1999 to 2000 Bombardier Traxter ATV service manual

I SECTION SUBSECTION PAGE SAFETY NOTICE ................................................................................................................................... III WHAT’S NEW ....................................................................................................................................... IV INTRODUCTION .................................................................................................................................. V 01 SERVICE TOOLS AND SERVICE PRODUCTS 01 – Table of contents...................................................................... 01-01-1 02 – Service tools ............................................................................. 01-02-1 03 – Service products....................................................................... 01-03-1 02 MAINTENANCE 01 – Table of contents...................................................................... 02-01-1 02 – Maintenance chart.................................................................... 02-02-1 03 – Maintenance and lubrication .................................................... 02-03-1 04 – Storage and pre-season preparation......................................... 02-04-1 03 ENGINE 01 – Table of contents...................................................................... 03-01-1 02 – Removal and installation........................................................... 03-02-1 03 – Cooling system......................................................................... 03-03-1 04 – Rewind starter .......................................................................... 03-04-1 04 FUEL SYSTEM 01 – Table of contents...................................................................... 04-01-1 02 – Fuel circuit ................................................................................ 04-02-1 03 – Carburetor and fuel pump ........................................................ 04-03-1 04 – Air intake silencer ..................................................................... 04-04-1 05 ELECTRICAL 01 – Table of contents...................................................................... 05-01-1 02 – Overview .................................................................................. 05-02-1 03 – Charging system ...................................................................... 05-03-1 04 – Starting system ........................................................................ 05-04-1 05 – Ignition system......................................................................... 05-05-1 06 – Electric shift system................................................................. 05-06-1 07 – Instruments and accessories ................................................... 05-07-1 06 DRIVE TRAIN 01 – Table of contents...................................................................... 06-01-1 02 – Front differential ....................................................................... 06-02-1 03 – Rear axle................................................................................... 06-03-1 07 STEERING/CONTROL SYSTEM 01 – Table of contents...................................................................... 07-01-1 02 – Steering/control systems ......................................................... 07-02-1 08 SUSPENSION 01 – Table of contents...................................................................... 08-01-1 02 – Front suspension ...................................................................... 08-02-1 03 – Rear suspension ....................................................................... 08-03-1 09 BRAKES 01 – Table of contents...................................................................... 09-01-1 02 – Hydraulic brakes ....................................................................... 09-02-1 TABLE OF CONTENTS

II 10 BODY/FRAME 01 – Table of contents ..................................................................... 10-01-1 02 – Body ......................................................................................... 10-02-1 03 – Frame ....................................................................................... 10-03-1 11 TECHNICAL DATA 01 – SI metric information guide...................................................... 11-01-1 02 – Engine and vehicle ................................................................... 11-02-1 12 WIRING DIAGRAM 01 – Wiring diagram......................................................................... 12-01-1 SECTION SUBSECTION PAGE TABLE OF CONTENTS

V INTRODUCTION This Shop Manual covers the following Bombar- dier made 1999 ATV: Models 1. Model number VEHICLE AND ENGINE SERIAL NUMBER LOCATION 1. Engine 2. Vehicle TRAXTER* (Canada) ................................ 7400 TRAXTER* (Canada) ................................ 7413 TRAXTER* (Canada) ................................ 7415 TRAXTER* (Canada) ................................ 7417 TRAXTER* (U.S.) ...................................... 7401 TRAXTER* (U.S.) ..................................... 7414 TRAXTER* (U.S.) ..................................... 7416 TRAXTER* (U.S.) ..................................... 7418 *Trademark of Bombardier Inc. V01A17A 1 V01A16A 1 2 INTRODUCTION http://ReadManuals.com

VI Serial Number Meaning 10 11 12 13 14 15 16 17 9 8 7 6 5 4 3 2 1 SECTION 1 SECTION 2 SECTION 3 SECTION 4 3 2 1 SECTION 1 Class Make Manufacturer 8 7 6 5 4 SECTION 2 Factory use Engine type II Engine type I Product line Type of drive 9 SECTION 3 Check digit 10 11 12 13 14 15 16 17 SECTION 4 Number sequentially assigned by the manufacturer in the production process Plant of manufacture Model year V01A0PS INTRODUCTION http://ReadManuals.com

VII ARRANGEMENT OF THE MANUAL The manual is divided into 12 major sections: 01 SERVICE TOOLS AND SERVICE PRODUCTS 02 MAINTENANCE 03 ENGINE 04 FUEL SYSTEM 05 ELECTRICAL 06 DRIVE TRAIN 07 STEERING/CONTROL SYSTEMS 08 SUSPENSION 09 BRAKES 10 BODY/FRAME 11 TECHNICAL DATA 12 WIRING DIAGRAM Each section is divided in various subsections, and again, each subsection has one or more division. LIST OF ABBREVIATIONS USED IN THIS MANUAL A ampere amp ampere A•h ampere-hour AC alternate current BDC bottom dead center BTDC before top dead center °C degree Celsius cm centimeter cm² square centimeter cm³ cubic centimeter DC direct current °F degree Fahrenheit fl. oz fluid ounce ft foot GRD ground hal. halogen I.D. inside diameter IDI induction discharge ignition imp. oz imperial ounce in inch in² square inch in³ cubic inch k kilo (thousand) kg kilogram km/h kilometer per hour kPa kilo pascal L liter lb pound lbf pound (force) lbf/in² pound per square inch LH left hand m meter MAG magneto Max. maximum Min. minimum mL milliliter mm millimeter MPEM multi-purpose electronic module MPH mile per hour N newton N.A. not applicable no. number 00.0 continuity 0.L overload (open circuit) O.D. outside diameter OPT optional oz ounce P/N part number PSI pound per square inch PTO power take off RPM revolution per minute Sp. Gr. specific gravity TDC top dead center U.S. oz ounce (United States) V volt Vac volt (alternative current) INTRODUCTION http://ReadManuals.com

VIII V01C15S 10 8 7 10 9 7 11 10 8 9 7 9 14 7 8 10 19 15 30 2 32 4 31 32 26 1 28 27 25 25 24 25 25 24 23 6 3 3 17 13 12 29 11 16 21 21 21 20 20 20 22 18 17 5 Therma Lube grease Therma Lube grease Therma Lube grease 12 48 Nm (35 lbfft) 48 Nm (35 lbfft) 24 Nm (17 lbfft) 24 Nm (17 lbfft) 10 Nm (97 lbfin) 24 Nm (17 lbfft) 48 Nm (35 lbfft) 10 Nm (97 lbfin) 03 02 1 Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION Page heading indicates section and subsection detailed. Bold face number indicates special procedure concerning this part. Ti ghtening torque nearby fastener. In this case, nut must be torqued to 48 Nm or 35 lbfft. This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. Exploded view assists you in identifying parts and related positions. TYPICAL PAGE V01A0QS Illustration number for publishing process. Subsection title indicates beginning of the subsection. Drop represents a liquid product to be applied to a surface. Page numbering system: 03: ENGINE section 02: REMOVAL AND INSTALLATION subsection 1: First page of this subsection CAUTION: Pay attention to torque specifications. Some of these are in lbfin instead of lbfft. Use appropriate torque wrench. INTRODUCTION http://ReadManuals.com

Section 03 ENGINE Subsection 02 (REMOVAL AND INSTALLATION) 03 02 2 1 Shifting valve 2 GBPS (Gear Box Pos tion Sensor) 3 Magneto/Trigger plug 4 Engine coolant hose Place the vehicle on jackstands and place the shifter no. 1 on park position Remove front wheels Drain engine oil and engine coolant Remove seat, front and rear fenders, inner fenders, side panels, steering cover, shifter guide cover and skid plate Refer to the section 09-02 BODY Disconnect BLACK negative cable from battery, then RED positive cable Front Part Preparation Remove fuel tank and fuel valve Refer to the section 03-02 FUEL CIRCUIT Disconnect the interlock cable no. 2 under shifter lever Remove seat pivot bar and unplug the clutching and clutch modulator valves connector Remove the STPS (Sub Transmission Position Sen- sor) ROD REMOVAL section Remove front propeller shaft Refer to the section 05-02 FRONT DIFFERENTIAL Unplug the VSS (Vehicle Speed Sensor), located under engine drive shaft Engine Preparation Unplug spark plug cables Unplug oil pressure sensor Remove radiator inlet hose Remove breather‘ hose Unplug the temperature sensor WARNING Always disconnect battery or starter cables exactly in the specified order, BLACK negative cable first. It is recommended to disconnect electrical connections prior to discon- necting fuel lines. 2 V01C0DA 4 3 1 6 5 1 3 V01C0EA 2 4 Vehicle Preparation 2 STPS (Sub Transmission Position Sensor) 3 VSS (Vehicle Speed Sensor) 4 Shifting engine rod 5 Oil pressure sensor 6 Engine coolant hose 1 Clutching and clutch modulator valves connector Remove exhaust pipe no. 5 Refer to the EXHAUST SYSTEM section Remove shifting rod no. 3 Refer to the SHIFTING ENGINE REMOVAL m TYPICAL PAGE Title indicates main procedure to be carried out. Reference to look up a certain section and subsection. In this case it concerns exhaust system. Bold face number following part name refers to exploded view at beginning of subsection. Call outs for above illustration. V01A0RS INTRODUCTION http://ReadManuals.com

X 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 obligation to install them on products previously manufactured. Due to late changes, it may have some differences between the manufactured product and the descrip- tion and/or specifications in this document. Bombardier Inc. reserves the right at any time to discontinue 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 which have the same or a similar function. CAUTION: Most components of those vehicles are built with parts dimensioned in the metric system. Most fasteners are metric and must not be replaced by customary fasteners or vice- versa. Mismatched or incorrect fasteners could cause damage to the vehicle or possible per- sonal injury. As many of the procedures in this manual are in- terrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or subsection in which the procedure is contained. A number of procedures throughout the book re- quire the use of special tools. Before commencing any procedure, be sure that you have on hand all the tools required, or approved equivalents. The use of RIGHT and LEFT indications in the text, always refers to driving position (when sitting on vehicle). 1. Left 2. Right 1 2 V01L25A INTRODUCTION http://ReadManuals.com

XI TIGHTENING TORQUES Tighten fasteners to torque mentioned in exploded views and text. When they are not specified refer to following table.The table also gives the metric conversion. N•m FASTENER SIZE (8.8) Lbf•in 1 9 2 M4 18 3 27 4 M5 35 5 44 6 53 7 62 8 71 9 80 10 M6 89 11 97 12 106 13 115 14 124 15 133 16 142 17 150 18 159 19 168 N•m FASTENER SIZE (8.8) Lbf•ft 20 15 21 15 22 16 23 M8 17 24 18 25 18 26 19 27 20 28 21 29 21 30 22 31 23 32 24 33 24 34 25 35 26 36 27 37 27 38 28 39 29 40 30 41 30 42 31 43 32 44 32 45 33 46 34 47 35 48 M10 35 49 36 50 37 51 38 52 38 53 39 54 40 55 41 56 41 57 42 58 43 59 44 60 44 61 45 62 46 63 46 64 47 INTRODUCTION http://ReadManuals.com

XII TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS N•m FASTENER SIZE (8.8) Lbf•ft 65 48 66 49 67 49 68 50 69 51 70 52 71 52 72 53 73 54 74 55 75 55 76 56 77 57 78 58 79 58 80 M12 59 81 60 82 60 83 61 84 62 85 63 86 63 87 64 88 65 89 66 90 66 91 67 92 68 93 69 94 69 95 70 96 71 97 72 98 72 99 73 100 74 101 74 102 75 103 76 104 77 105 77 106 78 107 79 108 80 N•m FASTENER SIZE (8.8) Lbf•ft 109 80 110 81 111 82 112 83 113 83 114 84 115 85 116 86 117 86 118 87 119 88 120 89 121 89 122 90 123 91 124 91 125 92 126 93 127 94 128 94 129 95 130 96 131 97 132 97 133 98 134 99 135 M14 100 136 100 137 101 138 102 139 103 140 103 141 104 142 105 143 105 144 106 145 107 146 108 147 108 148 109 149 110 150 111 INTRODUCTION http://ReadManuals.com

1999 to 2000 Bombardier Traxter ATV service manual

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