2004 Bombardier DS650 Repair Manual
2004 Bombardier DS650 Repair Manual
2004 Bombardier DS650 Repair Manual
INTRODUCTION .................................................................................................................................. IV
VMR2004_001_00_02A.FM I
TABLE OF CONTENTS
II VMR2004_001_00_02A.FM
INTRODUCTION
INTRODUCTION
This Shop Manual covers the following Bombardier VEHICLE AND ENGINE SERIAL
made 2004 ATVs:
NUMBER LOCATION
2004 Models
DS 650TM ..................................................... 7717 1
DS 650TM Baja.............................................. 7718
DS 650TM Baja X .......................................... 7995
DS 650TM Intl ............................................... 7719
DS 650TM Baja Intl ....................................... 7720
DS 650TM Baja X Intl.................................... 7997
V02A0QA
TYPICAL
1. Vehicle
V02A0PA 2. Engine
TYPICAL
1. Model number
IV VMR2004_001_00_02A.FM
INTRODUCTION
VMR2004_001_00_02A.FM V
INTRODUCTION
TYPICAL PAGE
Page heading
indicates section
and subsection
detailed.
Section 03 ENGINE
Subsection 05 (CYLINDER AND HEAD)
Exploded view
10 Nm
assists you in
(89 lbfin) identifying parts and
12
related positions.
33 Nm 22 Engine oil
(24 lbfft)
60 Nm 21
(44 lbfft)
4 Bold face number
Drop represents a indicates special
liquid product to procedure
be applied to concerning this
a surface. part.
Loctite 243
10 Nm
Tightening torque (89 lbfin)
nearby fastener. In this
case, nut must be
torqued to
10 Nm or 89 lbfin. 8
23 10 Nm
(89 lbfin)
27 10 Nm
(89 lbfin)
Illustration V02C0ES
number for
publishing
process.
VMR2000_007_03-05A.FM 03-05-1
V02A0TS
VI VMR2004_001_00_02A.FM
INTRODUCTION
TYPICAL PAGE
Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)
V02C05A 1
BEHIND OIL FILTER
1. Bleeding screw
VMR2000_004_03_02.FM 03-02-3
V02A0UT
VMR2004_001_00_02A.FM VII
INTRODUCTION
GENERAL INFORMATION
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. Bombardier Inc. however, main-
tains a policy of continuous improvement of its
products without imposing upon itself any obliga-
tion to install them on products previously manu-
factured.
Due to late changes, there may be some differences
between the manufactured product and the descrip-
tion and/or specifications in this document. 1 2
Bombardier Inc. reserves the right at any time to dis-
continue or change specifications, designs, features,
models or equipment without incurring obligation.
ILLUSTRATIONS AND
PROCEDURES
Illustrations and photos show the typical construc-
tion of the different assemblies and, in all cases,
may not reproduce the full detail or exact shape of
the parts shown, however, they represent parts
that have the same or a similar function.
V02L02A
CAUTION: Most components in the vehicles are
built with parts dimensioned in the metric sys- 1. Left
2. Right
tem. Most fasteners are metric and must not be
replaced by customary fasteners or vice- versa. SELF-LOCKING FASTENERS
Mismatched or incorrect fasteners could cause
damage to the vehicle or possible personal injury. PROCEDURE
As many of the procedures in this manual are in- The following describes the most common appli-
terrelated, we suggest, that before undertaking cation procedures when working with self-locking
any task, you read and thoroughly understand the fasteners.
entire section or subsection concerning the proce- Use a metal brush or a screwtap to clean the hole
dure. properly then use a solvent (Methyl-Chloride), let
A number of procedures throughout the book re- it sit during 30 minutes and wipe off. The solvent
quire the use of special tools. Before starting any ensures the adhesive works properly.
procedure, be sure that you have on hand all re-
quired tools, or approved equivalents. LOCTITE APPLICATION
The use of RIGHT and LEFT indications in the text, PROCEDURE
always refers to driving position (sitting on the ve-
hicle). The following describes the most common appli-
cation procedures when working with Loctite
products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.
VIII VMR2004_001_00_02A.FM
INTRODUCTION
2 1 3
A00A3LA
2
1. Apply here
2. Do not apply
A00A3MA
1. On threads
2. On threads and at the bottom of hole
VMR2004_001_00_02A.FM IX
INTRODUCTION
Case-In Components
Metallic Gaskets
A00A3PA
1. Apply here
2. Plunger
Mounting on Shaft
Mounting with a Press
A00A3VA 1
1. Proper strength Loctite
X VMR2004_001_00_02A.FM
INTRODUCTION
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in exploded views and text. When they are not specified refer to
following tables. The tables also give the metric conversion.
WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices (ex.: locking tab, elastic stop nut, 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.
In order to avoid a poor assembling, tighten screws and bolts in accordance with the following procedure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply the half of the recommended torque value.
CAUTION: Be sure to use the proper tightening torque for the proper strength grade.
NOTE: When possible, always apply torque on the nut.
3. Torque at the recommended torque value.
NOTE: Always torque screws, bolts and/or nuts in a criss-cross sequence.
VMR2004_001_00_02A.FM XI
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
SERVICE TOOLS.................................................................................................................... 01-02-1
VMR2004_033_01_01ATOC.FM 01-01-1
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
SERVICE TOOLS
This is a list of tools to properly service ATV vehicles. If you need to replace or add to your tool inventory,
these items can be ordered through the regular parts channel.
NEW
Following mention points out new tool:
VMR2004_002_01_02A.FM 01-02-1
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
MANDATORY
All Models
Insertion Jig Handle
420 877 650
RECOMMENDED
All Models
Vacuum/Pressure Pump
529 021 800
Low Speed Screw Adjuster
529 035 732
4
RECOMMENDED
3
2
1
All Models
Float Level Gauge
529 035 520
Carburetor Kit
404 112 000
01-02-2 VMR2004_002_01_02A.FM
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Terminal Remover
Snap-On TT660-4
Shock Tool
529 035 636
NEW
RECOMMENDED
Multimeter
529 035 868 All Models
NEW
All Models
Crimp Plier
529 035 730
Connection Tool
529 035 714
VMR2004_002_01_02A.FM 01-02-3
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Caillau Pliers
295 000 054
RECOMMENDED
DS 650/Baja/X
Youth models
Outlander 330 CV Boot Clamp Installation and
Outlander 400 Removal Tool
Quest 500/650 295 000 069
Traxter
Ring Compressor
Snap-On RC980
MANDATORY
DS 650/Baja/X
Outlander 330
Outlander 400
Quest 500/650
Traxter
Cable Luber
529 035 738
Crankshaft Protector
420 876 557
MANDATORY
DS 650/Baja/X
Outlander 330
Outlander 400
Crankshaft Locking Bolt Quest 500/650
529 035 617 Rally 200
RECOMMENDED
DS 650/Baja/X
Valve Stem Seal Pliers
Snap-On YA 8230 Outlander 330
Outlander 400
Quest 500/650 Flywheel Puller
Rally 200 529 035 748
01-02-4 VMR2004_002_01_02A.FM
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
RECOMMENDED
DS 650/Baja/X
Outlander 330
Outlander 400
Quest 500/650
Traxter
MANDATORY
529 035 401 41 mm Socket Outlander 330
PROTO 5541 Outlander 400
Quest 500/650
Traxter
RECOMMENDED
Outlander 330
Outlander 400
Quest 500/650
Rally 200
Traxter
Hub Puller
529 035 612
Shock Spring Disassembly Tool
529 035 504
RECOMMENDED
Needle Bearing Installer
(main shaft in crankcase) Outlander 330
529 035 762 Outlander 400
Quest 500/650
Backlash Measurement Tool Traxter
529 035 665
VMR2004_002_01_02A.FM 01-02-5
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
MANDATORY
Oil Seal Installer
(crankshaft oil seal Outlander 330
on magneto cover) Outlander 400
529 035 759 Quest 500/650
Drive Clutch Puller
529 035 746
Torque Angle
Water Pump Ceramic Seal Installer Snap-On TA 36
RECOMMENDED
529 035 766
Outlander 330
Outlander 400
MANDATORY
Quest 500/650
DS 650/Baja/X
Outlander 330
Engine Installation and Outlander 400
Removal Tool
529 035 619 Oil Seal Installer
(crankshaft oil seal on crankcase)
529 035 760
RECOMMENDED
01-02-6 VMR2004_002_01_02A.FM
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
MANDATORY
Rally 200
Traxter
46 mm Socket for Crankshaft/
Driven Pulley
529 035 648
RECOMMENDED
529 035 622
Outlander 330 UP to 2003 models
Outlander 400
Quest 500/650
MANDATORY
Rear Axle Nut
529 035 729
NEW
DS 650/Baja/X
Quest 500/650
Traxter
6 Pin Harness for Magneto
529 035 604
VMR2004_002_01_02A.FM 01-02-7
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
RECOMMENDED
Shock Charging Tool
529 035 570 DS 650/Baja/X
NEW
RECOMMENDED
DS 650/Baja/X
Ball Joint Guide
529 035 705
MANDATORY
Magneto Puller
Crankshaft Bushing Installer (4-stroke engines)
529 035 689 529 035 798
RECOMMENDED
DS 650/Baja/X
RECOMMENDED
ILLUSTRATION
NOT AVAILABLE Valve Seat Remover/Installer
(4-stroke engines)
529 035 794 Youth models
Flywheel Puller
(4-stroke engines)
529 035 792
MANDATORY
VMR2004_002_01_02A.FM 01-02-9
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
RECOMMENDED
529 035 926
(2-stroke engines)
529 035 799
Youth models
Valve Guide Remover
529 035 924
RECOMMENDED
Outlander 330
Piston Circlip Installer Outlander 400
529 035 921
MANDATORY
Outlander 330
Outlander 400
01-02-10 VMR2004_002_01_02A.FM
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
RECOMMENDED
Outlander 330
Starter drive needle bearing Outlander 400
Wear Ring Installer
installer (rear drive shafts)
529 035 934 529 035 915
MANDATORY
Trailing Arm Bearing
Remover/Installer (frame side) Quest 500/650
529 035 920
VMR2004_002_01_02A.FM 01-02-11
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
RECOMMENDED
Remover/Installer (MAG side)
529 035 753
Quest 500/650
Lifting Ring
529 035 770
Crankcase Support
(MAG side)
529 035 755
RECOMMENDED
MANDATORY
Clutch Support
Piston Circlip Installer 529 035 863
Rally 200
529 035 765
51 mm (2 in) Crow-Foot
529 035 884
01-02-12 VMR2004_002_01_02A.FM
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
RECOMMENDED
Rally 200
Water Pump Oil Seal Installer
529 035 849 Piston Circlip Installer
529 035 859
RECOMMENDED
Rally 200
Shifter Oil Seal Installer
529 035 851
Allen Wrench
529 035 861
Magneto Puller
(use bolt from magneto puller
P/N 529 035 748)
529 035 883
VMR2004_002_01_02A.FM 01-02-13
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Lifting Bar
529 035 610
Crimping Tool
(for AMP connectors)
295 100 164
Jumper for Self Diagnosis
529 035 605
RECOMMENDED
MANDATORY
Traxter Traxter
Crankshaft Locking Bolt Lifting Ring
529 035 645 529 035 644
UP to 2000
01-02-14 VMR2004_002_01_02A.FM
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
SERVICE PRODUCTS
This is a list of products to properly service ATV vehicles. If you need to replace or add to your tool inventory, these
items can be ordered through the regular parts channel.
NEW
Following mention points out new tool:
VMR2004_003_01_03A.FM 01-03-1
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
Loctite® 567
Pipe Sealant
(250 mL)
293 800 013
Loctite® 243
Medium-Strength Threadlocker
(10 mL) (blue) Suspension Synthetic Grease
293 800 060 (400 g)
293 550 033
Synthetic Grease
(400 g)
293 550 010
Loctite® 609
Retaining Compound Loctite RC All Models
(10 mL) (green)
413 703 100 All Models
01-03-2 VMR2004_003_01_03A.FM
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
All Models
All Models
VMR2004_003_01_03A.FM 01-03-3
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
DS 650/Baja/X
Quest 500/650
Traxter
Loctite® 271
High Strength Threadlocker
(10 mL) (red)
Bombardier Plastic & Vinyl Cleaner 293 800 005
(6 x 1 L)
413 711 200
All Models
Loctite® 277
High Strength Retaining Compound
(10 mL) (red)
293 800 073
Bombardier Synthetic
4-Stroke Oil 5W-40
(12 x 1 L)
293 600 039
Loctite® 384
Thermally Conductive Adhesive
(300 mL)
293 800 099
Silicone Dielectric Grease CAUTION: This product must be
(3 oz) stored at 5°C (41°F).
293 550 004
Loctite® 5150
Clear Silicone Sealant
(300 mL)
293 800 086
01-03-4 VMR2004_003_01_03A.FM
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
DS 650/Baja/X
DS 650/Baja/X Outlander 330
Outlander 330 Outlander 400
Outlander 400 Quest 500/650
Rally 200 Synthetic Grease
(60 g) Traxter
Traxter 293 550 019
Loctite® 648
High Temperature and Strength
Retaining Compound
(5 mL) (green)
413 711 400
VMR2004_003_01_03A.FM 01-03-5
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
Quest 500/650
Loctite® 406 Traxter
Instant Adhesive
(must be used with tapered tip)
(20 g)
293 800 095
DS 650/Baja/X
Smoothflow Tapered Tips
Kayaba shock absorber oil 16ga #511 rtt-b
(not sold by Bombardier),
293 600 035 call EFD Inc, 1 800 556-3484
Loctite® 5900
RTV Silicone Sealant
(300 mL)
293 800 066
Loctite® Maxi-Coat
Heavy Duty Rustproofing
(340 g)
293 800 105
01-03-6 VMR2004_003_01_03A.FM
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
Outlander 330
Outlander 400 Rally 200
Loctite®5910 Quest 500/650 Traxter
Flange Sealant
(300 mL) Molykote G-n Paste
293 800 081 (50 g)
711 297 433
Outlander 330
DS 650/Baja/X Outlander 400
Loctite® 515 Traxter Traxter
Paste Gasket Molykote PG 54
Gasket Eliminator (10 g)
(50 mL) 420 899 763
413 702 700
111
Molykote 111
(150 g)
413 707 000
Outlander 330
Outlander 400 DS 650/Baja/X
Quest 500/650 Rally 200
Traxter Traxter
VMR2004_003_01_03A.FM 01-03-7
Section 02 MAINTENANCE
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
MAINTENANCE CHART ........................................................................................................ 02-02-1
NOISE EMISSION CONTROL SYSTEM REGULATION ................................................... 02-02-1
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ....................................... 02-02-1
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING
ARE THE ACTS LISTED BELOW ....................................................................................... 02-02-1
MAINTENANCE CHART .................................................................................................... 02-02-2
VMR2004_033_02_01ATOC.FM 02-01-1
Section 02 MAINTENANCE
Subsection 02 (MAINTENANCE CHART)
MAINTENANCE CHART
NOISE EMISSION CONTROL SYSTEM REGULATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
U.S. Federal law and Canadian provincial laws may prohibit the following acts or the causing there of:
1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair or
replacement of any device or element of design incorporated into any new vehicle for the purpose of
noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or
2. The use of the vehicle after such device or element of design has been removed or rendered inoperative
by any person.
VMR2004_004_02_02A.FM 02-02-1
Section 02 MAINTENANCE
Subsection 02 (MAINTENANCE CHART)
MAINTENANCE CHART
EVERY 25 HOURS
EVERY 50 HOURS
OR ONCE A YEAR
I: Inspect, verify, clean, adjust, lubricate,
OR TWO YEARS
replace if necessary
THE SECTION
C: Clean
L: Lubricate
REFER TO
R: Replace
ENGINE/TRANSMISSION
Engine/transmission oil level EVERY INSPECTION N.A.
Engine/transmission oil and filter R R
Spark arrester C Maintenance/
Valve clearance I I Lubrication
Clutch lever I I
Oil reservoir strainer C Lubrication
Engine mount fasteners I I Removal and
Exhaust system I I Installation
Condition of seals I I
N.A.
Coolant level EVERY INSPECTION
Coolant ➀ I I R
Radiator cap/cooling system pressure test I I Cooling System
Radiator condition/cleanliness (radiator fines) I I
DRIVE TRAIN
Drive chain lubrication
Drive chain adjustment EVERY INSPECTION
Drive chain protector and roller condition
Sprockets I I Front Drive
Wheel bearing I I L and Rear Axle
02-02-2 VMR2004_004_02_02A.FM
Section 02 MAINTENANCE
Subsection 02 (MAINTENANCE CHART)
EVERY 25 HOURS
EVERY 50 HOURS
OR ONCE A YEAR
I: Inspect, verify, clean, adjust, lubricate,
OR TWO YEARS
replace if necessary
THE SECTION
C: Clean
L: Lubricate
REFER TO
R: Replace
STEERING/CONTROL SYSTEMS
Throttle/housing/cable I I
Handlebar fastener I I
Steering system I I Steering/
Controls System
Tie rod ends I I
Front wheel alignment I I
VMR2004_004_02_02A.FM 02-02-3
Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)
MAINTENANCE/LUBRICATION
ADJUST VALVE CLEARANCE Unfasten socket head screw beside support for oil
return and secure crankshaft with the crankshaft
Removal locking bolt (P/N 529 035 617).
Remove: NOTE: Check tightness with the allen key.
– fuel tank To adjust valves, remove the camshaft bridges and
the camshafts.
– valve cover
Remove adjusting plates, blow clean with com-
– spark plugs. pressed air.
Unfasten centre screw plug to right of engine
housing cover. Installation
NOTE: Before installation, check thickness of ad-
justing plates with micrometer.
For installation, reverse the removal procedure.
CLUTCH ADJUSTMENT
Loosen cable tension.
Adjust clutch release mechanism.
The release lever must locate on the spline in such
a way that dimension A is obtained. See the fol-
lowing illustration.
NOTE: If necessary, unscrew the Allen socket
screw and withdraw release lever. Replace the le-
ver at the appropriate position then tighten socket
V02C3LA 1 screw to 19 N•m (14 lbf•ft).
RH SIDE OF VEHICLE
1. Remove this screw plug
VMR2004_004_02_03A.FM 02-03-1
Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)
Adjust cable free play. Insert adjuster lock through rear hub and into ec-
centric axle housing.
1 4 3
A
V02D04A
DRIVE CHAIN
Adjustment
V02H16A 2
NOTE: Always adjust drive chain with the driver,
1. Drive chain
or equivalent weight, installed on the vehicle. 2. Adjuster lock
3. Sprocket hub
Select a level surface and set transmission to NEU- 4. Eccentric axle housing
TRAL.
Turn the axle forward to increase or backward to
Loosen rear axle lock bolts. decrease chain slack.
NOTE: Correct chain slack adjustment is 19 to
25.4 mm (3/4 to 1 in) at midway between sprockets.
Tighten the rear axle lock bolts to 23 N•m (17 lbf•ft).
Use the following sequence to tighten the rear
axle lock bolts correctly.
V02H15A 1
1. Rear axle lock bolts
V02H15B 26 4 3 15
02-03-2 VMR2004_004_02_03A.FM
Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)
V02A0DA 2
1. Latches
2. Air filter cover
V02A0CA 1 3 2
1. Air filter box
2. Drain plug
3. Clamp
VMR2004_004_02_03A.FM 02-03-3
Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)
Rinse air filter and foam with warm water. Drain all oil from oil tank by removing oil tank drain
Squeeze foam to remove excess water. Let dry air plug. Wipe out any oil spillage.
filter and foam thoroughly.
If air filter element or foam is dirty, replace with a
new one.
NOTE: Slight dust may be cleaned using a low-
pressure airgun. Blow compressed air backward
of operating air flow.
When the filter is dried, re-oil with air filter oil
(P/N 293 600 058 or an equivalent).
Properly reinstall removed parts in the reverse or-
der of their removal.
WARNING
The engine oil can be very hot. Wait until en-
gine oil is warm.
02-03-4 VMR2004_004_02_03A.FM
Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)
Remove oil filter and replace by a new. Bleeding Engine Oil Circuit
NOTE: Check and change the O-ring, if necessary. Remove oil filter.
1 3 Unfasten pressure bleeding screw.
V02C04A 2
TYPICAL — RH SIDE OF ENGINE
V02C05A 1
1. Oil filter cover
2. Oil filter BEHIND OIL FILTER
3. O-ring
1. Bleeding screw
Wipe out any oil spillage on engine. Unscrew and remove one spark plug.
Inspect gasket on engine drain plug and replace as Turn engine using starter until oil emerges in filter
necessary. Clean gasket area on engine and drain chamber.
plug then reinstall plug. Torque to 30 N•m (22 lbf•ft).
Tighten pressure bleeding screw. Torque to 25 N•m
Refill oil tank at the proper level with the recom- (18 lbf•ft).
mended oil. Refer to TECHNICAL DATA for capacity.
Install oil filter.
NOTE: The same oil lubricates both engine and
transmission. Do not use synthetic oil, other than
Bombardier brand name, any semi-synthetic oil SPARK ARRESTER
or any special additives. They affect the clutching The muffler must be periodically purged of accumu-
calibration. lated carbon. See the MAINTENANCE CHART.
Start engine and let idle for a few minutes. Removal
Check if the RED indicator lamp stays ON. If so,
stop engine and bleed system by removing oil fil- WARNING
ter and bleeding screw. See procedure below. Never perform this operation immediately af-
Ensure oil filter area, hose and drain plug areas are ter the engine has been run because exhaust
not leaking. system is very hot. Wear eye protection and
Stop engine and check oil level. Refill as necessary. gloves. Respect all applicable laws and regu-
lations.
Dispose oil as per your local environmental regula-
tions.
VMR2004_004_02_03A.FM 02-03-5
Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)
1 1
V02C08A
02-03-6 VMR2004_004_02_03A.FM
Section 02 MAINTENANCE
Subsection 03 (MAINTENANCE/LUBRICATION)
TIRES PRESSURE
FRONT REAR
RECOMMENDED
35 kPa (5 PSI) 35 kPa (5 PSI)
Tire/Wheel Condition
Check tire for damage and wear. Measure thread
height. It should be 4 mm (5/32 in) minimum. Re-
place if damaged or worn.
A
V02A10A
TYPICAL
A. 4 mm (5/32 in)
Wheel Removal
Untighten nuts then lift vehicle where needed.
Place a support under vehicle. Remove nuts then
withdraw wheel.
At installation, it is recommended to apply anti-
seize lubricant on threads. Gently tighten nuts in a
criss-cross sequence then apply a final torque of
53 N•m (39 lbf•ft).
ENGINE AREA
Check in the engine area, for leak or other dam-
age. Clean mud, leafs, etc. from engine area.
VMR2004_004_02_03A.FM 02-03-7
Section 02 MAINTENANCE
Subsection 04 (STORAGE/PRESEASON PREPARATION)
STORAGE/PRESEASON PREPARATION
STORAGE Reinstall the spark plugs, foam, air filter and air box
cover.
If the ATV is to be stored for an extended period
of time more than 1 month, be sure to thoroughly
check the vehicle for needed repairs and have
WARNING
This procedure must only be performed in a
them performed.
well-ventilated area. Do not run engine dur-
ing storage period.
FUEL STABILIZER
A fuel stabilizer (P/N 413 408 600) can be added in RAGS IN AIR INTAKE AND
fuel tank to prevent fuel deterioration and avoid
draining fuel system for storage. Follow manufac- EXHAUST SYSTEM
turer’s instructions for proper use. At storage preparation, block air intake inlets and
If above fuel stabilizer is not used, drain fuel sys- exhaust system outlets using clean rags.
tem including fuel tank and carburetor. The air intake tubes are located under fuel tank
CAUTION: Fuel stabilizer should be added prior cover.
to engine lubrication to ensure carburetor pro- NOTE: Remove those rags at preseason prepara-
tection against varnish deposit. tion.
VMR2004_005_02_04A.FM 02-04-1
Section 02 MAINTENANCE
Subsection 04 (STORAGE/PRESEASON PREPARATION)
COOLANT DENSITY
Test the density of the coolant using an antifreeze
hydrometer.
NOTE: Follow manufacturer’s instructions for proper
use.
A 50/50 mixture of antifreeze and distilled water
will provide the optimum cooling, corrosion protec-
tion and antifreeze protection.
Do not use tap water, straight antifreeze or straight
water in the system. Tap water contains minerals
and impurities which build up in the system.
Straight water or antifreeze will cause the system
to freeze.
Change coolant if necessary.
02-04-2 VMR2004_005_02_04A.FM
Section 02 MAINTENANCE
Subsection 04 (STORAGE/PRESEASON PREPARATION)
PRESEASON PREPARATION
TO BE PERFORMED BY
SYSTEM PRESEASON OPERATIONS REFER TO
CUSTOMER DEALER
Test Run Vehicle. Check Clutch and Transmission
✔ N.A.
Operation
Maintenance/
Engine Oil and Filter Oil Replacement ➀ ✔ Lubrication
Coolant Replacement and Pressurization ✔ Cooling System
of System
ENGINE/ Condition of Seals ✔ N.A.
TRANSMISSION
Spark Arrester ✔ Maintenance/
Lubrication
Exhaust System Condition ✔ Removal and
Installation
Maintenance/
Rags Removal (intake and exhaust) ➁ ✔ Lubrication
Fuel Line and Connectors Condition ✔ Fuel Circuit
Carburetor Adjustment ✔ Carburetor and Air
FUEL SYSTEM Throttle and Choke Cable Inspection/Adjustment ✔ Intake Silencer
Maintenance/
Air Filter Cleaning/Replacement ✔
Lubrication
Spark Plug Replacement ➂ ✔ Ignition System
Battery Condition/Charging and Installation ✔
Starting System
ELECTRICAL Starter Connections and Routing ✔
Operation of Lighting System ✔ Instruments and
Accessories
Drive Chain Lubrication ✔
Drive Chain Adjustment ✔
DRIVE TRAIN Rear Axle
Drive Chain Protector Condition ✔
Sprockets Inspection ✔
Steering System Inspection and Adjustment ✔ Steering/Controls
STEERING/ Handlebar Fastener Tightness ✔ System
CONTROL Wheel Tightness ✔
SYSTEM Maintenance/
Tire Pressure ✔ Lubrication
Tire Condition ✔
Suspension System Inspection ✔
A-Arm Lubrication ✔ Front/Rear
SUSPENSION
Bearing Condition ✔ Suspension
Swing Arm Condition ✔
Brake Fluid Change ✔
BRAKES Hydraulic Brakes
Brake Condition ✔
Frame and Skid Plate Condition ✔ Body and/or
BODY/FRAME
Seat Latch ✔ Frame
VMR2004_005_02_04A.FM 02-04-3
Section 03 ENGINE
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
TROUBLESHOOTING ............................................................................................................ 03-02-1
COOLING SYSTEM ........................................................................................................... 03-02-1
MAGNETO SYSTEM ......................................................................................................... 03-02-2
LUBRICATION.................................................................................................................... 03-02-4
CYLINDER AND HEAD ...................................................................................................... 03-02-5
CRANKSHAFT AND BALANCER SHAFT.......................................................................... 03-02-6
GEARBOX .......................................................................................................................... 03-02-7
ENGINE GENERAL ............................................................................................................ 03-02-8
VMR2004_033_03_01ATOC.FM 03-01-1
Section 03 ENGINE
Subsection 01 (TABLE OF CONTENTS)
03-01-2 VMR2004_033_03_01ATOC.FM
Section 03 ENGINE
Subsection 01 (TABLE OF CONTENTS)
CLUTCH.................................................................................................................................. 03-10-1
GENERAL ........................................................................................................................... 03-10-2
CLUTCH ADJUSTMENT ................................................................................................... 03-10-2
CLUTCH COVER ................................................................................................................ 03-10-2
PRESSURE PLATE ............................................................................................................. 03-10-3
PRESSURE PLATE BEARING............................................................................................ 03-10-3
FRICTION DRIVE PLATE, STEEL DRIVEN PLATE AND CLUTCH BASKET..................... 03-10-4
CLUTCH RELEASE SHAFT ................................................................................................ 03-10-6
VMR2004_033_03_01ATOC.FM 03-01-3
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
TROUBLESHOOTING
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 HIGH ENGINE OPERATING TEMPERATURE.
CONDITION NORMAL USE.
Test/Inspection 1. Check coolant level.
a. Coolant less than recommended level.
Refill.
2. Check temperature sensor for electrical/mechanical failure.
a. Temperature sensor defective.
Replace.
3. Check thermostat (located on cylinder head).
a. Thermostat defective (does not open when engine gets hot).
Replace thermostat.
4. Check weep hole (water pump housing area) if coolant leaks.
a. Coolant leaking from weep 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(s) on water pump housing.
a. Gasket on water pump housing leaks.
Retighten screws and/or replace gasket(s).
9. Check cylinder head and/or cylinder base gasket.
a. Worn out gasket(s) is(are) causing water leakage.
Replace.
10. Check cooling fan and connection.
a. Fan motor faulty.
Replace.
b. Wire harness is brittle or hard (no connection).
Replace.
VMR2004_006_03_02A.FM 03-02-1
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
MAGNETO SYSTEM
SYMPTOM NO SPARK.
CONDITION NORMAL USE.
Test/Inspection 1. Check spark plug electrode condition.
a. Gap is too big.
Readjust gap (refer to TECHNICAL DATA).
b. Spark plug tip light grey and therefore heat range is too high.
Replace by Bombardier recommended spark plug (refer to TECHNICAL DATA).
2. Check ignition coils for damage and/or electrical failure.
a. Ignition coils damaged.
Replace ignition coils.
b. Connector is corroded or ignition coils shows electrical failure.
Clean ignition coils area and replace ignition coils.
c. Wire harness is brittle or hard (no connection).
Replace.
3. Check wire harness for cracks or other damages.
a. Harness shows electrical failure and/or other damages.
Replace wire harness.
4. Check magneto for damage and/or electrical failure.
a. Windings of stator have electrical failure.
Replace magneto.
b. Connector on magneto 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. Connectors are corroded.
Clean and reconnect.
c. Electronic module has bad ground.
Clean metal surface for good ground.
6. Check engine stop switch position.
a. Engine stop switch is in OFF position.
Place engine stop switch to RUN position.
03-02-2 VMR2004_006_03_02A.FM
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
SYMPTOM NO SPARK.
CONDITION NORMAL USE.
7. Check battery.
a. Battery shows less power.
Charge battery.
b. Battery has electrical failure.
Replace battery.
8. Check condition of fuse(s).
a. Faulty fuse(s).
Replace.
9. Check Trigger coil for damage and/or electrical failure.
a. Connector is corroded.
Clean and reconnect.
b. Resistance value is out of specification (refer to TECHNICAL DATA).
Replace trigger coil.
LUBRICATION
SYMPTOM LOW OR NO OIL PRESSURE
CONDITION NORMAL USE.
Test/Inspection 1. Check oil level and search 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 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 weep hole if oil leaks.
a. Oil leaking from weep 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.
VMR2004_006_03_02A.FM 03-02-3
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
03-02-4 VMR2004_006_03_02A.FM
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
VMR2004_006_03_02A.FM 03-02-5
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
03-02-6 VMR2004_006_03_02A.FM
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
GEARBOX
SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATIONS
CONDITION NORMAL USE.
Test/Inspection 1. Check oil level in engine.
a. Oil leakage from engine.
Replace damaged gasket(s) and/or oil seal(s), torque screws and refill with oil up
to specified level (refer to TECHNICAL DATA).
2. Check for knocking noise.
a. Tooth of gears are damaged and/or worn.
Replace respective gears.
VMR2004_006_03_02A.FM 03-02-7
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
ENGINE GENERAL
SYMPTOM ENGINE BACKFIRES.
CONDITION NORMAL USE.
Test/Inspection 1. Check spark plug and/or electrical system.
a. Carbon accumulation caused by defective spark plug.
Clean carbon accumulation and replace spark plug.
b. Electrical system has failure.
Replace defective part(s).
2. Check leakage on intake manifold.
a. Air leak on intake system.
Retighten screws and/or replace intake manifold.
3. Check exhaust air leaking.
a. Exhaust gasket is leaking.
Retighten screws and/or replace exhaust gasket.
4. Check intake valve(s) for leaking.
a. Intake valve(s) is(are) leaking.
Repair or replace valve(s).
5. Check if fuel supply is too less at high RPM.
a. Fuel line is contaminated and/or bent (engine gets lean).
Clean and/or replace defective part(s).
03-02-8 VMR2004_006_03_02A.FM
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
VMR2004_006_03_02A.FM 03-02-9
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
03-02-10 VMR2004_006_03_02A.FM
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH
SYMPTOM
MAXIMUM OPERATING RPM.
CONDITION NORMAL USE.
Test/Inspection 1. Check items of ENGINE SUDDENLY TURNS OFF.
2. Check air intake system.
a. Air filter is clogged due to contamination.
Replace air filter.
3. Check spark plug condition and/or gap.
a. Fouled spark plug or wrong spark plug gap.
Readjust gap and clean spark plug or replace.
4. Check spark plug type.
a. Improper spark plug heat range.
Install recommended spark plug (refer to TECHNICAL DATA).
5. Perform engine leak test. Refer to ENGINE LEAK TEST procedure. Check for
possible piston seizure.
a. Damaged head gasket and/or seal and/or leaking inlet/exhaust valve(s).
Replace and/or repair defective parts.
6. Check for water in fuel or contaminated fuel by other products (kerosene,
diesel, etc.).
a. There is water in fuel or contaminated fuel.
Drain fuel system, search for leakage and refill it with appropriate fuel.
7. Check engine compression.
a. Worn piston(s) and/or piston ring(s).
Replace (refer to CYLINDER AND HEAD).
VMR2004_006_03_02A.FM 03-02-11
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
03-02-12 VMR2004_006_03_02A.FM
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
SYMPTOM ENGINE DOES NOT START - NO SPARK AT SPARK PLUG (SEE MAGNETO SYSTEM).
CONDITION AT ENGINE CRANKING.
Test/Inspection 1. Verify spark plug condition.
a. Defective, improperly set, worn out, fouled.
Identify source of problem and correct. Replace spark plug.
2. Verify ignition coils resistance with an ohmmeter.
a. Defective part.
Replace ignition coil(s).
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 coils.
a. Mechanically damaged part. Vibration problem. Electrically damaged part.
Replace ignition coil(s).
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. Check magneto for damage and/or electrical failure.
a. Windings of stator have electrical failure (no charging causes an empty battery).
Replace magneto.
VMR2004_006_03_02A.FM 03-02-13
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
03-02-14 VMR2004_006_03_02A.FM
Section 03 ENGINE
Subsection 03 (LEAK TEST)
LEAK TEST
VERIFICATION LEAK TEST PROCEDURE
Before performing the cylinder leak test, verify the
following: PREPARATION AND TEST
– clamp(s) tightness NOTE: The following procedures should be done
– radiator and hoses condition with a cold engine.
– oily contamination on leak indicator hole (under Disconnect battery.
water pump cover) means a damaged oil seal
on water pump shaft WARNING
Always respect this order for disassembly;
disconnect BLACK (-) cable first. Electrolyte or
fuel vapors can be present in engine compart-
ment and a spark may ignite them and possi-
bly cause personal injuries.
V02C3OA 1 2
1. Leak indicator hole
2. Water pump cover
VMR2004_007_03_03A.FM 03-03-1
Section 03 ENGINE
Subsection 03 (LEAK TEST)
On LH side, remove the larger socket screw then Torque the crankshaft locking bolt to lock crank-
quickly install the crankshaft locking bolt (P/N 529 shaft.
035 617) to avoid oil leakage. Do not tighten. Remove radiator cap and dipstick.
Connect leak tester to adequate air supply.
Set needle of measuring gauge to zero.
V02C3QA
V02C3TA
V02C3RA
03-03-2 VMR2004_007_03_03A.FM
Section 03 ENGINE
Subsection 03 (LEAK TEST)
VMR2004_007_03_03A.FM 03-03-3
Section 03 ENGINE
Subsection 04 (REMOVAL AND INSTALLATION)
Pipe sealant
2.5 Nm 36
(22 lbfin) 35
Pipe 1
sealant 3 Nm
(27 lbfin)
20 Nm Pipe
(15 lbfft) Pipe sealant sealant
20 Nm
5 Nm (15 lbfft)
(44 lbfin) 5 Nm
(44 lbfin)
31 29 2
2.5 Nm
32 34 (22 lbfin)
28 30 26 Nm
(19 lbfft) 3
26 17
27 33
4 64 Nm
25 25 Nm 19 Nm (47 lbfft)
(18 lbfft) (14 lbfft)
10 Nm 11
(89 lbfin)
64 Nm
25 Nm (47 lbfft)
(18 lbfft) 25 Nm
5 (18 lbfft)
39 18
64 Nm
Loctite (47 lbfft)
271 23 24 14
135 Nm 7 13
(100 lbfft) 26 Nm
10 Nm
(89 lbfin) Loctite (19 lbfft)
271 140 Nm 22 11 Nm
(103 lbfft) 64 Nm (97 lbfin)
8 (47 lbfft)
10
16 6
15 Nm
14 21 (133 lbfin)
9 15 20 19
7 Nm
(62 lbfin) 12 26 Nm 11 Nm
V02C43S
13 (19 lbfft) (97 lbfin)
VMR2004_008_03_04A.FM 03-04-1
Section 03 ENGINE
Subsection 04 (REMOVAL AND INSTALLATION)
V02C4XA 1
UNDER ENGINE
1. Engine oil plug
V02C44A 2 1 4 3
1. Spark plug cables
2. Oil pressure sensor
3. Temperature sensor
4. Temperature sender
5. Magneto and trigger coil connectors
V02C10A 1
On left side of vehicle, remove or disconnect the
following items:
LH SIDE OF ENGINE
1. Engine coolant plug
– oil tank vent no. 1 on the top of engine
– radiator outlet hose
– oil inlet hose no. 2
– self-bleeding line
– clutch cable
03-04-2 VMR2004_008_03_04A.FM
Section 03 ENGINE
Subsection 04 (REMOVAL AND INSTALLATION)
– starter cable
1 2
– oil outlet hose no. 3
– gearshift pedal no. 4.
4 5
V02C45A 1 2 6 3 V02C3KA 5 4 3
LH SIDE OF ENGINE RH SIDE OF ENGINE
1. Radiator outlet hose 1. Exhaust pipes
2. Oil inlet hose 2. Radiator inlet hose
3. Self-bleeding line 3. Vent oil line
4. Clutch cable 4. Brake pedal
5. Starter cable 5. Footrest
6. Oil outlet hose
– carburetor and carburetor adaptor (refer to CAR-
On the right side of vehicle, remove or disconnect BURETOR AND AIR INTAKE SILENCER)
the following items:
Unscrew neutral switch connector.
– exhaust pipe shield no. 5, exhaust pipes no. 6
and no. 7 (refer to EXHAUST SYSTEM section) Removal
– radiator inlet hose Remove the upper support bracket no. 11 com-
– oil line vent hose pletely.
– brake pedal (refer to HYDRAULIC BRAKES)
– RH footrest (refer to BODY)
– countershaft sprocket cover no. 8
– metallic chain guard no. 9
– countershaft sprocket no. 10
(refer to COUNTERSHAFT SPROCKET section)
V02C19A
VMR2004_008_03_04A.FM 03-04-3
Section 03 ENGINE
Subsection 04 (REMOVAL AND INSTALLATION)
Install engine lifting tool (P/N 529 035 610) then, COUNTERSHAFT SPROCKET
install a hoist.
Remove: Removal
– upper engine support bolt no. 12 Slack drive chain.
– lower bolts no. 13 retaining the engine support Remove countershaft sprocket cover no. 8 and
no. 14 on either side, then, remove supports metallic chain guard no. 9.
– front lower mounting bolt no. 15 Select the first gear.
– rear lower mounting bolt no. 16 Unlock tab washer then, unscrew the retaining nut.
– rear upper mounting bolt no. 17. NOTE: Discard the tab washer.
Remove engine no. 18 from vehicle. Remove countershaft sprocket no. 10 and drive
chain together.
ENGINE INSTALLATION
Inspection
For installation, reverse the removal procedure,
pay attention to the following details. Check sprocket for wear or other damage. Replace
if necessary.
Reattach cables, hoses, wiring harness, etc.
Adjust clutch cable. Installation
Bleed rear brake. CAUTION: Replace chain and sprocket togeth-
Before starting engine, remove oil filter. er to prevent rapid chain and sprocket wear.
Install a new tab washer each time the sprocket
Unfasten pressure bleeding screw. is removed.
For the installation, reverse the removal procedure.
Pay attention to the following details.
Install countershaft sprocket with lips on the
engine side.
V02C05A 1
BEHIND OIL FILTER
V02C1AA
1. Bleeding screw
Unscrew and remove one spark plug. NOTE: Install the countershaft sprocket with the
Turn engine using starter until oil emerges in filter chain assembly.
chamber. Install tab washer then retaining nut.
Tighten pressure bleeding screw. Torque to 25 N•m Torque retaining nut to 140 N•m (103 lbf•ft), then
(18 lbf•ft). lock tab washer.
Install oil filter. Adjust drive chain. Refer to MAINTENANCE.
This operation activated the oil pump. Check if ve-
hicle runs correctly.
03-04-4 VMR2004_008_03_04A.FM
Section 03 ENGINE
Subsection 04 (REMOVAL AND INSTALLATION)
VMR2004_008_03_04A.FM 03-04-5
Section 03 ENGINE
Subsection 05 (COOLING SYSTEM)
COOLING SYSTEM
RADIATOR
11 Nm
(97 lbfin)
25
9
19
3.5 Nm
(31 lbfin) 1
20
2
21
2.5 Nm
(22 lbfin)
11 Nm
(97 lbfin) 17
34
2.5 Nm
(22 lbfin) 2.5 Nm
(22 lbfin)
18
8 11 Nm
(97 lbfin) 29
27
28 2.5 Nm
(22 lbfin)
31
32 30
1.5 Nm Loctite 271
(14 lbfin)
V02C4ES
VMR2004_009_03_05A.FM 03-05-1
Section 03 ENGINE
Subsection 05 (COOLING SYSTEM)
WATER PUMP
6 Nm
(53 lbfin) 12 Nm
7 (106 lbfin)
35 Nm
26 (26 lbfft)
33
23
24
22
16
15
10 Nm
14 (89 lbfin)
3 11
4
Molykote 111
13
12
10 5 10 Nm
(89 lbfin)
6
V02C4FS
03-05-2 VMR2004_009_03_05A.FM
Section 03 ENGINE
Subsection 05 (COOLING SYSTEM)
V02C3OA 1 2
1. Weep hole
2. Water pump housing
INSPECTION
Check general condition of hoses and clamp tight-
ness.
Check the weep hole if there is oil or water.
NOTE: Water indicates a damaged seal no. 3. Oil V02C10A 1
out of the weep hole indicates a non working oil
1. Cooling plug
seal no. 4.
VMR2004_009_03_05A.FM 03-05-3
Section 03 ENGINE
Subsection 05 (COOLING SYSTEM)
COOLING SYSTEM REFILLING Remove thrust washer no. 14, needle pin no. 15
and gear no. 16.
Recommended Coolant Press out sealing rings no. 3 and no. 4.
Use a blend of 50% antifreeze with 50% water.
Inspection
CAUTION: To prevent rust formation or freezing
condition, always replenish the system with 50% Check shaft no. 13 for traces of sealing rings and
antifreeze and 50% water. Pure antifreeze without replace if necessary.
water freezes. Always use ethylene-glycol anti- Check if the O-ring no. 10 in water pump cover is
freeze containing corrosion inhibitors specifically brittle, hard or otherwise damaged.
recommended for aluminum engines.
Installation
System Capacity For installation, reverse the removal procedure.
Refer to TECHNICAL DATA. NOTE: Do not drive spring pin into impeller until
engine housing cover has been installed.
Refilling Procedure
Drive internal sealing ring no. 4 firmly into place.
With vehicle on a flat surface, engine cold, remove
the temperature sensor no. 7 on the top of ther- Fill cavity between sealing rings with Molykote 111
mostat housing. Fill radiator no. 8 until coolant get paste.
out by the temperature sensor hole. Install the Drive external sealing ring no. 3 into place with the
temperature sensor and continue the cooling sys- relevant adapter until flush with the race.
tem filling by the radiator. Fill coolant tank no. 9 up
to cold level mark. Install radiator pressure cap. RADIATOR
Run engine for brief period then stop engine. Refill
up to mark, if necessary. Removal
When engine has completely cooled down, re- Drain cooling system.
check coolant level in radiator no. 8 and coolant
tank no. 9 and top up if necessary. Remove:
Check coolant concentration (freezing point) with – front facia (refer to BODY)
proper tester. – inlet no. 17 and outlet no. 18 hoses
1
PRESSURE CAP
Check if radiator pressure cap no. 1 pressurizes
the system. If not, install a new 110 kPa (16 PSI)
radiator pressure cap (do not exceed this pres-
sure).
WATER PUMP
Removal
Drain coolant.
Remove water pump cover no. 6 from water
pump with O-ring no. 10.
Drive out spring pin no. 11 and remove impeller
no. 12.
Remove left engine housing cover. V02C11A 2
Remove shaft no. 13 by pulling inwards. 1. Radiator inlet hose
2. Radiator outlet hose
03-05-4 VMR2004_009_03_05A.FM
Section 03 ENGINE
Subsection 05 (COOLING SYSTEM)
Inspection
Check radiator air passage for clogging or damage.
Remove insects, mud or other obstructions with
compressed air or low pressure water.
Check for any coolant leakage from radiator and V02C12A 1
hoses.
RH SIDE OF ENGINE
1. Remove screws
Installation
For installation, reverse the removal procedure. Pull out thermostat. Catch spilled coolant.
Refill radiator. Remove O-ring no. 24. Check O-ring for damage
and change if necessary.
NOTE: Do not forget rubber bushings no. 34 un-
der radiator. Test
To check thermostat, put in water and heat water.
RADIATOR PROTECTOR Thermostat should begin to open when water
temperature reaches 75°C (167°F).
Removal
Remove screws no. 20 retaining protector no. 21 Installation
on radiator. For installation, reverse the removal procedure.
Inspection Install the thermostat cover then torque screws to
6 N•m (53 lbf•in).
Check protector air passage for damage.
Check coolant level in radiator and coolant tank
Remove insects, mud or other obstructions with and top up if necessary.
compressed air or low pressure water.
VMR2004_009_03_05A.FM 03-05-5
Section 03 ENGINE
Subsection 05 (COOLING SYSTEM)
V02G0UA 2 1
1. Fan relay
2. Electronic box
3. Fuel tank cover
V02G0TA 2
1. Fan (15 A)
2. Charging system (25 A)
03-05-6 VMR2004_009_03_05A.FM
Section 03 ENGINE
Subsection 05 (COOLING SYSTEM)
V02C4IA 1
1. Temperature switch
Removal
Unplug temperature switch connectors.
V02C4JA
Unscrew temperature switch no. 26.
1. Remove bolts (two bolts on each side)
VMR2004_009_03_05A.FM 03-05-7
Section 03 ENGINE
Subsection 05 (COOLING SYSTEM)
TEMPERATURE SENSOR
V02C4IB 1
1. Temperature sensor
Removal
Unplug temperature sensor connector.
Unscrew temperature sensor no. 7.
Test
Using a multimeter, measure the resistance be-
tween connector on the top of temperature sen-
sor and threads.
The multimeter should indicate an infinite resis-
tance (O.L.), if not change the temperature sensor.
If the resistance is infinite (O.L.), heat the temper-
ature sensor, above 115°C (239°F). The resistance
should be 0.1 Ω . If not, change the temperature
sensor.
Installation
The installation is the reverse of the removal pro-
cedure.
CAUTION: Do not apply any product on the
threads.
03-05-8 VMR2004_009_03_05A.FM
Section 03 ENGINE
Subsection 06 (MAGNETO SYSTEM)
MAGNETO SYSTEM
Sealing
10 Nm Compound
(89 lbfin) Dreibond
8 Nm
(71 lbfin) Loctite 243
2
Sealing
15 Compound
Dreibond
4
5
9 180 Nm (133 lbfft)
14 10 Nm (89 lbfin)
Engine
oil
10 Nm
6 (89 lbfin)
10 Loctite
1 648
Loctite Engine
243 oil
7
10 Nm 2
(89 lbfin) 3
Loctite 11
648 12 13
V02C0MT
VMR2004_010_03_06A.FM 03-06-1
Section 03 ENGINE
Subsection 06 (MAGNETO SYSTEM)
STATOR
WARNING
Never disconnect harness on ignition system
V02C4QA
while engine is running.
Removal Installation
For installation, reverse the removal procedure.
To reach the stator no. 1, unfasten socket screws
Pay attention to the following details.
on ignition cover.
Seal rubber grommet no. 8 on electrical line with
Unfasten central screw plug no. 5, screw in the
sealing compound Dreibond (P/N 420 297 906).
handle (P/N 529 035 622) and remove ignition
cover no. 6.
V02C4RA
V02C0NA
Screw handle in center bore.
RH SIDE Fit ignition cover and screw down.
Remove gasket. Unfasten handle and install screw plug in ignition
NOTE: Clean all metal component in a non-ferrous cover.
metal cleaner. Use Bombardier gasket remover NOTE: Install a new gasket on ignition cover.
(P/N 413 708 500) or suitable equivalent.
03-06-2 VMR2004_010_03_06A.FM
Section 03 ENGINE
Subsection 06 (MAGNETO SYSTEM)
ROTOR 2 1
Removal
Lock crankshaft with locking bolt (P/N 529 035
617). Refer to CRANKSHAFT/BALANCER SHAFT.
Remove ignition cover no. 6.
Unscrew nut no. 9 retaining rotor no. 2.
Remove lock washer no. 10.
Install magneto puller (P/N 420 976 235) and
crankshaft protector (P/N 420 876 557) then re-
move rotor.
V02C4SA
SPRAG CLUTCH
Removal
Remove rotor no. 2.
V02C0OA
Unscrew all socket screws no. 14 retaining rotor
and sprag clutch housing no. 12.
Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Apply light coat of Loctite 648 to taper on rotor hub
no. 11.
CAUTION: Taper on crankshaft and rotor must
be free of grease.
Oil sprag clutch no. 3 in sprag clutch housing
no. 12.
Slide rotor onto crankshaft. The woodruff key and
groove must be aligned in one line.
Rotate starter double gear counterclockwise to
enable the sprag clutch no. 3 to slide on the collar V02C4TA
VMR2004_010_03_06A.FM 03-06-3
Section 03 ENGINE
Subsection 06 (MAGNETO SYSTEM)
Installation
For installation, reverse the removal procedure.
NOTE: Apply engine oil on sprag clutch.
Install sprag clutch. The arrow should be visible.
V02C0PA
V02C0QA 2 1 3
1. Guide piece
TRIGGER COIL 2. Trigger coil
3. Feeler gauge
Test
GAP BETWEEN GUIDE PIECE 0.75 ± 0.25 mm
Refer to IGNITION SYSTEM for the proper proce- AND TRIGGER COIL (.03 ± .01 in)
dure.
If necessary, correct gap by bending the retaining
Removal plate.
Remove the ignition cover no. 6. Coat rubber grommet on trigger coil and line from
Unscrew taptite screws no. 15 retaining trigger magneto in ignition cover beside sealing face with
coil no. 4 to housing then remove trigger coil. sealing compound Dreibond (P/N 420 297 906).
Fit gasket.
Installation
Coat rubber grommet no. 8 of trigger coil with ROTOR HUB
sealing compound Dreibond (P/N 420 297 906)
The rotor hub no. 11 is located behind the rotor.
and install in housing.
Secure trigger coil with taptite screws and fix Removal
screws with Loctite 243.
Remove:
Twist rotor no. 2 until guide piece faces towards
trigger coil. – rotor no. 2
Use feeler gauge to measure gap between guide – sprag clutch housing no. 12 and sprag clutch
piece and trigger coil. no. 3
– socket screws no. 14 retaining rotor and rotor
hub assembly.
Separate rotor hub from rotor.
03-06-4 VMR2004_010_03_06A.FM
Section 03 ENGINE
Subsection 06 (MAGNETO SYSTEM)
Installation
Reinstall all parts.
Before torque, check if the protrusion of rotor is
aligned with the key way in the center of rotor hub.
1 2
V02C4UA
1. Rotor protrusion
2. Rotor hub key way
VMR2004_010_03_06A.FM 03-06-5
Section 03 ENGINE
Subsection 07 (LUBRICATION SYSTEM)
LUBRICATION SYSTEM
ENGINE LUBRICATION
8 9
25 Nm
1 (18 lbfft)
10 Nm
(89 lbfin) 3
11
10 Nm Loctite 243 13
(89 lbfin) 10 Nm
(89 lbfin) 16
15
10 Nm 14
(89 lbfin)
25 Nm
(18 lbfft)
10 Nm
(89 lbfin)
8 Nm
(71 lbfin)
Loctite 243
28
29
27
26
17 Loctite 243
23 6 Nm
(53 lbfin)
24
25 19
10
22 21
30 Nm 20
7 (22 lbfft) 18
V02C3VS
VMR2004_011_03_07A.FM 03-07-1
Section 03 ENGINE
Subsection 07 (LUBRICATION SYSTEM)
OIL TANK
Loctite
pipe sealant
2.5 Nm
(22 lbfin)
30
20 Nm 2 3.5 Nm
(15 lbfft) (31 lbfin)
Loctite
5 Nm Loctite pipe sealant
(44 lbfin) pipe sealant
6
20 Nm
(15 lbfft)
12
V02C3WS
03-07-2 VMR2004_011_03_07A.FM
Section 03 ENGINE
Subsection 07 (LUBRICATION SYSTEM)
SAE 20W50
BOMBARDIER SYNTHETIC OIL 5W40 (P/N 293 600 039)
100
ENGINE PRESSURE TEST
NOTE: The engine pressure test should be done 30
with a warm engine and with the recommended 80
oil at the proper level.
SAE 15W40
20
Remove the oil pressure switch no. 3 above oil
filter and install the engine oil pressure adapter 60
(P/N 529 035 652) and the oil pressure gauge SAE 10W40 10
(P/N 529 035 709).
SAE 10W30
2 1 40
0
SAE 5W30
20
-10
0
-20
-30 -20
V01A37A
V02C3XA
VMR2004_011_03_07A.FM 03-07-3
Section 03 ENGINE
Subsection 07 (LUBRICATION SYSTEM)
Drain all oil from oil tank no. 5 by removing oil tank NOTE: Check and change O-ring no. 9, if neces-
drain plug no. 6. Wipe out any oil spillage. sary.
1 3
V02C04A 2
V02C3YA 1 2 TYPICAL — RH SIDE OF VEHICLE
1. Oil tank drain plug 1. Oil filter cover
2. Oil tank strainer 2. Oil filter
3. O-ring
Place a drain pan under the engine drain plug area.
Wipe out any oil spillage on engine.
Unscrew engine drain plug no. 7.
Change gasket no. 10 on engine drain plug. Clean
gasket area on engine and drain plug then reinstall
plug. Refill oil tank 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, hoses and drain plug areas are not
leaking.
Check if the RED indicator lamp stays ON, if so,
stop engine and bleed system by removing oil
filter and bleeding screw no. 11. Refer to BLEED-
V02C4XA 1 ING ENGINE OIL CIRCUIT below.
UNDER VEHICLE If the RED indicator light turns OFF, the system is
1. Oil drain plug good.
Wait a while to allow oil to flow out of oil filter. Stop engine and recheck oil level. Refill as neces-
Unscrew oil filter cover no. 8. sary.
Remove oil filter and replace by a new. Dispose oil as per your local environmental regu-
lations.
03-07-4 VMR2004_011_03_07A.FM
Section 03 ENGINE
Subsection 07 (LUBRICATION SYSTEM)
V02C05A 1
BEHIND OIL FILTER
1. Bleeding screw
VMR2004_011_03_07A.FM 03-07-5
Section 03 ENGINE
Subsection 07 (LUBRICATION SYSTEM)
V02C3ZA 1
1. Return oil pump
V02C41A
C
V01C1VA
03-07-6 VMR2004_011_03_07A.FM
Section 03 ENGINE
Subsection 07 (LUBRICATION SYSTEM)
A 1
Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Markings on inner rotor and oil pump rotor must
be visible.
V02C3ZB
Removal
Separate both crankcase housings. Refer to
CRANKSHAFT/BALANCER SHAFT section.
Unscrew the bolts no. 28 retaining the oil strainer
guide no. 29.
Installation
For installation, reverse the removal procedure.
VMR2004_011_03_07A.FM 03-07-7
Section 03 ENGINE
Subsection 07 (LUBRICATION SYSTEM)
OIL TANK
The oil tank is located under front facia, near the
headlight.
Removal
Drain oil tank.
Remove the front facia.
Unscrew headlight then disconnect and remove it.
Remove nut no. 30.
Unscrew bolts retaining fuel tank cover and oil
tank to the frame.
Unplug all hoses then remove oil tank.
Installation
The installation is the reverse of the removal pro-
cedure.
03-07-8 VMR2004_011_03_07A.FM
Section 03 ENGINE
Subsection 08 (CYLINDER AND HEAD)
10 Nm
(89 lbfin) 2
10 Nm
(89 lbfin)
6
60 Nm 20
(44 lbfft)
21
22
29
18 10 Nm
(89 lbfin)
30 10 Nm
(89 lbfin)
V02C47S
VMR2004_012_03-08A.FM 03-08-1
Section 03 ENGINE
Subsection 08 (CYLINDER AND HEAD)
VALVE
Engine oil
23
24
25
Super Lube
grease 28
26
31
Engine oil
32 32
27
Anti-seize
lubricant
8
10
16 17
Engine oil
5 9
40 Nm
15 (30 lbfft)
12 13
7 14
Loctite 4
9 243 10 Nm
(89 lbfin)
50 Nm
Loctite (37 lbfft)
648
11
V02C4YS
03-08-2 VMR2004_012_03-08A.FM
Section 03 ENGINE
Subsection 08 (CYLINDER AND HEAD)
VMR2004_012_03-08A.FM 03-08-3
Section 03 ENGINE
Subsection 08 (CYLINDER AND HEAD)
3 2
V02C3LA 1
RH SIDE OF VEHICLE
1. Remove this screw plug
V02C0HA 1
Move crankshaft into TDC setting with an Allen key.
1. Chain guide
Use feeler gauge to check valve clearance and 2. Timing chain
change adjusting plates if necessary. 3. Timing gears
VALVE CLEARANCE
Remove the upper section of camshaft carrier no. 6.
SERVICE LIMIT
Exhaust 0.10 to 0.15 mm
Intake (.004 to .006 in)
03-08-4 VMR2004_012_03-08A.FM
Section 03 ENGINE
Subsection 08 (CYLINDER AND HEAD)
V02C49A V02C4AB
V02C4AA
VMR2004_012_03-08A.FM 03-08-5
Section 03 ENGINE
Subsection 08 (CYLINDER AND HEAD)
Installation
A
CAUTION: Install the timing gears so that the
markings on the gears must be aligned and so
that the dowel pin on each camshaft must be lo-
cated on the top, as shown in the next illustration.
V02C0JA
V02C0IA 1
1. Align marks
03-08-6 VMR2004_012_03-08A.FM
Section 03 ENGINE
Subsection 08 (CYLINDER AND HEAD)
VMR2004_012_03-08A.FM 03-08-7
Section 03 ENGINE
Subsection 08 (CYLINDER AND HEAD)
If valve seat contact width is too wide, too narrow VALVE GUIDE
or has spots, the seat must be ground or cylinder
head replaced. Inspection
Installation Insert a new valve in valve guide until it contacts
the seal.
Install valve.
NOTE: Clean valve guide to remove carbon de-
NOTE: Remove assembly sleeve once again. posits before measuring.
Install valve spring and valve plate spring. Measure the maximum tilt clearance with a dial
NOTE: Install valve tappets with a small amount gauge placed as shown in the following illustra-
of grease to facilitate assembly. tion.
V02C4CA
TILT CLEARANCE
V02C4BA
SERVICE LIMIT
Exhaust
6.080 mm (.239 in)
Intake
03-08-8 VMR2004_012_03-08A.FM
Section 03 ENGINE
Subsection 08 (CYLINDER AND HEAD)
V02C50A
V02C4ZA
1. Valve guide remover/installer
2. Valve guide
Using valve guide remover/installer (P/N 529 035 3. Hammer
852), remove valve guide no. 32.
Valve guide to be grinded in diameter by using a
2 1 3 hand reamer.
V02B0XA
HAND REAMER
V02C50A
VMR2004_012_03-08A.FM 03-08-9
Section 03 ENGINE
Subsection 08 (CYLINDER AND HEAD)
1. Valve guide
A. Valve guide diameter
V02C52A
SERVICE LIMIT
R175motr92A 1 2
Exhaust TYPICAL
6.080 mm (.239 in) 1. Valve seat
Intake 2. Valve face (contact surface to valve seat)
3. Turn valve while pushing again cylinder head
03-08-10 VMR2004_012_03-08A.FM
Section 03 ENGINE
Subsection 08 (CYLINDER AND HEAD)
Inspection
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.
V02C0LA
Installation
Coat piston rings with oil and slide the ring com-
pressor over piston rings from above, allowing pis-
ton to protrude approximately 2 mm (3/32 in) from
ring compressor.
1
Slide timing chain through chain duct, then slide
cylinder over piston.
Remove the ring compressor.
Secure cylinder on crankcase housing with the
socket screws no. 30. Do not torque yet.
V01C1JA Fit cylinder head then torque nuts and bolts.
TYPICAL Torque socket screws.
1. Measure at three points
VMR2004_012_03-08A.FM 03-08-11
Section 03 ENGINE
Subsection 09 (CRANKSHAFT/BALANCER SHAFT)
CRANKSHAFT/BALANCER SHAFT
2
8
1
Engine oil 8
13
7
Anti-seize
lubricant
6
11 Engine
oil
14
Anti-seize 10
lubricant
9
Loctite
5 243
Anti-seize
lubricant
15
12
V02C3FT
VMR2004_013_03-09A.FM 03-09-1
Section 03 ENGINE
Subsection 09 (CRANKSHAFT/BALANCER SHAFT)
V02C4MA
V02C4KA
PISTON
Remove one piston pin circlip no. 8 then press out
piston pin no. 1. Removal
Inspection Remove piston pin no. 1.
Check piston pin for crack or other damage. Detach piston from connecting rod.
Measure piston pin with a micrometer. NOTE: Mark base of piston on exhaust end.
Inspection
Inspect piston for scoring, cracking or other dam-
ages.
V02C4LA A A A
A. Piston pin diameter
03-09-2 VMR2004_013_03-09A.FM
Section 03 ENGINE
Subsection 09 (CRANKSHAFT/BALANCER SHAFT)
Using a micrometer, measure piston at 16 mm With the micrometer set to the dimension, adjust
(5/8 in) perpendicularly (90°) to piston pin axis. a cylinder bore gauge to the micrometer dimen-
sion and set the indicator to 0 (zero).
2 1
A
V01C3KA
1
TYPICAL F00B09A
1. Measuring perpendicularly (90°) to piston pin axis
A. 16 mm (5/8 in) 1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
The measured dimension should be as described
in the previous table. If not, replace piston.
PISTON MEASUREMENT
SERVICE LIMIT 99.94 mm (3.9346 in)
Piston/Cylinder Clearance
PISTON/CYLINDER CLEARANCE
VMR2004_013_03-09A.FM 03-09-3
Section 03 ENGINE
Subsection 09 (CRANKSHAFT/BALANCER SHAFT)
Installation
A
For installation, reverse the removal procedure.
A A
NOTE: Install piston with removal mark (on base
of piston) in direction of exhaust end.
PISTON RINGS
Inspection
Piston Ring/Piston Groove Clearance 1
Using a feeler gauge measure each piston ring/piston
groove clearance. If the clearance is too large, the pis-
2
ton should be replaced.
03-09-4 VMR2004_013_03-09A.FM
Section 03 ENGINE
Subsection 09 (CRANKSHAFT/BALANCER SHAFT)
– oil filter
– all bolts retaining housing.
NOTE: Do not forget the bolts inside the oil filter
housing.
2 1 4 3
V02C4NA
V02C4PA 1
V02C4OA 1 3 2
1. Rotor V02C0SA 1 3 2
2. Spacer
3. Thrust washer 1. Balancer shaft
4. Sprag clutch gear 2. Crankshaft
5. Starter double gear 3. Marks on housing
6. Idle gear
VMR2004_013_03-09A.FM 03-09-5
Section 03 ENGINE
Subsection 09 (CRANKSHAFT/BALANCER SHAFT)
03-09-6 VMR2004_013_03-09A.FM
Section 03 ENGINE
Subsection 09 (CRANKSHAFT/BALANCER SHAFT)
Installation
For installation, refer to balancer shaft installation.
COUNTER GEAR
Removal
Clamp crankshaft in vise with protective jaws.
Using extractor (P/N 529 035 624) extract counter
gear.
V02C0VA
Installation
3 Heat engine housing to 100°C (212°F).
2
Coat bushing with Klueber grease (P/N 711 297 616)
and drive home with punch (P/N 529 035 689), strik-
ing from inside.
V02C0UA
1. Counter gear
2. Crankshaft
3. Extractor
Inspection
Check counter gear teeth for damage. Replace if
necessary.
V02C0WA
Installation
Heat counter gear to 140°C (284°F). CAUTION: Mark position of oil hole in bushing
on housing. Align mark on punch with mark on
CAUTION: The roller pin no. 14 must not pro-
housing. Bushing must be inset behind oil
trude from bore in counter gear; this is the sup-
holes. The notch on the bushing should always
port face for the thrust washer.
face the balancer shaft.
CRANKSHAFT BUSHING BALL BEARINGS IN HOUSING
Removal Removal
Heat engine housing to 100°C (212°F).
Heat output shaft in the housing to 80°C (176°F).
Drive out bushing with punch (P/N 529 035 688).
Using a suitable slide hammer, extract ball bearing.
Installation
Place the housing in oven to 100°C (212°F).
VMR2004_013_03-09A.FM 03-09-7
Section 03 ENGINE
Subsection 09 (CRANKSHAFT/BALANCER SHAFT)
NOTE: The sealed ends of the cage must point RECENTER BALANCER SHAFT
outwards.
NOTE: Only fit shim on clutch end.
RECENTER CRANKSHAFT Place balancer shaft into left engine housing
(clutch side). Do not install shim on clutch side.
NOTE: Only fit shim on clutch end. On magneto
side, the washer is always 1.0 mm (.04 in). Using depth gauge, measure distance between
the top of balancer gear and housing joint. This is
Place crankshaft into right engine housing (mag- the dimension “B”.
neto side). Do not install shim on clutch side.
Using depth gauge, measure distance between
crank web and housing joint. This is the dimension
“B”.
V02C3IA
V02C3JA
03-09-8 VMR2004_013_03-09A.FM
Section 03 ENGINE
Subsection 10 (CLUTCH)
CLUTCH
Super
Lube
8 Nm grease
(71 lbfin)
22
19 21
20
10 Nm
(89 lbfin)
8
Super
Engine Lube
oil grease
17
10 Nm
(89 lbfin)
15
18 16 7
140 Nm
(103 lbfft)
14
10 Nm
5 3 (89 lbfin)
13
Anti-seize
lubricant Loctite Super
243 Lube
grease
2 1
4 10
11
12
9
10 Nm
V02D06U (89 lbfin)
VMR2004_014_03-10A.FM 03-10-1
Section 03 ENGINE
Subsection 10 (CLUTCH)
Always disconnect BLACK (-) cable first and A. 3.5 ± 0.5 mm (9/64 ± 1/64 in)
reconnect last.
CLUTCH COVER
When the repair is done. Test drive to confirm all
is working well. If the test drive is good, perform Removal
a change of engine oil. Drain engine oil and coolant.
Detach clutch cable.
CLUTCH ADJUSTMENT
Remove:
The clutch adjustment is necessary after any works
– LH footpeg
in the clutch system.
– shifting pedal
Loosen cable tension.
– water pump cover
Adjust clutch release mechanism.
– starter bolts
The release lever must locate on the spline in such
a way that dimension A is obtained. See the fol- – all bolts retaining clutch cover
lowing illustration. – clutch cover no. 8.
NOTE: If necessary, unscrew the Allen socket
screw and remove release lever. Replace the lever 4
at the appropriate position then tighten socket
screw to 8 N•m (71 lbf•in).
V02D0EA 3 2 5 1
V02D03A
1. Footpeg
A. 68 to 75 mm (2-11/16 to 2-31/32 in) 2. Shifting pedal
3. Water pump cover
4. Starter bolts
5. Clutch cover
03-10-2 VMR2004_014_03-10A.FM
Section 03 ENGINE
Subsection 10 (CLUTCH)
PRESSURE PLATE
Removal
Remove clutch cover.
Unfasten screws no. 9, retaining clutch spring
no. 10 and pressure plate no. 1, crosswise.
V02D0FA 1
1. Pressure plate bearing
V02D09A
Inspection
Check pressure plate for crack or other damage.
Change if necessary.
Installation 1
V02D0GA
For installation, reverse the removal procedure.
1. Splines of clutch actuator rack
CAUTION: Never pull clutch release lever back-
wards. The pressure plate bearing may come
out of pressure plate.
VMR2004_014_03-10A.FM 03-10-3
Section 03 ENGINE
Subsection 10 (CLUTCH)
Disassembly 1 2 3
Remove the retaining ring no. 12 with retaining ring
pliers.
V02D0IA
Assembly
For assembly, reverse the disassembly order.
CAUTION: Never pull clutch release lever back-
wards. The pressure plate bearing may come
out of pressure plate.
03-10-4 VMR2004_014_03-10A.FM
Section 03 ENGINE
Subsection 10 (CLUTCH)
V02D0LA
Clutch Basket
V02D0JA
Check slots of clutch basket for damage or wear
Friction drive plates must be replaced when thick- caused by friction drive plates.
ness is 27.5 mm (1.0827 in) thick or less for the Change if necessary.
whole package.
V01D09A
TYPICAL
V02D0KA
VMR2004_014_03-10A.FM 03-10-5
Section 03 ENGINE
Subsection 10 (CLUTCH)
V01D0AA V01D0DA
V01D0CA
TYPICAL
Assembly
Assembly in the reverse sequence of disassembly.
Pay attention to the following details.
Install the needle bearings.
V02D0MA 2 3
NOTE: Install small needle bearing underneath.
1. Retaining ring
2. Clutch release shaft
3. Clutch cover
03-10-6 VMR2004_014_03-10A.FM
Section 03 ENGINE
Subsection 10 (CLUTCH)
2
1
V02D0BA
1. Clutch cover
2. Extractor
Installation
Drive in lower and upper needle bearing together
using the punch (P/N 529 035 691).
V02D0CA
TRANSMISSION
15
16
13 20 17 19 18
7 8
4
1
2 10
Engine
oil 9
Engine oil
6
Engine oil Anti-seize
5 lubricant
21 22 23 24 14
V02E07S
VMR2004_015_03-11A.FM 03-11-1
Section 03 ENGINE
Subsection 11 (TRANSMISSION)
SHIFTING MECHANISM
Removal
Remove engine from vehicle. Refer to REMOVAL
AND INSTALLATION.
Separate both crankcase housings. Refer to
CRANKSHAFT/BALANCER SHAFT.
Press shift pawl slightly outwards and withdraw
shift shaft no. 1 with shift pawl.
Remove index lever no. 2 and index spring no. 3.
Remove shift fork shafts nos. 4 and 5 from shift
forks nos. 6, 7 and 8.
Swivel shift forks outwards and remove.
Withdraw shift drum no. 9.
Inspection
Check for:
– worn or scored shifting forks V02E08A A
– rounded engagement dogs and slots A. Shift fork claw thickness
– bent shift forks Measure the O.D. of the shift fork shaft in three
– bent shift fork shafts places using an outside micrometer.
– worn tracks on shift drum.
O.D. OF SHIFT FORK SHAFT
Measure the shift fork claw thickness.
SERVICE LIMIT 5.85 mm (.230 in)
SHIFT FORK CLAW THICKNESS
SERVICE LIMIT 3.45 mm (.136 in) Installation
1 4
V02E04A 3 2
1. Index lever
2. Index spring
3. Pawl spring
4. Sleeve
03-11-2 VMR2004_015_03-11A.FM
Section 03 ENGINE
Subsection 11 (TRANSMISSION)
TRANSMISSION V02E05A
Using a plastic mallet, tap mainshaft no. 13 to as- Clutch side 24.97 mm (.98 in)
sist withdrawing mainshaft together with clutch
shaft no. 14. Run-out 0 mm (0 in)
VMR2004_015_03-11A.FM 03-11-3
Section 03 ENGINE
Subsection 11 (TRANSMISSION)
2 1
V02E06A
1. Magneto end
2. Clutch side
TRANSMISSION SHAFT
BEARINGS
Removal
Heat left or right engine housing to 80 - 100°C
(170 - 212°F).
Using the suitable bearing extractor to remove
bearings.
Tap out the mainshaft sealing ring from the inside.
Installation
Place new bearings in a freezer for 10 minutes be-
fore installation.
Place left or right engine housing in oven to 100°C
(212°F) to ease bearings installation.
NOTE: Always replace the mainshaft sealing ring
by a new one.
03-11-4 VMR2004_015_03-11A.FM
Section 04 FUEL SYSTEM
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
FUEL CIRCUIT........................................................................................................................ 04-02-1
FUEL LINE .......................................................................................................................... 04-02-2
FUEL TANK ........................................................................................................................ 04-02-2
FUEL VALVE ...................................................................................................................... 04-02-2
FUEL SYSTEM PRESSURIZATION ................................................................................... 04-02-3
VMR2004_033_04_01ATOC.FM 04-01-1
Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)
FUEL CIRCUIT
6
7 Nm
(62 lbfin)
5
5 Nm
(44 lbfin)
V02F0JS
VMR2004_016_04_02A.FM 04-02-1
Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)
04-02-2 VMR2004_016_04_02A.FM
Section 04 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)
FUEL SYSTEM PRESSURIZATION Using air pump (P/N 529 021 800) inject air into
fuel tank. See next photo.
Fill up fuel tank no. 1.
Remove seat.
Install on fuel tank the special cap included in the
fuel and oil system tester kit (P/N 529 033 100).
Install hose pinchers (P/N 295 000 076) on fuel
tank vent line no. 6 and on the outlet hose no. 3
at carburetor, as shown in the following photos.
V02N05A 2 1
1. Special cap on tank
2. Air pump
V02N04B 1
1. Hose pincher installed on fuel pump outlet
VMR2004_016_04_02A.FM 04-02-3
Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER)
10
12
11
6
3
V02F0BS
VMR2004_017_04_03A.FM 04-03-1
Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER)
13
22
18
14
Engine 17
18 19
1.2 Nm
0.6 Nm (10 lbfin)
(5 lbfin)
25 23
28
24 0.6 Nm
(5 lbfin) 17
19
1 2.5 Nm
(22 lbfin)
27
Super Lube
grease 26 20
10 Nm 10 Nm
(89 lbfin) (89 lbfin)
16 15
1.2 Nm
(10 lbfin)
V02F0CS
04-03-2 VMR2004_017_04_03A.FM
Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER)
WARNING
Solvent with a low flash point such as gaso-
line, naphtha, benzol, etc., should not be used
as they are flammable and explosive.
VMR2004_017_04_03A.FM 04-03-3
Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER)
Carburetor Adjustments
1
90°
V02F0EA
Installation
V02F05A 2 3
To install carburetor on engine, inverse removal pro-
cedure, as described: BOTTOM VIEW
1. Idle speed screw
– Inspect throttle cable housing prior to installa- 2. Pilot screw
tion. 3. Drain tube and screw
– Reinstall and adjust throttle cable, then side cov- Pilot Screw Preliminary Adjustment
er. Refer to CARBURETOR ADJUSTMENTS. NOTE: The pilot screw no. 5 is factory pre-set.
– Reinstall carburetor on engine. Adjustment is not necessary unless the carburetor
When reinstalling carburetor on engine, pay atten- is overhauled or replaced.
tion to the following: Completely close the pilot screw (until a slight
CAUTION: The carburetor adaptor must be seating resistance is felt) then back off as speci-
checked for cracks and/or damage. At assembly, fied.
the carburetor adaptor must be perfectly matched Refer to TECHNICAL DATA for specifications.
with the carburetor and intake adaptor or severe
engine damage will occur.
Install clamps in a way that their tightening bolts
are staggered, not aligned.
04-03-4 VMR2004_017_04_03A.FM
Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER)
Idle Speed Preliminary Adjustment Turn the pilot screw clockwise until you hear the
Adjust idle speed screw no. 6 to 1-1/2 turn or so engine misses or decreases air speed, then turn
that throttle valve no. 7 closes bypass hole by half, counterclockwise until the engine again misses or
as shown in the next photo. decreases air speed.
Center the pilot screw exactly between these too
extreme positions.
If idle speed changes after adjustment of the pilot
screw, readjust the idle speed screw.
Diaphragm Installation
Carefully replace diaphragm no. 8 in its original po-
sition.
Make sure spring no. 9 is located properly in car-
buretor cover no. 10 before screwing.
V01F0WA V02F06A
TYPICAL
1. Bypass hole closes to halfway NOTE: Check and place correctly the indexation lob.
Idle Speed Adjustment
Start engine and allow it to warm then adjust idle
speed to specifications by turning idle speed
screw clockwise to increase engine speed or
counterclockwise to decrease it.
NOTE: Use the digital induction tachometer
(P/N 529 014 500). Turn tachometer wire around
spark plug wire, about 4 or 5 turns, for the best
measure.
CAUTION: Do not attempt to set the idle speed
by using the pilot screw.
Refer to TECHNICAL DATA for idle speed specifi- V02F07A
cations.
Pilot Screw Adjustment
NOTE: The pilot screw is factory pre-set. Adjust-
ment is not necessary unless the carburetor is
overhauled or replaced. Warm the engine to oper-
ating temperature.
VMR2004_017_04_03A.FM 04-03-5
Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER)
Removal
Remove carburetor side cover no. 11.
V02F0HA
V02F0FA 1
1. Carburetor side cover
V02F0IA 1
1. Loosen this nut
04-03-6 VMR2004_017_04_03A.FM
Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER)
V01I0ZA
1. Remove screws
Remove:
– the cable from the throttle lever
2 1
V00I03A
WARNING
Always wear eye protection and gloves
when you lubricate a cable.
VMR2004_017_04_03A.FM 04-03-7
Section 04 FUEL SYSTEM
Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER)
Carburetor Adaptor
Removal
V02I04A 2 3 4 1 Remove carburetor.
1. Throttle lever Unscrew clamp no. 23.
2. Protector
3. Cable adjuster Separate the carburetor adaptor no. 24 from the
4. Lock nut
A. 3 to 8 mm (1/8 to 5/16 in) intake adaptor no. 25.
Inspection
AIR INTAKE SILENCER
Check carburetor adaptor for cracks or other dam-
Air Filter Box ages. Change it if necessary.
Removal Installation
Remove: For installation, reverse the removal procedure.
– seat
Intake Adaptor
– air box cover no. 13
Removal
– air filter no. 14
Remove carburetor.
– rectifier located under air filter box.
Unscrew socket screws no. 26 and washers no. 27
Disconnect the air intake tube no. 15 from carbu- then remove intake adaptor no. 25.
retor.
Unplug from air intake tube, the hose no. 16 on Inspection
the LH side. Check intake adaptor for cracks or other damages,
Unscrew clamps no. 17 retaining the vent hoses change if necessary.
no. 18 to the deflectors no. 19. Check O-rings no. 28 and change if necessary.
Unscrew bolts no. 20. Installation
Pull air filter box no. 21 out of frame with air intake For installation, reverse the removal procedure.
tube.
Inspection
Check air filter box for cracks or other damages.
Change air filter box if necessary.
Check air filter box latches no. 22 for cracks or
other damages. Change the air filter box latches if
necessary.
04-03-8 VMR2004_017_04_03A.FM
Section 05 ELECTRICAL
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
OVERVIEW............................................................................................................................. 05-02-1
GENERAL OPERATION INFORMATION ........................................................................... 05-02-1
CHARGING SYSTEM......................................................................................................... 05-02-1
STARTING SYSTEM .......................................................................................................... 05-02-1
IGNITION SYSTEM............................................................................................................ 05-02-2
ACCESSORIES ................................................................................................................... 05-02-2
GENERAL TESTING/ TROUBLESHOOTING INFORMATION ......................................... 05-02-2
FUSES LOCATION............................................................................................................. 05-02-3
SERVICING PACKARD CONNECTORS ............................................................................ 05-02-3
SERVICING DEUTSCH CONNECTORS ............................................................................ 05-02-3
IDENTIFICATION OF MAJOR CONNECTOR PINS .......................................................... 05-02-5
VMR2004_033_05_01ATOC.FM 05-01-1
Section 05 ELECTRICAL
Subsection 01 (TABLE OF CONTENTS)
05-01-2 VMR2004_033_05_01ATOC.FM
Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
OVERVIEW
GENERAL OPERATION Battery
INFORMATION The battery supplies the entire vehicle. Therefore, DC
current only is used in the entire electrical system.
The electrical system consists of different sub-
systems where some are inter-related:
STARTING SYSTEM
• charging system
• starting system When ignition switch is turned on and start button
is pressed, a signal is sent to the starting solenoid.
• ignition system The battery then supplies the starter through the
• accessories. starting solenoid to start the engine.
The following gives an outline of each components.
CHARGING SYSTEM 2
1
It is the source of electrical energy to charge the
battery and keep it at a full state of charge. The mag-
neto is coupled to the engine and it transforms mag-
netic field into electric current through a 3-phase, 3
6
delta wound stator on 18 poles.
4
The magneto supplies unregulated AC (alternative
current) to the voltage regulator/rectifier.
5
V02G05A
2
TYPICAL
4 1. Battery
2. Ignition switch
3. Start button
4. Electronic module
5. Solenoid
6. Electric starter
Voltage Regulator/Rectifier
A 3-phase full-wave series-type voltage regulator/
rectifier receives the AC voltage and rectifies (con-
verts) it into DC. The voltage is also regulated to a
maximum of 14.7 ± 0.4 volts (DC).
VMR2004_018_05_02A.FM 05-02-1
Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
05-02-2 VMR2004_018_05_02A.FM
Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
Before replacing any electric or electronic part(s), Fuses are located under seat, between engine and
always check electrical connections. Make sure air box.
that they are very tight and they make good con-
tact and that they are corrosion-free. The voltage
and current might be too weak to go through dirty
wire pins. Check carefully if posts show signs of
moisture, corrosion or if they look dull. Clean pins
properly and then coat them with silicon-based di-
electric grease or other appropriate lubricant (ex-
cept if otherwise specified) when reassembling
them. See connectors information below.
IMPORTANT: In usual electric circuit, the battery
supplies a switch which then supplies the electric
consumer. Therefore the switch opens and closes 1
the positive side of the circuit. Take this into ac- 2
count when troubleshooting the electrical system. V02A0OA
VMR2004_018_05_02A.FM 05-02-3
Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
V01G0OA 1
FEMALE HOUSING
1. Female lock
V01G0QA 1
FEMALE CONNECTOR HOUSING
1. Retaining tab
To install:
– For insertion of signal contact, make sure the
lock is removed.
– Insert contact into appropriate circuit cavity and
push as far as it will go.
– Pull back on the contact wire to be sure the re-
tention fingers are holding the contact.
– After all required contacts have been inserted,
the lock must be installed.
CAUTION: Never apply dielectric grease on con-
V01G0PA 1 tacts in plug connector. The use of dielectric
grease will make the seal swell and move out of
MALE HOUSING
the connector. Do not lubricate.
1. Male lock
05-02-4 VMR2004_018_05_02A.FM
Section 05 ELECTRICAL
Subsection 02 (OVERVIEW)
85
A A B 2 87
1
87a
B B A 1 86 30 2
2
1
A A
A A
A
B B
C C B B
B
C
A
B
C C A 3
A 1
B 21
A C B 2
A C 3
B B
A B A C
C B
D A A B
C B D A B A
B C
A B
A B
D C A
B A B 4
C D 1
2
3
1
4 2
3
PACKARD
A A
B B
C
6
5
1 4 1
2 2
3 6 3
5
4
A
A
B B
A C
B A
C 12
D CB 11
D 1 10 1
FE 2
3 12
9
8
2
3
4 11 7 4
5 10 5
6 9 6
8
A 7
A
B CB
D
V01G0ES D
C FE
VMR2004_018_05_02A.FM 05-02-5
Section 05 ELECTRICAL
Subsection 03 (CHARGING SYSTEM)
CHARGING SYSTEM
TESTING PROCEDURE If multimeter reads over 15 volts, voltage regulator/
rectifier is defective. Replace it.
NOTE: First, ensure that battery is in good condi-
NOTE: Whatever the voltmeter type used (peak
tion prior to performing the following test using a
voltage or RMS), the voltage must not exceed
current inductive ammeter such as Snap-on MT
15 V. A faulty voltage regulator/rectifier will allow
110.
voltage to exceed 15 V as engine speed is in-
If the battery is regularly discharged, check main creased.
(25 amp) fuse condition.
NOTE: If the battery will not stay charged, the
The voltage regulator/rectifier could be the culprit problem can be any of the charging circuit compo-
of a blown fuse. To check, simply disconnect the nents. If these all check good, you would be accu-
voltage regulator/rectifier from the circuit. rate in assuming the problem to be in the voltage
If the fuse still burns, check for a defective wire. regulator/rectifier.
CAUTION: Do not use a higher rated fuse as this If there is no charging at the battery with the pre-
can cause severe damage. ceding voltage test, the following test can also be
performed.
Voltage Regulator/Rectifier NOTE: If the voltage regulator/rectifier is within
STATIC TEST: CONTINUITY the specification, the wiring harness between the
voltage regulator/rectifier and battery is defective.
1. Due to internal circuitry, there is no static test If the voltage regulator/rectifier is out of specifica-
available. tion and the stator test good, the voltage regulator/
DYNAMIC TEST rectifier is defective.
Current Test Stator
Proceed as follows:
STATIC TEST: CONTINUITY
– Start engine.
1. Disconnect the magneto wiring harness connec-
– Lay an inductive ammeter on positive cable of tor. With the recommended multimeter, place
battery. the 2 meter test probes onto the stator wire
– Bring engine to approximately 3500 RPM. leads AC-1 and AC-2 of the stator. The resis-
tance should be between 0.1 Ω and 1.0 Ω.
Depending on battery charge, current reading
should be approximately 5 amperes. If not, check
magneto output prior to concluding that voltage
regulator/rectifier is faulty.
Voltage Test
Proceed as follows:
– Start engine.
– Connect a multimeter to battery posts. Set mul-
timeter to Vdc scale.
– Bring engine to approximately 3500 RPM. YL
YL
YL
BL
GN-YL
V02G01A
TYPICAL
VMR2004_019_05_03A.FM 05-03-1
Section 05 ELECTRICAL
Subsection 03 (CHARGING SYSTEM)
2. Place either meter test probe into the remaining DYNAMIC TEST
stator lead (AC-3) and note the resistance (same 1. Unplug magneto wiring harness connector.
as step no. 1). If the readings are out of specifi-
cation, the stator will need to be replaced. 2. On magneto side, connect test probes of the
multimeter to two of the YELLOW wires.
3. Set multimeter to Vac scale.
4. Start engine. The obtained value should be be-
tween 10 and 12 Vac.
5. Repeat operation 3 times.
6. If the stator is out of specification, replace it.
YL
YL
YL
BL
GN-YL
V02G02A
TYPICAL
YL
YL
YL
BL
GN-YL
V02G03A
TYPICAL
05-03-2 VMR2004_019_05_03A.FM
Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
STARTING SYSTEM
BATTERY Load Test
This is the best test of battery condition under a
TROUBLESHOOTING starting load. Use a load testing device that has an
adjustable load.
SYMPTOM: DISCHARGED OR WEAK BATTERY Apply a load of 3 times the ampere-hour rating of
CAUSE REMEDY the battery. At 14 seconds into the test, check bat-
tery voltage; if battery is in good condition, it will
1. Battery posts and/or Clean and coat with have at least 10.5 Vdc.
cable terminal oxidized. dielectric grease.
2. Loose or Check wiring and REMOVAL
bad connections. connector cleanliness,
damaged or short Disconnect BLACK (-) cable first then positive cable.
circuit.
WARNING
3. Faulty battery Replace.
(doesn’t keep a full Always respect this order for disassembly;
charge loose rectifier). disconnect BLACK (-) cable first. Electrolyte
or fuel vapors can be present in engine com-
4. Main system fuse burnt First check charging partment and a spark may ignite them and
or faulty voltage system. If it is in good possibly cause personal injuries.
regulator/rectifier.* condition replace fuse
or rectifier. Remove bolts retaining battery holder from rack.
5. Faulty charging system Replace.
generator coil.*
BATTERY TESTING
There are 2 types of battery tests: unloaded and
loaded. An unloaded test is made on a battery with-
out discharging current. It is the simplest and com-
monly used. However, be aware that the voltage
test can be good while the battery has not enough
power to start the engine. A load test gives more
accuracy of the battery condition. V02F01A 2 1
1. Battery holder
Unload Test 2. Rack
Check charge condition using a multimeter.
With a multimeter, voltage readings appear instant- CLEANING
ly to show the state of charge. Always respect po- Clean the battery casing, cables and battery posts
larity. A fully charged battery will have a reading of using a solution of baking soda and water.
12.6 Vdc.
Remove corrosion (if so) from battery cable termi-
nals and battery posts using a firm wire brush.
Rinse with clear water and dry well.
VMR2004_020_05_04A.FM 05-04-1
Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
05-04-2 VMR2004_020_05_04A.FM
Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
VMR2004_020_05_04A.FM 05-04-3
Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
05-04-4 VMR2004_020_05_04A.FM
Section 05 ELECTRICAL
Subsection 04 (STARTING SYSTEM)
Electronic Module
When other components have been tested above
and are good, the electronic module can be sus-
pected. Ensure wiring and connectors are in good
condition prior to replacing the electronic module.
ELECTRIC STARTER
A
REMOVAL A32E2QA
Disconnect BLACK (-) cable from battery. NOTE: Make sure not to cut wire strands while
stripping the wire.
WARNING
Always disconnect BLACK (-) cable first and
reconnect last.
A32E2RA
INSTALLATION OF TERMINAL
A32E2UA
05-04-6 VMR2004_020_05_04A.FM
Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)
IGNITION SYSTEM
IGNITION SYSTEM TESTING IGNITION SYSTEM TEST
PROCEDURE
Safety Precautions
GENERAL
WARNING
Ignition Problems To prevent powerful electric shocks while
cranking engine, neither touch any electronic
When dealing with ignition problems, the follow-
ignition components (ignition coil, high ten-
ing items should be checked in this order. After
sion wire, wire harness, etc.) nor tester lead
one item has been checked and it is found not to
clips. Also make sure that tester leads do not
be the problem, continue with the next item:
touch any metallic object.
1. main fuse condition
2. spark occurrence Main Fuse Condition
3. battery condition Check main fuse condition. Replace burnt fuse as
4. ignition switch necessary.
5. trigger coil
Spark Occurrence
6. ignition coil
Remove one spark plug and connect to its cable.
7. electronic module.
While holding the spark plug against a metallic part
of the engine, start the engine. Look for a spark at
Intermittent Ignition Problems the spark plug tip. Proceed the same with the oth-
In dealing with intermittent problems there is no er spark plug. Replace defective spark plug.
easy diagnosis. For example, problems that occur NOTE: If a spark plug is found defective, replace
only at normal engine operating temperature have both spark plugs at the same time.
to be tested under similar conditions.
Both spark plugs must be checked individually. If
In most cases of temperature and/or vibration fail- one works and the other doesn’t, try another spark
ure, only parts replacement might solve the prob- plug.
lem as most of these failures return to normal
when engine is not running. Keep in mind that a spark plug might test good this
way while not being able to work properly under
Multiple Problems combustion chamber mixture and pressure.
There is always the possibility of more than one If known good spark plug(s) does(do) not work,
faulty part. If after a component has been re- continue the other tests.
placed, the problem still persists, carefully repeat NOTE: Spark occurrence can be checked with a
the complete test procedure to find the other tester such as Superex Canada Ltd (P/N 15-785)
faulty part. or the equivalent.
VMR2004_021_05_05A.FM 05-05-1
Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)
TROUBLESHOOTING
NOTE: Check that the transmission is in NEUTRAL position and the engine stop switch is in RUN
position. Check that main fuse is not burned and if battery is fully-charged before diagnosing.
CORRECT LOOSENESS
CORRECT INCORRECT
INCORRECT CORRECT
Faulty electronic Faulty ignition coil. Poor connection of Faulty spark plug.
module. the spark plug cap.
Poor connection of
ignition connector.
V02G1RS
05-05-2 VMR2004_021_05_05A.FM
Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)
VMR2004_021_05_05A.FM 05-05-3
Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)
Electronic Module
A C E
V06G06A B D F A B C D E F
A 2.18 MΩ 2.18 MΩ UP to- ∞ 2.18 MΩ 2.18 MΩ
B O.L. 2590 Ω UP to- ∞ 2590 Ω 5.58 KΩ
When every other components above have been If a fault is detected, the electronic module must
tested and are good, the electronic module can be be replaced.
suspected. Ensure wiring and connectors are in
good condition prior to replacing the electronic IGNITION TIMING
module.
It is impossible to check the ignition timing with a
TEST timing lamp because there is no access window or
NOTE: On the multimeter, set measuring range mark.
from 1 KΩ − 10 KΩ. Make sure that positive and
negative tester probes are installed on the appro-
priate wires.
WH Ο Ο Ο Ο
OR Χ ∆ ∆ Χ
RD Ο Ο Ο Ο
BK Ο Ο Ο Ο
SYMBOLS:
Ο: Open circuit, value/pointer change continuously
Χ: No open circuit, value/pointer do not register any change
∆: Value/pointer changer and move to ∞
05-05-4 VMR2004_021_05_05A.FM
Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)
A00E0AA 1 2 3
TYPICAL
1. Overheated (light grey, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, grey, melted coating)
VMR2004_021_05_05A.FM 05-05-5
Section 05 ELECTRICAL
Subsection 05 (IGNITION SYSTEM)
V04G0DS
05-05-6 VMR2004_021_05_05A.FM
Section 05 ELECTRICAL
Subsection 06 (ACCESSORIES)
ACCESSORIES
REMOVAL AND Detach bulb and replace.
INSTALLATION
CAUTION: It is recommended to always dis-
connect the battery when replacing any electric
or electronic parts.
HEADLAMP
Bulb Replacement
Remove front facia.
Remove rubber boot.
V02G1OA
V02G1MA
V02G1PA
Removal
Remove front facia and dashboard. Refer to BODY.
V02G1NA Unscrew the bolts retaining headlamp then un-
plug the connector.
Installation
Properly reinstall removed parts in the reverse or-
der of their removal.
VMR2004_022_05_06A.FM 05-06-1
Section 05 ELECTRICAL
Subsection 06 (ACCESSORIES)
1 1
V02G1QA 2
1. Headlamp
2. Adjustment screw
V02G0NA 2
Adjust beam height to your convenience then re-
install the front facia. 1. Auxiliary headlamp
2. Support
V02A06A 2 1 2
V02G0OA 1
1. Lens
2. Screws 1. Remove these screws
Removal
Remove dashboard.
Unplug wires under tachometer.
Push the tachometer out of dashboard.
V02G0PA
Installation
Detach bulb and replace. The installation is the reverse of removal proce-
dure.
NOTE: Make sure the retainer is inserted be-
tween the tachometer and the rubber grommet.
IGNITION SWITCH
Test
Refer to IGNITION SYSTEM.
Removal
Lift the dashboard and unscrew the ignition switch
nut.
Unplug the switch connectors.
Installation
V02G0QA
For the installation, reverse the removal proce-
BULB WITH WIRE ASSEMBLY
dure.
NOTE: ALWAYS USE A 35 WATTS BULB. If the
55 watts bulb is used, the regulator might not be INDICATOR LIGHTS
able to recharge the battery properly.
Properly reinstall removed parts in the reverse or- Test
der of their removal. Refer to TESTS section.
CAUTION: Never touch glass portion of an halo-
gen bulb with bare fingers, it shortens its operat- Removal
ing life. If glass is touched, clean it with isopropyl Remove dashboard.
alcohol which will not leave a film on the bulb.
Unplug wires on indicator lamp.
VMR2004_022_05_06A.FM 05-06-3
Section 05 ELECTRICAL
Subsection 06 (ACCESSORIES)
Press both tabs then push indicator lamp out of hole. Using a multimeter, measure the resistance be-
tween the following wires.
POSITION WIRE RESISTANCE
RED/VIOLET
Switch OFF Infinite (0.L)
1 1 and GREEN
RED/VIOLET
Switch OFF Infinite (0.L)
and BLUE
RED/VIOLET
Switch to LO 0.4 Ω max.
and GREEN
RED/VIOLET
Switch to HI 0.4 Ω max.
and BLUE
INDICATOR LIGHTS
Remove steering cover.
V02A0FA
05-06-4 VMR2004_022_05_06A.FM
Section 06 DRIVE TRAIN
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
FRONT DRIVE ........................................................................................................................ 06-02-1
GENERAL ........................................................................................................................... 06-02-2
WHEEL HUB....................................................................................................................... 06-02-2
WHEEL HUB BEARING ..................................................................................................... 06-02-2
KNUCKLE ........................................................................................................................... 06-02-3
VMR2004_033_06_01ATOC.FM 06-01-1
Section 06 DRIVE TRAIN
Subsection 02 (FRONT DRIVE)
FRONT DRIVE
135 Nm
(100 lbfft)
MINIMUM
4
5
2 1
7
2
Synthetic 6
grease
52.5 Nm
(39 lbfft)
Synthetic
grease
3
3
6
2
7 1
2 135 Nm
Synthetic (100 lbfft)
grease MINIMUM
5
52.5 Nm
(39 lbfft)
Synthetic
grease 4
V02H18S
VMR2004_023_06_02A.FM 06-02-1
Section 06 DRIVE TRAIN
Subsection 02 (FRONT DRIVE)
Inspection
Check hub for cracks or other damage. Replace as
necessary.
Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Apply grease to wear ring located on the knuckle.
V02H08A
Install a new seal into wheel hub until it is flush
with hub surface. TYPICAL
Tighten castellated nut to the specific torque and Remove the inside bushing no. 7 and drive out the
further tighten until its grooves align with cotter outer bearing.
pin hole.
06-02-2 VMR2004_023_06_02A.FM
Section 06 DRIVE TRAIN
Subsection 02 (FRONT DRIVE)
Installation Use a ball joint remover and detach upper and low-
er A-arm from knuckle.
Drive in a new bearing squarely until it is fully seat-
ed. CAUTION: Never hit the knuckle with a hammer.
Install inside bushing and drive the outer new
bearing squarely until it is fully seated.
Inspection
Install a new seal. Check knuckle for damage, cracks or pitting. Re-
place as necessary.
KNUCKLE Installation
Removal The installation is the reverse of the removal pro-
cedure. However, pay attention to the following
Remove: details.
– wheel hub Install knuckle onto the upper and lower A-arms
– tie-rod from knuckle with hardened washer and castellated nut.
(refer to STEERING AND CONTROLS SYSTEM) Tighten castellated nut to the specific torque and
– cotter pins from the upper and lower A-arm ball further tighten until its grooves align with the next
joints (discard cotter pins) cotter pin hole.
– castellated nuts Install a new cotter pin. Both ends of cotter pin
– hardened washer. must be folded.
3
2
4
V02I0XA 6
1. Knuckle
2. Castellated nut
3. Cotter pin
4. Hardened washer
5. Upper A-arm
6. Lower A-arm
VMR2004_023_06_02A.FM 06-02-3
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
REAR AXLE
4 Nm 16
10 (35 lbfin) 17
23 Nm
(17 lbfft) 18
22
3
11
19 1 235 Nm
23 13 (173 lbfft)
22 53 Nm
(39 lbfft)
21
24 15
7
80 Nm
(59 lbfft)
2
14
Synthetic
grease 26
XL845
27
28
4 Nm 23 Nm
(35 lbfin) (17 lbfft)
9
Synthetic
grease 6
XL845 Synthetic 12
grease
7 XL845
24 4 Nm
21 (35 lbfin)
Loctite
29 609 Grease
Texaco
4 Synthetic
grease XL845 25
20 8
3 Grease
18 Texaco
17
16
Grease
53 Nm Texaco 5
235 Nm
(173 lbfft) (39 lbfft)
V02H19S
VMR2004_024_06-03A.FM 06-03-1
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
WARNING 1 4 3
V02H15B 26 4 3 15
06-03-2 VMR2004_024_06-03A.FM
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
Inspection SLIDER-SHOE
With the drive chain no. 1 installed on vehicle and
the free play adjusted correctly, measure the dis- Removal
tance between a span of 13 links from pin center Remove swing arm. Refer to REAR SUSPENSION.
to pin center.
Remove slide-shoe.
A
Installation
Installation is the reverse of the removal.
Inspection
Check wheel hub for cracks splines wear or other
damage. Change if necessary.
VMR2004_024_06-03A.FM 06-03-3
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
Installation
CAUTION: Replace chain, engine sprocket and
rear sprocket together to prevent rapid chain
and sprockets wear. Install a new tab washer
each time the engine sprocket is removed.
For installation, reverse the removal procedure.
V02H1AA
06-03-4 VMR2004_024_06-03A.FM
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
V02H1DA
Inspection
Check brake disc hub for cracks or other damage.
Replace if necessary.
Check for worn splines and free play on the rear
axle splines.
Check if wear ring no. 21 is worn or damaged. If
the ring is grooved, it must be replaced. Remove
old ring and, using tool P/N 529 035 694, press a
new one in place.
Press the wear ring on the hub until it bottoms.
V02H1CA
VMR2004_024_06-03A.FM 06-03-5
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
3
Install the nut. Pay attention to position the
flanged side of nut against the hub.
V02H1QA 1
V02H1RA
1. Flanged side against brake hub
1. Wear ring
2. Tool (P/N 529 035 694) Temporarily tighten nut by hand.
3. Press until it bottoms
Install brake caliper and tighten bolts to 25 N•m
If the brake disc hub has been damaged, replace (18 lbf•ft).
it too. Place transmission on first gear and/or apply rear
Check for distorted or enlarged locking tab. If so, brake.
replace with a new one. Use rear axle key (P/N 529 035 951) to tighten
brake hub locking nut.
Installation and Bearing Preload
Ensure to install the tool perpendicularly (90°) to
It is very important to set the correct amount of torque wrench to apply the proper torque to the
preload on the brake hub nut to properly apply the nut.
preload to the rear axle bearings.
Clean splines of rear axle and hubs with pulley
flange cleaner (P/N 413 711 809).
Install a new O-ring no. 29.
90°
Apply synthetic grease (P/N 293 550 019) on splined 1
region of the axle. V02H1EA
IMPORTANT: Do not apply grease on axle 1. Tool perpendicular (90°) to torque wrench
threads. CAUTION: Not installing the tool as shown will
Slide the brake disc hub over the axle. change the torque applied to the nut. Proper
torque and tightening sequence are important.
To properly set the parts, first apply a preload
torque of 92 N•m (68 lbf•ft). Then, loosen nut
and apply a torque of 28 N•m (21 lbf•ft).
06-03-6 VMR2004_024_06-03A.FM
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
NOTE: If slots of nut are not properly aligned with REAR AXLE
slots of disc hub, continue tightening nut until
slots align without exceeding 35 N•m (26 lbf•ft). Removal
Lift rear of vehicle and install jack stands under the
frame to support the rear of vehicle out off the
ground.
Remove rear wheels.
Loosen chain. Refer to DRIVE CHAIN above.
Remove the LH wheel hub no. 3 and brake disc
hub no. 4.
Remove protector no. 8.
Unscrew the 6 bolts retaining the sprocket to its
sprocket hub.
Separate the sprocket from the sprocket hub and
place it away with the chain over the swing arm
tube. This will ease the removal and the insertion
of the axle into the swing arm because the chain
will not be in the way.
V02H1OA 1 3 2 Loosen the locking bolts on the swing arm used
to set the chain tension.
1. Slot of nut
2. Slot of brake hub
3. If not aligned, continue tightening
V02H1PA 1 V02H15A 1
1. Slots aligned. Do not exceed 35 N•m (26 lbf•ft) 1. Rear axle lock bolts
Slide locking tab over nut and insert properly in Slide out the axle from the right side of the swing
slots. arm. If the vehicle ran with failed bearings, it may
Release rear brake. have damaged many parts around the bearing area.
It is possible that the axle will not slide out easily if
Install rear wheel hub (refer to procedure men-
the bearings are seized on it.
tioned above).
VMR2004_024_06-03A.FM 06-03-7
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
Installation 2
Insert the axle assembly into the chain first, then
into the swing arm from the right side.
Install the brake disc hub and wheel hub.
CAUTION: It is important to follow the preload
procedure to avoid seal and bearing damage.
Refer to BRAKE DISC HUB for the procedure.
Install sprocket and tighten bolts to 61 N•m (45
lbf•ft).
Install protector no. 8.
Install both rear wheels and tighten nuts to 53 N•m
(39 lbf•ft) in a criss-cross sequence.
3
CAUTION: Always use the recommended wheel
nuts (P/N 732 610 084). Using a different nut could
cause damages to the rim.
Perform drive chain adjustment. Refer to DRIVE
V02H1SA 1
CHAIN above.
1. Rear sprocket hub
2. Steel tube used as a pusher
3. C-clip
WARNING
Wear asbestos gloves to handle the parts to
protect your hands from the heated parts.
06-03-8 VMR2004_024_06-03A.FM
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
Turn rear axle upside down. Apply some synthetic grease (P/N 293 550 019)
Press the hub out of rear axle. on splines.
IMPORTANT: Do not apply grease on axle
threads.
1 Using the same steel tube as for removal, press
hub until the C-clip groove allows C-clip insertion.
CAUTION: Be careful not to press more than
needed. Otherwise, the O-ring might be dam-
aged.
Install C-clip.
Press hub in the opposite direction until hub bot-
toms on the C-clip.
V02H1KA
Discard hub.
Installation
CAUTION: Never reinstall a removed sprocket
hub. Always install a new one.
Install a new wear ring on sprocket hub. Using an
appropriate steel tube as a pusher, press the wear
ring on the hub until it bottoms.
NOTE: The wear ring could be installed after V02H10A 1 2
sprocket hub installation.
1. Caliper bracket
Clean rear axle splines with pulley flange cleaner 2. Snap ring
(P/N 413 711 809).
Remove the caliper bracket by pulling it out.
Install a new O-ring on rear axle and properly seat
Slide out the eccentric axle housing from the right
against the axle flange.
side of the swing arm.
Dirt inside the swing arm may cause resistance
during removal procedure. Carefully spread swing
arm split using screwdrivers.
V02H1NA 1
1. Push the new O-ring against the flange
VMR2004_024_06-03A.FM 06-03-9
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
CAUTION: Be carful not to damage the seal be- ECCENTRIC AXLE LH O.D.
tween surfaces.
SERVICE LIMIT 75 mm (2.95 in)
V02H1GA
V02H1HA
06-03-10 VMR2004_024_06-03A.FM
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
– Align its hole with swing arm hole then insert Install the circlip into the groove of the eccentric
a screw to retain the seal in place. axle housing.
NOTE: Make sure it is fully seated.
Install all other parts.
CAUTION: It is important to follow the preload
procedure to avoid seal and bearing damage.
Refer to BRAKE DISC HUB for the procedure.
WARNING
Clean all grease, outside and inside, from ec-
V02H1FA 1 2 centric housing before putting in oven.
1. Eccentric axle housing
2. Position thin side here Using a bearing packer, pack the bearing with
Bombardier Sea-Doo® bearing grease (P/N 293
Install caliper bracket in place. 550 010).
VMR2004_024_06-03A.FM 06-03-11
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
Installation
For installation, reverse the removal procedure.
CAUTION: The preload procedure is very im-
portant to avoid seals and bearings damages.
Refer to BRAKE DISC HUB for the procedure.
V02H11A 1 2 3
TYPICAL
1. Eccentric axle housing
2. Packed with grease
3. Seal installed flush with edge of eccentric axle housing
06-03-12 VMR2004_024_06-03A.FM
Section 07 STEERING SYSTEM
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
STEERING SYSTEM .............................................................................................................. 07-02-1
GENERAL ........................................................................................................................... 07-02-2
HANDLEBAR GUARD........................................................................................................ 07-02-2
HANDLEBAR GRIP ............................................................................................................ 07-02-2
HANDLEBAR ...................................................................................................................... 07-02-3
STEERING COLUMN ......................................................................................................... 07-02-3
TIE-ROD.............................................................................................................................. 07-02-3
STEERING COLUMN BEARING........................................................................................ 07-02-4
MULTI-FUNCTION SWITCH ............................................................................................. 07-02-4
THROTTLE HANDLE.......................................................................................................... 07-02-5
VMR2004_033_07_01ATOC.FM 07-01-1
Section 07 STEERING SYSTEM
Subsection 02 (STEERING SYSTEM)
STEERING SYSTEM
DS 650 Baja/Baja X
23 Nm
(17 lbfft) 1
6 Loctite .4 Nm
406 (3.5 lbfin)
7 5 4
35
DS 650
5 Nm 34
(44 lbfin) Loctite 12
406 9
33
10
8 11 32
2 3 Nm
3 36 23 Nm (27 lbfin)
10 Nm (17 lbfft)
(89 lbfin) 14 15 16 Synthetic
DS 650 Baja/Baja X grease
23
23 Nm
(17 lbfft)
22 15 13
34 Nm
21 (25 lbfft)
27
28
26
10 Nm 29
(89 lbfin)
25 70 Nm
Loctite (52 lbfft)
243 24
30
19 31
26
17 20
18
38 Nm 24
(28 lbfft) 26 70 Nm
V02I0ZS
25 (52 lbfft)
VMR2004_025_07_02A.FM 07-02-1
Section 07 STEERING SYSTEM
Subsection 02 (STEERING SYSTEM)
Installation
The installation is the reverse of removal procedure.
NOTE: Install a new handlebar grip screw.
HANDLEBAR GRIP
Removal
DS 650 Models A32G2BA
Remove:
CAUTION: Installing handlebar grip without the
– throttle lever and/or multi-function switch from special tool is likely to damage it.
handlebar
Position the insertion tool at the outside end of grip.
– screw no. 4
Using a plastic hammer, tap on tool to push grip
– end cap no. 5. on. Continue to tap until grip bottoms.
Baja and Baja X Models Install all other removed parts.
Remove:
– handlebar guard no. 2
– adjusting sleeve no. 6
– tightening sleeve no. 7.
07-02-2 VMR2004_025_07_02A.FM
Section 07 STEERING SYSTEM
Subsection 02 (STEERING SYSTEM)
HANDLEBAR Inspection
Removal Inspect steering column for cracks, bending or oth-
er damages. Replace if any problem is detected.
Remove:
Check if the O-rings no. 23 are brittle, hard or oth-
– steering cover no. 8 erwise damaged. Replace if necessary.
– steering clamp mounting bolts no. 9, reinforce- Check steering column bearing for excessive play
ments no. 10 and steering clamps no. 11 and smooth operation. Replace if necessary. See
– handlebar no. 12. further in this section for the proper procedure.
NOTE: Remove throttle lever, multi-function switch
and handlebar guards from the handlebar if it is re- Installation
placed with a new one. For the installation, reverse the removal procedure.
NOTE: Install new cotter pin. Both ends of cotter
Inspection pin must be folded.
Inspect the handlebar for damage, cracks or bend-
ing, replace if any problem is detected. TIE-ROD
Installation Removal
For the installation, reverse the removal procedure. Place the vehicle on jack stands and remove front
wheel(s).
STEERING COLUMN Remove front fender with fender support. Refer to
Removal BODY.
Top Side Remove cotter pins no. 24 (discard), castellated
nuts no. 25 and hardened washers no. 26.
Remove:
Remove tie-rod no. 27.
– front facia and dashboard (refer to BODY)
CAUTION: Never tap the knuckle with a hammer.
– handlebar
– fuel tank (refer to FUEL CIRCUIT) Inspection
NOTE: Do not remove fuel tank completely, sep- Inspect tie-rod ends no. 21 and no. 28 for wear or
arate fuel tank from frame only. Do not remove looseness, if excessive, replace.
fuel lines.
Check for cracks on rubber boot.
– headlamp (refer to ACCESSORIES)
– oil tank (refer to REMOVAL AND INSTALLATION) Installation
– half housing bolts no. 13 For the installation, reverse the removal proce-
– stopper plates no. 14 dure. Pay attention to the following details.
– half housings no. 15 At the time of the reinstallation or the new tie-rod(s)
– housing bushings no. 16. installation, screw threaded end of tie-rod into ball
joint.
Bottom Side
NOTE: Match the corresponding left or right threads
Remove: of tie rod end with ball joint.
– cotter pin no. 17 (discard)
– castellated nut no. 18
– flat washer no. 19
– washer no. 20
– tie-rod ends no. 21 from the steering column
no. 22. Refer to TIE-ROD section.
Pull steering column.
VMR2004_025_07_02A.FM 07-02-3
Section 07 STEERING SYSTEM
Subsection 02 (STEERING SYSTEM)
The maximum length for tie-rod groove to ball joint STEERING COLUMN BEARING
end must be the value A in the following chart:
Removal
B Place vehicle on jack stands and remove front
wheels.
Remove steering column.
V01I0YA A A
Remove bolts no. 29 and first bearing flange no. 30.
MODEL A B Remove bearing no. 31.
mm 20 ± 5 311 ± 1 Installation
DS
in 25/32 ± .197 12-1/4 ± .039
For installation, reverse the removal procedure.
Before installing tie-rods, ensure that both heads Pay attention to the following detail.
of tie-rod ends are aligned. If the heads are not Place flanged collar toward outside.
aligned, the tie-rod end play and its durability will
be greatly reduced.
Install new cotter pin. Both ends of cotter pin must
be folded.
Perform the toe-out adjustment.
Toe Adjustment
Place vehicle on level surface.
Check that handlebar is straight.
Use a long rule and check if the rear and front
wheels are aligned. V02I08A 1 2
Adjust alignment with tie-rod. 1. Flanged collar
2. Bearing
Adjust toe-out to 0.5 ± 0.5 mm (.0197 ± .0197 in)
on each side.
MULTI-FUNCTION SWITCH
NOTE: Take measure on the rim.
Test
Refer to ACCESSORIES.
Removal
Remove screws no. 32 under multi-function switch
no. 33.
B A
V02I09A 1
V02I0AB B A
TYPICAL
A - B = 0.5 ± 0.5 mm (.0197 ± .0197 in) on each side
1. Remove the screws
07-02-4 VMR2004_025_07_02A.FM
Section 07 STEERING SYSTEM
Subsection 02 (STEERING SYSTEM)
Separate multi-function switch from handlebar. Unscrew the locking nut of the cable adjuster then
Remove front facia. Refer to BODY. screw the adjuster to release the cable tension.
Unplug multi-function switch connector. Remove throttle cable no. 36 from housing.
2 1
Installation
For installation, reverse the removal procedure.
THROTTLE HANDLE
Removal
Remove screws no. 34 under throttle handle
no. 35.
V01I10A
TYPICAL
1. Throttle handle housing
2. Throttle cable
VMR2004_025_07_02A.FM 07-02-5
Section 08 SUSPENSION
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
FRONT SUSPENSION ........................................................................................................... 08-02-1
GENERAL ........................................................................................................................... 08-02-2
SHOCKS ABSORBER ASS’Y............................................................................................. 08-02-2
SHOCK ABSORBER REBUILDING .................................................................................... 08-02-3
UPPER A-ARM ................................................................................................................... 08-02-7
LOWER A-ARM .................................................................................................................. 08-02-9
BALL JOINT ....................................................................................................................... 08-02-10
VMR2004_033_08_01ATOC.FM 08-01-1
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
FRONT SUSPENSION
Baja/Baja X
6 Baja X
5
48 Nm
3 (35 lbfft)
63 Nm
Suspension synthetic grease (46 lbfft)
1
17
14 8
Suspension
16 synthetic grease
4 13
50 Nm 11 48 Nm Loctite
(37 lbfft) 10 (35 lbfft) 609
12
9 12
11 50 Nm
10 (37 lbfft)
15
Loctite 609
Suspension
synthetic grease
17
V02J1BS
VMR2004_026_08_02A.FM 08-02-1
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
GENERAL
CAUTION: The Baja and Baja X models are
equipped with shocks absorber protectors. Open
or remove them if the vehicle is used intensively 1
or if the ambient temperature is high. Otherwise, 2
shock absorber performance degradation or
damage can occur.
NOTE: On Baja X models, do not remove the shock
absorber protectors if the vehicle is used in a stony
area.
During assembly/installation, use the torque val-
ues and service products as in the exploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE AP- 1
PLICATION at the beginning of this manual for com-
plete procedure.
WARNING V02J0LA
08-02-2 VMR2004_026_08_02A.FM
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
Adjustment
WARNING V02J1CA
Adjust both springs to the same load. Uneven Place the needle guide of gas refill needle type
adjustment can cause poor handling and loss shock tool (P/N 503 190 102) on the shock valve.
of stability, and/or control, and increase the
risk of an accident. WARNING
Whenever working with high pressure gas,
Preload Adjustment use eye wear protection. Never direct gas
Shorten the spring for a firmer ride and rough road pressure toward anybody. Allow gas to es-
condition. cape before removing components.
Lengthen the spring for a light load and a smooth
Press the detente pin and push forward the needle
road condition.
assembly very slowly towards rubber of needle
valve.
SHOCK ABSORBER REBUILDING Push on shock tool valve center rod to release gas
Baja X Models pressure.
Remove spring and adjuster. See SHOCK AB- 503 190 102
SORBER ASS’Y above.
Disassembly
Clean all the parts prior to disassembling.
Tightly secure the shock absorber bottom eyelet
in a vise with soft jaws.
CAUTION: Never clamp on shock absorber body.
Remove screw on top of valve.
A32F37A
VMR2004_026_08_02A.FM 08-02-3
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
NOTE: If an oil mist occurs, it is an indication of a Hold a rag over shock absorber end to catch float-
faulty sealing of the floating piston either caused ing piston. Allow room for parts to leave shock ab-
by wear of shock absorber or floating piston seal- sorber. Using compressed air pressure in valve
ing. hole, carefully push piston out.
Remove tool from shock.
Remove valve from shock absorber.
V02J1FA
Inspection
Check the following:
– Compression bumpers for chipping, cracking
or missing.
V02J1DA
– O-rings for nicks, cuts or cracks.
Using an appropriate open wrench, unscrew – Piston rod for straightness, wear, nicks or
shock absorber seal carrier cover. burrs.
– Seal carrier and rod seals.
– Piston seal ring for wear.
– Valve discs for kinks or waves.
– Inner walls of shock absorber and reservoir
for scratches, burrs or excessive wear.
– Floating piston seal for wear, cuts, chipped or
nicked edges.
– Inner wall of shock absorber for excessive
wear in working area of floating piston.
Replace any defective/worn part.
V02J1EA
Valving
Gently pull piston rod out. Remove slowly to re- Rebound stack:
duce oil spillage and prevent piston seal damage Ø32 x t0.30
on body threads. Wrap body in a rag to capture oil
overflow while removing piston rod. Ø28 x t0.30
Empty oil from shock absorber. Ensure to dispose Ø25 x t0.15
oil according to your local environmental regula- Ø18 x t0.10
tions.
Remove floating piston as follows.
08-02-4 VMR2004_026_08_02A.FM
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
Compression stack:
Ø28 x t0.38 2
Ø32 x t0.30
Ø33 x t0.25
Ø18 x t0.30
Ø33 x t0.3
Piston: A
1 - Ø2.4
Assembly
1
Tightly secure the shock absorber base in a vise
with soft jaws.
Apply shock absorber oil on floating piston seal.
V02J1HA
1 Bleeding
Pour Ryde FX slide high performance lube (P/N 503
190 103) in shock absorber. Fill shock absorber up
to bottom of threads.
CAUTION: Use new oil only. Do not reuse the
same oil. Do not use any other oil.
Allow a few minutes for air bubbles to surface.
NOTE: Although we do not measure the exact
V02J1GA
amount of oil added, approximately 185 mL (6.3 U.S.
oz) will be used.
1. Hollow side here
Wrap shock absorber in a rag to capture oil over-
CAUTION: Failure to install floating piston cor- flow while installing piston rod.
rectly could result in shock damage. Apply shock absorber oil on piston seal ring.
Using a machinist square, position floating piston Carefully insert piston rod in shock absorber.
at 204 mm (8.0 in) from top.
CAUTION: Pay attention not to damage piston
seal on shock absorber threads.
Push seal carrier down, close to piston.
VMR2004_026_08_02A.FM 08-02-5
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
3
4
A06F0QA
Be careful not to drive the shaft any deeper into the Proceed as follows:
oil than it is necessary to just cover the shim stack. 1. Adjust nitrogen tank regulator to 0 kPa (0 PSI).
Be also careful to maintain oil above piston stack. 2. Install the gas refill needle type shock tool (P/N
Otherwise repeat the operation. 503 190 102) on gas shock valve tool
Seal carrier assembly can now be screwed into 3. Turn tappet valve of gas shock valve tool clock-
body. This should be done slowly to minimize float- wise up to the end.
ing piston displacement.
After the seal carrier is completely installed, avoid
pushing the piston rod into the body until the nitro-
gen charge is added.
Using an appropriate open wrench, torque seal
carrier cover to 75 N•m (55 lbf•ft).
WARNING
Do not use any other type of gas than Nitrogen
(N2).
V02J1JA
Use the gas shock valve tool (P/N 529 035 570)
and tightly install it to the nitrogen tank.
4. Place the needle guide of gas refill tool on the
shock valve. While depressing the detente pin
of the gas refill tool and pushing forward the
needle assembly, insert the needle through the
rubber core of the pressure valve assembly of
the shock. Ensure to firmly keep the tool sat
squarely on shock valve.
08-02-6 VMR2004_026_08_02A.FM
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
A32F38A
UPPER A-ARM
NOTE: For replacement of the needle or filling the Removal
shock, carefully follow the instructions provided NOTE: Both upper no. 8 and lower no. 9 A-arms
with the gas refill needle type tool kit (P/N 503 190 can be removed without removing the tie rods.
102).
Detach brake hose from upper A-arm.
5. Open nitrogen tank valve and gradually set pres-
sure of regulator to 2068 kPa (300 PSI), this gas Discard screws.
pressure will restore the correct pressure of the 1 2 3
shock absorber.
WARNING
Stay away from shock absorber when apply-
ing pressure to avoid possible projected out
components that might have been improper-
ly installed.
VMR2004_026_08_02A.FM 08-02-7
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
Installation
Position upper A-arm and install bolts no. 14 and
nuts.
Torque nuts to 63 N•m (46 lbf•ft).
Attach upper A-arm to knuckle. Install hardened
washer no. 12 and castellated nut no. 11.
Tighten castellated nut to 50 N•m (37 lbf•ft) and
further tighten until its grooves align with cotter
V02J0NA 2 1 pin hole.
1. Remove cotter pin Install a new cotter pin. Both ends of cotter pins
2. Castellated nut must be folded.
3. Upper ball joint
Secure brake hose to upper A-arm.
Remove wheel(s).
CAUTION: When reinstalling the brake line, install
Use a ball joint remover and detach upper A-arm new screws with regular M6 threads. Reinstalling
from knuckle. self tapping screws would damage the A-arm
CAUTION: Never tap the knuckle with a hammer. threads.
Remove bolts no. 14 retaining upper A-arm to Install wheel(s).
frame. NOTE: Do not interchange left and right tires.
Check direction of rotation mark on tires.
V02J0CA 2 1 2
V02J09A
1. Upper A-arm
2. Remove bolts DIRECTION OF ROTATION
Remove upper A-arm no. 8 from vehicle. Torque wheel nuts to 53 N•m (39 lbf•ft) in a criss-
cross sequence.
Grease each A-arm pivot.
08-02-8 VMR2004_026_08_02A.FM
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
Installation
For assembly, reverse the disassembly proce-
dure. However, pay attention to the following.
Position lower A-arm and install bolts no. 16 and
nuts.
Torque nuts to 63 N•m (46 lbf•ft).
Attach lower A-arm to knuckle. Install hardened
washer no. 12 and castellated nut no. 11.
Reinstall A-arm protector (if so equipped).
Tighten castellated nut to 50 N•m (37 lbf•ft) and
further tighten until its grooves align with cotter
V02J0OA 1 2 pin hole.
1. Lower A-arm Install a new cotter pin. Both ends of cotter pins
2. Remove nut and bolt
must be folded.
Use a ball joint remover and detach knuckle from Install wheel(s).
the lower A-arm.
NOTE: Do not interchange left and right tires.
CAUTION: Never tap the knuckle with a hammer. Check direction of rotation mark on tires.
Remove A-arm protector (if so equipped).
Remove nuts and bolts no. 16 retaining lower A-arm
to frame.
V02J09A
DIRECTION OF ROTATION
VMR2004_026_08_02A.FM 08-02-9
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
BALL JOINT
Inspection
Upper Ball Joint
Take the top of tire and check upper ball joint lateral
play, by push and pull. The maximum lateral play
should be 1.5 mm (.060 in). If the lateral play is out
of specification, change the ball joints no. 13.
A
A
V02J0HA
V02J0GA
V02J0IA
08-02-10 VMR2004_026_08_02A.FM
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
Removal
Remove upper or lower A-arm.
Remove the circlip no. 17.
Extract the ball joint.
Installation
CAUTION: The ball joints have an oblong shape
and therefore must be properly installed in their
oblong openings in the A-arms. Use the appro-
priate template, supplied at the end of this sec-
tion to ensure proper orientation of the ball joint
relative to the A-arm.
NOTE: Use the same tools for the lower and up-
per ball joints. V02I0PA 2 1
Attach template page on a light cardboard. 1. Shock bracket
2. Flat grooves
Cut the templates.
Right/Left Lower Ball Joints Remove the template and keep the orientation of
the ball joint.
NOTE: Use the same template for the lower RH
and LH ball joints. Use both ball joint drivers (P/N 529 035 705 and
P/N 529 035 706) and a press machine to press
Apply a layer (0.3 mL) of Loctite 609 on the outside the ball joint in place. A hammer may also be used
diameter of new ball joint (surface that contacts but care should be taken.
arm). Wipe any excess.
Insert the ball joint into the template with the cor- 1
rect orientation. Flat grooves of ball joint must be
in contact with the flat sides of the template.
1
V02I0LA 2 3 5 4
1. Flat bar
2. Driver
3. Arm
V02I0QA 4. Driver
5. Tab lock
1. Flat grooves
NOTE: Be sure that the flat groove is perpendicu-
Place the ball joint and the template on the A-Arm lar to rotation axis before mounting.
and orient it into place, the narrow section of the
template aligns inside the shock bracket.
VMR2004_026_08_02A.FM 08-02-11
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
V02I0LA 2 3 5 4
1. Flat bar
2. Driver
3. Arm
4. Driver
5. Flat groove
08-02-12 VMR2004_026_08_02A.FM
V02I0SS
Bend down Bend down
this section this section
and place and place
VMR2004_026_08_02A.FM
between between
Insert the 2 tubes the 2 tubes
this section
into shock
bracket
RIGHT LEFT
upper Upper
A-arm A-arm
Lower
A-arm
08-02-13
Section 08 SUSPENSION
Subsection 02 (FRONT SUSPENSION)
Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
REAR SUSPENSION
85 Nm
(63 lbfft)
5
3 3.5 Nm
(31 lbfin)
16
18
12 6 85 Nm
Suspension (63 lbfft)
synthetic
grease 17 Synthetic
12 grease
15
17
18
14
Loctite 243
2
See special
procedure inside
Baja
Baja X
7
8
11
13
10
9
V02J0QS
VMR2004_027_08_03A.FM 08-03-1
Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
GENERAL
CAUTION: The Baja and Baja X models are
equipped with shocks absorber protectors.
Open or remove them if the vehicle is used in-
tensively or if the ambient temperature is high.
Otherwise, shock absorber performance deg-
radation or damage can occur.
For installation, use the torque values and Loctite
products from the exploded views. Clean threads
before using Loctite when installing the screws.
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (ex.: locking tabs, elastic stop
nuts, self-locking fasteners, etc.) must be in-
stalled or replaced with new ones where V02J0RA 1
specified. If the efficiency of a locking device 1. LH plug removed to access shock absorber bolt
is impaired, it must be renewed.
Unscrew the lower bolt no. 6.
V02J0VA
TYPICAL
1. Upper bolt and nut
2. Lower bolt and nut
3. Reservoir
4. Clamps
5. Brake caliper
6. Disc brake hub
08-03-2 VMR2004_027_08_03A.FM
Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
Adjustment
WARNING
The shock absorber contains high pressure ni-
trogen gas. Do not attempt to disassemble
before removing the pressure. Dispose of gas
as per your local environmental regulations.
Gas Pressure
Refer to SHOCK ABSORBER REBUILDING be-
low.
Spring Preload
Spring preload may vary from rider to rider depend-
ing upon their weight. Preload can be changed by
V02J1KA setting the two adjusting nuts up or down to com-
press the spring to different lengths. Shortening or
Check shock absorber body for leaks, dents, ab- lengthening the spring length will increase or de-
normal wear and piston rod dents or bend. Re- crease the preload.
place any defective part.
Fully compress piston rod. When released, it
should extend smoothly.
VMR2004_027_08_03A.FM 08-03-3
Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
V02A0WA
08-03-4 VMR2004_027_08_03A.FM
Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
WARNING
Whenever working with high pressure gas,
use eye wear protection. Never direct gas
pressure toward anybody. Release gas pres-
sure before removing components.
Disassembly
Clean all the parts prior to disassembling.
Turn compression and rebound adjusters counter-
clockwise so that their valves are the most open.
Reservoir 1
Gently secure the reservoir in a vise with soft
jaws.
V02J0YA
V02J0ZA
V02J0XA
1. C-clip
VMR2004_027_08_03A.FM 08-03-5
Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
V02J12A
V02J10A
2
V02J13A
V02J11A
1. Cover and its holes
1. Bladder
2. Cover
08-03-6 VMR2004_027_08_03A.FM
Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
Valving
V02J14A Rebound stack:
1. Gently push seal carrier ass’y down to free C-clip Ø36 x t0.30 x 10
2. C-clip
Ø22 x t0.30 x 1
CAUTION: Be careful not to scratch inside wall of
Compression stack:
shock absorber or C-clip. Also be careful not to dis-
tort the C-clip. Ø40 x t0.25 x 9
Gently pull piston rod out. Remove slowly to re- Ø22 x t0.20 x 1
duce oil spillage and prevent piston seal damage Ø40 x t0.25 x 12
on body groove. Wrap body in a rag to collect oil
Ø22 x t0.30 x 2
overflow while removing piston rod.
Piston:
NOTE: If piston rod is hard to remove, use com-
pressed air as described below. 1 - Ø2.0
Hold a rag over shock absorber end to catch piston
rod. Allow room for parts to leave shock absorber. Assembly
Using compressed air pressure in hose hole, care- Turn compression and rebound adjusters counter-
fully push piston rod out. clockwise so that their valves are the most open.
Reinstall hose to shock absorber and reservoir. En-
sure to position properly.
Tightly secure the shock absorber base in a vise
with soft jaws.
Bleeding
Hold reservoir higher than shock absorber and
V02J17A pour Kayaba shock absorber oil (P/N 293 600 035)
in reservoir. Half fill reservoir.
Empty oil from shock absorber.
CAUTION: Use new oil only. Do not reuse the
Clean inner walls of shock absorber and reservoir oil. Only use the recommended oil.
with Pulley flange cleaner (P/N 413 711 809). Be
careful not to splash O-rings, piston and seals etc.
Dry parts with compressed air.
VMR2004_027_08_03A.FM 08-03-7
Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
V02J18A
WARNING
V02J19A If C-clip is not properly locked, parts might be
PUMP BLADDER TO BLEED HOSE
projected out when filling with high pressure
1. Bladder installed upside down nitrogen.
08-03-8 VMR2004_027_08_03A.FM
Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
stack. Be also careful to maintain oil above piston 1. High pressure hose
stack. Otherwise repeat the operation. 2. Two stage regulator
3. High pressure cylinder filled with industrial grade nitrogen (N2)
Fill shock absorber up to 10 mm (3/8 in) below cir- 4. Gas shock valve tool
clip groove.
Proceed as follows:
Seal carrier assembly can now be pushed into body.
NOTE: Proceeding this way and using the recom-
This should be done slowly ensuring some oil flows
mended tool will prevent any pressure leak of
out to ensure no air is trapped inside shock absorb-
shock absorber when removing valve tool. When
er. Push down just enough to secure C-clip.
removing valve tool, the leaking sound comes
After the seal carrier is completely installed, avoid from the remaining nitrogen in tank hose.
pushing the piston rod into the body until the nitro-
1. Adjust nitrogen tank regulator to 0 kPa (0 PSI).
gen charge is added.
2. Tightly screw gas shock valve tool to reservoir
WARNING valve. Turn its tap clockwise up to the end.
If C-clip is not properly locked, parts might be 2
projected out when filling with high pressure
nitrogen.
2°
Reinstal cover.
Nitrogen (N2) can now be added in the reservoir.
Gas Pressure
WARNING 1°
Do not use any other type of gas than Nitro-
gen (N2).
Use the Gas shock valve tool (P/N 529 035 570)
and tightly install it to the nitrogen tank.
V02J0WA 1
1. Valve tool
2. Valve tool tap
VMR2004_027_08_03A.FM 08-03-9
Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
3. Open nitrogen tank valve and gradually set reg- Reinstall valve cap.
ulator pressure to 980 kPa (142 PSI), this gas Reinstall spring and adjuster, then perform adjust-
pressure will restore the correct pressure into ments. See shock absorber ASS’Y.
the reservoir.
2°
V02J0WB
08-03-10 VMR2004_027_08_03A.FM
Section 08 SUSPENSION
Subsection 03 (REAR SUSPENSION)
Installation
Installation is essentially the reverse of removal
procedure. However, pay attention to the follow-
ing details.
Insert O-rings no. 12 in the groove into frame.
Place O-rings no. 18 on bushings no. 17 then in-
stall the swing arm.
Install the swing arm shaft no. 16 then push the
O-rings no. 18 between frame and bushings. En-
sure the flat sides of shaft are well positionned in
V02J0SA 1 frame.
1. Unfasten from swing arm
Inspection
V02J0TA
Check condition of swing arm. Inspect for distor-
tion, bending, pitting, cracks or other damage. Re- 1. Ensure shaft is well inserted in frame
place swing arm with a new one if damaged.
Install the nut no. 15. Torque to 90 N•m (66 lbf•ft)
Check condition of bushings no. 17 with their nee- then, unscrew the nut a quarter turn.
dle bearings and O-rings nos. 18 and 12. Change
if necessary. NOTE: Check if the swing arm moves freely.
Apply Loctite 243 and install the other nut no. 14.
Torque to 90 N•m (66 lbf•ft).
NOTE: Hold the first nut with a key when the sec-
ond nut is torqued.
CAUTION: When reinstalling the brake line, in-
stall new screws with regular M6 threads. Re-
installing self tapping screws would damage
V02J0UA
the swing arm threads.
Install rear shock and rear axle.
1. Bushing with its bearing
Apply grease through grease fitting.
Ensure bushings no. 17 are well seated against
swing arm. Otherwise, press them until they bot- Adjust shock absorber preload and damping then
tom. adjust drive chain.
Check condition of swing arm shaft no. 16. With
your finger nail, feel bearing contact surface of
shaft. If any irregular surface is found, replace
shaft.
VMR2004_027_08_03A.FM 08-03-11
Section 09 BRAKES
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
HYDRAULIC BRAKES............................................................................................................ 09-02-1
FRONT BRAKES ................................................................................................................ 09-02-1
REAR BRAKE ..................................................................................................................... 09-02-2
GENERAL ........................................................................................................................... 09-02-3
HYDRAULIC BRAKES SYSTEM ........................................................................................ 09-02-3
MASTER CYLINDER .......................................................................................................... 09-02-4
CALIPER ............................................................................................................................. 09-02-6
BRAKE PADS ..................................................................................................................... 09-02-7
BRAKE DISC....................................................................................................................... 09-02-8
BRAKE LEVER .................................................................................................................... 09-02-9
BRAKE PEDAL ................................................................................................................... 09-02-9
BRAKE LIGHT SWITCH ..................................................................................................... 09-02-10
REAR CALIPER BRACKET ................................................................................................. 09-02-10
VMR2004_033_09_01ATOC.FM 09-01-1
Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
HYDRAULIC BRAKES
FRONT BRAKES
13 Nm 20 Nm
(115 lbfin) (15 lbfft)
12
1
21 2
13 8
4 45
11
10 38
23
22 9 39
25 Nm
(18 lbfft)
28 Nm
(21 lbfft) 32
31
36
33
30 35
3
31
35
34 Nm
(25 lbfft) 29
38 39 34
28 37
25 Nm
(18 lbfft)
15 Nm
28 Nm 31 (133 lbfin) 25 Nm
28 (18 lbfft)
(21 lbfft) 35 3
33
32 29
34
36 6
33 37
V02K0NS 35
VMR2004_028_09_02A.FM 09-02-1
Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
REAR BRAKE
15 Nm 3
(133 lbfin)
36
34
35 47
37
48
35 31
28 Nm 39
29 34 Nm
25 Nm 28 (21 lbfft) 38
(18 lbfft) (25 lbfft)
5 Nm
(44 lbfin)
8 Nm 46
(71 lbfin) Loctite 567 18
16 pipe sealant
25 Nm
1,2 (18 lbfft) 44
17 43
14 42
3 Nm 20
(27 lbfin) 41
40
Synthetic
grease
25
24 6 Nm
(53 lbfin) 5
15 19
27
26
V02K05V
09-02-2 VMR2004_028_09_02A.FM
Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
GENERAL 2 1
For installation, use the torque values and Loctite
products from the exploded views. Clean threads
before using Loctite when installing the screws.
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (ex.: locking tabs, elastic stop
nuts, self-locking fasteners, etc.) must be in-
stalled or replaced with new ones where
specified. If the efficiency of a locking device
is impaired, it must be renewed.
VMR2004_028_09_02A.FM 09-02-3
Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
NOTE: Check fluid level often to prevent air from MASTER CYLINDER
being pumped into the system.
Repeat the procedures until air bubbles don’t ap- Removal
pear in bleed hose. Front Brakes
NOTE: For the front brake system, switch to LH Drain brake fluid from master cylinder no. 8.
and RH caliper. Turn handle bar to full RH side Remove Banjo bolt no. 9 and sealing washers
when bleeding right caliper no. 6 and turn to the no. 10 retaining brake hose no. 11 to master cyl-
LH side for the left caliper no. 7. This helps the inder.
bleeder to reach air into the caliper.
Discard sealing washers.
Close bleed valves and operate brake lever no. 4
or brake pedal no. 5. If it still feels spongy, bleed Remove screws no. 12 from master cylinder hold-
system again. er no. 13 and remove master cylinder from han-
dlebar.
Fill reservoir to the upper level with DOT 4 brake
fluid. 2
Install diaphragm and cover on reservoir.
If brake bleeder is not available, use the following
procedure.
Install a tube to bleed valve.
Open bleeder. Fill reservoir and pump lever until
fluid freely flows out of the tube.
Close bleed valve.
Pump up system pressure with brake lever or brake
pedal until lever or pedal resistance is felt.
Squeeze brake lever or depress brake pedal, open
bleed valve and then close it.
V01K12A 3 1 4
NOTE: Do not release brake lever or brake pedal
until bleed valve has been closed. For the front TYPICAL
1. Oil level mark
brake system, switch to LH and RH caliper. Turn 2. Bolt
handle bar to full RH side when bleeding right cal- 3. Sealing washers
4. Remove screws
iper no. 6 and turn to the LH side for the left caliper
no. 7. This helps the bleeder to reach air into the Rear Brake
caliper.
Remove RH foot protector. Refer to BODY.
Release brake lever or brake pedal slowly.
Unplug brake switch connectors from rear
Repeat the procedures until air bubbles don’t ap- brake switch no. 46.
pear in tube and lever or pedal is stiff.
Drain brake fluid from rear master cylinder no. 14.
Disconnect flexible hose no. 15 from master cyl-
inder and plug the end to avoid brake fluid spillage.
NOTE: At this time, check hoses and fittings for
damages or leaks.
Remove banjo fitting no. 16 and sealing washers
no. 17 retaining brake hose no. 18 to master cyl-
inder.
09-02-4 VMR2004_028_09_02A.FM
Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
Discard sealing washers. – master cylinders and pistons for scoring, scratch-
Unhook push rod no. 19 from brake pedal no. 5. es or other damage.
Remove bolts no. 20 retaining master cylinder to Change part(s) if necessary.
frame. Check locking pin no. 26 for excessive wear, re-
place if necessary.
3 5 1
NOTE: If master cylinder is damaged or leaking,
replace as an assembly.
Assembly
Front Master Cylinder
Coat master piston and piston cups with clean
brake fluid.
Install:
– spring onto master piston
– master piston into master cylinder
– snap ring into groove in the master cylinder
– boot into master cylinder and the groove in pis-
V02K06B 7 6 2 4
ton.
1. Master cylinder
2. Flexible hose Apply silicone grease to the brake lever contacting
3. Rear brake hose surface of the piston.
4. Push rod
5. Remove bolts Install brake lever and locking mechanism.
6. Rear brake switch
7. Rear brake switch connectors NOTE: Apply silicone grease on lever pivot bolt.
Disassembly Rear Master Cylinder
Front Master Cylinder For the rear master cylinder use the same proce-
dure that front master cylinder, however pay at-
Remove brake lever no. 4 and locking mechanism tention to the following:
no. 21 for parking brake.
If push rod yoke no. 27 is reinstalled, adjust push
Remove piston boot no. 22, snap ring no. 23, rod length, see the following illustration.
master piston and spring.
Rear Master Cylinder
Remove boot no. 24 from master cylinder.
Remove snap ring no. 25 and push rod no. 19 us-
ing snap ring pliers.
Remove master piston and spring.
Clean reservoirs, master pistons and master cylin- A. 3 ± 1 mm (1/8 ± 1/32 in)
ders thoroughly with clean brake fluid.
Installation
Check:
For the installation, reverse the removal proce-
– boots nos. 22 and 24 for cracks
dure, pay attention to the following details.
– springs for damage
NOTE: Always replace with standard screw, if
– piston cups for wear, deterioration or damage ever the brake hose retaining clip taptite screw
has been removed.
VMR2004_028_09_02A.FM 09-02-5
Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
V02K08A 1
RH FRONT BRAKE
1. Caliper
2. Brake hose
V01K13A
Drain brake fluid from brake system.
Remove Banjo bolt no. 28 with sealing washers
TYPICAL
no. 29 and detach brake hose no. 18 or no. 30 from
Connect brake hose no. 11 to master cylinder caliper.
with Banjo bolt no. 9 and new sealing washers. Catch spilled fluid with a rag.
Bleed front brake system. Unscrew bolts no. 31 retaining caliper to knuckle
Check for leaks and make sure the brakes operate and remove caliper. Discard bolts.
normally before driving.
2 3
Rear Brake
Install master cylinder to frame.
Install rear brake hose no. 18 to master cylinder
using new sealing washers.
Connect flexible hose from master cylinder.
Fill up reservoir with clean brake fluid.
CAUTION: Do not mix different types of brake
fluid. Use only DOT 4 brake fluid from a sealed
container. Do not use brake fluid taken from old
or already opened containers.
Bleed rear brake system.
Check for leaks and make sure the brakes operate
normally before driving.
CALIPER V02K09A 1 2
TYPICAL
Removal 1. Remove Banjo bolt and washers
2. Unscrew bolts
Loosen wheel nuts. 3. Brake hose
09-02-6 VMR2004_028_09_02A.FM
Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
Disassembly Installation
Remove brake pads, see the following section. For the installation, reverse the removal proce-
Remove: dure, pay attention to the following details.
– caliper bracket no. 32 Use new sealing washers when installing Banjo
bolt retaining brake hose to caliper.
– slide pins no. 33
Install caliper to knuckle with the new self-locking
– pad spring no. 34. bolts.
Place rag over piston. If hose was disconnected, bleed the brakes.
Place caliper body with piston down and apply Check for leaks and make sure the brakes operate
small squirts of air pressure to the fluid inlet to normally before driving.
remove piston.
Inspection
If boots no. 35 are deteriorated or hard, replace by
the new ones.
Check caliper cylinder and piston for scratches,
rust or other damages. If so, replace caliper.
Assembly
Coat piston seal with clean brake fluid and install
it into piston grooves in caliper.
Coat piston with clean brake fluid and install into
cylinder with the closing toward caliper body.
Apply silicone grease into sliding bores and install V02K0MA 2 3 1
slide pins.
TYPICAL
NOTE: Make sure that rubber boots no. 35 are 1. Pad pins
correctly installed in slide pins grooves. 2. Caliper bracket
3. Pads
Install pad spring, caliper bracket and pads.
Remove caliper from knuckle.
CAUTION: Don’t let the caliper hang by the hose
and don’t stretch or twist the hose.
It’s very important to clean remaining O.D. of pis-
ton out from caliper with brake fluid before push-
ing the piston back in. Make sure the piston is free
of any contaminant and is shiny.
Push piston all the way in to allow installation of
new pads.
VMR2004_028_09_02A.FM 09-02-7
Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
Inspection
CAUTION: Do not clean brake pads in petro-
leum based solvent. Use brake system cleaner.
Soiled brake pads must be replaced by new
ones.
Measure brake pad lining thickness.
Brake pads must be replaced when lining is 1 mm
(1/32 in) thick or less, or, look at the hollow places
on both sides on the pad lining. V02K0BA 1 2
There are four hollow places on one set of brake 1. Pad spring
pads. When the pad wear reaches one of the hol- 2. Piston
low places, the pad change is necessary even if Install new brake pads.
the pad wear does not reach another hollow place.
Install new pad pins by pushing in the pads against
pad spring to align pad slots in the pads and caliper
1 body.
Install brake caliper so the disc is positioned be-
tween pads.
NOTE: Be careful not to damage pads and that
pads are correctly inserted in their location.
V02K0FA
After the job is completed, firmly depress the
1. Hollow place brake lever a few times to bring the pads in con-
tact with the disc.
BRAKE PAD LINING
1 mm (1/32 in) Check for leaks and make sure the brakes operate
MINIMUM THICKNESS
normally before driving. The pads must rest flat on
CAUTION: Brake pads must always be replaced the disc.
in pairs.
BRAKE DISC
WARNING
Avoid getting oil or grease on brake pads. Inspection
Contaminated brake pads can affect stopping
capacities. Discard any contaminated pads. WARNING
A contaminated brake disc reduces stopping
power. Clean a contaminated disc with a high
Installation quality brake degreasing agent.
For installation, reverse the removal procedure.
Paying attention to the following details. Brake discs no. 38 can be inspected without re-
moving from the vehicle.
Make sure that pad spring no. 34 is in position.
Raise vehicle and support it securely. Remove
wheels and visually inspect disc surfaces for scratch-
es or grooves. Make sure to check both sides of disc.
09-02-8 VMR2004_028_09_02A.FM
Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
DISC MINIMUM
3.5 mm (.13 in)
BRAKE PEDAL
THICKNESS
MAXIMAL DISC RUN
Removal
0.5 mm (.02 in)
OUT Remove RH side foot protector.
Refer to BODY for removal procedure.
Removal Unhook the return spring no. 40.
Front Brake Disc 1 3
Remove caliper as described previously.
After removing the caliper, suspend it out of the
way.
CAUTION: Do not let the caliper hang by the
hose and don’t stretch or twist the hose.
Wheel hub has to be removed from vehicle to re-
place brake disc Refer to FRONT DRIVE.
Remove screws no. 39 retaining brake disc no. 38
to wheel hub. Discard screws.
NOTE: Heat up disc around screws to facilitate re-
moval.
Rear Brake Disc
Refer to REAR AXLE for brake hub removal instruc-
tions.
V02K0DA 2
Installation 1. Master cylinder
Install brake disc on hub and tighten in a criss- 2. Return spring
3. Brake pedal
cross sequence.
Remove circlip no. 41, washer no. 42 and O-ring
no. 43 then remove pedal no. 5 from pivot.
1 Remove the O-ring no. 44 on the pivot.
NOTE: Clean O-ring and pivot pin with BOMBARDIER
LUBE (P/N 293 600 016).
3 4
Installation
For installation, reverse the removal procedure.
Check O-rings for damage, change if necessary.
2
Apply synthetic grease (P/N 293 550 010).
V02K0OA
VMR2004_028_09_02A.FM 09-02-9
Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
Inspection
Check for wear or other damage on the O-ring,
eccentric bearing carrier and on the bracket. Re-
place parts if free play is excessive.
Installation
V02K0EA 1 For installation, reverse the removal procedure.
1. Front brake light switch
09-02-10 VMR2004_028_09_02A.FM
Section 10 BODY/FRAME
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
BODY...................................................................................................................................... 10-02-1
BODY PARTS ..................................................................................................................... 10-02-1
SEAT................................................................................................................................... 10-02-3
SEAT................................................................................................................................... 10-02-4
DASHBOARD ..................................................................................................................... 10-02-4
FRONT SKID PLATE/FRONT BUMPER............................................................................. 10-02-4
MUDGUARD/FRONT FENDER/SUPPORT........................................................................ 10-02-4
FRONT FACIA .................................................................................................................... 10-02-5
FRONT FACIA BRACKET................................................................................................... 10-02-5
AUXILIARY HEADLAMP SUPPORT.................................................................................. 10-02-5
FUEL TANK COVER ........................................................................................................... 10-02-5
FOOT PROTECTOR/FOOT PROTECTOR SUPPORT ........................................................ 10-02-6
REAR FENDER ................................................................................................................... 10-02-6
REAR BUMPER .................................................................................................................. 10-02-6
ENGINE SKID PLATE......................................................................................................... 10-02-6
A-ARM PROTECTOR PLATE ............................................................................................. 10-02-7
NERF BAR .......................................................................................................................... 10-02-8
LATCH BASE/LATCH LEVER/SPRING .............................................................................. 10-02-8
SEAT ADJUSTMENT ........................................................................................................ 10-02-8
SEAT COVER REPLACEMENT .......................................................................................... 10-02-9
SEAT CLEANING ............................................................................................................... 10-02-9
DECALS REPLACEMENT .................................................................................................. 10-02-9
PLASTIC MAINTENANCE/REPAIR ................................................................................... 10-02-10
MAINTENANCE ................................................................................................................. 10-02-10
REPAIR................................................................................................................................ 10-02-10
VMR2004_033_10_01ATOC.FM 10-01-1
Section 10 BODY/FRAME
Subsection 02 (BODY)
BODY
BODY PARTS
DS 650 Models
23 Nm
(17 lbfft) 38
37
36 32
23 Nm
33 (17 lbfft)
8 Nm (71 lbfin)
34
35
10 Nm 30
(89 lbfin)
39
4 Nm
(35 lbfin)
27
28
2 Nm 4 27 29
40 30
(18 lbfin)
3.5 Nm
(31 lbfin)
45
5 10 Nm
(89 lbfin) 31
4 2 Nm 26 24
(18 lbfin) 23 18
17 2.5 Nm
2.5 Nm 19 (22 lbfin)
(22 lbfin)
2.5 Nm 23 25
(22 lbfin) 6.5 Nm
(58 lbfin)
20 3.5 Nm
(31 lbfin)
10 Nm
(89 lbfin)
9 12
8 14 11
2.5 Nm 10
(22 lbfin) 23 Nm
(17 lbfft) 13
6
8 5 Nm
(44 lbfin)
16 10 Nm
8 23 Nm (89 lbfin)
7 (17 lbfft) 15
6 2.5 Nm 23 Nm
(22 lbfin) (17 lbfft)
V02L0IS
VMR2004_029_10_02A.FM 10-02-1
Section 10 BODY/FRAME
Subsection 02 (BODY)
V02L0TS
10-02-2 VMR2004_029_10_02A.FM
Section 10 BODY/FRAME
Subsection 02 (BODY)
SEAT
5 Nm
(44 lbfin) 1
43
42
5.5 Nm 41
(49 lbfin) 3
Loctite 271
44
Loctite 271
29 Nm
(21 lbfft)
V02L0KS
VMR2004_029_10_02A.FM 10-02-3
Section 10 BODY/FRAME
Subsection 02 (BODY)
SEAT WARNING
Removal Periodically, verify the seat lock pin and tighten
if needed. Make sure seat is securely latched
Pull latch lever no. 1 upward while gently lifting before riding.
rear of seat no. 2. Continue lifting movement until
you can release the front retaining devices, then,
completely remove seat. DASHBOARD
Removal
Remove screws no. 4.
Lift dashboard no. 5.
Disconnect:
– ignition switch
– indicator lamps
– tachometer (Baja models).
Remove dashboard completely.
Installation
V02L0CA 1 2 3 Installation is the reverse order of removal.
1. Seat
2. Latch FRONT SKID PLATE/FRONT
3. Seat lock pin
BUMPER
Installation Removal
Insert seat front tabs into hooks. Pull latch lever to Front Skid Plate
insert it over the seat lock pin no. 3. Release latch
lever then firmly push on rear of the seat to DS 650 Models
relatch. Remove screws no. 6.
WARNING Front Bumper
Make sure both front tabs are properly hooked Remove front skid plate no. 7 (DS 650 models).
on frame before riding. Remove bolts no. 8 then the front bumper no. 9.
2 1
Installation
Installation is the reverse order of removal.
MUDGUARD/FRONT FENDER/
SUPPORT
Removal
Mudguard
Remove screws no. 10 and dart no. 11.
Front Fender
Remove screws nos. 10 and 12.
V02L07A
Front Fender Support
1. Seat front tab
2. Body hook If necessary, remove mudguard no. 13 and front
fender no. 14.
10-02-4 VMR2004_029_10_02A.FM
Section 10 BODY/FRAME
Subsection 02 (BODY)
FRONT FACIA
WARNING
Never perform this operation immediately af-
ter the engine has been run because the oil
Removal
tank can be very hot. Wait until oil tank is warm.
Remove screws no. 17 under headlamp.
Removal
Remove the front facia.
Unscrew the bolts no. 20 retaining the front facia
bracket to the oil tank.
Installation
For the installation, reverse the removal procedure.
AUXILIARY HEADLAMP
SUPPORT
V02L0UA Baja Models
Remove screws no. 18 on each side of fuel tank Removal
cover. Remove:
– front facia
– bolt no. 21 retaining the auxiliary headlamp sup-
port no. 22 to the upper bracket of shock ab-
sorber.
Disconnect the auxiliary headlamps.
Installation
For installation, reverse the removal procedure.
V02L0VA
FUEL TANK COVER
If required, remove the headlamp cover no. 45.
WARNING
Never perform this operation immediately af-
ter the engine has been run because the oil
tank can be very hot. Wait until oil tank is warm.
Removal
Remove:
– seat
– front facia
V02L0WA
– fuel tank cap.
Remove the front facia no. 19.
VMR2004_029_10_02A.FM 10-02-5
Section 10 BODY/FRAME
Subsection 02 (BODY)
Installation
Installation is the reverse order of removal. V02L0XA 1 1 1
1. Bolts to be removed
REAR BUMPER
Installation
Removal
All Models
Remove screws no. 37 then the screw retaining
rear bumper no. 38 and muffler. Installation is the reverse of the removal.
NOTE: Install all bolts before torquing.
10-02-6 VMR2004_029_10_02A.FM
Section 10 BODY/FRAME
Subsection 02 (BODY)
Baja X Models only On wheel side, secure with a bolt no. 52 and a nut
Installation is the reverse of the removal but pay no. 51.
attention to the following: Fully turn the handlebar into both directions and
– align skid plate no. 46 then secure it starting check for interference.
with middle square hole; tighten loosely Fully compress front suspension and check for in-
– then secure in this sequence: forward square terference.
hole, forward round holes and rearward round Adjust as necessary, secure in place and torque fas-
holes; tighten loosely teners.
– validate proper positioning of skid plate, then
torque all bolts and nuts NERF BAR
– safely lower vehicle back on the ground.
Removal
A-ARM PROTECTOR PLATE WARNING
Removal Engine and muffler must be cold before re-
moving the nerf bar. Otherwise, serious inju-
Baja X Models only ries may occur.
Procedure for RH and LH side is the same.
Remove the A-arm protector retaining nuts Baja X Models only
no. 49, and no. 51 and U-clamps.
3 4 5 6
1
V02L0YA 2 1
1. Nuts to be removed
2. U-Clamps
Inspection
Check nerf bar for cracks or bents and net strap
for wear. Change or repair as required. 1
Installation
Installation is essentially the reverse of removal
procedure but pay attention to the following:
2
After installing the net strap on the frame, make A
sure to tight it properly.
WARNING 3
Make sure the net is not too tight on nerf bar
tube. Check for clearance by standing up on
footpegs and moving feet in all directions.
Feet must not interfere with nerf bar net. Oth-
erwise, serious injuries may occur. V02L0EB
1. Lock pin
2. Lock pin nut (apply Loctite 271)
LATCH BASE/LATCH LEVER/ 3. Adjustment nut (apply Loctite 271)
A. 14 ± 2 mm (9/16 ± 5/64 in)
SPRING
Torque the lock pin nut.
Removal
Latch Base SEAT COVER REPLACEMENT
Remove bolts no. 41 and separate latch base Remove the old seat cover. Check the foam and
no. 42 from latch lever no. 1 and spring no. 43. replace if necessary.
Latch Lever Install staples with an electric tacker such as Ar-
Remove latch base. row tacker no. ETN-50 or with a manual tacker
Separate latch lever from spring. such as Arrow tacker no. T-50.
NOTE: For an easier installation, it’s highly recom-
Spring mended to use an electric tacker.
Remove latch base. Ensure that the seat rests firmly against a hard sur-
Separate spring from latch base and latch lever. face such as a piece of wood. This is done to get
the staples completely pushed in place.
SEAT ADJUSTMENT
For lock pin no. 3 adjustment, unscrew the lock
pin nut no. 44 and screw or unscrew the lock pin
to the best height. See the following illustration.
10-02-8 VMR2004_029_10_02A.FM
Section 10 BODY/FRAME
Subsection 02 (BODY)
Installation
There are 2 types of decals used on ATV’s. One
has a protective film on back side and the other
has a protective film on both sides. They are used
on 2 types of materials; plastic and metal.
Decals Having a Protective Film
on Back Side Only
These decals usually contain written information
(ex.: warning).
Clean surface with a good solvent such as ACRYL-
ICLEAN DX 330 from PPG or equivalent (refer to
manufacturer instructions).
Using a pencil and the decal as a template, mark
the area where decal will be located.
Remove half of the decal back protective film and
align decal with marks. Start sticking it from center
and remove the other half of the film to stick it
1 completely. Carefully squeegee decal beginning at
center and working outward using, firm, short,
F01L3YA 2 overlapping strokes.
TYPICAL Decals Having a Protective Film on Both Sides
1. Piece of wood
2. ETN-50 (electric) or T-50 (manual) These decals usually contain graphics.
After cover installation cut the excess of material Installation on Plastic
all around the seat. Clean surface with isopropyl alcohol.
Using a pencil and the decal as a template, mark
SEAT CLEANING the area where decal will be located.
It is recommended to clean the seat with a solu- Apply an activator (P/N 293 530 036) to prepare the
surface using a clean cloth. After a few seconds,
tion of warm soapy water, using a soft clean when the activator evaporates, the surface is ready.
cloth.
CAUTION: Do not use soapy water to locate de-
CAUTION: Avoid use of harsh detergents such cal on plastic parts.
as strong soaps, degreasing solvents, abrasive
cleaners, paint thinners, etc. that may cause Remove back protective film from decal and care-
damage to the seat cover. fully align decal with marks. When well aligned
squeegee decal beginning at center and working
outward using firm, short, overlapping strokes.
DECALS REPLACEMENT
Removal PLASTIC
Using a heat gun warm up one end of decal for a
MAINTENANCE/REPAIR
few seconds until decal can roll off when rubbing
with your finger. MAINTENANCE
Pull decal slowly and when necessary apply more Clean the vehicle thoroughly, removing all dirt and
heat to ease removal on the area that has to be grease accumulation.
peeled off.
To clean use a soft clean cloth and either soapy
If decal tears while pulling off, it has to be heated
for a few seconds longer. If decal tends to stretch water or isopropyl alcohol.
while pulling off, stop heating and wait a few sec- To remove grease, oil or glue use isopropyl alcohol.
onds to let it cool, then peel it off. CAUTION: Do not apply isopropyl alcohol or ac-
etone directly on decals.
VMR2004_029_10_02A.FM 10-02-9
Section 10 BODY/FRAME
Subsection 02 (BODY)
REPAIR
The plastic parts are produced in high density poly-
ethylene (HDPE) or in low density polyethylene
(LDPE). These materials are not reparable.
10-02-10 VMR2004_029_10_02A.FM
Section 10 BODY/FRAME
Subsection 03 (FRAME)
FRAME
23 Nm
(17 lbfft)
3
2 8
48 Nm 8
4 (35 lbfft)
9
7 48 Nm
(35 lbfft) 9
11
12
10
5 6 10 Nm
(89 lbfin)
6 1
10 Nm
(89 lbfin)
5
DS 650 Baja/Baja X
6 10 Nm
5 (89 lbfin)
6 1
10 Nm
(89 lbfin) DS 650
V02L0QS
VMR2004_030_10_03A.FM 10-03-1
Section 10 BODY/FRAME
Subsection 03 (FRAME)
FOOTPEG Inspection
Removal Check for cracks or bent tube. Change or repair if
necessary.
Baja X Models
Remove short plates no. 10,bolt no. 11 and nut Installation
no. 12. For installation, reverse the removal procedure.
10-03-2 VMR2004_030_10_03A.FM
Section 10 BODY/FRAME
Subsection 03 (FRAME)
Cleaning
Clean frame no. 4 and rear extension frame no. 3
with appropriate cleaners and rinse with high pres-
sure hose.
Touch up all metal spots where paint has been
scratched off. Spray all bare metal parts of vehicle
with metal protector.
Welding
Steel Frame:
– electric welding
– amperage: 70 - 110 A
– voltage: 20 - 24 V
– rod: E-7014 (3/32 in).
CAUTION: Before performing electrical weld-
ing anywhere on the vehicle, unplug the elec-
tronic module. Also unplug the negative cable
and the voltage regulator. This will protect the
electronic module and battery against damage
caused by flowing current when welding.
NOTE: Install the ground as close as possible to
the repaired area.
CAUTION: If welding is to be done near plastic
material, it is recommended to either remove the
part from the area or to protect it with aluminum
foil to prevent damage.
VMR2004_030_10_03A.FM 10-03-3
Section 11 TECHNICAL DATA
Subsection 01 (SI METRIC INFORMATION GUIDE)
TECHNICAL DATA
SI* METRIC INFORMATION GUIDE
BASE UNITS
DESCRIPTION UNIT SYMBOL
PREFIXES
CONVERSION FACTORS
TO CONVERT TO † MULTIPLY BY
NOTE: Conversion factors are rounded off to 2 decimals for easier use.
VMR2004_031_11_01A.FM 11-01-1
Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)
11-02-2 VMR2004_031_11_02A.FM
Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)
VMR2004_031_11_02A.FM 11-02-3
Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)
Engine/Transmission Oil or Bombardier synthetic oil 5W40 (P/N 293 600 039).
Recommended Do Not Use Synthetic Oil, other than Bombardier brand name or
any Synthetic Blend Oil.
Refer to OIL VISCOSITY CHART for proper grade.
Capacity 250 mL (8.5 U.S. oz)
Hydraulics Brakes
Recommended Brake Fluid DOT 4, ONLY
Capacity 1.75 L (0.58 U.S. gal)
Cooling System
Recommended Use Coolant Specially Designed for Aluminum Engine
Ethylene-Glycol Concentration 50%
11-02-4 VMR2004_031_11_02A.FM
Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)
VMR2004_031_11_02A.FM 11-02-5
Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)
11-02-6 VMR2004_031_11_02A.FM
Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)
BRAKE
Caliper Brake Screws 24 N•m (17 lbf•ft)
Brake Disk Screws 34 N•m (25 lbf•ft)
BODY/FRAME
Front Bumper 24 N•m (17 lbf•ft)
Rear Extension Frame 48 N•m (35 lbf•ft)
Footrest 10 N•m (89 lbf•in)
Skid Plate 4 N•m (35 lbf•in)
VMR2004_031_11_02A.FM 11-02-7
Section 12 WIRING DIAGRAMS
Subsection 01 (WIRING DIAGRAMS)
WIRING DIAGRAMS
WARNING
Ensure all terminals are properly crimped on
the wires and all connector housings are
properly fastened.
WIRE COLORS
It identifies the color of a wire. When a 2-color
scheme is used, the first color is the main color
while the second color is the tracer color.
Example: YL/BK is a YELLOW wire with a BLACK
stripe.
COLOR CODE
BK — BLACK PK — PINK
BL — BLUE RD — RED
BR — BROWN TA — TAN
GN — GREEN VI — VIOLET
GY — GREY WH — WHITE
OR — ORANGE YL — YELLOW
VMR2004_032_12_01A.FM 12-01-1
12-01-2
DS 650
DS 650 KEY SWITCH FRONT BRAKE SWITCH
CC FV
OFF ON
RD / VI RD / OR
NEUTRAL LED OIL/TEMP LED TAIL LIGHT
GREEN RED TA PR
NEUTRAL CHECK REAR BRAKE SWITCH BK
FR
LT
BK / GY RD
RD / VI MULTI-FUNCTION SWITCH
MG
RD / VI YL / GY
HI MG MG
FAN SWITCH FAN FUSE
IT BF2 LOW START RUN
BR / BK BR / WH 15A
OFF OFF
RD / VI YL / RD BK BK / WH
GN BL BL
TA GN
HEAD LIGHT
PV
Section 12 WIRING DIAGRAMS
BK
Subsection 01 (WIRING DIAGRAMS)
FAN THERMOSTATIC RD
FT
RD / VI
+12V
BK / YL
IN +
BK VI / BL BK ELECTRONIC MODULE
RD IN - ME
MAIN FUSE BK / WH
BF1 STARTER OUT
SOLENOID BK
SS GND
25A
RD D1
YL / GY
IGNITION COILS
CLUTCH NEUTRAL
SWITCH SWITCH BK / WH
BA
IE IN
BK / GY
BATTERY
BK / YL
BK RD
M TRIGGER COIL
CA
BK
STARTER
VOLTAGE REGULATOR
RV
YL MAGNETO
RD
YL MA
BK YL
V02Z01
VMR2004_032_12_01A.FM
Section 12 WIRING DIAGRAMS
Subsection 01 (WIRING DIAGRAMS)
DS 650 Baja/Baja X
DS 650 BAJA/BAJA X
V02Z03
VMR2004_032_12_01A.FM 12-01-3