbfin)
22 6 Nm (53 lbfin)
19
10
30
29 22 10 Nm (89 lbfin) 29
13
3
7 17 21
Synthetic grease 18 17
9 48 Nm (35 lbfft)
28
5 23 Nm (17 lbfft)
6
2
6 17 21
Synthetic grease
18 17
39 10 Nm 41 (89 lbfin) 5 23 Nm (17 lbfft) 16
6
04-04-2
10 Nm (89 lbfin)
41
35 38
1
Loctite 243
37 10 Nm (89 lbfin) 33 34 32
10 Nm (89 lbfin) 33 V01C3TS
23 Nm (17 lbfft)
40 31
27 11 Nm (97 lbfin)
34
36 23 Nm (17 lbfft)
34 34
31
10 Nm (89 lbfin)
VMR2004_051_04_04A.FM
Section 04 ENGINE – TRAXTER Subsection 04 (REMOVAL AND INSTALLATION)
ENGINE REMOVAL Vehicle Preparation Place the vehicle on jack stands and place the shifter no. 1 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 SYSTEM section. Remove radiator inlet hose. Disconnect breather hose. Unplug temperature sensor. All Models except XL Disconnect TPS connector.
V01C3SB
2
1
UNDER ENGINE 1. 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.
VMR2004_051_04_04A.FM
V01C2VA
1. 2. 3. 4. 5. 6.
3
6
4
1
5
2
Spark plug cable Exhaust pipe Radiator inlet hose Breather hose Temperature sensor TPS connector
04-04-3
Section 04 ENGINE – TRAXTER Subsection 04 (REMOVAL AND INSTALLATION)
All Models Remove carburetor no. 4. Refer to CARBURETOR AND FUEL PUMP. Remove engine impulse line.
V01J0WA
2
1
1. Pivot bolt jam nut 2. LH pivot bolt
On RH side, remove the other pivot bolt. V01C0FA
1
1
1. 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.
04-04-4
V01J0XA
TYPICAL 1. RH pivot bolt
Pull out swing arm. Unplug magneto/trigger wiring harness connector. Remove radiator outlet hose. Remove starter.
VMR2004_051_04_04A.FM
Section 04 ENGINE – TRAXTER Subsection 04 (REMOVAL AND INSTALLATION)
On RH side, remove the 3 bolts no. 5 retaining engine bracket no. 6 to frame.
V01C2ZA
TYPICAL V01C2WA
1
1. Engine bracket bolts
Remove the rear engine mounting nut no. 7, do not remove bolt no. 8 yet.
V01C2XA
Check if exhaust gasket no. 13 is removed. Install engine lifting tool (P/N 529 035 610) then install a hoist. Remove front propeller shaft bolt.
V01C30A
TYPICAL
Unscrew front mounting bolt no. 9. On LH side, remove engine mounting nut no. 10, do not remove bolt no. 11 yet.
Place rewind starter handle in frame.
V01C2YA
TYPICAL
Remove engine bracket bolts no. 12.
V01C31A
TYPICAL
VMR2004_051_04_04A.FM
04-04-5
Section 04 ENGINE – TRAXTER 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.
V01C33A
Install the 3 bolts no. 5 retaining engine supports no. 6 to frame. Torque all engine supports.
V01C0HA
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. 11 in LH engine support. Do not tighten. Install LH engine bracket bolts no. 12. Do not tighten.
BOLT
TORQUE
M8
23 N•m (17 lbf•ft)
M10
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.
V01C32A
Install rear engine support bolt no. 8 on RH side. Do not tighten. V01C34A
04-04-6
VMR2004_051_04_04A.FM
Section 04 ENGINE – TRAXTER 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 271 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 11 N•m (97 lbf•in). Move the swing arm up and down several times and retighten LH pivot bolt. Retorque LH pivot bolt to 11 N•m (97 lbf•in). Torque RH pivot bolt to 147 N•m (108 lbf•ft). Install jam nut and torque to 147 N•m (108 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 293 550 010). Apply grease (P/N 293 550 019) 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. 1
2
V01C17A
Before starting the engine, remove spark plugs no. 15 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.
V01J0AA
1. RH pivot bolt 2. Pivot bearing
VMR2004_051_04_04A.FM
04-04-7
Section 04 ENGINE – TRAXTER Subsection 04 (REMOVAL AND INSTALLATION)
ANTI-VIBRATION SYSTEM Anti-Vibration System Removal Remove flanged bolt no. 8, 9 or 11, elastic nut no. 7, 10 or 16 and engine brackets no. 6 or 14. RH Anti-Vibration System Remove anti-vibration bushing no. 17, push out with a punch. Insert a punch in hole of anti-vibration bushing no. 17 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. 19 and push support bushing no. 20 and antivibration bushing out the housing. Use punch to remove the other bushing.
Install a new O-ring no. 21 in anti-vibration bushing grooves. Apply grease on anti-vibration bushings and insert in engine support, one on each side. For installation, use a 152 mm (6 in) bolt for LH side and 102 mm (4 in) for RH side, three washers and a nut. Refer to the following illustration. 1 2
2
3
V01C0TA
Anti-Vibration System Installation
1. Bolt 2. Washers (3) 3. Nut
Insert support bushing in engine support. Before inserting support bushing, spray BOMBARDIER LUBE (P/N 293 600 016) in support.
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. V01C0SA
04-04-8
VMR2004_051_04_04A.FM
Section 04 ENGINE – TRAXTER 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).
1
3 2 2
V01C18A
1
Step 1 : Bottom screw Step 2 : Rear screw Step 3 : Screws on top
Exhaust Pipe Removal Remove the exhaust pipe nuts no. 27. V03C01A
1. 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.
V01C0JA
Remove screw no. 28 from exhaust pipe bracket.
VMR2004_051_04_04A.FM
04-04-9
Section 04 ENGINE – TRAXTER Subsection 04 (REMOVAL AND INSTALLATION)
Remove springs no. 29 retaining exhaust pipe and muffler no. 26.
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. V01C19A
1
TYPICAL — TRAXTER SHOWN 1. 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. 13 and make sure that it is properly installed.
V01C1MA
2
1
1. 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.
V01C0LA
1
TYPICAL 1. Exhaust pipe gasket 04-04-10
VMR2004_051_04_04A.FM
Section 04 ENGINE – TRAXTER 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. 31, one on LH ball joint and one on RH ball joint. V01I0JA
Shifter Tie-Rod Installation For installation, reverse the removal procedure, pay attention to the following details. Pre-adjust shifter tie-rod no. 32 to 150 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.
LEVER SPRING INSTALLATION
Shifter Column Removal Remove shifter lever no. 1. Remove shifter tie-rod no. 32.
Shifter Column Installation For installation, reverse the removal procedure.
Shift Rod Removal A B
V01I0IA
1. 2. 3. A. B.
3
1
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.
2
Shifter tie-rod Jam nut Ball joint Shifter tie-rod length 150 mm (5-29/32 in) Ball joint length 20 mm (25/32 in) maximum
1
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. 1 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. VMR2004_051_04_04A.FM
V01I0KA
1. Shifting rod
Unscrew elastic nuts from RH ball joint. Remove retaining clamp no. 40 and half rings no. 41.
Shift Rod Installation For installation, reverse the removal procedure. 04-04-11
Section 04 ENGINE – TRAXTER Subsection 05 (COOLING SYSTEM)
COOLING SYSTEM
0
VEHICLE SIDE 12 4 15
16
3 9 Nm (80 lbfin)
14
13 11 Nm (97 lbfin)
19
20 17
18 4.5 Nm (40 lbfin)
10 11
5
2
1 V01C3US
VMR2004_052_04_05A.FM
04-05-1
Section 04 ENGINE – TRAXTER Subsection 05 (COOLING SYSTEM)
ENGINE SIDE
29
30
Molykote 111 Engine oil
28
31
9 Nm (80 lbfin)
Engine oil
2.5 Nm 27 (22 lbfin) 25
26
24
7
23
22 9 Nm (80 lbfin)
9 Nm (80 lbfin)
6 9 Nm (80 lbfin)
21
V01C3VS
04-05-2
VMR2004_052_04_05A.FM
Section 04 ENGINE – TRAXTER Subsection 05 (COOLING SYSTEM)
GENERAL
COOLING SYSTEM LEAK TEST
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 APPLICATION at the beginning of this manual for complete procedure.
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 529 021 400) instead of the radiator cap then pinch the overflow hose no. 5 with a small hose pincher (P/N 295 000 076).
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.
V04B0VA
1
2
1. Special radiator plug 2. Small hose pincher
Using the pump (P/N 529 021 800), pressurize all system to 103 kPa (15 PSI).
COOLANT LEVEL Place the vehicle on a level surface and check the coolant in the coolant tank no. 1. 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.
VMR2004_052_04_05A.FM
V01C09A
NOTE: The rear fender removal is not necessary. The fender has been removed for a better comprehension.
04-05-3
Section 04 ENGINE – TRAXTER 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 293 600 038) 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.
Replacement Procedure 1
V01C37A
1. 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.
Drain system completely. Lift the rear of vehicle, about 2 or 3 inches, then pinch engine outlet hose no. 10 between radiator and thermostat housing with a large hose pincher (P/N 529 032 500).
DRAINING THE SYSTEM To drain cooling system, unscrew plug under engine and remove the radiator cap no. 4.
V01C3SA
1
V03C03A
1. Cooling plug
04-05-4
VMR2004_052_04_05A.FM
Section 04 ENGINE – TRAXTER 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. 10 and inlet no. 11 hoses. 1
V01C0BB
1
1. 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. 1 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. 1 and top up if necessary. Every 100 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 110 kPa (16 PSI) cap (do not exceed the pressure specified on the old cap).
RADIATOR Inspection
V01C0AA
2
TYPICAL 1. Engine outlet hose 2. Engine inlet hose
Remove overflow hose no. 5. Remove upper mounting bolts no. 12. Unplug temperature sender no. 13. Pull the radiator upwards.
Installation For installation, reverse the removal procedure. Pay attention to the following detail. Install the rubber cushion no. 14 between radiator and frame. Replace any defective cushions. Install the metal sleeves no. 15 into the rubber grommet no. 16 on the top of the radiator. Replace any defective grommets. Fill up radiator. Refer to COOLANT REPLACEMENT, above in this section.
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.
VMR2004_052_04_05A.FM
04-05-5
Section 04 ENGINE – TRAXTER Subsection 05 (COOLING SYSTEM)
THERMOSTAT
COOLANT TANK
The thermostat is a single action type and it is located on the top of engine, to the right of cylinder head.
The coolant expands as the temperature (up to 100 - 110°C (212 - 230°F)) and pressure rise in the system. If the limiting system working radiator cap is reached 110 kPa (16 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 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.
Removal Remove overflow hose no. 5. Pull coolant tank no. 1 upward. Empty coolant tank.
Installation 1
The installation is the reverse of the removal procedure.
FAN AND OUTLET DEFLECTOR Test V01C0BA
1. Remove screws
NOTE: Install a rag around thermostat housing to catch any spillage. Remove thermostat with gasket out of hole. Discard gasket.
Unplug temperature sender connector. Install a jumper wire end in connector. Replace fan no. 17 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 (167°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.
04-05-6
R610dvrs01A
VMR2004_052_04_05A.FM
Section 04 ENGINE – TRAXTER Subsection 05 (COOLING SYSTEM)
Fan Removal
Outlet Deflector Installation
Remove rear fender. Refer to BODY. Remove bolts no. 18 and fan supports no. 19.
The installation is the reverse of the removal procedure.
1
2
1
TEMPERATURE SENDER Test Remove temperature sender no. 13, 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
V01G0AA
1
2
1
TYPICAL 1. Remove bolts 2. Fan supports
Unplug fan connector. 1
Change temperature sender if the resistance does not change when the water temperature is equal or over specification.
Removal Unplug temperature sender connectors.
V01G0BA
TYPICAL 1. Fan connector
Remove fan.
Fan Installation For the installation, reverse the removal procedure.
Outlet Deflector Removal Remove fan no. 17. Remove radiator. Pull outlet deflector no. 20 upward. VMR2004_052_04_05A.FM
90 °C to 95 °C (194 °F to 203 °F)
R610motr40A
2
1
TYPICAL 1. Temperature sender connector 2. Engine inlet hose
Unscrew temperature sender no. 13.
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. 04-05-7
Section 04 ENGINE – TRAXTER Subsection 05 (COOLING SYSTEM)
WATER PUMP HOUSING
WATER PUMP SHAFT
Removal
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.
Drain cooling system. Remove: – engine inlet hose no. 11 – formed tube no. 21 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.
04-05-8
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. 31. Discard oil seal.
Installation For installation, reverse the removal procedure. Install a new oil seal no. 31. 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. 31. 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
Section 04 ENGINE – TRAXTER Subsection 05 (COOLING SYSTEM)
Installation To insert the ceramic seal in place, use the water pump ceramic seal installer (P/N 529 035 766).
V01B0YA
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
04-05-9
Section 04 ENGINE – TRAXTER Subsection 06 (REWIND STARTER)
REWIND STARTER
5 Nm (44 lbfin) 15
0
1
Loctite 243
Molykote PG 54 3 4 6 7
2
8
21 Nm (15 lbfft) 10 12 14
5 9
11
13
Loctite 243
V01C1BU
VMR2004_053_04_06A.FM
04-06-1
Section 04 ENGINE – TRAXTER Subsection 06 (REWIND STARTER)
REWIND STARTER Removal
1
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. 15 and pull rewind starter.
Disassembly To remove rope no. 5 from rewind starter mechanism: – First remove flat washer no. 10 and screw no. 11, 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. 1. – Disengage key no. 4 and pull out rope no. 5.
V01C0WA
TYPICAL 1. 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 420 899 763) 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. 1
A01C12A
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.
04-06-2
V01C0XA
TYPICAL 1. Apply Molykote PG 54 inside spring guide
VMR2004_053_04_06A.FM
Section 04 ENGINE – TRAXTER 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.
V01C0ZA
1 V01C10A
TYPICAL 1. 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.
1
TYPICAL 1. Locking spring
Install locking ring.
Installation Thread starter rope no. 5 through rope guide when applicable. Reinstall rewind starter assembly on engine. NOTE: Before torque mounting bolts no. 15, 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.
V01C0YA
TYPICAL
Position pawl no. 6, pawl lock no. 7 and locking spring washer no. 8. Install locking spring no. 9.
VMR2004_053_04_06A.FM
A01C18A
TYPICAL
04-06-3
Section 04 ENGINE – TRAXTER Subsection 06 (REWIND STARTER)
STARTING PULLEY Removal Remove rewind starter. Remove screw no. 12 and O-ring no. 13 retaining starting pulley no. 14 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 21 N•m (15 lbf•ft).
04-06-4
VMR2004_053_04_06A.FM
Section 04 ENGINE – TRAXTER Subsection 07 (MAGNETO SYSTEM)
MAGNETO SYSTEM 10
8
0
Loctite 243 9 Nm 7 Nm (80 lbfin) (62 lbfin) 150 Nm (111 lbfft) Loctite 15 243 9 14 7 13
12 Engine oil
6 Loctite 648
Loctite 11 243 3 23 Nm 9 Nm (17 lbfft) (80 lbfin)
4
5
7 Nm (62 lbfin)
2 1 V01C38S
VMR2004_054_04_07A.FM
9 Nm (80 lbfin)
04-07-1
Section 04 ENGINE – TRAXTER 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 APPLICATION at the beginning of this manual for complete procedure.
Remove: – rear swing arm and rear propeller shaft (refer to REAR AXLE) – water pump housing (refer to COOLING SYSTEM) – GBPS (Gear Box Position Sensor)
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. V01C2IA
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.
V01C3SB
2
1
1. Gear Box Position Sensor
– all bolts retaining ignition cover – ignition cover no. 1 – 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 413 708 500) 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.
1
UNDER ENGINE 1. Engine oil plug 2. Engine coolant plug
04-07-2
VMR2004_054_04_07A.FM
Section 04 ENGINE – TRAXTER Subsection 07 (MAGNETO SYSTEM)
If it has a space between ignition cover and crankcase, remove ignition cover and re-align the hydraulic piston.
V01C39A
V01D0JA
1
1. Hydraulic piston
STATOR AND TRIGGER COIL Removal Remove the ignition cover. Inside ignition cover, unscrew bolts no. 15 and the wire support no. 14. Unscrew bolts no. 3 and no. 13 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 SYSTEM for the stator and IGNITION SYSTEM for the trigger coil.
Installation For installation, reverse the removal procedure.
ROTOR Removal Remove: – magneto housing cover no. 1 – pawl no. 5. Install a strap wrench around rotor.
VMR2004_054_04_07A.FM
1
2
3
1. 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 420 976 235) and crankshaft protector (P/N 420 876 557) then remove rotor.
Installation For installation, reverse the removal procedure. Paying attention to the following details. Insert ring gear in sprag clutch no. 10. Install nut on crankshaft end. Apply Loctite 243 on threads. Torque to 150 N•m (111 lbf•ft).
SPRAG CLUTCH Removal Remove rotor no. 8. Unscrew all socket screws no. 11 retaining rotor and sprag clutch housing no. 12. 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.
04-07-3
Section 04 ENGINE – TRAXTER Subsection 08 (LUBRICATION SYSTEM)
LUBRICATION SYSTEM
0
10 Nm (89 lbfin)
Engine oil
11 12
10
Engine oil
13
9
8
14 15
7 16 Nm (142 lbfin)
16 17
Loctite 243 18
19
20
5 4 3 6 2 1 10 Nm (89 lbfin)
Loctite 243
24
Engine oil V01C2CS
VMR2004_055_04_08A.FM
23
22
25
21 21 Nm (15 lbfft)
04-08-1
Section 04 ENGINE – TRAXTER 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 APPLICATION 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 529 035 709) with the adapter (P/N 529 035 652). 3
2
When the hydraulic shifter is used, the engine oil pressure must increase up to about 810 kPa (118 PSI) at 3500 RPM. NOTE: Since gear change happen very quickly, making the 1 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 1 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.
V01C3SC
1
1. Oil drain plug
V01C3HA
1
1. Oil pressure gauge 2. Adapter 3. Oil filter
The engine oil pressure should be between 101 kPa (14.7 PSI) and 608 kPa (88 PSI) at the idle.
04-08-2
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
Section 04 ENGINE – TRAXTER 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.
ENGINE OIL PRESSURE REGULATOR The engine oil pressure regulator is located near exhaust pipe bracket. It controls engine oil pressure when not shifting.
V01C1UA
1
1. Engine oil pressure regulator
OIL STRAINER
The pressure should be between 101 kPa (14.7 PSI) and 500 kPa (72.5 PSI).
Removal
Removal
Ensure vehicle is on a level surface. Remove: – skid plate under vehicle – engine oil – screws no. 1 retaining oil strainer cover no. 2 – oil collector no. 3 and O-ring no. 4 – oil strainer no. 5.
Remove the plug screw no. 7, sealing ring no. 8, compression spring no. 9 and piston no. 10.
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.
VMR2004_055_04_08A.FM
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 (1.71 in)
SERVICE LIMIT
42 mm (1.65 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.
04-08-3
Section 04 ENGINE – TRAXTER 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. 11 – oil pump gear no. 12 – needle pin no. 13 – thrust washer no. 14 – oil pump cover no. 15 – oil pump shaft no. 16 – oil pump outer rotor no. 18 – oil pump inner rotor no. 17 – oil pump housing no. 19 – 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
1
A
V01C3SB
2
1
UNDER ENGINE 1. 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 04-08-4
B C V01C1VA
1. 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.
VMR2004_055_04_08A.FM
Section 04 ENGINE – TRAXTER 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 (116 PSI).
Removal Remove water pump and magneto cover. Refer to MAGNETO SYSTEM. Unscrew plug no. 21. 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)
61.5 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
04-08-5
Section 04 ENGINE – TRAXTER Subsection 09 (CYLINDER AND CYLINDER HEAD)
CYLINDER AND CYLINDER HEAD
0
10 Nm 1 (89 lbfin)
2 3 12
Antiseize lubricant
10 Nm (89 lbfin) 10
14 15
9
10 Nm (89 lbfin) 18
13 Engine oil 50 Nm 7 (37 lbfft)
17
11
22 Nm (16 lbfft) 4
Engine oil
5
25
6
20 19
23
8 21
22
Engine oil
Engine oil
24
23
Engine oil 16
Engine oil
V01C1CT
VMR2004_056_04_09A.FM
04-09-1
Section 04 ENGINE – TRAXTER Subsection 09 (CYLINDER AND CYLINDER HEAD)
GENERAL
VALVE COVER
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 APPLICATION at the beginning of this manual for complete procedure.
Removal
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.
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. 1. 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.
V01C3SA
1
UNDER ENGINE 1. Engine coolant plug
04-09-2
VMR2004_056_04_09A.FM
Section 04 ENGINE – TRAXTER 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. 1
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.
V01C1DA
1
1. Flanged nuts
Pull up cylinder head.
Inspection Check for crack between valve seats, if so, replace cylinder head.
VMR2004_056_04_09A.FM
ROCKER ARM Removal Remove: – cylinder head no. 5 – holding strip no. 10. Extract rocker arm shaft no. 11 using a M8 x 53.5 screw. NOTE: Use a flanged bolt no. 4 retaining cylinder head to cylinder.
04-09-3
Section 04 ENGINE – TRAXTER Subsection 09 (CYLINDER AND CYLINDER HEAD)
Measure of shaft diameter. ROCKER ARM SHAFT DIAMETER MINIMUM (new)
13.683 mm (.5386 in)
MAXIMUM (new)
13.694 mm (.5391 in)
SERVICE LIMIT
13.67 mm (.5382 in)
Any area worn excessively will require part replacement.
Installation 3
V01C1EA
1
2
1. Rocker arm shaft 2. Flanged bolt 3. Rocker arm
For installation, reverse the removal procedure. NOTE: Apply anti-seize lubricant on rocker arm shaft.
VALVE SPRING
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. A
Removal Remove: – cylinder head no. 5 – rocker arm no. 12. Compress valve spring no. 13. Use valve spring compressor clamp (P/N 529 035 724) and valve spring compressor cup (P/N 529 035 725). Remove valve cotters no. 14. Remove spring compressor clamp, valve spring retainer no. 15 and valve spring.
Inspection V01C1FA
Check valve spring for rust or corrosion, free length and squareness.
A. Rocker arm bore diameter
ROCKER ARM BORE DIAMETER MINIMUM (new)
13.715 mm (.540 in)
MAXIMUM (new)
13.740 mm (.541 in)
SERVICE LIMIT
13.765 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.
A R610motr122A
A. Valve spring length
04-09-4
VMR2004_056_04_09A.FM
Section 04 ENGINE – TRAXTER Subsection 09 (CYLINDER AND CYLINDER HEAD)
VALVE SPRING FREE LENGTH SERVICE LIMIT
39 mm (1-1/2 in)
VALVE SPRING MAXIMUM SQUARENESS SERVICE LIMIT
1.1 mm (.043 in)
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.
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. VALVE SEAT CONTACT WIDTH NEW Exhaust
1.25 to 1.55 mm (.049 to .061 in)
Intake
1.45 to 1.75 mm (.057 to .069 in)
VALVE Removal Remove valve spring no. 13. Push the valve stem then pull valve no. 16 out of valve guide.
SERVICE LIMIT Exhaust
2 mm (.078 in)
Intake
1.8 mm (.07 in)
Inspection 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.
If valve seat contact width is too wide, too narrow or has spots, the seat must be ground or cylinder head replaced.
A
B
VALVE STEM DIAMETER SERVICE LIMIT Exhaust 6.95 mm (.274 in) Intake
V01C1HA
VALVE GUIDE CLEARANCE SERVICE LIMIT Exhaust 0.13 mm (.005 in) Intake VMR2004_056_04_09A.FM
A. Valve face contact width B. Valve seat contact width
Installation For installation, reverse the removal procedure. NOTE: Apply engine oil on valve stem.
04-09-5
Section 04 ENGINE – TRAXTER Subsection 09 (CYLINDER AND CYLINDER HEAD)
VALVE STEM SEAL
Inspection
Removal Remove valve(s). Remove circlip on the bottom of valve stem seal no. 17.
2
Cylinder Check cylinder for cracks, scoring, rust and wear ridges on the top and bottom of the cylinder. Cylinder Taper Measure cylinder diameter 16 mm (5/8 in) from top of cylinder then half-way through and finally at 13 mm (1/2 in) from bottom.
1
V01C1JA V01C1IA
1
1. 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.
1. Measure at three points
CYLINDER TAPER MAXIMUM (new)
0.035 mm (.001 in)
SERVICE LIMIT
0.090 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.
CYLINDER Removal Remove: – cylinder head no. 5 – water cooling hose from cylinder no. 19 – push rods no. 9 – all flanged screws no. 18 retaining cylinder no. 6 to the crankcase housing. Pull cylinder.
04-09-6
VMR2004_056_04_09A.FM
Section 04 ENGINE – TRAXTER Subsection 09 (CYLINDER AND CYLINDER HEAD)
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.
A B
LIFTER AND LIFTER BORE SERVICE LIMIT Lifter
22.19 mm (.874 in)
Lifter bore
22.27 mm (.876 in)
LIFTER BORE CLEARANCE
V01C1KA
SERVICE LIMIT
A. Perpendicular to crankshaft axis B. Parallel to crankshaft axis
CYLINDER OUT-OF-ROUND MAXIMUM (new)
0.005 mm (.0002 in)
SERVICE LIMIT
0.015 mm (.006 in)
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. 21 into cylinder. Install bolts no. 18 first, then flanged bolts no. 4, then flanged nuts no. 7.
LIFTER
0.08 mm (.003 in)
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. 21. Detach piston from connecting rod.
Inspection Inspect piston for scoring, cracking or other damages. Using a micrometer, measure piston at 16 mm (5/8 in) perpendicularly (90°) to piston pin axis.
Removal Remove cylinder no. 6. Pull hydraulic lifters no. 22 out of crankcase.
VMR2004_056_04_09A.FM
04-09-7
Section 04 ENGINE – TRAXTER 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
1
2
1
V01C3KA
TYPICAL 1. Measuring perpendicularly (90°) to piston pin axis A. 16 mm (5/8 in)
The measured dimension should be as described in the previous table. If not, replace piston.
F00B09A
1. Use the micrometer to set the cylinder bore gauge 2. Dial bore gauge
PISTON MEASUREMENT SERVICE LIMIT
88.9 mm (3.5 in)
Piston/Cylinder Clearance PISTON/CYLINDER CLEARANCE NEW
0.016 to 0.044 mm (.0006 to .002 in)
SERVICE LIMIT
0.090 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. 1
1 F00B0AA
TYPICAL 1. Indicator set to 0 (zero)
Position the dial bore gauge at 16 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.
F00B08A
1. Micrometer set to the piston dimension
04-09-8
VMR2004_056_04_09A.FM
Section 04 ENGINE – TRAXTER 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.
V01C1LA
A. Measure here
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 End Gap RING END GAP MINIMUM (new)
RING/PISTON GROOVE CLEARANCE
Upper compression ring
0.15 mm (.006 in)
MINIMUM (new)
Lower compression ring
0.15 mm (.006 in)
Oil scraper ring
0.15 mm (.006 in)
Upper compression ring
0.03 mm (.001 in)
Lower compression ring
0.03 mm (.001 in)
Oil scraper ring
0.02 mm (.0008 in)
MAXIMUM (new)
MAXIMUM (new) Upper compression ring
0.35 mm (.014 in)
Upper compression ring
0.062 mm (.0024 in)
Lower compression ring
0.40 mm (.016 in)
Lower compression ring
0.062 mm (.0024 in)
Oil scraper ring
0.35 mm (.014 in)
Oil scraper ring
0.055 mm (.0022 in)
SERVICE LIMIT All
SERVICE LIMIT All
1.5 mm (.06 in)
0.15 mm (.006 in)
Position ring 16 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
04-09-9
Section 04 ENGINE – TRAXTER 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.
1 2 3 A31C2NA
1. 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 120° apart and do not align the gaps with the piston pin bore or the thrust side axis. A A
A
1
2
A31C2OA
1. DO NOT align ring gap with piston thrust side axis 2. DO NOT align ring gap with piston pin bore axis A. 120°
04-09-10
VMR2004_056_04_09A.FM
Section 04 ENGINE – TRAXTER Subsection 10 (CRANKSHAFT/BALANCER SHAFT)
CRANKSHAFT/BALANCER SHAFT
230 Nm (170 lbfft) 4 Loctite 243 22 Nm (16 lbfft) 6 7
8
150 Nm (111 lbfft) 11
5 Anti-seize lubricant
Engine oil
Loctite 243 12
0
3
Loctite 243
13 10
Engine oil
Anti-seize lubricant 14
Anti-seize lubricant 9
2
1
Anti-seize lubricant
Anti-seize lubricant
V01C2DT
VMR2004_057_04_10A.FM
04-10-1
Section 04 ENGINE – TRAXTER Subsection 10 (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 APPLICATION 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 529 035 645). 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.
V01C3IA
2
1
1. 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 16 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.
1 2
3
4 V01C3JA
1. 2. 3. 4.
Crankshaft locking bolt 16 mm socket Universal joint Extension
NOTE: Do not forget to remove crankshaft locking bolt before installing the clutch cover. 04-10-2
VMR2004_057_04_10A.FM
Section 04 ENGINE – TRAXTER Subsection 10 (CRANKSHAFT/BALANCER SHAFT)
CAMSHAFT Removal To remove camshaft no. 1, 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. 10.
Drain engine oil and engine coolant by removing drain plugs.
V01C1XA
V01C3SB
2
1
UNDER ENGINE 1. Engine oil plug 2. Engine coolant plug
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.
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1. 2. 3. 4. 5. 6.
2
1
6
3
4
5
Crankshaft gear nut Crankshaft gear Cam shaft gear Control gear Balancing shaft gear Oil pump gear
Unscrew the screws retaining the camshaft housing then remove the housing. Remove camshaft.
04-10-3
Section 04 ENGINE – TRAXTER Subsection 10 (CRANKSHAFT/BALANCER SHAFT)
Inspection
BALANCER SHAFT
Check each lobe for scoring, scuffing, cracks, or other sign of wear. Measure each end of camshaft.
Removal
CAMSHAFT ENDS mm (in) SERVICE LIMIT Clutch side
31.95 (1.258)
Magneto side
17.96 (.707)
1
1
V01C1ZA
1. 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. CAMSHAFT BORE mm (in) SERVICE LIMIT Clutch housing
32.036 (1.261)
Magneto housing
18.035 (.71)
Subtract the camshaft end diameter from the proper bore diameter to find clearance. CAMSHAFT END CLEARANCE mm (in) SERVICE LIMIT Clutch side
0.086 (.0034)
Magneto side
0.075 (.0029)
If necessary, change camshaft and/or camshaft housing and/or crankcase.
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. 1 – crankshaft gear nut no. 4, use 46 mm socket (P/N 529 035 648), then remove crankshaft gear no. 5 NOTE: Do not forget. The crankshaft must be locked to remove clutch drum and all nuts. – nut no. 11 and lock washer no. 12 retaining control gear no. 13 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.
Installation 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). 04-10-4
VMR2004_057_04_10A.FM
Section 04 ENGINE – TRAXTER Subsection 10 (CRANKSHAFT/BALANCER SHAFT)
CRANKSHAFT
Connecting Rod/Piston Pin Clearance Measure piston pin. Compare to inside diameter of connecting rod.
Removal Use the same removal procedure as balancer shaft. Remove crankshaft no. 3 and adjusting washer no. 14.
CONNECTING ROD SMALL END DIAMETER SERVICE LIMIT
Inspection
PISTON PIN DIAMETER
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)
1
22.07 mm (.869 in)
1
SERVICE LIMIT
21.99 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”.
V01C2EA
1. 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
1.3 (.05)
Radial play
0.08 (.003)
VMR2004_057_04_10A.FM
V01C2FA
04-10-5
Section 04 ENGINE – TRAXTER Subsection 10 (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”.
V01C2GA
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
0.1 to 0.4 mm (.004 to .016 in) THICKNESS
ADJUSTING SPACERS AVAILABLE
1.3 mm (.051 in) 1.5 mm (.060 in) 1.8 mm (.071 in)
04-10-6
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Section 04 ENGINE – TRAXTER Subsection 11 (CLUTCH)
CLUTCH
0
Loctite 243 270 Nm (199 lbfft)
1
4
Engine oil
2
Engine oil 3
5
Loctite 243
Engine oil
12
Engine oil
150 Nm (111 lbfft) 20
6 7 Nm (62 lbfin)
Engine oil
10
21 15
9 7
Engine oil
8
14
11 13
18
17
19
16
Engine oil
V01D0PS
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04-11-1
Section 04 ENGINE – TRAXTER Subsection 11 (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 529 035 645).
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
1
V01D02A
1. Crankshaft locking bolt
Unscrew nut no. 1 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 140.4 mm (5-17/32 in), change clutch drum.
04-11-2
V01D03A
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_11A.FM
Section 04 ENGINE – TRAXTER Subsection 11 (CLUTCH)
Measure length of weight springs. If they are longer than 21.6 mm (.85 in), change the clutch weight assembly. A
V01D0EA
A. 21.6 mm (.85 in)
Check weight springs for wear or other damage. Replace the clutch weight assembly if necessary.
Assembly 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 7 2 6
V01D05A
V01D04A
1. Out side mark
VMR2004_058_04_11A.FM
1
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
8 4
9 10 5 3 1
Front output shaft Collar sleeve Helical spring Parking locking lever Shaft Tension spring Indicator shaft Actuating lever Circlip Output gear
– clutch housing.
04-11-3
Section 04 ENGINE – TRAXTER Subsection 11 (CLUTCH)
Install the crankshaft locking bolt (P/N 529 035 645).
V01D06A
1
2
FRICTION DRIVE PLATE MINIMUM THICKNESS
2.8 mm (.11 in)
3
1. 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 529 035 647). Unscrew the clutch lock nut no. 10 then remove tab washer. Remove: – clutch hub no. 11 – friction drive plates no. 12 – steel driven plates no. 13 – inner plate no. 14 – thrust washer no. 15 – O-ring no. 21 – clutch basket no. 16 – needle bearings no. 18 and no. 19 – large thrust washer no. 17.
V01D07A
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 (.01 in) or if they show signs of discoloration. STEEL DRIVEN PLATE MAXIMUM WARPAGE
0.25 mm (.01 in)
Inspection Friction Drive Plate Measure each friction drive plate thickness. Friction drive plates must be replaced when lining is 2.8 mm (.11 in) thick or less.
04-11-4
V01D08A
VMR2004_058_04_11A.FM
Section 04 ENGINE – TRAXTER Subsection 11 (CLUTCH)
Clutch Basket Check slots of clutch basket for damage or wear caused by friction drive plates. Change if necessary.
1
V01D0BA
1. Retaining plate bearing V01D09A
Clutch Hub Check grooves of clutch hub for damage or wear caused by steel driven plates.
Clutch Spring Measure each clutch springs free length. CLUTCH SPRING MINIMUM LENGTH
32.5 mm (1.28 in)
V01D0CA V01D0AA
Assembly 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.
VMR2004_058_04_11A.FM
For assembly, reverse the disassembly procedure. Pay attention to the following details. Install large thrust washer no. 17, the wide needle bearing no. 19 then the narrow needle bearing no. 18. Assemble friction drive plates, steel driven plates, inner plate and clutch hub in clutch basket. Apply engine oil on each friction drive plate. 04-11-5
Section 04 ENGINE – TRAXTER Subsection 11 (CLUTCH)
NOTE: Place the last friction drive plate in short slots of clutch basket. 2 1
3
V01D0DA
1. 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.
V01D0IA
04-11-6
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Section 04 ENGINE – TRAXTER Subsection 12 (TRANSMISSION)
TRANSMISSION
0
GEAR SHIFT SYSTEM
1 Engine oil
10 N•m (89 lbf•in) 4 5
Engine oil 6 7 22
2 10 N•m (89 lbf•in)
Engine oil 23 15
Engine oil
3
Engine oil
17 Engine oil 8
Engine oil 16
21 Engine oil
Loctite 243
18 20
12
11 10
13 Engine oil 14
9 10 N•m (89 lbf•in) 10 N•m (89 lbf•in)
V01E0LS
VMR2004_059_04_12A.FM
04-12-1
Section 04 ENGINE – TRAXTER Subsection 12 (TRANSMISSION)
TRANSMISSION 17
Anti-seize Loctite lubricant 243
18
Anti-seize lubricant
19 16 21
20
Anti-seize lubricant
Anti-seize lubricant Molykote G-n Loctite 243
10 Nm (89 lbfin) 15
Anti-seize lubricant
23 22
Anti-seize lubricant
V01E0MS
04-12-2
Anti-seize lubricant
24
Anti-seize lubricant
VMR2004_059_04_12A.FM
Section 04 ENGINE – TRAXTER Subsection 12 (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. 1
Rear Side Remove: – water pump and magneto cover – nut no. 8 retaining shift drum gear 2
Callout
3
V01E0QA
1
1. Shift drum gear nut 2. Lock washer 3. Index gear
1
V01E0OA
1. Shift shaft
– screw no. 9, washer no. 10, index lever no. 11 and index spring no. 12.
– socket screw no. 2 and lock washer retaining index gear no. 3
2
4
3
1
V01E0PA
1. 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. VMR2004_059_04_12A.FM
V01E0RA
1. 2. 3. 4.
1
Screw Washer Index lever Index spring
04-12-3
Section 04 ENGINE – TRAXTER Subsection 12 (TRANSMISSION)
Remove the tension spring no. 13 then pull shift shaft with pawl no. 14 out of housing.
1
V01E0FA
V01E0SA
2
3
1. Indicator shaft 2. Shift shaft 3. Transmission actuating lever
1
Magneto Side Reassemble in the reverse order of disassembly.
1. 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. 1
V01E0EA
2
TRANSMISSION Disassembly Remove gear shift mechanism. Separate both housing of crankcase. Remove the shift fork shafts no. 15, no. 16 and no. 17. Remove shift fork no. 18 then pull shift drum no. 19. Pull all gears and shafts, at the same time.
2
1. Index gear 2. Shift shaft
After clutch housing installation, align mark on shift shaft with mark on indicator shaft.
04-12-4
V01E0GA
VMR2004_059_04_12A.FM
Section 04 ENGINE – TRAXTER Subsection 12 (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. 21, no. 22 and no. 23 in the proper shift drum tracks before install the transmission in half housing. Place the last shift fork no. 18 in after transmission is installed in housing half. Install the shift drum.
VMR2004_059_04_12A.FM
NOTE: Verify shaft pin is properly installed in drum slot before installing housing. 1
2
V01E0IA
1. 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.
04-12-5
