2006 - 2015 Service Manual
2006 - 2015 Service Manual
2006 - 2015 Service Manual
Service Manual
DS 250
TABLE OF CONTENTS
01 MAINTENANCE
01 – MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
NOISE EMISSION CONTROL SYSTEM REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
02 – PRESEASON PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
03 – STORAGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CVT TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
04 – SPECIAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ATV IMMERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
02 TROUBLESHOOTING
01 – TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CVT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ENGINE GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
03 ENGINE
01 – ENGINE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
02 – ENGINE LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
03 – AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
AIR FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
AIR FILTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
AIR INJECTION VALVE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
04 – EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
I
TABLE OF CONTENTS
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPARK ARRESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
05 – LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ENGINE OIL PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ENGINE OIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
06 – COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
COOLING SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
LEAK INDICATOR HOLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
COOLING SYSTEM LEAK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
THERMO-SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
COOLING FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
07 – MAGNETO AND STARTER DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
MAGNETO COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
TRIGGER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
CRANKSHAFT END BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
STARTER REDUCTION GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
STARTING CLUTCH GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
08 – CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
CYLINDER HEAD REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
PARTS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
09 – PISTON AND CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10 – CRANKSHAFT AND CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
11 – GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
GEARBOX OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
GEARBOX OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
GEARBOX SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
II
TABLE OF CONTENTS
04 FUEL SYSTEM
01 – CARBURETOR AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
CARBURETOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
FUEL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
CHOKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
05 ELECTRICAL SYSTEM
01 – CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
VOLTAGE REGULATOR/ RECTIFIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
02 – IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
FUSES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
ENGINE STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
TRIGGER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
IGNITION MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
SHIFT GEAR CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
OVERRIDE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
03 – STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
FUSES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
ENGINE STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
START SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
STARTING SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
ELECTRICAL CABLES OR CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
ELECTRIC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
SHIFT GEAR CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
PART REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
ELECTRIC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
04 – LIGHTS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
III
TABLE OF CONTENTS
FUSES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
HEADLAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
TURN SIGNAL LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
POSITION LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
PILOT LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
12-VOLT POWER OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
06 TRANSMISSION
01 – CONTINUOUSLY VARIABLE TRANSMISSION (CVT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
DRIVE BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
CVT COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
CVT COVER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
DRIVE PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
DRIVEN PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
IV
TABLE OF CONTENTS
09 BRAKING SYSTEM
01 – FRONT AND REAR BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
ALL MODELS EXCEPT EUROPEAN MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
CALIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
MASTER CYLINDERS OF BRAKE LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
REAR BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
MASTER CYLINDER OF REAR BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
PRESSURE CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
BRAKE LIGHT SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
EUROPEAN MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
PARKING BRAKE (CABLE AND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
CALIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
MASTER-CYLINDERS OF BRAKE LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
REAR BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
MASTER CYLINDER OF REAR BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
FRONT BRAKE PRESSURE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
REAR BRAKE PRESSURE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
BRAKE LIGHT SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
10 BODY/FRAME
01 – BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
PARTS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
SEAT LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
FUEL TANK COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
RADIATOR SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
FRONT FENDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
REAR FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
FOOTREST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
PLASTIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
PLASTIC REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
02 – FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
FRONT BUMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
FOOTPEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
FOOTREST SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
V
TABLE OF CONTENTS
11 TECHNICAL SPECIFICATIONS
01 – DS 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
12 WIRING DIAGRAMS
01 – WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
WIRE COLORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
VI
SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair the 2006 DS 250™ ATVs as
describe in the model list in the INTRODUCTION.
This edition was primarily published to be used by mechanical technicians who are already familiar with
all service procedures relating to BRP products. Mechanical technicians should attend training courses
given by BRP Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This Vehicle Shop Manual uses technical terms which may be slightly different from the ones used in the
PARTS CATALOG.
It is understood that this manual may be translated into another language. In the event of any discrepan-
cy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser-
vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read
and understand these. It does not include dealer modifications, whether authorized or not by BRP, after
manufacturing the product.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of BRP parts is most strongly recommended when considering replacement of any component.
Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those for which it was designed.
WARNING
Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair
procedures.
This manual emphasizes particular information denoted by the wording and symbols:
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including pos-
sibility of death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo-
nents.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
This information relates to the preparation and use of Bombardier† ATV and has been utilized safely and
effectively by BRP. However, BRP disclaims liability for all damages and/or injuries resulting from the
improper use of the contents. We strongly recommend that any services be carried out and/or verified
by a highly skilled professional mechanic. It is understood that certain modifications may render use of
the vehicle illegal under existing federal, provincial and state regulations.
vmr2006-060 VII
INTRODUCTION
INTRODUCTION
GENERAL INFORMATION ENGINE SERIAL NUMBER
This Shop Manual covers the following 2006 ATV LOCATION
models:
MODEL
MODEL
NUMBER
DS 250 CE
3J6B
(European Community models)
DS 250 (North America and
3J6C
International models)
between the manufactured product and the de- E.I.N. (ENGINE IDENTIFICATION NUMBER)
scription and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod- ARRANGEMENT OF THE
els or equipment without incurring obligation. MANUAL, ILLUSTRATIONS
AND PROCEDURES
VEHICLE SERIAL NUMBER The manual is divided into many major sections as
LOCATION you can see in the main table of contents at the
beginning of the manual.
Each section is divided in various subsections, and
again, each subsection has one or more division.
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.
CAUTION: Most components in the 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
1 personal injury.
2
vmo2006-014-004_a
vmr2006-060 IX
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)
Drop represents a 4 Bold face number
liquid product to be indicates special
applied to a surface. procedure
concerning this
part.
Loctite 243
Tightening torque
nearby fastener. In this 10 Nm
(89 lbfin)
case, nut must be
torqued to
10 Nm or 89 lbfin.
8
CAUTION: Pay attention
to torque specifications. 23 10 Nm
(89 lbfin)
Some of these are in
lbfft instead of lbfin. 27 10 Nm
(89 lbfin)
Use appropriate
torque wrench.
V02C0ES
31
V00A2NS
X vmr2006-060
INTRODUCTION
TYPICAL PAGE
Title indicates
main procedure Section 03 ENGINE
to be carried-out. Subsection 06 (MAGNETO SYSTEM)
R610motr12A
Reference to look
up a certain section
and subsection.
In this case it
concerns
IGNITION SYSTEM.
82
V00A2OS
vmr2006-060 XI
INTRODUCTION
LOCTITE® APPLICATION
PROCEDURE
A00A3MA
The following describes the most common ap-
plication procedures when working with Loctite 1. On threads
2. On threads and at the bottom of hole
products.
NOTE: Always use proper strength Loctite prod- – Clean threads (bolt and hole) with solvent.
uct as recommended in this SHOP MANUAL. – Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
Threadlocker seconds.
Uncovered Holes (bolts and nuts) – Choose proper strength Loctite threadlocker.
– Apply several drops along the threaded hole and
at the bottom of the hole.
– Apply several drops on bolt threads.
1 – Tighten as required.
Stud in Blind Holes
1 3
2
2
A00A3LA
1. Apply here
2. Do not apply
XII vmr2006-060
INTRODUCTION
– Apply drops of proper strength Loctite on un- NOTE: if it is difficult to readjust, heat screw with
covered threads. a soldering iron (232°C (450°F)).
– Tighten nuts as required.
Stripped Thread Repair
Preassembled Parts
5
1
6
8
1
2
A00A3QA 4 7
1. Release agent
2. Stripped threads
2 3. Form-A-Thread
A00A3OA 4. Tapes
5. Cleaned bolt
1. Apply here 6. Plate
2. Do not apply 7. New threads
8. Threadlocker
vmr2006-060 XIII
INTRODUCTION
1 2
3
A00A3UA
1. Bearing
2. Proper strength Loctite
3. Shaft
A00A3VA 1
1. Proper strength Loctite
vmr2006-060 XV
INTRODUCTION
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in exploded views and/or text, When they are not specified, refer
to following table.
WARNING
Torque wrench tightening specifications must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed
or replaced with new ones, where specified. If the efficiency of a locking device is impaired, it
must be renewed.
In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the following pro-
cedure:
– Manually screw all screws, bolts and/or nuts.
– 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.
– Torque to the recommended torque value.
NOTE: Always torque screws, bolts and/or nuts in a criss-cross sequence.
4.8 8.8 9.8 10.9 12.9
Property
class
and 4.8 8.8 9.8 10.9 12.9
head
markings 4.8 8.8 9.8 10.9 12.9 12.9
Property 5 10 10 12
class
and
10
10
12
5
nut
markings
A00A8BS
XVI vmr2006-060
Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)
MAINTENANCE CHART
NOISE EMISSION CONTROL SYSTEM REGULATION
Tampering with noise control system is 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 inoper-
ative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1. Removal or alteration or the puncturing of the muffler or any engine component which conducts re-
moval of engine exhaust gases.
2. Removal or alteration or the puncturing of any part of the intake system.
3. Replacing any moving parts of the vehicle or parts of the exhaust or intake system, with parts other
than those specified by the manufacturer.
4. Lack of proper maintenance.
vmr2006-061 1
Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)
MAINTENANCE CHART
The schedule should be adjusted according to operating conditions and use.
NOTE: The chart gives an equivalence between number of hours and months/year. Perform the mainte-
nance operation to whatever time comes first.
IMPORTANT: ATV rental operations or intensive use of ATV, will require greater frequency of inspection
and maintenance.
2 vmr2006-061
Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)
vmr2006-061 3
Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)
Seat fasteners (4) (4) (4) (4) (4) BODY AND FRAME
Frame I
Engine and vehicle cleaning and protection (4) (4) (4) (4) (4)
(1) More often under severe use such as dusty area, sand, snow, wet or muddy conditions.
(2) Every 100 hours, check coolant strength.
(3) Make sure that the spark plug gap is correct.
(4) Every inspection.
N.A.: Not Applicable.
4 vmr2006-061
Section 01 MAINTENANCE
Subsection 02 (PRESEASON PREPARATION)
PRESEASON PREPARATION
SERVICE PRODUCTS
Description Part Number Page
pulley flange cleaner............................................................. 413 711 809 ............................................. 5
vmr2006-062-001_aen
vmr2006-062 5
Section 01 MAINTENANCE
Subsection 03 (STORAGE PROCEDURES)
STORAGE PROCEDURES
SERVICE PRODUCTS
Description Part Number Page
BRP Cleaner ......................................................................... 293 110 001 ............................................. 8
BRP Vinyl & Plastic Cleaner.................................................. 413 711 200 ............................................. 8
fuel stabilizer......................................................................... 413 408 600 ............................................. 7
storage oil ............................................................................. 413 711 600 ............................................. 7
storage oil ............................................................................. 413 711 900 ............................................. 7
XP-S Lube ............................................................................. 293 600 016 ............................................. 8
If the ATV is not used for an extended period of – Inject storage oil until the engine stalls or until a
time, more than 4 months, be sure to thorough- sufficient quantity of oil has entered the engine
ly perform the following procedures for each in- (approximately a quarter of can).
volved system. – Remove spark plug and spray storage oil into
cylinder. Press start button, 1 or 2 seconds
FUEL SYSTEM maximum, to lubricate cylinder.
– Reinstall the spark plug, air filter and air filter
With the new fuel additives, it is critical to use the
housing cover.
fuel stabilizer (P/N 413 408 600) to prevent fuel de-
terioration, gum formation and fuel system com- – Turn the fuel valve to OFF and drain carburetor.
ponents corrosion. Follow the manufacturer's in-
structions for proper use. ELECTRICAL SYSTEM
CAUTION: Fuel stabilizer should be added pri- Battery
or to engine lubrication to protect fuel compo-
nents (carburetor) against varnish deposits. Remove battery from vehicle. Refer to CHARG-
Pour fuel stabilizer in fuel tank. Fill up fuel tank. ING SYSTEM for battery removal and storage pro-
cedures.
ENGINE COOLING SYSTEM
Engine internal parts must be lubricated to protect
them from rust formation during the storage peri- Test coolant density using an antifreeze hydrome-
od. ter.
NOTE: Follow manufacturer's instructions for
WARNING proper use.
This procedure must only be performed in a A 50/50 mixture of antifreeze and distilled water
well-ventilated area. Do not run engine dur- will provide the optimum cooling, corrosion pro-
ing storage period. tection and antifreeze protection.
CAUTION: Do not use tap water, straight
Proceed as follows: antifreeze or straight water in the system.
– Start the engine and allow it to run at idle speed Tap water contains minerals and impurities
until the engine reaches its operating tempera- which build up in the system. Straight water
ture. will cause the system to freeze while straight
– Stop the engine. antifreeze will cause system temperature prob-
lems.
– Change engine oil and clean engine oil strainer.
Refer to LUBRICATION SYSTEM. Change coolant if necessary. Refer to COOLING
– Remove air filter housing cover and air filter to SYSTEM.
spray storage oil (P/N 413 711 600) into carbu-
retor.
NOTE: For USA, use storage oil (P/N 413 711 900)
only.
– Restart engine and run at idle speed.
vmr2006-063 7
Section 01 MAINTENANCE
Subsection 03 (STORAGE PROCEDURES)
CVT TRANSMISSION
Remove drive belt from pulleys.
Inspect and clean pulleys then spray XP-S Lube
(P/N 293 600 016) on pulley faces.
Do not reinstall drive belt. Close CVT cover.
VEHICLE
Cleaning
To facilitate the inspection and ensure adequate
lubrication of components, it is recommended to vmr2006-063-001_a
clean the entire vehicle. CVT AIR INLET HOSE — FRONT OF VEHICLE
1. CVT air inlet hose
Wash and dry the vehicle. 2. Radiator cap
3. Front fender
CAUTION: Never use a high pressure washer
to clean the vehicle. USE LOW PRESSURE ON-
LY (like a garden hose). The high pressure can
cause electrical or mechanical damages.
Remove any dirt or rust.
To clean the vinyl or plastic parts, use only flannel
clothes with BRP Vinyl & Plastic Cleaner (P/N 413
711 200).
CAUTION: It is necessary to use flannel cloths
on plastic parts to avoid damaging surfaces.
Never clean plastic parts with strong detergent,
degreasing agent, paint thinner, acetone, prod-
ucts containing chlorine, etc.
To clean the entire vehicle, including metallic parts
use BRP Cleaner (P/N 293 110 001).
Inspect the vehicle and repair any damage. Touch vmr2006-063-002_a
up all metal spots where paint has been scratched CVT AIR OUTLET HOSE — RH REAR SIDE OF VEHICLE
off. Spray all metal parts with XP-S Lube (P/N 293 1. CVT air outlet hose
2. Protective box for end of hose
600 016).
Rags Installation
Using cleans rags, block the following locations:
CVT inlet and outlet hoses, air filter box inlet and
muffler. The rags will prevent the intrusion of
small animals, leaves or other debris.
CAUTION: Do not forget, these rags must be
removed during preseason preparation before
starting the vehicle.
vmr2006-063-003_a
8 vmr2006-063
Section 01 MAINTENANCE
Subsection 03 (STORAGE PROCEDURES)
vmr2006-063-004
Protection
Protect the vehicle with a cover to prevent dust
accumulation during storage.
CAUTION: The vehicle has to be stored in a
cool and dry place and covered with an opaque
tarpaulin. This will prevent sun rays and grime
from affecting plastic components and vehicle
finish.
vmr2006-063 9
Section 01 MAINTENANCE
Subsection 04 (SPECIAL PROCEDURES)
SPECIAL PROCEDURES
SERVICE PRODUCTS
Description Part Number Page
XP-S Lube ............................................................................. 293 600 016 ........................................... 11
ATV IMMERSION
ATV Submerged for a Long Time
(over one hour)
Disassemble engine and transmission to clean the
internal parts and check if there is no rust or corro-
sion on any internal parts. Refer to ENGINE sec-
tion.
Drain air filter box then clean and dry air filter. vmr2006-064-001_a
Remove muffler and empty it. Let muffler dry 1. CVT cover drain tube
then reinstall it on the vehicle. 2. CVT cover
3. LH footrest
Flush fuel tank and refill with new gas.
Clean and lubricate carburetor. Refer to CARBU- – Lubricate all cables. Check if the cables operate
RETOR. properly.
Look for water in brake system. Replace brake – Remove spark plug then crank engine slowly
fluid if necessary. several times.
– Add a small quantity of engine oil in cylinder
Lubricate all cables. Check if the cables operate (approximately 2 teaspoonfuls). Do not reinstall
properly. spark plug at this moment.
Spray all metal parts with XP-S Lube (P/N 293 600 – Refill engine at the proper level with the recom-
016). mended oil. Crank engine several times.
Test drive to confirm all is working well (electrical – Check condition of spark plug. If spark plug ap-
and mechanical components). pears good reinstall it, if not install a new one.
– Start the engine and allow it to run at idle speed
ATV Submerged for a Short Time until the engine reaches its operating tempera-
(fewer one hour) ture.
Check if engine oil is contaminated (oil will be – Stop the engine.
milky). If so, perform the following instructions. – Change engine oil and clean oil strainer.
– Drain engine oil. NOTE: Change oil as many times as necessary,
– Drain air filter housing then clean and dry air until there is no white appearance in engine oil.
filter.
Spray all metal parts with XP-S Lube (P/N 293 600
– Look for water in fuel tank, in doubt, flush fuel 016).
tank and refill with new gas.
– Remove the drain tube underneath CVT cover Test drive to confirm all is working well (electrical
to drain water. Remove the CVT cover then and mechanical components).
clean and check all parts of CVT. Refer to CVT.
vmr2006-064 11
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
TROUBLESHOOTING CHART
The following charts are provided to help in diagnosing the probable source of troubles. It should be used
as a guideline.
COOLING SYSTEM
Symptom: HIGH ENGINE OPERATING TEMPERATURE.
1. Check coolant level.
- Check coolant level.
2. Check radiator condition.
- Radiating fins clogged. Clean radiating fins.
- Radiator is perforated. Change radiator.
3. Check radiator fan operation.
- Fuse burnt. Replace
- Thermo-switch defective. Replace
- Fan defective (does not turn when engine gets hot). Replace fan.
4. Check condition of hoses and hose clamps fixation.
- Hoses are brittle and/or hard. Replace.
- Hose clamps are loose. Retighten clamps.
5. Check coolant bleeding screw on thermostat housing.
- Screw looses and/or gasket ring is missing. Retighten screw and/or place gasket ring.
6. Check thermostat (located on cylinder head).
- Thermostat defective (does not open when engine gets hot). Replace thermostat.
7. Check thermo-switch for electrical/mechanical failure.
- Thermo-switch defective. Replace.
8. Check leak indicator hole (under magneto cover) if coolant leaks.
- Coolant leaking from leak indicator hole means a damaged oil seal and/or O-ring on water pump
cover. Replace both oil seals and O-rings (refer to COOLING SYSTEM).
9. Check condition of water pump impeller.
- Impeller fins broken and/or impeller thread is damaged. Replace.
10. Check cylinder head and/or cylinder base gasket.
- Worn out gasket(s) is (are) causing water leakage. Replace.
ELECTRICAL SYSTEM
Symptom: ENGINE DOES NOT START — NO SPARK.
1. Check spark plug electrode condition.
- Gap is too large. Readjust gap (refer to TECHNICAL SPECIFICATIONS).
2. Check ignition coil for damage and/or electrical failure.
- Ignition coil damaged. Vibration problem. Electrically damaged part. Replace ignition coil.
- Connector is corroded or ignition coil shows electrical failure. Clean connector area and/or re-
place ignition coil.
vmr2006-065 13
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
LUBRICATION SYSTEM
Symptom: LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION.
1. Check oil level and search for leakage on crankcase and/or defective sealing ports.
- Crankcase is leaking due to damage. Rebuild engine with new crankcase and gasket parts.
- Crankcase is leaking due to loose screws. Retighten screws with recommended torque.
- Sealing rings, O-rings and/or gaskets are brittle and/or hard or damaged. Replace damaged parts.
- Piston rings worn out (blue colored engine exhaust gas). Replace piston rings (refer to PISTON
AND CYLINDER).
- Piston rings are broken (low compression and blue colored engine exhaust gas. Replace piston
rings (refer to PISTON AND CYLINDER).
- Valve stem seal damaged and/or sealing lip is hard and/or brittle. Replace all valve stem seals.
2. Check oil strainer screw on engine bottom.
- Screw is loose and/or gasket is damaged, brittle or hard. Retighten screw and/or replace gasket.
3. Check oil pressure relief valve function.
- Valve spring damaged (valve always open). Replace spring.
- Valve stays open in crankcase PTO due to contamination (metallic particles). Clean and/or repair
valve piston.
4. Check oil drain plug on engine bottom.
- Plug is loosed and/or gasket ring is missing. Retighten the plug and/or place gasket ring.
14 vmr2006-065
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
CYLINDER HEAD
Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATION AT IDLE SPEED.
1. Check oil pressure relief valve function.
- Valve opens due to contamination and/or spring damaged (valve remains open). Clean and/or
replace spring and/or mechanism.
- Faulty chain tensioner. Replace spring and/or mechanism.
vmr2006-065 15
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
CRANKSHAFT
Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATIONS.
1. Check crankshaft deflection.
- The crankshaft deflection is out of specification. Replace.
2. Check crankshaft bearings.
- Ball bearings do not turn smoothly and freely. Replace bearings.
3. Check connecting rod bearing.
- Broken or wear needle bearings. Replace crankshaft.
4. Check balancing shaft bearings and balancing shaft phasing with crankshaft.
- Defective balancing shaft bearings. Replace.
- Balancing shaft is not in phase with crankshaft. Install balancing shaft correctly.
5. Check starting clutch.
- Defective starting clutch. Replace.
GEARBOX
Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATIONS.
1. Check oil level in gearbox.
- Oil leakage through plug cover area. Replace O-ring and retighten screw with recommended
torque.
- Oil leakage in gearbox cover gasket area. Replace gasket and do the torque procedure (refer to
GEARBOX).
2. Check bearings in the gearbox for free movement.
- Bearing(s) do(es) not move freely. Replace bearing(s).
3. Check for whistling noise inside gearbox.
- Countershaft and intermediate shaft are noisy. Replace countershaft and intermediate shaft the
same time.
4. Check for gear noise.
- Teeth of gears are damaged and/or worn. Replace respective gears.
16 vmr2006-065
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
CVT
Symptom: THE ATV ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED.
1. Check drive belt condition.
- Belt is too narrow (drive belt engagement is higher in drive pulley). Replace belt if width is less
than specified (refer to CONTINUOUSLY VARIABLE TRANSMISSION or TECHNICAL SPECIFI-
CATIONS).
2. Check centrifugal clutch on driven pulley.
- Liners of centrifugal clutch are out of specification (refer to CONTINUOUSLY VARIABLE TRANS-
MISSION). Replace centrifugal clutch assembly.
3. Check roller on drive pulley inner sheave.
- Rollers are worn and/or wrong installed and/or otherwise damaged (refer to CONTINUOUSLY
VARIABLE TRANSMISSION). Replace all rollers at the same time (roller kit).
4. Check function of sprag clutch on driven pulley.
- Sprag clutch is clogged and/or worn out (refer to CONTINUOUSLY VARIABLE TRANSMISSION).
Replace sprag clutch together with ball bearing and oil seal (refer to CONTINUOUSLY VARIABLE
TRANSMISSION).
Symptom: ENGINE MAXIMUM RPM IS TOO HIGH AND TOP SPEED IS NOT REACHED.
1. Check items 1 to 3 of THE ATV ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED.
2. Check driven pulley spring tension.
- Spring tension is too stiff. Replace spring (recommended BRP spring).
vmr2006-065 17
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
18 vmr2006-065
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
ENGINE GENERAL
Symptom: ENGINE BACKFIRES.
1. Check spark plug and/or electrical system.
- Carbon accumulation caused by defective spark plug. Clean carbon accumulation and replace
spark plug.
- Electrical system failure. Replace defective part(s).
2. Check leakage on intake manifold.
- Air leak on intake system. Retighten screws and/or replace intake manifold.
3. Check exhaust air leaking.
- Exhaust gasket is leaking. Retighten screws and/or replace exhaust gasket.
4. Check intake valve(s) for leaking.
- Intake valve(s) is (are) leaking. Repair or replace valve(s).
5. Check if fuel supply is to less at high RPM.
- Fuel line is contaminated and/or bent (engine gets lean). Clean and/or replace defective part(s).
vmr2006-065 19
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
Symptom: ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH
MAXIMUM OPERATING RPM.
1. Check items 1 and 2 of engine suddenly turns off.
2. Check air intake system.
- Air filter is clogged due to contamination. Replace air filter.
3. Check spark arrester.
- Spark arrester is clogged. Clean or replace spark arrester.
4. Check spark plug condition and/or gap.
- Fouled spark plug or wrong spark plug gap. Readjust gap and clean spark plug or replace.
5. Check spark plug type.
- Improper spark plug heat range. Install recommended spark plug (refer to TECHNICAL SPECI-
FICATIONS).
6. Perform engine leak test. Check for possible piston seizure.
- Damaged head gasket and/or seal and/or leaking inlet/exhaust valve(s). Replace and/or repair
defective parts.
20 vmr2006-065
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
Symptom: ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH
MAXIMUM OPERATING RPM. (cont’d)
7. Check for water in fuel (wrong fuel).
- There is water in fuel or wrong fuel. Drain fuel system, search for leakage and refill it with ap-
propriate fuel.
8. Check drive belt.
- Worn belt. Replace belt if width is less than specified (refer to CONTINUOUSLY VARIABLE
TRANSMISSION).
9. Check engine compression.
- Worn piston and/or piston ring(s). Replace (refer to PISTON AND CYLINDER).
STARTING SYSTEM
Symptom: STARTER DOES NOT TURN.
1. Proper combination of switches, brake and gearbox is not met.
- Refer to STARTING SYSTEM for engine starting requirements.
2. Burnt fuse.
- Check main fuse, 15 A fuse (ignition and shift gear control modules supply) and wiring condition.
vmr2006-065 21
Section 02 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
22 vmr2006-065
Section 03 ENGINE
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)
GENERAL
WARNING
Before performing any service or inspection
operation on the vehicle, wait until the engine
and exhaust have cooled down to avoid po-
tential burns.
WARNING
Always disconnect battery or starter cables
exactly in the specified order, BLACK (-) cable
first.
REMOVAL
Turn fuel valve to OFF.
Drain engine oil. Refer to LUBRICATION SYS-
TEM.
Remove seat.
Disconnect battery posts.
vmr2006-066-001_a
vmr2006-066 23
Section 03 ENGINE
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)
mmr2006-066-001_a
vmr2006-066-014_a
vmr2006-066-002_b
vmr2006-066-004_a
24 vmr2006-066
Section 03 ENGINE
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)
vmr2006-066-007_a
vmr2006-066-008_a
vmr2006-066-009_a
vmr2006-066_a
vmr2006-066-010_a vmr2006-066-012_a
Turn steering on RH side to make room. Carefully pull out engine from left side.
Install engine removal hook (P/N 529 035 829), in
engine hook and lift tool to support engine weight.
26 vmr2006-066
Section 03 ENGINE
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)
vmr2006-069-006_b
INSTALLATION
Installation is the reverse procedure of removal.
However, pay attention to the following.
Align shift lever dot with flat surface on shift shaft.
vmr2006-066-015_a
1. Dot
2. Flat surface
vmr2006-066 27
Section 03 ENGINE
Subsection 02 (ENGINE LEAK TEST)
GENERAL PROCEDURES
Before performing the engine leak test, verify the Preparation
following:
– clamp(s) tightness CAUTION: Perform leak down testing with the
engine cold. Introducing cold air into a hot en-
– radiator and hoses. gine can warp or fracture valves and/or other
engine parts.
Repair Tips
Disconnect battery. Refer to CHARGING SYS-
– Blue exhaust gas means damaged/worn piston TEM.
rings.
– Oily contamination on leak indicator hole (under Remove radiator cap located under front cover.
magneto cover) means a damaged oil seal on Unplug and remove spark plug cable.
water pump shaft. Remove spark plug from cylinder head.
– Coolant out of leak indicator hole means a dam- Remove CVT cover.
aged rotary seal on water pump shaft (refer to
COOLING SYSTEM). How to Position Piston at TDC
(compression)
NOTE: The engine must be set to precisely TDC
(compression); if this is not ensured the engine
will continue to rotate when pressure builds up.
– On right side of engine, remove the cylinder
head side cover.
vmr2006-071-011_a
vmr2006-067 29
Section 03 ENGINE
Subsection 02 (ENGINE LEAK TEST)
mmr2006-073-005_a mmr2006-073-008_a
vmr2006-067-001
Leak Test
Thread the correct adaptor hose of the leak down
mmr2006-073-006_a
tester (P/N 529 035 661) into the spark plug hole.
TCD MARK BESIDE THE T ALIGNED Do not connect the adaptor hose to the leak down
tester at this time.
– Check if marks are aligned on camshaft gear
as shown. Otherwise, continue turning drive
pulley until crankshaft and camshaft marks are
properly positioned.
30 vmr2006-067
Section 03 ENGINE
Subsection 02 (ENGINE LEAK TEST)
LEAKAGE ENGINE
PERCENTAGE CONDITION
0% to 15% Excellent condition
16% to 25% Good condition
Fair condition; engine
will run and in some
26% to 40%
cases, performance
might be affected
Poor condition, diagnose
41% and higher
and repair engine
Diagnosis
Listen for air leaks.
– air escaping from intake side means leaking in-
take valve(s)
– air escaping from exhaust side means leaking
exhaust valve(s)
– air bubbles out of radiator means leaking cylin-
der head gasket
– air/oil escaping from crankcase means dam-
aged gasket and/or loosened screws
– air/coolant escaping from cylinder/head means
damaged gasket(s) and/or loosened screws
– air escaping into crankcase area means exces-
sively worn cylinder and/or broken piston rings.
Reassembly
Reverse the preparation procedure. Ensure to
respect torque values and use of appropriate
products/lubricants. Refer to exploded views of
other sections as required.
vmr2006-067 31
Section 03 ENGINE
Subsection 03 (AIR INTAKE SYSTEM)
12 Nm
(106 lbfin) 12 Nm
(106 lbfin)
4 Nm
(35 lbfin)
Loctite 5150
(silicone sealant)
vmr2006-068-001_a
vmr2006-068 33
Section 03 ENGINE
Subsection 03 (AIR INTAKE SYSTEM)
GENERAL
If vehicle is used in dusty area, inspect more fre-
quently than specified in maintenance chart.
CAUTION: Do not start engine when liquid or
deposits are found in the drain tube. If you
have oil in the air filter housing, check engine
oil level. Maybe oil level is too high.
CAUTION: Never remove or modify any com-
ponent in the air filter housing. Otherwise, en-
gine performance degradation or damage can
occur. The engine carburetion is calibrated to
operate specifically with these components.
Disconnect battery before working on fuel sys-
tem. vmo2006-014-046_a
1. Clamp
WARNING 2. Retaining screw
vmo2006-014-045_a
34 vmr2006-068
Section 03 ENGINE
Subsection 03 (AIR INTAKE SYSTEM)
vmr2006-068-003_a
Removal
Unscrew clamp retaining air intake hose to carbu-
retor.
vmr2006-068-004_a
Installation
Properly reinstall removed parts in the reverse or-
der of their removal.
Apply Loctite 5150 (silicone sealant) (P/N 293 800
vmr2006-068-002_a
086) to air intake hose groove to seal the hose and
1. Air intake hose air filter housing.
2. Carburetor
Unscrew air intake duct clamp from air filter hous- AIR INJECTION VALVE FILTER
ing.
Removal
From the left side of vehicle, disconnect hoses
from air injection valve.
vmr2006-068 35
Section 03 ENGINE
Subsection 03 (AIR INTAKE SYSTEM)
vmo2006-014-066_b
vmo2006-014-073_a
Cleaning
Pour cleaning solution (P/N 219 700 341) or an
equivalent into a bucket. Put filters in to soak.
While filters soak, clean inside of air injection
valve.
Rinse filters with warm water until all cleaning so-
lution disappears.
NOTE: If filters are still dirty, replace them with
new ones.
Then, let filters dry completely.
Installation
Properly reinstall removed parts in the reverse or-
der of their removal.
36 vmr2006-068
Section 03 ENGINE
Subsection 04 (EXHAUST SYSTEM)
EXHAUST SYSTEM
vmr2006-069-001
vmr2006-069 37
Section 03 ENGINE
Subsection 04 (EXHAUST SYSTEM)
GENERAL
WARNING
Before performing any service or inspection
operation on the vehicle, wait until the engine
and exhaust have cooled down to avoid po-
tential burns.
WARNING
Always disconnect battery or starter cables
exactly in the specified order, BLACK (-) cable
first.
WARNING vmr2006-069-002_a
PROCEDURES
MUFFLER
Removal
Remove screws and pull out heat shield.
vmr2006-069-004_a
Inspection
Check part for cracks, rust or any other default.
Also check mounting bracket area.
Installation
Installation is the reverse procedure of removal.
EXHAUST PIPE
Removal
Remove muffler.
vmr2006-069-001_a
Remove retaining nuts from cylinder head then
Loosen muffler clamp. pull out exhaust pipe.
38 vmr2006-069
Section 03 ENGINE
Subsection 04 (EXHAUST SYSTEM)
vmr2006-069-005_a vmo2006-014-042_a
Installation
Installation is the reverse procedure of removal.
However, pay attention to the following.
Loosely install pipe and muffler before tightening
all parts. Torque exhaust pipe nuts first.
SPARK ARRESTER
All Models except Europe
The spark arrester must be periodically purged of
accumulated carbon.
WARNING vmo2006-013-006_a
vmr2006-069 39
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)
LUBRICATION SYSTEM
20 Nm
(15 lbfft)
15 Nm
(133 lbfin)
vmr2006-070-001_a
vmr2006-070 41
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)
1
vmr2006-070-002_a
ENGINE LUBRICATION
1. Oil strainer
2. Oil pump
3. Lubrication outlet
4. Connecting rod
5. Lubrication spray
6. Camshaft
7. Valve rocker arm
42 vmr2006-070
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)
The engine oil can be very hot. Wait until en- SAE 10W30
gine oil is warm. XP-S 10W40 Mineral Oil
(P/N 219 700 346)
During assembly/installation, use the torque val- SAE 15W40
ues and service products as in the exploded
views. SAE 20W50
Temperature Range
WARNING
50°C (122°F)
Torque wrench tightening specifications 40°C (104°F)
must strictly be adhered to. 30°C (86°F)
Locking devices (ex.: locking tabs, elastic 20°C (68°F)
stop nuts, self-locking fasteners, cotter pin, 10°C (50°F)
etc.) must be installed or replaced with new 0°C (32°F)
ones where specified. If the efficiency of - 10°C (14°F)
a locking device is impaired, it must be re- - 20°C (- 4°F)
newed. - 30°C (- 22°F)
Oil Viscosity
SAE 5W30 is recommended for all seasons.
However, during the hottest days of the summer
the BRP XP-S 10W40 mineral oil (P/N 219 700 346)
can be used.
NOTE: For improved overall performance and all vmo2006-007-013_a
vmr2006-070 43
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)
vmo2006-014-035_a
Oil Change
Oil is to be replaced and oil strainer cleaned at
the same time. Oil change should be done with
a warm engine.
WARNING vmo2006-014-036_a
The engine oil can be very hot. Wait until en- RH SIDE OF ENGINE
1. Oil strainer cover
gine oil is warm.
Remove oil strainer and spring.
Ensure vehicle is on a level surface.
To clean oil strainer, use a solvent then dry with
Remove dipstick. compressed air.
Clean the drain plug area.
Place a drain pan under the engine drain plug area.
WARNING
Always wear eye protector. Chemicals can
Unscrew drain plug. cause a rash break out and an injury to your
eyes.
44 vmr2006-070
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)
vmo2006-014-037_a
1. Cover
2. O-ring
3. Spring
4. Strainer
vmr2006-070-003_a
Reinstall oil strainer, spring, O-ring and torque cov- 1. Bypass hole
er to 15 N•m (133 lbf•in).
Verify drain plug washer condition and replace it if NOTE: If oil pressure is low (as per ENGINE OIL
necessary. PRESSURE), check ball of oil pressure relief valve
for contamination.
Clean washer area on engine and drain plug then
reinstall plug and torque it to 40 N•m (30 lbf•ft). Removal
Refill engine at the proper level with the recom- Drain engine oil.
mended oil.
Remove magneto cover. Refer to MAGNETO
NOTE: Engine oil quantity is written on the dip- AND STARTER DRIVE.
stick.
Remove circlip then spring and ball.
Start engine and let idle for a few minutes. Ensure
oil strainer and drain plug areas are not leaking. WARNING
Stop engine. Wait a while to allow oil to flow Spring is compressed and will go out with
down to crankcase then check oil level. Refill as some force.
necessary.
vmr2006-070-007_a
Inspection
vmr2006-070-004
Inspect and clean oil passages.
Remove circlip.
Check inner rotor and oil pump housing for pitting,
scratches or other damage.
Check side contact surface of rotor and friction
plate.
vmr2006-070-011_b
vmr2006-070-008
vmr2006-070-011_a
vmr2006-070-009
vmr2006-070-006_a
Assembly
Assembly is the reverse procedure of disassem-
bly. However, pay attention to the following.
Align indent on driving shaft with that of inner ro-
tor.
Install pump shaft and roller. Install pump housing
and align pins properly. vmr2006-070-005_a
vmr2006-070 47
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)
48 vmr2006-070
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)
COOLING SYSTEM
SERVICE TOOLS
Description Part Number Page
special radiator cap ............................................................... 529 035 991 ........................................... 52
water pump oil seal installer................................................. 529 036 052 ........................................... 57
SERVICE PRODUCTS
Description Part Number Page
Loctite 5910.......................................................................... 293 800 081 ........................................... 57
Loctite 592 (pipe sealant) .................................................... 293 800 018 ........................................... 55
vmr2006-071 49
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)
WATER PUMP
12 Nm
(106 lbfin)
vmr2006-071-001_a
50 vmr2006-071
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)
COOLING SYSTEM
Loctite 592
vmr2006-071-002_a
vmr2006-071 51
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)
GENERAL
The engine removal is not necessary when work-
ing on water pump, thermostat or thermo-switch.
Check general condition of hoses and clamp tight-
ness.
Air bubbles in radiator when engine is running in-
dicates a leaking engine gasket.
WARNING
In order to avoid getting burned, do not re-
move or loosen the radiator cap or the engine
drain plug when the engine is hot.
COOLING SYSTEM
INSPECTION
LEAK INDICATOR HOLE
Check the leak indicator hole if there is oil and/or
coolant and replace oil seals in water pump cover
if necessary (refer to WATER PUMP).
NOTE: Coolant leakage indicates a faulty seal on
impeller side and oil leakage indicates a faulty seal
on crankcase side.
vmr2006-071-010_a
52 vmr2006-071
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)
Coolant Level
Remove front cover. Refer to BODY.
WARNING
Check coolant level with engine cold. Never
add coolant in cooling system when engine is
hot.
vmr2006-066-002_a
vmo2006-014-022_a
vmr2006-071 53
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)
vmr2006-071-012_a vmr2006-071-013_a
Run engine until air bubbles have all escaped from Pull thermostat out.
bleed nipple.
Stop engine. Reinstall bleed tube.
Carefully remove radiator cap.
WARNING
Let engine cool down. Otherwise, coolant
under pressure will rush out and you might
get burned.
Run engine.
Ensure there is no air bubbles in coolant and that
level is stable. vmr2006-071-014
Stop engine.
Refill radiator as necessary.
Test
Visually inspect thermostat for damage.
Reinstall radiator cap.
Put thermostat in a container filled with coolant
Adjust coolant level in coolant reservoir.
and heat container. Use a suitable thermometer
to measure coolant temperature.
RADIATOR CAP
Test
Use a suitable pressure tester and check radiator
cap. It should stand a pressure of 76 - 103 kPa
(11 - 15 PSI) and release pressure above that val-
ue.
THERMOSTAT
Removal
Drain cooling system.
Remove thermostat retaining screws.
vmr2006-071-015
54 vmr2006-071
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)
Installation
Apply Loctite 592 (pipe sealant) (P/N 293 800 018)
on thermo-switch threads before installation.
Refill cooling system with recommended coolant.
Pressure test cooling system.
WATER PUMP
vmr2006-071-016
Disassembly
Refill cooling system. Ensure there is no leak. Drain cooling system.
Remove water pump cover.
THERMO-SWITCH
Removal
NOTE: The thermo-switch is located on RH bot-
tom of radiator.
Drain cooling system.
Unplug connector from thermo-switch.
vmr2006-066-002_d
vmr2006-071-007_b
Unscrew thermo-switch.
vmr2006-071 55
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)
vmr2006-072-002_a vmr2006-071-018
new ones.
Remove bearing circlip.
vmr2006-071-019_a
56 vmr2006-071
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)
vmr2006-071-020 vmr2006-071-022
Assembly
Assembly is the reverse of disassembly proce-
dure. However, pay attention to the following.
Apply Loctite 5910 (P/N 293 800 081) on mating
surface of seal with its bore.
Use water pump oil seal installer (P/N 529 036
052) to properly install mechanical seal.
CAUTION: Using an inappropriate pusher may
damage seal or may install seal inadequately.
vmr2006-071-020
vmr2006-071-021
vmr2006-071-023
vmr2006-071 57
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)
vmr2006-071-024
Install circlip.
vmr2006-071-027
vmr2006-071-025
vmr2006-071-026_a
58 vmr2006-071
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)
vmr2006-071-007_b
Fan should turn. If so, check thermo-switch and Disconnect top hoses from radiator.
wiring.
If fan does not turn, directly connect wires from a
12 Vdc battery to fan motor connector. If fan does
not turn, replace it. If it turns, check its fuse and
wiring.
Reconnect all connectors.
Replacement
Refer to RADIATOR.
RADIATOR
Removal
Drain cooling system.
Remove radiator shield. Refer to BODY.
Clean radiator with low pressure water and com-
pressed air as necessary. vmr2006-071-005_a
vmr2006-071 59
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)
vmr2006-071-007_a vmr2006-071-009_a
Assembly
Assembly is the reverse procedure of disassem-
bly.
Installation
Installation is the reverse procedure of removal.
However, pay attention to the following.
Refill and bleed cooling system with recommend-
ed coolant.
Pressure test cooling system.
vmr2006-071-008_a
vmr2006-071-008_b
10 Nm
(89 lbfin)
Loctite 243
55 Nm
(41 lbfft)
12 Nm
(106 lbfin)
vmr2006-072-001_a
vmr2006-072 61
Section 03 ENGINE
Subsection 07 (MAGNETO AND STARTER DRIVE)
GENERAL
Always disconnect battery.
WARNING
Always disconnect battery cables exactly in
the specified order, BLACK (-) cable first.
Locking devices (ex.: locking tabs, elastic Remove dowel pins and gasket.
stop nuts, self-locking fasteners, cotter pin,
etc.) must be installed or replaced with new
ones where specified. If the efficiency of
a locking device is impaired, it must be re-
newed.
PROCEDURES
MAGNETO COVER
Removal
Drain engine oil. Refer to LUBRICATION SYS-
TEM.
Drain engine coolant. Refer to COOLING SYS- vmr2006-072-020_a
TEM.
Disconnect coolant hoses. Inspection
Inspect bearing. See CRANKSHAFT END BEAR-
ING in this section.
Installation
Remove water pump cover.
Install dowel pins and a new gasket.
vmr2006-066-002_c
62 vmr2006-072
Section 03 ENGINE
Subsection 07 (MAGNETO AND STARTER DRIVE)
vmr2006-072-020_a
vmr2006-072-021_a
Install magneto cover.
Properly torque cover screws.
Pay attention to engage water pump shaft end
onto oil pump shaft. Turn coolant impeller as re- Reinstall water pump cover with a new gasket.
quired.
vmr2006-072-003_a
vmr2006-072-019_a
vmr2006-066-002_c
TRIGGER COIL
Test
Refer to IGNITION SYSTEM.
Removal
Remove magneto cover.
Remove trigger coil screws and pull trigger coil
out.
vmr2006-072-004_b
Installation
Install stator in magneto cover. Position wiring
harness in recess of crankcase.
CAUTION: Ensure to route wiring harness un-
der trigger coil.
vmr2006-072-004_a
Installation
Installation is essentially the reverse procedure of
removal. However, pay attention to the following.
If removed, install stator in magneto cover prior to
trigger coil.
STATOR
Test
Refer to CHARGING SYSTEM for the stator test. vmr2006-072-018_a
64 vmr2006-072
Section 03 ENGINE
Subsection 07 (MAGNETO AND STARTER DRIVE)
R610outi03A
Installation
Use an appropriate pusher to install magneto cov-
er bearing.
CAUTION: Always support cover properly
when installing bearing.
vmr2006-072-005_a Never use a hammer to install bearing. Use a
press only.
Removal Always heat cover housing up to 100°C (212°F)
Remove magneto cover. before installing bearing. Use a heat gun.
NOTE: It is not necessary to remove stator to re-
move bearing. WARNING
Always heat bearing bore up to 100°C (212°F) be- Clean oil, outside and inside, from housing
fore removing its bearing. Use a heat gun. before heating. Oil is inflammable.
vmr2006-072-005_a
vmr2006-072-008
vmr2006-072 65
Section 03 ENGINE
Subsection 07 (MAGNETO AND STARTER DRIVE)
vmr2006-072-017_a
vmr2006-075-025_b
vmr2006-072-010_a
Installation
Inspection
CAUTION: Before installing flywheel, ensure
taper is clean and free of grease. Check for wear and damage.
NOTE: Make sure starter reduction gear is in-
stalled first.
Install flywheel and align its keyway with woodruff
key on crankshaft.
66 vmr2006-072
Section 03 ENGINE
Subsection 07 (MAGNETO AND STARTER DRIVE)
vmr2006-072-016
Installation
Installation is essentially the reverse procedure of
removal. vmr2006-072-015_a
vmr2006-072-015_b
vmr2006-072-013_a
Firmly hold flywheel while turning starting clutch A. Inner diameter
gear counterclockwise. Gear must turn freely. B. Outer diameter
vmr2006-072 67
Section 03 ENGINE
Subsection 07 (MAGNETO AND STARTER DRIVE)
vmr2006-072-014 vmr2006-072-011_a
vmr2006-072-015
vmr2006-072-012_a
1. Retaining screws
2. One way clutch
3. Starting clutch
Installation
Install one way clutch on flywheel. Properly
torque screws.
68 vmr2006-072
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
CYLINDER HEAD
SERVICE TOOLS
Description Part Number Page
valve spring compressor clamp ............................................ 529 035 724 ..................................... 74, 80
valve spring compressor cup................................................ 529 035 764 ..................................... 74, 80
12 Nm
(106 lbfin)
12 Nm 38 Nm
(106 lbfin) (28 lbfft)
26 Nm
(19 lbfft)
12 Nm
(106 lbfin)
12 Nm
(106 lbfin) 11 Nm
(97 lbfin)
9 Nm
(80 lbfin)
11 Nm
(97 lbfin)
12 Nm
(106 lbfin)
vmr2006-073-001_a
vmr2006-073 69
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
VALVE CLEARANCE
ADJUSTMENT
NOTE: Engine temperature must be below 35°C
(95°F) to perform valve adjustment.
mmr2006-073-006_a
70 vmr2006-073
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
mmr2006-073-008_a
vmr2006-073-032_a
1. Adjusting screw
Adjustment 2. Lock nut
When marks are properly aligned, check valve
clearance with a feeler gauge. Turn adjustment screw as required.
NOTE: All valves can be adjusted in this position. When adjustment is appropriate, hold adjusting
screw while tightening locking nut.
VALVE CLEARANCE Recheck adjustment.
0.08 - 0.12 mm Reinstall cylinder head side cover.
INTAKE
(.003 to .005 in) NOTE: It is a good opportunity to check the engine
0.13 - 0.17 mm lubrication system. See ENGINE OIL PRESSURE
EXHAUST
(.005 - .007 in) in the LUBRICATION SYSTEM section.
Reinstall remaining removed parts.
Insert the appropriate thickness feeler gauge be-
tween valve stem end and rocker arm contact sur-
face.
CYLINDER HEAD REMOVAL
Clean engine.
Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION.
NOTE: Rocker arms can be removed when engine
is in vehicle.
Remove timing chain tensioner.
vmr2006-073-031
vmr2006-073 71
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
mmr2006-073-002_a mmr2006-073-004_a
Remove air injection system pipe and spark plug. Remove magneto access plug.
mmr2006-073-003_a
mmr2006-073-007_a
72 vmr2006-073
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
mmr2006-073-009_a
mmr2006-073-010_a
mmr2006-073-008_a
vmr2006-073 73
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
vmr2006-073-012_a
mmr2006-073-011_a
WARNING
Always wear safety glasses when disassem-
bling valve springs. Be careful when unlock-
ing valves. Components could fly away be-
cause of the strong spring preload.
vmr2006-073-011_b
74 vmr2006-073
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
R610motr121A
R610motr125A
vmr2006-073-017_a
1. Valve cotter
PARTS INSPECTION
Reed Valve
Remove reed valve from valve cover.
vmr2006-073 75
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
vmr2006-0-73-021_a
1. Bearing
vmr2006-073-050_a 2. Lobe
3. Bearing
Replace valve as necessary.
Measure cam lobe with a micrometer.
Cylinder Head
Check if spark plug and valve ports are cracked.
Check also between valve seats.
Measure cylinder head warpage with a straight
edge and a feeler gauge.
vmr2006-073-021_b
CAMSHAFT LOBE
DESCRIPTION INTAKE EXHAUST
34.880 mm 34.740 mm
vmr2006-020 New
(1.3732 in) (1.3677 in)
34.860 mm 34.725 mm
WARPAGE Service limit
(1.3724 in) min. (1.367 in) min.
Service limit 0.50 mm (.020 in)
If any component does not meet requirements,
Camshaft replace camshaft as a set with bearings.
Check each lobe of camshaft for scoring, scuffing, Rocker Arm
cracks or other signs of wear.
Inspect each rocker arm for cracks and scored
Manually turn each bearing to see if it turns freely, friction surfaces. Ensure lubrication hole is not
smoothly and noiselessly. Check for radial and plugged.
axial play.
Measure rocker arm bore diameter.
76 vmr2006-073
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
A
R610motr122A
vmr2006-073-023
vmr2006-073 77
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
Valve Guide
Clean valve guide with a 5 mm (.1968 in) reamer
to remove carbon deposits before measuring.
R610motr127A
TYPICAL
1. Valve seat
2. Valve stem
3. Valve face (contact surface to valve seat)
VALVE SEAT CONTACT WIDTH Measure each valve guide inner diameter at 3 dif-
ferent places.
Service limit 1.60 mm (.063 in)
vmr2006-073-025
78 vmr2006-073
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
Chain Tensioner
Check tensioner notches for damage.
Install spring and screw. Tensioner pusher should
go out.
Try to push in pusher. It must not go in. Other- vmr2006-073-029
wise, replace it. Position inner spring with its tightest coils against
cylinder head.
Position painted area of outer spring against valve
spring retainer.
vmr2006-073 79
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
vmr2006-073-027_a
WARNING vmr2006-073-012_a
Never remain facing valve springs end. You Install cylinder head and properly torque screws.
might be injured if case of tool failure.
vmr2006-073-011_b
vmr2006-073-028
80 vmr2006-073
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
vmr2006-073-034_a
1. Marks aligned
mmr2006-073-006_a
vmr2006-073-033_a
vmr2006-073-034_a
1. Marks aligned
mmr2006-073-010_a
– Install timing chain on sprocket then bring them
to camshaft aligning timing marks as shown.
vmr2006-073 81
Section 03 ENGINE
Subsection 08 (CYLINDER HEAD)
vmr2006-073-035
vmr2006-073-037
mmr2006-073-008_a
vmr2006-073-036
82 vmr2006-073
Section 03 ENGINE
Subsection 09 (PISTON AND CYLINDER)
12 Nm
(106 lbfin)
vmr2006-074-001_a
vmr2006-074 83
Section 03 ENGINE
Subsection 09 (PISTON AND CYLINDER)
GENERAL
When diagnosing an engine problem, always per-
form an engine leak test. This will help pinpoint a
problem. Refer to the instructions included with
your leak tester and ENGINE LEAK TEST section
for procedures.
Always place the vehicle on level surface.
Always disconnect the negative wire from the bat-
tery before working the engine.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
WARNING vmr2006-073-015_a
Torque wrench tightening specifications Remove cover crankcase opening with a clean
must strictly be adhered to. cloth.
Locking devices (ex.: locking tabs, elastic Remove piston pin circlips.
stop nuts, self-locking fasteners, cotter pin,
etc.) must be installed or replaced with new WARNING
ones where specified. If the efficiency of Piston ring circlips are spring loaded.
a locking device is impaired, it must be re-
newed.
Discard circlips.
When disassembling parts that are duplicated in Push piston pin out and remove piston.
the engine, (valves, springs, etc.), it is strongly
recommended to note their position and to keep
the parts of the same assembly as a “group”. If
you find a defective component, it will be much
easier to find the cause of the failure among its
group of parts (for example, if you found a worn
valve guide, a bent spring could be the cause; it
will be easy to know which one of the springs is
the cause and to replace it). Besides, since parts
are matched together, it is a good practice to rein-
stall parts in the same position.
Intake port/air filter contaminated (clogged) with
dirt, sand, etc. (leads to worn valves, piston rings
and finally to leak of power).
CAUTION: In case of piston rings and/or valve vmr2006-073-014
replacement, always clean the whole engine
and change oil. Clean piston pin from deposits using synthetic
abrasive woven.
DISASSEMBLY Remove gasket and dowel pins.
Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION.
Remove cylinder head. Refer to CYLINDER
HEAD.
Remove coolant hose then cylinder.
84 vmr2006-074
Section 03 ENGINE
Subsection 09 (PISTON AND CYLINDER)
vmr2006-073-016_a
vmr2006-074-008_a
1. Top
2. Center
3. Bottom
vmr2006-074-013
CYLINDER DIAMETER
Clean piston grooves.
Service limit 71.10 mm (2.799 in)
NOTE: A broken ring works well.
Clean piston from carbon deposits.
INSPECTION
Cylinder
Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder. If found,
replace cylinder.
Measure cylinder bore at 3 positions; top, center
and bottom. Measure along X and Y axis.
vmr2006-074 85
Section 03 ENGINE
Subsection 09 (PISTON AND CYLINDER)
vmr2006-074-050_a
vmr2006-074-020
A. 20 mm (.787 in) from top
CYLINDER WARPAGE
RING END GAP
Service limit 0.50 mm (.020 in)
0.15 - 0.30 mm
Top ring
(.006 - .012 in)
Replace cylinder if out of specifications.
0.30 - 0.45 mm
Nominal (new) 2nd ring
Piston Ring (.006 - .018 in)
Using a feeler gauge, measure top and second 0.20 - 0.70 mm
Oil ring
rings clearance with piston groove. (.008 - .028 in)
0.50 mm
Top ring
(.020 in)
Service limit 0.65 mm
2nd ring
(.026 in)
Oil ring —
Piston
Inspect piston for scoring, cracking or other dam-
ages. Replace piston as necessary.
Using a micrometer, measure piston as shown.
vmr2006-074-014
PISTON/RING CLEARANCE
0.015 - 0.050 mm
Nominal (new)
(.0006 - .020 in)
Service limit 0.09 mm (.004 in)
PISTON DIAMETER
70.430 - 70.480 mm
Nominal (new)
(2.773 - 2.775 in)
Service limit 70.380 mm (2.771 in)
vmr2006-074-010
PISTON PIN
16.994 - 17.000 mm
Nominal (new)
(.6691 - .6693 in)
Service limit 16.960 mm (.6677 in)
Connecting Rod
PISTON PIN BORE
Using a small diameter bore gauge, measure small
17.002 - 17.008 mm end connecting rod diameter.
Nominal (new)
(.6694 - .6696 in)
Service limit 17.020 mm (.6701 in)
Piston Pin
CONNECTING ROD SMALL END
Inspect piston pin for scoring, cracking or other
damages. 17.016 - 17.034 mm
Nominal (new)
Using a micrometer, measure piston pin diameter. (.6699 - .6706 in)
Service limit 17.06 mm (.6717 in)
vmr2006-074 87
Section 03 ENGINE
Subsection 09 (PISTON AND CYLINDER)
ASSEMBLY
Assembly is essentially the reverse procedure of
disassembly. However, pay attention to the fol-
lowing.
Carefully install piston ring with their openings on
piston as shown.
Install oil ring first then other rings going up.
Do not align ring openings with piston thrust side
axis or piston pin axis.
vmr2006-074-003_a
529036048
vmr2006-074-002_a
1. Oil scraper
2. 2nd ring
3. Top ring
88 vmr2006-074
Section 03 ENGINE
Subsection 09 (PISTON AND CYLINDER)
3 2
R175motr103B 5 vmr2006-074-006_a
vmr2006-074-007
vmr2006-074-005_a TYPICAL
CORRECT POSITION
1. Circlip opening Install remaining components.
2. Cutout
vmr2006-074 89
Section 03 ENGINE
Subsection 10 (CRANKSHAFT AND CRANKCASE)
12 Nm
(106 lbfin)
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
39 Nm
(29 lbfft)
vmr2006-075-020_a
vmr2006-075 91
Section 03 ENGINE
Subsection 10 (CRANKSHAFT AND CRANKCASE)
GENERAL 1 2
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (ex.: locking tabs, elastic
stop nuts, self-locking fasteners, etc.) must
be installed or replaced with new ones where
specified. If the efficiency of a locking device
is impaired, it must be renewed.
Oil Seals
NOTE: Oil seals can be replaced when engine is R175motr114A
CRANKCASE DISASSEMBLY
Remove the timing chain locking plate then chain.
1 2
Loosen the pivot bolt and remove the chain guide.
V06C2LA
TYPICAL
1. Oil seal in its housing
2. Awl or pick
92 vmr2006-075
Section 03 ENGINE
Subsection 10 (CRANKSHAFT AND CRANKCASE)
vmr2006-075-001_a
1. Locking plate
2. Chain guide
vmr2006-075-003_a
vmr2006-075-002_a
vmr2006-075-004
vmr2006-075 93
Section 03 ENGINE
Subsection 10 (CRANKSHAFT AND CRANKCASE)
vmr2006-075-005_a
INSPECTION
Crankshaft
NOTE: Crankshaft axial play is took up by a wave
washer. If washer is worn, replace with a new
one.
Use a feeler gauge and measure axial clearance of
connecting rod big end.
vmr2006-075-006_a
vmr2006-075-009_a
AXIAL CLEARANCE
New 0.10 - 0.40 mm (.004 - .016 in)
Service limit 0.60 mm (.024 in)
vmr2006-075-007
94 vmr2006-075
Section 03 ENGINE
Subsection 10 (CRANKSHAFT AND CRANKCASE)
vmr2006-075-010 vmr2006-075-025_a
Crankshaft Bearing
Manually turn the bearing to see if it turns freely,
smoothly and noiselessly. Check for radial and ax-
ial play.
vmr2006-075-009_b
A. 90 mm
B. 60 mm
CRANKSHAFT DEFLECTION
Service limit 0.10 mm (.004 in)
vmr2006-075 95
Section 03 ENGINE
Subsection 10 (CRANKSHAFT AND CRANKCASE)
vmr2006-075-015
vmr2006-075-013_a
CRANKCASE ASSEMBLY
Install wave washer into right half crankshaft bear-
ing seat.
vmr2006-075-016_a
vmr2006-075-014_a
vmr2006-075-017_a
96 vmr2006-075
Section 03 ENGINE
Subsection 10 (CRANKSHAFT AND CRANKCASE)
vmr2006-075-004
vmr2006-075-003_a vmr2006-075-019
Properly torque bolts on the right half crankcase. Install the chain guide and tighten the pivot bolt.
Properly torque bolt.
Install the timing chain.
Install the timing chain locking plate.
vmr2006-075-002_a
vmr2006-075 97
Section 03 ENGINE
Subsection 10 (CRANKSHAFT AND CRANKCASE)
vmr2006-075-001_a
1. Locking plate
2. Chain guide
98 vmr2006-075
Section 03 ENGINE
Subsection 11 (GEARBOX)
GEARBOX
SERVICE TOOLS
Description Part Number Page
countershaft needle bearing installer .................................. 529 036 053 ......................................... 105
SERVICE PRODUCTS
Description Part Number Page
synthetic grease ................................................................... 293 550 014 ......................................... 103
vmr2006-076 99
Section 03 ENGINE
Subsection 11 (GEARBOX)
40 Nm
(30 lbfft)
10 Nm
(89 lbfin)
28 Nm
(21 lbfft)
vmr2006-076-001_a
100 vmr2006-076
Section 03 ENGINE
Subsection 11 (GEARBOX)
GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin,
etc.) must be installed or replaced with new
ones where specified. If the efficiency of
a locking device is impaired, it must be re-
newed. vmo2006-014-039_a
vmr2006-076 101
Section 03 ENGINE
Subsection 11 (GEARBOX)
GEARBOX SWITCH If any test fail, check wiring and if good, replace
gearbox switch. Remove driven pulley to have
Disconnect gearbox switch connectors. access to switch. Refer to CONTINUOUS VARI-
ABLE TRANSMISSION.
NOTE: Also pay attention to shift drum contact pin
condition.
vmr2006-066-005_a
SHIFT LEVER
WIRE RESISTANCE
POSITION vmr2006-076-051_a
1 2
vmr2006-076-050_a V06C2LA
102 vmr2006-076
Section 03 ENGINE
Subsection 11 (GEARBOX)
vmr2006-066-004_a
R175motr114A
TYPICAL
1. Oil seal
2. Seal pusher
vmr2006-076-005_a
vmr2006-076-006
vmr2006-076 103
Section 03 ENGINE
Subsection 11 (GEARBOX)
vmr2006-076-007_a vmr2006-076-009_a
1. Spindle
2. Shift fork
Remove drive shaft towards inside of case.
3. Shift drum
vmr2006-076-010
vmr2006-076-008_a
Bearings
1. Output shaft All bearings must turn smoothly and freely.
2. Countershaft
3. Reverse shaft No excessive axial or radial play must be detected
during inspection.
Remove drive shaft bearing setting plate. Replace a defective or suspicious bearing with a
CAUTION: Do not remove drive shaft needless- new one.
ly. If removed, replace its bearing and seal. Always heat bearing bore up to 100°C (212°F) be-
fore removing its bearing. Use a heat gun.
WARNING
Clean oil, outside and inside, from case be-
fore heating. Oil is inflammable.
104 vmr2006-076
Section 03 ENGINE
Subsection 11 (GEARBOX)
F01J0ZA
vmr2006-076-004_a
vmr2006-076-003_a
R610outi03A
CAUTION: Always support crankcase properly CAUTION: Not using the appropriate pusher
when installing a bearing. will damage bearing.
Unless otherwise instructed, never use hammer
to install a bearing. Use a press only.
Always heat crankcase housing up to 100°C
(212°F) before installing bearing. Use a heat gun.
WARNING
Clean oil, outside and inside, from housing
before heating. Oil is inflammable.
vmr2006-076 105
Section 03 ENGINE
Subsection 11 (GEARBOX)
GEARBOX INSPECTION
Check shift spindle for wear or damage.
vmr2006-076-020_a
vmr2006-076-021_a
TYPICAL
A. Claw thickness
Check shift drum for wear or damage. B. Bore diameter
Push the contact pin. It must move freely and
remain in its housing. SHIFT FORK
CLAW BORE
CONDITION
THICKNESS DIAMETER
12.016 -
5.93 - 6.00 mm
New 12.043 mm
(.233 - .236 in)
(.4731 - .4741 in)
5.73 mm 12.01 mm
Service limit
(.226 in) min. (.473 in) max.
vmr2006-076-022_a
vmr2006-076-024_a
106 vmr2006-076
Section 03 ENGINE
Subsection 11 (GEARBOX)
vmr2006-076-027_a
GEARBOX ASSEMBLY
Assembly is essentially the reverse procedure of
disassembly. However, pay attention to the fol-
lowing.
Apply grease on seal lip of output shaft seal.
vmr2006-076-025_a
vmr2006-076-011_a
vmr2006-076-026_a
vmr2006-076-012_a
vmr2006-076 107
Section 03 ENGINE
Subsection 11 (GEARBOX)
vmr2006-076-013
vmr2006-076-014_a
vmr2006-076-016_a
108 vmr2006-076
Section 03 ENGINE
Subsection 11 (GEARBOX)
vmr2006-076-006 vmr2006-076-005_b
vmr2006-076-017_a
1. Align dots
vmr2006-076-018_a
SERVICE PRODUCTS
Description Part Number Page
cable lubricant....................................................................... 293 600 041 ................................. 120–121
vmr2006-077 111
Section 04 FUEL SYSTEM
Subsection 01 (CARBURETOR AND FUEL TANK)
12 Nm
(106 lbfin)
4 Nm
(35 lbfin)
vmr2006-077-001_a
112 vmr2006-077
Section 04 FUEL SYSTEM
Subsection 01 (CARBURETOR AND FUEL TANK)
CARBURETOR
vmr2006-077-002_a
vmr2006-077 113
Section 04 FUEL SYSTEM
Subsection 01 (CARBURETOR AND FUEL TANK)
GENERAL PROCEDURES
Before performing any repair on the fuel system,
always turn fuel valve to OFF position and discon- CARBURETOR
nect battery before working on fuel system. CAUTION: Although some jets can be replaced
by other jets from other carburetors, such
WARNING modifications should not be performed. They
Always disconnect battery exactly in the can greatly affect engine calibration and can
specified order, BLACK (-) cable first. It is cause severe damage to engine. Use only rec-
ommended jetting specific for this carburetor.
recommended to disconnect electrical con-
nections prior to disconnecting fuel lines. Removal
When draining a fuel tank or whenever a
fuel line is disconnected, obstruct line with Turn fuel valve to OFF.
a small hose pincher (P/N 295 000 076) or
equivalent device. Fuel is flammable and
explosive under certain conditions. Ensure
work area is well ventilated. Do not smoke
or allow open flames or sparks in the vicinity.
Locking devices (e.g.: locking tabs, elastic Unscrew the air intake hose from carburetor.
stop nuts, self-locking fasteners, cotter pin,
etc.) must be installed or replaced with new
ones where specified. If the efficiency of
a locking device is impaired, it must be re-
newed.
Fuel Lines
WARNING
Whenever working on fuel system, always
verify for water or dust infiltration in reser-
voir. Replace any damaged, leaking or dete- vmr2006-077-004_a
When replacing fuel lines, be sure to use hoses Loosen the choke cable retaining plate then re-
as available from BRP parts department. This will move choke cable from its lever.
ensure continued proper and safe operation.
WARNING
Use of improper fuel lines could compromise
fuel system integrity.
114 vmr2006-077
Section 04 FUEL SYSTEM
Subsection 01 (CARBURETOR AND FUEL TANK)
vmr2006-077-005_a
vmr2006-077-007_a
1. Choke cable retaining plate
2. Choke lever on carburetor Remove carburetor.
Install a small hose pincher (P/N 295 000 076) on Cleaning and Inspection
fuel line then disconnect the fuel line from carbu-
retor. The entire carburetor should be cleaned with a
general solvent and dried with compressed air be-
fore disassembly.
CAUTION: Heavy duty carburetor cleaner may
be harmful to the float material and to the rub-
ber parts, O-rings, etc. Therefore, it is recom-
mended to remove those parts prior to clean-
ing.
Carburetor body and jets should be cleaned in
a carburetor cleaner following manufacturer's
instructions.
WARNING
vmr2006-077-006_a
Solvent with a low flash point such as gaso-
1. Small hose pincher
line, naphtha, benzol, etc., should not be used
2. Fuel line as they are flammable and explosive.
vmr2006-077 115
Section 04 FUEL SYSTEM
Subsection 01 (CARBURETOR AND FUEL TANK)
Carburetor Adjustments
Float Level
Correct fuel level in float chamber is vital for maxi-
mum engine efficiency. To check for correct float
level proceed as follows:
– Remove carburetor.
– Turn the carburetor upside down and remove
float bowl.
vmr2006-077-009_a
TYPICAL
1. Gauge tips
2. “L” arm
A. Height
vmr2006-077-018_a
– Measure height between bowl seat and the GAUGE ALIGNED WITH MAIN JET
top edge of float arm. Use float level gauge
(P/N 529 035 520). To adjust height, bend the contact tab of float arm
– Keep float level gauge perfectly horizontal and until the specified height is reached.
in line with main jet hole. CAUTION: When adjusting contact tab, do not
Ensure that both float level gauge tips are properly pry on. This would apply pressure on needle
positioned on carburetor body and that “L” arm is and damage valve seat/needle.
leaning on float while compressing valve spring.
Refer to following photos for proper float level CARBURETOR FLOAT LEVEL ADJUSTMENT
gauge positioning. FLOAT LEVEL 14.8 mm (.5827 in)
Pilot Screw
Place vehicle on a level surface and apply parking
brake.
Turn the pilot screw clockwise until it sits lightly
then unscrew of 2 turns.
116 vmr2006-077
Section 04 FUEL SYSTEM
Subsection 01 (CARBURETOR AND FUEL TANK)
vmr2006-077-011_a vmr2006-077-006_a
vmr2006-077-012_a
1. Fuel valve
2. Fuel filter
vmr2006-077-011_b
Installation
1. Idle speed screw The installation is the reverse of the removal pro-
cedure.
Connect an exhaust analyze. Refer to manufactur-
er's instructions concerning the proper procedure. FUEL VALVE
The recommended CO value is 1.0~1.5%.
Make sure idle speed and CO are in the recom- Inspection
mended values when engine speed is stable. If To check if the valve works correctly, turn it to OFF
idle speed and CO values are fluctuating, repeat position and unplug from fuel valve, the fuel line
the adjustment procedures as described above. going to fuel filter.
FUEL FILTER
Removal
Turn fuel valve to OFF position.
Install a small hose pincher (P/N 295 000 076) on
fuel line then disconnect the fuel line from carbu-
retor.
vmr2006-077 117
Section 04 FUEL SYSTEM
Subsection 01 (CARBURETOR AND FUEL TANK)
vmr2006-077-012_a vmr2006-077-012_a
No fuel should leak from fuel valve in this position. Unscrew fuel valve from frame.
Turn fuel valve to ON to check if the valve works Unscrew bolts retaining the front of fuel tank to
properly. Close valve when fuel leaks from fuel frame.
valve.
Removal
Turn fuel valve to OFF position.
Install a small hose pincher (P/N 295 000 076) on
the main fuel line and on the reserve fuel line then
remove all hoses from fuel valve. Identify each
hose for reinstallation.
Remove screws securing the fuel valve to frame.
vmr2006-077-013_a
vmr2006-077-012_b
vmr2006-077-014_a
Installation
1. Fender bracket
For installation, reverse the removal procedure. 2. Fuel tank rear bolts
FUEL TANK Turn handlebar fully to right then lift up fuel tank
and remove it from the left side of vehicle.
Removal
Installation
Remove front fender. Refer to BODY.
For installation, reverse the removal procedure.
Turn fuel valve to OFF position.
Unplug fuel line (between filter and valve) from
fuel valve.
118 vmr2006-077
Section 04 FUEL SYSTEM
Subsection 01 (CARBURETOR AND FUEL TANK)
THROTTLE CABLE
Removal
WARNING
Ensure the key is turned OFF, prior to per-
forming the throttle cable removal.
vmr2006-083-006_a
Carburetor Side
Unscrew carburetor cover from the carburetor.
Compress the carburetor spring to expose the
throttle cable.
Push throttle cable forward out of the throttle
valve piston.
vmr2006-083-007
vmr2006-077 119
Section 04 FUEL SYSTEM
Subsection 01 (CARBURETOR AND FUEL TANK)
Installation
For installation, reverse the removal procedure.
Adjustment
WARNING
Ensure the key is turned OFF, prior to perform
the throttle cable adjustment.
Lubrication
The throttle cable must be lubricated with cable
lubricant (P/N 293 600 041) or an equivalent.
WARNING
Always use a silicone-based lubricant. Us-
ing another lubricant (like a water-based lu-
bricant) could cause the throttle lever/cable
vmo2006-014-052_a
sticking or stiffness.
TYPICAL
1. Throttle lever
To lubricate the throttle cable, remove cable from 2. Rubber protector
3. Cable adjuster
throttle lever and from carburetor. A. 1 to 3 mm (.039 to .118 in)
Install the cable luber (P/N 529 035 738) on cable.
Tighten lock nut and reinstall protector.
Insert the needle of lubricant can on cable luber
hole. With the transmission lever in NEUTRAL position,
start the engine. Check if the throttle cable is ad-
WARNING justed correctly by turning handlebar fully to the
Always wear eye protection and gloves when right and left. If the engine RPM increases, read-
lubricating cables. just the throttle cable or verify the cable routing.
WARNING
Always use a silicone-based lubricant. Us-
ing another lubricant (like a water-based lu-
bricant) could cause the throttle lever/cable
sticking or stiffness.
Installation
Install the choke cable by reversing the removal
procedure.
vmr2006-077-016_a
1. Choke cable
2. Choke lever
3. Multifunction switch
Align the choke cable end with the lever slot then
remove the cable.
vmr2006-077-017
vmr2006-077 121
Section 05 ELECTRICAL SYSTEM
Subsection 01 (CHARGING SYSTEM)
CHARGING SYSTEM
SERVICE TOOLS
Description Part Number Page
multimeter Fluke 111 ........................................................... 529 035 868 ......................................... 123
SERVICE PRODUCTS
Description Part Number Page
dielectric grease ................................................................... 293 550 004 ......................................... 126
GENERAL PROCEDURES
For best results, use the multimeter Fluke 111
(P/N 529 035 868).
STATOR
vmr2006-078-004_a Static Test: Continuity
1. Fan fuse removed (10 A) Disconnect magneto wiring harness connector.
2. 30 A fuse removed
Read current.
YL
YL
YL
vmr2006-078-005_a V07G05A
Read voltage.
124 vmr2006-078
Section 05 ELECTRICAL SYSTEM
Subsection 01 (CHARGING SYSTEM)
vmr2006-078-002_b Troubleshooting
(discharched or weak battery)
Set multimeter to .
– battery posts and/or cable terminal oxidized
Connect multimeter as follows.
– loose or bad connections
– faulty battery (does not keep a full charge)
– main fuse burnt, faulty voltage regulator/rectifi-
er or stator
– short circuit or battery drain (proceed with cur-
rent leakage test).
vmr2006-078 125
Section 05 ELECTRICAL SYSTEM
Subsection 01 (CHARGING SYSTEM)
vmr2006-078-003_a
126 vmr2006-078
Section 05 ELECTRICAL SYSTEM
Subsection 01 (CHARGING SYSTEM)
WARNING
Ensure to store battery in a safe place, out of
reach for children.
Installation
Reinstall battery in vehicle.
Properly secure retaining bracket.
Reconnect battery cables.
WARNING
Connect RED (+) cable first then BLACK (-) ca-
ble. Always connect RED (+) cable first.
vmr2006-078 127
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
IGNITION SYSTEM
SERVICE TOOLS
Description Part Number Page
digital/inductive type tachometer ......................................... 529 014 500 ......................................... 141
multimeter Fluke 111 ........................................................... 529 035 868 ......................................... 130
vmr2006-079 129
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
REPAIR PROCEDURES
Safety Precautions
WARNING
To prevent powerful electric shocks while
cranking engine, neither touch any electronic
ignition components (ignition coil, wire har-
ness, etc.) nor tester lead clips. Also make
sure that tester leads do not touch any metal-
lic object.
TROUBLESHOOTING
Ignition Problems 529 035 868
When dealing with ignition problems, the follow-
ing items should be checked in this order. After
one item has been checked and it is found not to
be the problem, continue with the next item:
130 vmr2006-079
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
FUSES Fouling
Check condition of main fuse and 15 A fuse (sup- Fouling of the spark plug is indicated by irregular
plying ignition module and shift gear control mod- running of the engine, decreased engine speed
ule). Replace burnt fuse as necessary. due to misfiring, reduced performance, and in-
creased fuel consumption. This is due to a loss
of compression. Other possible causes are: pro-
longed idling or low-speed riding, or running on a
too rich mixture due to abuse of choke, a clogged
air filter, a faulty carburetor adjustment, incorrect
fuel, defective ignition system, incorrect ignition
timing, incorrect spark plug gap, lubricating oil en-
tering the combustion chamber, or too cold spark
plug. The plug face of a fouled spark plug has ei-
ther a wet black deposit or a black carbon fouling.
Such coatings form a conductive connection be-
tween the center electrode and ground.
Analysis
vmr2006-078-001_b
1. Fuses
vmr2006-079 131
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
All Models
If test failed, perform the following tests.
Remove front cover. Refer to BODY.
Disconnect ignition switch connector with the
RED wire.
1 2
A00E0BA
1. Proper socket
2. Improper socket
BATTERY
At least 8 V is required for proper operation of the
ignition system (however 10.2 V is required for en-
vmr2006-079-004_a
gine starting). Check battery voltage and condi-
tion. Refer to CHARGING SYSTEM section. Measure voltage between RED supply wire and
battery ground.
IGNITION SWITCH
vmo2006-014-029_a
TYPICAL vmr2006-079-010_a
1. Ignition switch
2. OFF position
3. ON position (lights on) If reading is lower than battery voltage, test wiring
harness. If voltage is good, test switch.
Use a multimeter and measure the resistance be-
Test tween the following wires.
All Models except Europe
As a quick test to check if ignition key works prop-
erly, turn switch ON. If tail light turns on (assuming
bulb is good), ignition switch is good.
European Models
As a quick test to check if ignition key works prop-
erly, turn it ON. Press horn button. If horn sounds
(assuming it is good), ignition switch is good.
132 vmr2006-079
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
vmr2006-079-004_a
European Models
vmr2006-079 133
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
vmo2006-014-011_b vmr2006-079-012_a
TRIGGER COIL
vmr2006-079-009_a
134 vmr2006-079
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
vmr2006-079-013_a vmr2006-079-013_a
2. Use a multimeter and set it to . Read resis- 2. Use a multimeter and set it to Vac.
tance as follows. 3. Set engine stop switch to RUN.
4. Press START button.
NOTE: On European models, set transmission to
Neutral and press any brake while starting.
5. Read voltage as follows.
vmr2006-079-014_a
TRIGGER COIL
WIRE RESISTANCE
BLUE/YELLOW and vmr2006-079-014_b
446 - 545
GREEN/WHITE
TRIGGER COIL
Dynamic Test: Voltage WIRE RESISTANCE
1. Disconnect trigger coil connector.
BLUE/YELLOW and
0.4 and 0.7 Vac
GREEN/WHITE
Replacement
Refer to MAGNETO AND STARTER DRIVE.
vmr2006-079 135
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
IGNITION COIL
vmr2006-079-015_a
vmr2006-079-005_a
vmr2006-079-015
vmr2006-079-015_b
136 vmr2006-079
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
If there is no voltage, either wiring harness, elec- If resistance is good, continue tests. Otherwise,
tronic module or shift gear control module is faulty. replace ignition coil.
IGNITION MODULE
vmr2006-079-016_a
vmr2006-078-001_c
Test
NOTE: Bad grounding of ignition module through
its GREEN wire may cause engine misfire or a no
spark condition.
Disconnect ignition module connectors.
vmr2006-079-017_a
IGNITION COIL
TERMINALS RESISTANCE
GREEN terminal and
2.8 - 3.4 k
spark plug cable end
vmr2006-079-006_a vmr2006-079-018_b
vmr2006-079-018_a
IGNITION MODULE
2-PIN 3-PIN
VOLTAGE
CONNECTOR CONNECTOR
vmr2006-079-019_a
Battery
BLACK/WHITE GREEN BATTERY AND IGNITION MODULE GROUNDS
voltage
(CLOSE TO REAR BRAKE MASTER CYLINDER)
There should be battery voltage. If there is still no voltage, check shift gear sup-
Otherwise, measure voltage as follows. ply voltage (it provides power to ignition module).
See SHIFT GEAR CONTROL MODULE below.
When every other components above have been
tested and are good, ignition module can be sus-
pected. Ensure wiring and connectors are in good
condition prior to replacing it.
Removal
Remove seat.
Unplug connectors.
Slide module out of its retaining strap.
138 vmr2006-079
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
Installation
For the installation, reverse the removal proce-
dure.
vmr2006-079-022_a
vmr2006-079-022_b
Use a multimeter and set it to Vdc. If there is voltage, check module ground wire.
Read voltage as follows. If there is no voltage, wiring harness is faulty be-
tween battery and shift gear control module.
Reconnect connector.
Removal
Unplug connector.
Slide module out of its retaining strap.
vmr2006-079 139
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
Installation
For the installation, reverse the removal proce-
dure.
OVERRIDE SWITCH
NOTE: If engine RPM is not limited in reverse op-
eration, check GREEN/WHITE wire between gear-
box and ignition module.
vmr2006-076-052_a
OVERRIDE
WIRE SWITCH RESISTANCE
POSITION
Pressed and
WHITE/BLUE with 0.5 max.
held
GREEN wire
Released Infinite (0L.)
vmr2006-076-053_a
OVERRIDE
vmr2006-079-009_b
WIRE SWITCH RESISTANCE
POSITION
Using a multimeter, check switch as follows.
Pressed and
GREEN with battery 0.5 max.
held
ground
Released Infinite (0L.)
140 vmr2006-079
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
ADJUSTMENT
IGNITION TIMING
Ignition timing is not adjustable. However, its in-
tegrity can be checked to ensure components are
working properly.
Remove magneto access plug.
vmr2006-079-001_a
mmr2006-073-005_a
F01B1GA
Start engine.
Bring engine speed to 1600 RPM and ensure the
line besides “F” properly aligns using the timing
light.
vmr2006-079 141
Section 05 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)
STARTING SYSTEM
SERVICE TOOLS
Description Part Number Page
multimeter Fluke 111 ........................................................... 529 035 868 ......................................... 143
SERVICE PRODUCTS
Description Part Number Page
dielectric grease ................................................................... 293 550 004 ......................................... 147
GENERAL
Starting System Components Location
Engine Starting
The following conditions must be met to allow en-
gine cranking.
TESTING PROCEDURES
NOTE: Ensure to turn on the appropriate switches
to perform the tests.
FUSES
Make sure main fuse and 15 A fuse (supplying
ignition module and shift gear control module) are
in good condition. If fuses test good, continue
vmr2006-080-010_a
with next tests.
Use a multimeter and set it to Vdc.
Read voltage as follows.
vmr2006-078-001_b
1. Fuses
144 vmr2006-080
Section 05 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)
NOTE: On European models, ensure brake switch If switch tests good, check starting solenoid
is working properly. Refer to BRAKING SYSTEM. winding. See below. If winding tests good,
If voltage is good, continue testing. check power supply to shift gear control module.
Refer to IGNITION SYSTEM.
Remove front cover. Refer to BODY.
Reconnect switch connector.
Disconnect start switch connector with the
YELLOW/RED and YELLOW/BLACK wires.
STARTING SOLENOID
Inspect connections and clean as necessary.
vmr2006-079-009_a
vmr2006-080-010_a
vmr2006-080-012_a
START SWITCH
POSITION WIRE RESISTANCE
Switch
Infinite (0L.)
released
YELLOW/RED and
Switch YELLOW/BLACK
depressed 0.6 max.
and held
vmr2006-080 145
Section 05 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)
ELECTRICAL CABLES OR
CONNECTIONS
Check all connections, cables and wires. Tight-
en any loose connections. Replace any chafed
wires/cables.
If wiring and connectors are good, check the elec-
tric starter. See below.
ELECTRIC STARTER
Using booster cables, carefully supply current
from the battery directly to the starter. Connect
the RED (+) cable first. Then connect the remain-
ing jumper cable from the battery then to the
vmr2006-080-011_b
starter.
If starter turns ensure the cables/connections
SOLENOID CONNECTOR RESISTANCE from solenoid to starter are in good condition.
1 2 Approximately 4 If starter does not turn, replace starter.
WARNING
Always disconnect BLACK (-) cable first and
reconnect last.
vmr2006-080-010_b
146 vmr2006-080
Section 05 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)
WARNING
Always connect RED (+) cable first then
BLACK (-) cable last. Whenever connecting
the RED (+) cable to the starter motor, make
sure the battery cables are disconnected to
prevent electric shock.
vmr2006-066-001_b
vmr2006-080-001_a
Installation
Installation is the reverse of removal procedure.
However, pay particular attention to the following.
Make sure that starter and engine mating surfaces
are free of debris. Serious problem may arise if
the starter is not properly aligned. Tighten starter
screws.
Connect the RED (+) cable to the starter and tight-
en nut. Apply dielectric grease (P/N 293 550 004)
on terminal and nut.
First connect RED (+) cable to battery then con-
nect the BLACK (-) cable.
vmr2006-080 147
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmr2006-079-003_b
vmr2006-081 149
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
FUSES
vmr2006-081-004_a
A15E0KA
TYPICAL
1. Fuse
2. Check if melted
vmr2006-081-005_a
If a fuse is damaged, replace it with one of the
EUROPEAN MODELS
same rating.
CAUTION: Do not use a higher rated fuse as
this can cause severe damage.
150 vmr2006-081
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmr2006-081-003_a
vmr2006-081-004_b
vmr2006-081-006_a
vmr2006-081 151
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmr2006-081-003_a vmr2006-079-009_a
vmr2006-081-006_a
152 vmr2006-081
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmr2006-081-009_a
WHITE TERMINALS
vmr2006-081-008_a
vmr2006-081 153
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmr2006-081-008_a
vmr2006-081-009_a
WHITE TERMINALS
154 vmr2006-081
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
European Models
vmo2006-014-057_b
vmo2006-014-058_a
1. Bulb holder
2. Unlock (open)
1. Headlamp housing
3. Lock (close)
2. Beam height adjustment
vmo2006-013-007_b
vmr2006-081-010_a
FRONT
vmr2006-081 155
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmr2006-081-011_a
REAR
vmr2006-081-012_a
vmr2006-081-014_a
156 vmr2006-081
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
HAZARD CONTROL MODULE SUPPLY VOLTAGE HAZARD CONTROL MODULE SUPPLY VOLTAGE
WIRE COLOR VOLTAGE WIRE COLOR VOLTAGE
RED GREEN Battery voltage BLACK GREEN Battery voltage
vmr2006-081-014_b vmr2006-081-014_b
HAZARD CONTROL MODULE SUPPLY VOLTAGE HAZARD CONTROL MODULE SUPPLY VOLTAGE
WIRE COLOR VOLTAGE WIRE COLOR VOLTAGE
Battery Battery
RED Battery voltage BLACK Battery voltage
ground ground
If there is now voltage, check ground wire. If there is now voltage, check ground wire.
If there is no voltage, check wire from battery to If there is no voltage, check wire from ignition
module. switch to module. Also ensure ignition switch is
Check module power supply (switched) as fol- good. Refer to IGNITION SYSTEM.
lows. Input Signals from Ignition Switch to Module
Disconnect 6-pin connector. IMPORTANT: Ensure hazard switch is OFF.
Use a multimeter and set it to Vdc. Turn ignition switch on.
Turn ignition switch on. Activate turn signal switch and read voltage as fol-
Read voltage as follows. lows.
vmr2006-081-014_a
vmr2006-081-014_a
vmr2006-081 157
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmr2006-081-015_a
vmr2006-081-017_a
Remove front fender. Refer to BODY. If switch test failed, replace the auxiliary multi-
Unscrew retaining screw then pull out module. function switch. See STEERING AND FRONT
SUSPENSION.
Disconnect module.
Use a multimeter and set it to Vdc. Front Turn Signal Bulb Replacement
Activate indicator light switch and read voltage as Remove rubber protector then pull on rubber bulb
follows. housing to gain access to bulb.
Replace bulb.
TURN FLASHER MODULE INPUTS
SIGNAL (from hazard module)
SWITCH WIRE COLOR VOLTAGE
Left turn ORANGE
Pulsating battery
LIGHT GREEN
Right turn voltage
BLUE
vmo2006-014-065_a
vmo2006-014-067_a
POSITION LIGHT
European Models
Test
Remove steering cover. Refer to STEERING AND
FRONT SUSPENSION. vmo2006-014-069_a
160 vmr2006-081
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmo2006-014-070_a
1. Bulb housing
vmr2006-081-019_a
Validate light works.
If there is no voltage, check wire from battery to
PILOT LAMPS lamp socket.
If battery voltage is present, continue the follow-
Tests ing tests.
For all tests, turn ignition switch on. Check gearbox switch. Refer to GEARBOX.
Remove faulty bulb. See procedure below. If test succeeded, check suspected wire from
Activate proper switch so that suspected lamp gearbox switch connector to shift gear control
turns on (for example, set shift lever to neutral to module.
validate neutral switch).
Using a multimeter, measure voltage at socket ter-
minals. Battery voltage should be read.
vmr2006-066-005_a
vmr2006-081-019_b
vmr2006-081 161
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmr2006-079-008_a
PILOT LAMP
SWITCH FUNCTION WIRE COLOR
Forward BROWN/YELLOW If wire test failed, repair/replace wire as neces-
sary.
Neutral GREEN/RED
If wire tests good, try a new shift gear control
Reverse GREEN/WHITE module.
vmr2006-079-008_a
vmr2006-081-001_a
162 vmr2006-081
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmr2006-081-002
vmr2006-081-020_a
vmr2006-081-020_d
Apply directly 12 Vdc on GREEN/BLACK wire and If so, try a new module.
connect battery ground to the other wire.
Otherwise, measure voltage between WHITE/
Measure voltage at lamp socket. Battery voltage BLACK supply wire and battery ground. You
should be read. should read battery voltage.
vmr2006-081 163
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmr2006-081-020_e
164 vmr2006-081
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmr2006-081-021_a
TAIL LIGHT
WIRES VOLTAGE
BROWN GREEN Battery voltage
vmr2006-081-022_a
1
V06G0UA
1. Lens
2. Screws
vmr2006-081 165
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
HORN TERMINALS
HORN
SWITCH WIRE VOLTAGE
POSITION
Pressed LIGHT GREEN and Battery
and held GREEN wires voltage
vmr2006-081-022_b
166 vmr2006-081
Section 05 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS AND ACCESSORIES)
vmr2006-081-024_a
Removal
Unplug the connectors of the power outlet.
Unscrew the retaining nut.
Installation
Reverse the removal procedure.
vmr2006-081 167
Section 06 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))
CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)
SERVICE TOOLS
Description Part Number Page
blind hole puller kit................................................................ 529 036 056 ......................................... 172
driven pulley holding support................................................ 529 035 864 ......................................... 176
driven pulley support ............................................................ 529 035 863 ......................................... 176
driven pulley support tab kit ................................................. 529 036 047 ......................................... 176
pulley holder ......................................................................... 529 036 054 ......................... 172, 175–176
SERVICE PRODUCTS
Description Part Number Page
Isoflex grease ....................................................................... 293 550 021 ......................................... 178
pulley flange cleaner............................................................. 413 711 809 ................................. 174, 176
vmr2006-082 169
Section 06 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))
Isoflex grease
Isoflex grease
Isoflex
grease
95 Nm
(70 lbfft)
55 Nm
(41 lbfft)
Isoflex grease
4 Nm 9 Nm
(35 lbfin) (80 lbfin)
55 Nm
9 Nm (41 lbfft)
(80 lbfin)
4 Nm
(35 lbfin)
9 Nm
(80 lbfin)
vmr2006-082-001_a
170 vmr2006-082
Section 06 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))
WARNING
Never use any type of impact wrench at drive
pulley removal and installation.
WARNING R175motr31A
vmr2006-082 171
Section 06 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))
Removal
Remove CVT cover from engine.
Remove both screws retaining the bearing plate
vmr2006-082-002_a
to CVT cover.
vmr2006-082-004_a
Using the blind hole puller kit (P/N 529 036 056),
vmr2006-082-003_a remove the bearing from CVT cover.
NOTE: Remove the center top screw last. This
screw allows to support the cover during removal.
Pull CVT cover.
Inspection
Check CVT cover for cracks or other damages.
Replace if necessary.
Check if the gasket is brittle, hard or otherwise
damaged. Replace if necessary.
Check if the CVT cover bearing turns smoothly and
freely. Otherwise, replace it. See CVT COVER
BEARING below. vmr2006-082-023
Installation Installation
Install the gasket on CVT cover. Clean bearing area.
Install the CVT cover. Align the end of driven pul- Using a suitable pusher, install the new bearing
ley nut with the ball bearing. into CVT cover.
NOTE: Do not force the CVT cover to install it. Install CVT cover on engine.
Install the center top screw of cover in first.
DRIVE PULLEY
Install the other screws then torque them in a
crisscross sequence. Removal of Drive Pulley
Install CVT cooling hoses then torque clamps. Remove CVT cover.
Hold fixed sheave with the pulley holder (P/N 529
036 054). Remove drive pulley nut and thrust
washer then pull the fixed sheave.
172 vmr2006-082
Section 06 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))
2 1
vmr2006-082-024_a
1. Pulley holder
2. Fixed sheave of drive pulley
R175motr37A 3
TYPICAL
1. Ramp plate
2. Sliding shoes
3. Spacer
vmr2006-082-007
vmr2006-082-009_a
1. Roller
2. Contact surface to sliding shoes
3. Ramp for the rollers
vmr2006-082 173
Section 06 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))
Spacer
Check if the outer surface of spacer is worn or
damaged. Replace as required.
Measure the sliding sheave spacer. If the exter-
nal diameter is out of specification, replace as re-
quired.
R175motr39A 1
TYPICAL
1. Faces of drive pulley
Only use petrol base cleaner when cleaning bush- SLIDING SHEAVE SPACER
ings inside sliding sheave.
29.962 mm
CAUTION: Do not use acetone to clean bush- SERVICE LIMIT
(1.180 in)
ing.
Sliding Sheave
Inspection of Drive Pulley
Check sliding sheave for cracks and sliding con-
Drive pulley should be inspected annually. tact surface for excessive wear. Replace sliding
Roller sheave if necessary.
Check outer surface of rollers for roundness or flat Measure bushing diameters of sliding sheave.
surfaces. Replace as required. Use a dial bore gauge to measure bushing diame-
ter. Measuring point must be at least 5 mm (1/4 in)
from each bushing edge.
vmr2006-082-010_a
174 vmr2006-082
Section 06 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))
SLIDING SHEAVE BUSHING Insert slider shoes into ramp plate to properly slide
in guides of drive pulley sliding sheave.
30.060 mm
SERVICE LIMIT
(1.184 in) Installation of Drive Pulley
Replace sliding sheave if bushing(s) is(are) out of For installation, reverse the removal procedure.
specification. Visually inspect coatings. Pay attention to the following details.
R175motr44A 1 2
1. Splines on crankshaft PTO side
2. Drive pulley fixed sheave splines
1
1
1 2
vmr2006-082-012_a vmr2006-082-024_a
vmr2006-082 175
Section 06 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))
vmr2006-082-025_a
1. Pulley holder
2. Clutch drum vmr2006-082-015_a
1. Seal collar
Remove the clutch drum.
Remove the driven pulley with the drive belt. Using long nose pliers, remove guide pins with
their rollers.
Disassembly of Driven Pulley
Remove centrifugal clutch nut as per following
procedure.
Install the driven pulley support (P/N 529 035 863)
in a vise and place the driven pulley assembly on
it.
Replace tabs on the driven pulley holding support
(P/N 529 035 864) with the driven pulley support
tab kit (P/N 529 036 047).
Mount the holding support on driven pulley and
unscrew the centrifugal clutch nut.
vmr2006-082-016_a
176 vmr2006-082
Section 06 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))
vmr2006-082-018_a
A. Free length
2 1
R175motr50A
vmr2006-082 177
Section 06 TRANSMISSION
Subsection 01 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))
vmr2006-082-019_a
vmr2006-082-022_a
A. Outside diameter
178 vmr2006-082
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
SERVICE PRODUCTS
Description Part Number Page
Loctite 406 (glue).................................................................. 293 800 100 ......................................... 181
pulley flange cleaner............................................................. 413 711 809 ......................................... 181
synthetic grease XP-S........................................................... 293 550 010 ......................................... 187
vmr2006-083 179
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
20 Nm
(15 lbfft)
40 Nm
(30 lbfft)
33 Nm
(24 lbfft)
45 Nm 35 Nm
(33 lbfft) (26 lbfft)
90 Nm 45 Nm
(66 lbfft) (33 lbfft)
65 Nm
35 Nm (48 lbfft)
(26 lbfft)
49 Nm
(36 lbfft)
35 Nm
65 Nm 49 Nm (26 lbfft)
(48 lbfft) (36 lbfft)
vmr2006-083-001_a
180 vmr2006-083
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
GENERAL
During assembly/installation, use torque values as
in the exploded view.
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin,
etc.) must be installed or replaced with new
ones where specified. If the efficiency of
a locking device is impaired, it must be re- vmr2006-083-002_a
newed.
Remove CVT air inlet hose to reach multifunction
switch connectors.
PROCEDURES Unplug multifunction switch connectors.
Unscrew multifunction switch screws.
HANDLEBAR GRIP
Removal
The handlebar grips are glued on handlebar. Using
a knife, cut and remove handlebar grip.
Installation
Remove all rubber residues of the old grip before
installing the new.
Clean the handlebar with pulley flange cleaner
(P/N 413 711 809) or alcohol to remove any greasy
matter on it. vmr2006-083-003_a
MULTIFUNCTION SWITCH
Test
Refer to ELECTRICAL SYSTEM.
Removal
All Models except Europe
Remove front cover.
vmr2006-083 181
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
vmr2006-083-004_a
vmr2006-083-035_a
TYPICAL
1. Multifunction switch pin
Remove CVT air inlet hose to reach multifunction 2. Handlebar hole
switch connectors.
Unplug multifunction switch connectors.
Unscrew multifunction switch screws. AUXILIARY MULTIFUNCTION
SWITCH
European Models Only
Replacement
Remove front cover.
vmr2006-083-003_a
TYPICAL
1. Left brake lever
2. Choke lever
3. Multifunction switch screws
TANK.
Remove CVT air inlet hose to reach auxiliary
Installation switch connector.
For installation, reverse the removal procedure. Unplug auxiliary switch connector.
When installing multifunction switch, position the Unplug brake switch connectors from LH brake
switch by inserting the switch pin in the handlebar lever and remove screw retaining auxiliary switch
hole. to handlebar.
182 vmr2006-083
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
vmr2006-083-012_a
THROTTLE LEVER
Removal
Procedure for Handlebar Replacement
Unscrew throttle clamp.
vmr2006-083-007
1
Tighten adjustment screw to its maximum.
Using long nose pliers, disconnect throttle cable
from throttle lever.
V06i1CA
TYPICAL
1. Throttle clamp screws
vmr2006-083 183
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
MASTER CYLINDER
Refer to BRAKING SYSTEM.
HANDLEBAR
Removal
Procedure if Handlebar is not Replaced
All Models except Europe
Remove steering cover by unscrewing both retain-
ing screws.
vmr2006-083-009
vmr2006-083-011_a
V06i1CA
TYPICAL
1. Throttle clamp screws
Installation
For installation, reverse the removal procedure.
Make sure gasket inside cover is installed proper-
ly.
vmr2006-083-013_a
1. Handlebar bolt
2. Steering clamps
3. Steering cover support
vmr2006-083-010_a
1. Gasket
2. Throttle housing cover
TIE-ROD
Removal
Place the vehicle on jack stands and remove ap-
propriate front wheel.
Remove cotter pin, nut and tie-rod assembly. Dis-
card cotter pin and nut.
vmr2006-083-005_a
vmr2006-083-014_a
vmr2006-083-043_a
1. Handlebar bolt
2. Washer
3. Steering clamp
vmr2006-083 185
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
Installation
For the installation, reverse the removal proce-
dure.
Install a new nut and a new cotter pin. Both ends
of cotter pin must be folded.
Perform a steering adjustment. See further in this
section.
STEERING COLUMN
vmr2006-083-028_a
vmr2006-083-026_a
1. Holder
vmr2006-083-029
Unlock locking tabs from steering bolts.
Move steering column upward to separate steer-
ing column from steering column bearing.
Rotate steering column 1/2 turn then pull it be-
tween A-arm and frame.
vmr2006-083-027_a
1. Locking tabs
2. Steering bolt
Inspection
Inspect steering column for damage, cracks or
bending, replace if any problem is detected.
Check bearing at the end of steering column. The
bearing should turns smoothly and freely.
186 vmr2006-083
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
Installation
For the installation, reverse the removal proce-
dure.
Apply synthetic grease XP-S (P/N 293 550 010) on
both seals when installing half housings.
Install a new cotter pin. Both ends of cotter pin
must be folded.
vmr2006-083-032
vmr2006-083-026_a
vmr2006-083-033
vmr2006-083-027_a Installation
1. Locking tabs For installation, reverse the removal procedure.
2. Steering bolt
To install the bearing, use the following items:
Loosen steering bolts. – bolt M8
Separate tie-rods from steering column. – nut M8
Remove cotter pin and steering nut. – washer (P/N 224 081 301)
Lift up the steering column until it is free from – large washer (P/N 517 302 322).
bearing.
Remove seal.
vmr2006-083 187
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
vmr2006-083-034_a
1. Washer
2. Large washer
vmr2006-083-021
WHEEL BEARING
Inspection
To verify the wheel bearings, the wheel hub re-
moval is necessary.
vmr2006-083-019_a
Turn each bearing with a finger. The bearings
Remove caliper from knuckle (refer to BRAKING must turn smoothly and freely. Replace bearings
SYSTEM). Place it on lower A-arm. if necessary.
Remove and discard the cotter pin.
Removal
Unscrew the castle nut then remove the washer.
Remove wheel hub from vehicle.
Remove seals on both sides.
Using a blind hole puller, extract the outer bearing.
Remove the inner spacer.
Turn hub upside down and remove the inner bear-
ing.
Installation
CAUTION: Never reuse bearings. Always re-
place both bearings at the same time.
vmr2006-083-020_a
Push the inner bearing and its seal.
1. Cotter pin Turn hub upside down and install the inner spacer.
2. Castle nut
3. Washer Install the outer bearing and its seal.
Reinstall all other removed parts.
188 vmr2006-083
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
Removal
NOTE: Front wheel removal is not necessary to
remove a front shock absorber.
Lift front of vehicle until front shock absorbers
are fully extended. Install jack stands under the
frame.
Remove the lower bolt that attach shock absorber
to lower A-arm.
vmr2006-083-015_a
KNUCKLE SIDE
1. Cotter pin
2. Nut
3. Knuckle
vmr2006-083-036_a
vmr2006-083-025_a
Installation vmr2006-083-037_a
vmr2006-083 189
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
Disassembly Inspection
To remove spring from the shock absorber, use Inspect the spring for damage. Replace if neces-
the shock/spring remover (P/N 529 036 007). sary.
Inspect shock for oil leakage. Extend and com-
press the shock several times over its entire
stroke. Check that it moves smoothly and with
uniform resistance with rod up. Any of the fol-
lowing conditions will denote a defective shock:
529036007
– A skip or hang up when reversing stroke at mid
travel.
Place the tool in a vise. – Seizing or binding conditions except at extreme
end of either stroke.
– A gurgling noise after completing one full com-
pression and extension stroke.
Replace shock if any of these conditions are
found.
vmr2006-026-004
Position the shock absorber in the tool and install Assembly and Installation
the spring compressor pins. For assembly and installation, reverse the disas-
sembly and removal procedures.
LOWER A-ARM
Inspection
Before removing A-arm, do the following:
– Move A-arm from side to side. There should
be no noticeable looseness. Replace A-arm if
necessary.
– Move A-arm up and down. There should be no
noticeable looseness. Replace A-arm if neces-
sary.
vmr2006-026-010 Check lower A-arms for distortion or damage. Re-
place as required.
Tighten the shock spring remover screw until the
spring is sufficiently compressed to remove spring Check rubber bushings for excessive wear, cracks
locking devices. or other damages. Replace A-arm if necessary.
Remove spring stopper and its cap then release Check ball joint bellows for cracks or any other
the shock spring remover screw. damage. Replace A-arm if necessary.
Inspect ball joint end for damage. Ensure it's mov-
ing freely. Replace A-arm if necessary.
Removal
NOTE: Use the same procedure to remove RH or
LH A-arm.
Lift front of vehicle and place jack stands under
frame.
Remove appropriate wheel.
Remove the lower bolt of shock absorber.
vmr2006-026-011
190 vmr2006-083
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
vmr2006-083-036_a
vmr2006-083-039_a
vmr2006-083-040_a
vmr2006-083-015_a
1. Lower A-arm
KNUCKLE SIDE 2. Bolts and nuts
1. Cotter pin 3. Upper A-arm
2. Nut
3. Knuckle Remove A-arm from vehicle.
Remove the lower ball joint nut. Installation
NOTE: Install all bolts before torquing them.
Position A-arm on frame, then install bolts and
nuts.
Insert ball joint end into knuckle and install ball joint
nut.
Install shock absorber bolt.
Torque all bolts.
TORQUE
A-arm bolts 49 N•m (36 lbf•ft)
vmr2006-083-038
Shock
45 N•m (33 lbf•ft)
Separate lower ball joint from knuckle. absorber bolt
Remove screws holding brake hose to lower 49 N•m (36 lbf•ft)
A-arm. Further tighten until one of its
Ball joint nut grooves is aligned with a cotter pin
hole. Install a new cotter pin. Both
ends of cotter pin must be folded.
vmr2006-083 191
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
UPPER A-ARM
Inspection
Before removing A-arm, do the following:
– Move A-arm from side to side. There should
be no noticeable looseness. Replace A-arm if
necessary.
– Move A-arm up and down. There should be no
noticeable looseness. Replace A-arm if neces-
sary.
Check lower A-arms for distortion or damage. Re-
place as required. vmr2006-083-041
Check rubber bushings for excessive wear, cracks Remove bolts retaining A-arm to frame.
or other damages. Replace A-arm if necessary.
Check ball joint bellows for cracks or any other
damage. Replace A-arm if necessary.
Inspect ball joint end for damage. Ensure it's mov-
ing freely. Replace A-arm if necessary.
Removal
NOTE: Use the same procedure to remove RH or
LH A-arm.
Lift front of vehicle and place jack stands under
frame.
Remove appropriate wheel. vmr2006-083-042_a
Installation
NOTE: Install all bolts before torquing them.
Position A-arm on frame, then install bolts and
nuts.
Insert ball joint end into knuckle and install ball joint
nut.
vmr2006-083-015_a
Torque all bolts.
KNUCKLE SIDE
1. Cotter pin
2. Nut TORQUE
3. Knuckle
A-arm
49 N•m (36 lbf•ft)
Remove upper ball joint nut. bolts
49 N•m (36 lbf•ft)
Further tighten until one of its
Ball joint
grooves is aligned with a cotter pin
nut
hole. Install a new cotter pin. Both
ends of cotter pin must be folded.
192 vmr2006-083
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
ADJUSTMENT
STEERING ALIGNMENT
Toe-In Adjustment
Place vehicle on a level surface (wheels on
ground).
Check that handlebar is straight. Attach handlebar
to make sure it does not move during adjustment.
Check pressure in each tires. Always follow rec-
ommended pressure.
Place a rope around the vehicle and using an elas- vmr2006-083-046
tic, link both ends together.
Then, bring the rope back until it touches the spac-
Install spacers on rear rims. These spacers will
er.
prevent the rope from touching tire.
vmr2006-083-044_a
TYPICAL vmr2006-083-047
1. Rear rim
2. Spacers Keep this position and measure the distance be-
tween rope and rim. To the front and to the rear
NOTE: Different items can be used as spacers, of wheel.
like magnets (recommended).
The rope must be placed at the center of the
wheels. Do not place rope on tire threads.
vmr2006-083-048
FRONT DISTANCE
vmr2006-083-045
vmr2006-083 193
Section 07 STEERING AND FRONT SUSPENSION
Subsection 01 (STEERING AND FRONT SUSPENSION)
vmr2006-083-049
REAR DISTANCE
194 vmr2006-083
Section 08 REAR SUSPENSION AND AXLE
Subsection 01 (REAR SUSPENSION AND AXLE)
SERVICE PRODUCTS
Description Part Number Page
Loctite 271 (red) ................................................................... 293 800 005 ......................................... 203
Loctite 277 (green) ............................................................... 293 800 073 ......................................... 203
suspension synthetic grease ................................................ 293 550 033 ................. 201–203, 205, 207
vmr2006-084 195
Section 08 REAR SUSPENSION AND AXLE
Subsection 01 (REAR SUSPENSION AND AXLE)
45 Nm
(33 lbfft)
Suspension
synthetic
grease
Suspension
synthetic
grease
12 Nm
12 Nm (106 lbfin)
(106 lbfin)
Suspension
synthetic
grease
40 Nm
(30 lbfft)
130 Nm
27 Nm 27 Nm (96 lbfft)
(20 lbfft) (20 lbfft)
50 Nm
(37 lbfft)
Loctite 271
29 Nm
Suspension (21 lbfft) Loctite
synthetic 277
grease Loctite
271 Suspension
synthetic
grease Suspension
synthetic
grease
140 Nm
(103 lbfft)
vmr2006-084-001_a
196 vmr2006-084
Section 08 REAR SUSPENSION AND AXLE
Subsection 01 (REAR SUSPENSION AND AXLE)
GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic vmr2006-084-003_a
stop nuts, self-locking fasteners, cotter pin,
TYPICAL
etc.) must be installed or replaced with new 1. Lower bolt
ones where specified. If the efficiency of
a locking device is impaired, it must be re- Remove shock absorber.
newed.
Disassembly
After a repair is completed, ride vehicle for a few To remove spring from the shock absorber, use
minutes to verify the following. Axle is not loose, the shock/spring remover (P/N 529 036 007).
drive chain adjustment, chain is not rubbing on any
part or making noise, rear brake operates correct-
ly, etc.
PROCEDURES
REAR SHOCK 529036007
vmr2006-026-010
vmr2006-084 197
Section 08 REAR SUSPENSION AND AXLE
Subsection 01 (REAR SUSPENSION AND AXLE)
vmr2006-026-011
Inspection vmo2006-014-048_a
DRIVE CHAIN
Adjustment
NOTE: Never adjust drive chain with the driver
seated on the vehicle. Remove all load on vehicle.
Select a level surface and set transmission to
NEUTRAL.
Loosen chain tensioner lock bolts and caliper sup-
port bolt.
vmr2006-084-004_a
TYPICAL
1. Drive chain
2. Adjuster lock
3. Sprocket hub
4. Chain tensioner
198 vmr2006-084
Section 08 REAR SUSPENSION AND AXLE
Subsection 01 (REAR SUSPENSION AND AXLE)
V06H06A
Inspection
Check the deflection of drive chain and adjust if
necessary. Replace drive chain when adjustment
can not be reached with the chain tensioner.
Check for damage or missing O-ring or rollers.
Clean the side surfaces of the chain with a dry 1. Locking clip
2. Removable link
cloth.
NOTE: Do not brush chain. Remove locking clip, master link and O-rings.
Lubricate only with an approved O-ring chain lubri- Remove drive chain.
cant. Other commercial chain lubricants may con-
tain solvent which could damage the O-rings. Installation
NOTE: When changing drive chain, always replace
Removal sprockets at the same time to prevent rapid chain
Lift the rear of vehicle and install jack stands under and sprocket wear.
frame to support the rear of vehicle off the ground. The installation is the reverse of the removal pro-
Remove drive chain protector. cedure. However, pay attention to the following.
Use the following illustration to position the lock-
ing clip correctly.
vmr2006-084 199
Section 08 REAR SUSPENSION AND AXLE
Subsection 01 (REAR SUSPENSION AND AXLE)
vmr2006-084-007_a
ENGINE SPROCKET
V02H02A
Removal 1. Good
Remove drive chain protector. 2. Replace
Installation
The installation is the reverse of the removal pro-
cedure.
AXLE SPROCKET
Removal
vmr2006-084-005_a
Lift the rear of vehicle and install jack stands under
Loosen drive chain. frame to support the rear of vehicle off the ground.
Remove screws of engine sprocket locking plate. Remove RH rear wheel.
Loosen drive chain.
Unfasten nuts retaining axle sprocket to sprocket
hub.
vmr2006-084-008_a
1. Screws
2. Engine sprocket locking plate
3. Engine sprocket
200 vmr2006-084
Section 08 REAR SUSPENSION AND AXLE
Subsection 01 (REAR SUSPENSION AND AXLE)
Inspection
Check the axle sprocket for distortion, excessive
wear or other damages.
vmr2006-084-010_a
2 1. Cotter pin
2. Castle nut
3. Wheel hub
Installation Installation
The installation is the reverse of the removal pro-
For installation, reverse the removal procedure.
cedure. Pay attention to the following.
WHEEL HUB Apply suspension synthetic grease (P/N 293 550
033) on splines before installing hubs.
Removal Torque castle nut to 135 N•m (100 lbf•ft) and fur-
Lift the rear of vehicle and install jack stands under ther tighten until one of its grooves is aligned with
frame to support the rear of vehicle off the ground. a cotter pin hole.
Apply parking brake. Install a new cotter pin. Both end of cotter pin
must be folded.
Remove appropriate wheel.
Remove and discard the cotter pin. BRAKE DISC HUB
Removal
Remove the LH wheel hub. Refer to WHEEL HUB
above.
Using a pair of rear axle key (P/N 529 036 046),
unscrew axle nuts.
vmr2006-084 201
Section 08 REAR SUSPENSION AND AXLE
Subsection 01 (REAR SUSPENSION AND AXLE)
Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Apply suspension synthetic grease (P/N 293 550
033) on splines before installing hub.
Torque each axle nuts to 140 N•m (103 lbf•ft).
REAR AXLE
Removal
vmr2006-084-011 Lift the rear of vehicle and install jack stands under
Release parking brake and unscrew bolts that re- frame to support the rear of vehicle off the ground.
tain caliper to its bracket. Remove both wheel hubs. Refer to WHEEL HUB
above in this section.
Loosen drive chain and remove chain from axle
sprocket.
vmr2006-084-012_a
1. Caliper bolts
Inspection
Check axle for bending, torsion or other damage.
Replace if necessary.
Check axle for rust. Rust indicates a possible
vmr2006-084-013_a
damage to axle. Replace it.
If bearings are seized on the axle, it must be
Inspection cleaned, inspected and replaced if necessary.
Check hub for cracks or other damages. Replace The bearings must still have a slide fit on the axle,
it if necessary. otherwise it will result in a faulty reassembly and
a failure may occur. Bearing races on the axle
Check splines of hub for wear or damages. Re- must be in good condition.
place hub if necessary.
If the sprocket hub has been damaged, replace it
also.
202 vmr2006-084
Section 08 REAR SUSPENSION AND AXLE
Subsection 01 (REAR SUSPENSION AND AXLE)
SPROCKET HUB
Removal
Remove rear axle from vehicle.
vmr2006-084-031_a
Unscrew axle sprocket bolts and remove sprock-
1. Sprocket hub spacer
et. 2. O-ring
Remove the sprocket hub spacer.
Installation
The installation is the reverse of the removal pro-
cedure. Pay attention to the following.
Apply Loctite 271 (red) (P/N 293 800 005) on
sprocket hub splines.
The flat side of sprocket hub must be pointed to-
ward the circlip on the axle. In this position, studs
are pointed outside.
Apply suspension synthetic grease (P/N 293 550
vmr2006-084-015_a
033) on O-ring inside sprocket hub spacer.
1. Sprocket hub spacer Install sprocket hub spacer with the machined side
toward hub.
Heat hub to break the threadlocker. Using an ham-
mer, remove hub from axle. Strike on each branch
of hub. If the hub is seized on axle, use a press
with a pipe to push hub.
vmr2006-084-017_a
1. Machined side
vmr2006-084-016
CHAIN TENSIONER
Inspection Removal
Check hub splines for wear or damages. If splines Remove rear axle. See procedure above.
are defective, change hub. Remove the circlip retaining caliper support to the
Check hub branches for straightness. If a branch chain tensioner.
is bent or distorted, replace hub.
vmr2006-084 203
Section 08 REAR SUSPENSION AND AXLE
Subsection 01 (REAR SUSPENSION AND AXLE)
vmr2006-084-021_a
vmr2006-084-019_a
Remove seal.
Slide out chain tensioner from the right side of the
swing arm.
NOTE: Dirt between swing arm and chain ten-
sioner may cause resistance during removal pro-
cedure. If required, use a soft hammer to strike on
the chain tensioner or a pry bar to open the swing
arm split.
vmr2006-084-022
Remove spacer.
vmr2006-084-020_a
Inspection
The rear axle should turn smoothly and freely in-
side chain tensioner. Replace bearings if a prob-
lem is detected.
204 vmr2006-084
Section 08 REAR SUSPENSION AND AXLE
Subsection 01 (REAR SUSPENSION AND AXLE)
Assembly
To install new bearings, use the crankcase support
sleeve tool (P/N 529 036 031) to push them in the
chain tensioner. Do not forget the inner sleeve
when installing the second bearing.
vmr2006-084-023
vmr2006-084-032_a
SWING ARM
Lubrication
The swing arm's lubrication is necessary. Lubri-
cate it with suspension synthetic grease (P/N 293
550 033).
Removal
Lift rear of vehicle until rear shock absorber is fully
extended.
Install jack stands under the frame to support the
vmr2006-084-025_a
vehicle.
1. Bearing
2. Inner sleeve Procedure With Rear Axle Installed
3. Window
Remove the lower bolt of shock absorber.
Turn chain tensioner upside down. Reinstall the
inner sleeve with the windows on top and use
the same procedure as above to remove the other
bearing.
Discard seals, bearings and inner sleeve.
vmr2006-084 205
Section 08 REAR SUSPENSION AND AXLE
Subsection 01 (REAR SUSPENSION AND AXLE)
vmr2006-084-003_a
1. Lower bolt
vmr2006-084-027
vmr2006-084-028
EUROPEAN MODELS
vmr2006-084-028
Assembly
Press new bushings into swing arm.
Insert swing arm shaft.
Install new seals on both ends of swing arm.
vmr2006-084-026
Installation
Remove swing arm bolt. For installation, reverse the removal procedure.
Remove swing arm. Position drive chain on the front part of swing arm
then install swing arm.
Disassembly
NOTE: Check if the swing arm moves freely.
Remove seals on both ends of swing arm.
Grease swing arm pivot with suspension synthetic
grease (P/N 293 550 033).
Install all removed parts.
vmr2006-084-029_a
vmr2006-084-030_a
Inspection
Check swing arm for distortion, rust, cracks, bend
or other damages. Change if necessary.
vmr2006-084 207
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
SERVICE PRODUCTS
Description Part Number Page
GTLMA brake fluid................................................................ 293 600 062 ................................. 212, 225
suspension synthetic grease ................................................ 293 550 033 ................................. 219, 232
vmr2006-085 209
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
35 Nm
(26 lbfft)
5 Nm
(44 lbfin)
9 Nm
(80 lbfin)
9 Nm 35 Nm
(80 lbfin) (26 lbfft)
9 Nm
(80 lbfin)
5 Nm
(44 lbfin) 35 Nm 27 Nm
(26 lbfft) (20 lbfft)
9 Nm
(80 lbfin)
27 Nm
(20 lbfft)
vmr2006-085-001_a
210 vmr2006-085
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
REAR BRAKE
35 Nm
(26 lbfft)
35 Nm
(26 lbfft)
9 Nm
(80 lbfin)
35 Nm 9 Nm
(26 lbfft) (80 lbfin)
5 Nm
(44 lbfin)
9 Nm
(80 lbfin)
27 Nm
(20 lbfft) 5 Nm
(44 lbfin)
15 Nm
(133 lbfin)
27 Nm
(20 lbfft)
vmr2006-085-002_a
vmr2006-085 211
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins,
etc.) must be installed or replaced with new
ones where specified. If the efficiency of
a locking device is impaired, it must be re-
newed.
vmr2006-085-004
and replaced with new proper ones every time RH FRONT BRAKE FLUID RESERVOIR
a Banjo fitting is unscrewed.
Visually inspect lever boot condition. Check for
MAINTENANCE cracks, tears, etc. Replace if damaged.
Add fluid as required. Do not overfill.
BRAKE FLUID Brake Fluid Reservoir for Rear Brake Pedal
The brake fluid must be changed in accordance With vehicle on a level surface, check brake fluid
with the maintenance chart. in reservoir for proper level. It should be above
MIN. mark.
Recommended Fluid
Clean reservoir cover before removing.
Use brake fluid meeting the specification DOT 3
or DOT 4 such as GTLMA brake fluid (P/N 293 600
062) sold by BRP.
Fluid Level
NOTE: A low level may indicate leaks or worn
brake pads.
212 vmr2006-085
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
vmo2006-014-032_b
vmr2006-085-008_a
vmr2006-085-006_a
– When brake fluid freely flows out of RH caliper
1. RH brake fluid reservoir cover (without bubbles), close the bleeding screw.
– Continue to push brake fluid until reservoir is
– Connect a clear hose to the RH caliper bleeding
half full.
screw. Place the other end of hose in a contain-
er. – Close bleeding screw on LH caliper.
– Loosen bleeding screw and pump brake lever – Fill reservoir.
until no more fluid flows out of bleeding screw. NOTE: The reservoir is full when the fluid reaches
Repeat procedure on LH side caliper. the top of window.
– Squeeze brake lever. It should be firm.
– If yes, install diaphragm and cover on reservoir.
– If not, bleed front brake circuit as per procedure
in BRAKE SYSTEM BLEEDING.
Rear Brake Lever Circuit
The removal of rear fender is necessary to drain,
fill and bleed rear brake. Refer to BODY.
To drain and fill the brake lever circuit, use the
following procedure:
– Remove reservoir cover of the master cylinder.
vmr2006-085-007_a
vmr2006-085 213
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
1. LH reservoir cover
vmo2006-014-032_b
1. Reservoir cover
vmr2006-085-013
vmr2006-085 215
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
BRAKE PADS
vmr2006-085-012_a Removal
1. Front caliper bolts (RH) Loosen pad pins.
vmr2006-085-016_a
1. Pad pins
vmr2006-085-015_a
2. Caliper
1. Rear caliper bolts
Remove caliper. See procedure above.
If the caliper is not being removed from the vehicle Remove pad pins.
as during brake pad replacement, simply hang the
caliper with a piece of wire. Push piston all the way in to allow removal and
installation of new pads.
CAUTION: Do not let the caliper hang by the
hose and do not stretch or twist the hose.
If the caliper is being removed for replacement,
remove Banjo fitting and its sealing washers. Re-
move the caliper from the vehicle and discard seal-
ing washers.
Catch spilled fluid with a rag. Attach the brake
hose in a position to prevent the fluid from flowing
out.
Inspection
Check piston for scratches, rust or other damages.
If so, replace caliper. vmr2006-085-017
MASTER CYLINDERS OF
BRAKE LEVERS
Removal
Master Cylinder of LH Rear Brake Lever
Drain the rear brake lever circuit. Refer to BRAKE
vmr2006-085-018_a FLUID REPLACEMENT in this section.
1. Wear groove on pad lining Remove banjo fitting and the sealing washers.
Unplug brake light switch connectors. Note posi-
BRAKE PAD MINIMUM tion of wires for reinstallation.
2 mm (5/64 in)
THICKNESS
Installation
Clean the visible portion of piston with clean brake
fluid.
Make sure that pad spring is in position.
vmr2006-085-020_a
vmr2006-085-019_a
1. Pad spring
brake lever a few times to bring the pads in con- 1. Master cylinder holder
tact with the disc. The pads must rest flat on the 2. Bolts
disk
Remove master cylinder of rear brake lever.
Check for leaks and make sure the brakes operate
normally before driving. Master Cylinder of RH Front Brake Lever
Drain the front brake circuit. Refer to BRAKE FLU-
ID REPLACEMENT in this section.
Remove banjo fitting and the sealing washers.
Unplug brake light switch connectors. The con-
nectors are located under front cover. Note posi-
tion of wires for reinstallation.
vmr2006-085 217
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
WARNING
Bleed rear brake lever and rear brake pedal
circuits before riding vehicle.
Removal
vmr2006-085-021_a Remove the RH footrest. Refer to BODY.
1. Master cylinder holder Detach brake pedal spring and brake pedal switch
2. Bolts spring.
Remove master cylinder of front brake lever.
Installation
Master Cylinders of Front or Rear Brake Levers
For installation, reverse the removal procedure.
However, pay attention to the following.
Install the master cylinder holder with the arrow in
the proper position.
vmr2006-085-023_a
vmr2006-085-022
218 vmr2006-085
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
vmr2006-085-024_a
vmr2006-085-025_a
vmr2006-085-027_a
Installation
The installation is the reverse of the removal pro-
cedure.
vmr2006-085 219
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
WARNING
Bleed rear brake lever and pedal circuits be-
fore riding vehicle.
BRAKE DISCS
vmr2006-085-028_a
Inspection
1. Brake fluid reservoir hose Brake discs can be inspected without removing
2. Banjo fitting them from the vehicle.
3. Brake hose
4. Master cylinder bolts NOTE: To verify the front brake discs, raise vehicle
and support it securely. Remove wheels.
Installation Visually inspect disc surfaces for scratches or
grooves. Make sure to check both sides of disc.
For installation, reverse the removal procedure.
Measure thickness of the disc.
Refill and bleed rear brake pedal circuit.
Bleed rear brake pedal circuit before riding Front and rear 2 mm (5/64 in)
vehicle.
Replace disc if not within specifications.
CAUTION: Brake discs should never be ma-
PRESSURE CONTROL VALVE chined.
Turn the brake disc and check warpage.
Removal
Remove rear fender. Refer to BODY. MAXIMUM DISC WARPAGE
Disconnect the three brake hoses. Discard seal- Front
ing washers and catch spilled fluid with a rag. 0.1 mm (1/32 in)
Rear
Unscrew bolts securing pressure control valve to
frame. Removal
Front Brake Disc
Remove caliper. Refer to CALIPER in this section.
Remove front wheel hub. Refer to STEERING
AND FRONT SUSPENSION.
Unscrew brake disc screws. Heat up brake disc
around screws to facilitate removal.
Rear Brake Disc
vmr2006-085-029_a Remove brake hub. Refer to REAR SUSPENSION
1. From LH brake lever
AND AXLE.
2. From rear master cylinder Unscrew brake disc screws. Heat up brake disc
3. Toward rear caliper
4. Pressure control valve bolts around screws to facilitate removal.
Installation
Installation The installation is the reverse of removal proce-
The installation is the reverse of the removal pro- dure. However, pay attention to the following de-
cedure. tails.
220 vmr2006-085
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
BRAKE HOSES
Inspection
Brake hoses should be inspected frequently for
leaks and damages. vmr2006-085-047_a
Check if the hoses are crushed or damaged. Any FRONT CALIPER SHOWN
deformation can restrict the proper flow of fluid 1. Banjo fitting
2. Sealing washers
and cause braking problems.
Check hoses for cracking or scrapes. This dam- Install any retaining clips or brackets. Crimp clips
age can cause hose failure under pressure. properly to firmly secure rubber grommets in
When hoses are removed or disconnected, clean- place.
liness must be observed. Clean all joints and con- Refill and bleed brake circuit(s).
nections before disassembly. New hoses should
be cleaned with brake fluid before installation to BRAKE LIGHT SWITCHES
remove any contamination.
NOTE: There is a brake light switch for each lever
Replace any defective parts.
and the pedal.
Removal
Inspection
NOTE: Before removing any hoses, drain the ap-
Check switch for dirt or corrosion. Make sure it is
propriate brake circuit.
operating properly.
Remove all necessary parts to reach the hoses.
Depress brake pedal and check for brake light to
Thoroughly clean the area around the joints that turn on. Repeat with each brake lever.
will be disconnected.
Place a drain pan under the joint that will be dis- Test
connected. Disconnect switch connector(s).
Disconnect any retaining clips or brackets holding
the hoses.
Installation
Install the new hose.
Make sure the piece will not rub against any other
part.
When there is a Banjo fitting securing the hoses
to the calipers, pressure control valve or to mas-
ter cylinders, always replace sealing washers with
new ones.
vmr2006-085-030_a
BRAKE PEDAL
1. Brake pedal switch connector
vmr2006-085 221
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
vmr2006-085-020_a
vmr2006-085-033_a
LH REAR BRAKE LEVER
1. Brake fluid reservoir 1. Brake pedal switch
2. Brake light switch connectors 2. Brake pedal
3. Choke lever
vmr2006-085-032_a
Removal
Front and Rear Brake Levers
The brake light switches on brake levers are not
available in spare parts. Replace brake levers.
Rear Brake Pedal
The brake pedal switch is located over brake ped-
al.
222 vmr2006-085
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
EUROPEAN MODELS
FRONT BRAKES
9 Nm
(80 lbfin) 35 Nm
(26 lbfft) 5 Nm
(44 lbfin)
9 Nm
(80 lbfin)
35 Nm
(26 lbfft)
27 Nm
(20 lbfft)
35 Nm
(26 lbfft)
5 Nm 9 Nm
(44 lbfin) (80 lbfin)
9 Nm
(80 lbfin)
27 Nm
(20 lbfft)
Dielectric grease
vmr2006-085-036_a
vmr2006-085 223
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
REAR BRAKE
35 Nm
(26 lbfft)
35 Nm
(26 lbfft)
9 Nm
(80 lbfin)
35 Nm 9 Nm
(26 lbfft) (80 lbfin)
35 Nm
27 Nm (26 lbfft)
(20 lbfft)
5 Nm
(44 lbfin)
15 Nm
(133 lbfin)
27 Nm
(20 lbfft)
vmr2006-085-037_a
224 vmr2006-085
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins,
etc.) must be installed or replaced with new
ones where specified. If the efficiency of
a locking device is impaired, it must be re-
newed. vmr2006-085-038
Fluid Level
NOTE: A low level may indicate leaks or worn
brake pads.
vmr2006-085 225
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
226 vmr2006-085
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
vmr2006-085-042
Removal
Screw in the parking brake cable adjuster on the
RH handle lever. vmr2006-085-041_a
1. Socket screws
2. Lever plate
3. Parking brake lever
4. Cable adjuster
Installation
vmr2006-085-039_a The installation is the reverse of the removal pro-
1. Cable adjuster cedure.
2. Parking brake cable
3. Parking brake lever
4. RH handle brake lever CALIPERS
Disconnect cable from rear caliper. Removal
Front Calipers
Loosen wheel nuts, raise vehicle and support it
securely then remove appropriate wheel.
Remove caliper bolts then the caliper.
vmr2006-085 227
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
Inspection
Check piston for scratches, rust or other damages.
If so, replace caliper.
Check brake pads. Refer to BRAKE PAD further
in this section.
Installation
For the installation, reverse the removal proce-
dure, pay attention to the following details.
Use new sealing washers when installing Banjo
fitting retaining brake hose to caliper. Torque Ban-
vmr2006-085-012_a jo fitting to 35 N•m (26 lbf•ft).
RH CALIPER SHOWN Install caliper in its original position. Torque caliper
1. Front caliper bolts
bolt to 27 N•m (20 lbf•ft).
NOTE: If the caliper is not being removed from the Refill and bleed the braking system.
vehicle as during brake pad replacement, simply Adjust parking brake (rear caliper). Refer to PARK-
hang the caliper with a piece of wire. ING BRAKE .
CAUTION: Do not let the caliper hang by the Check for leaks and make sure the brakes operate
hose and do not stretch or twist the hose. normally before driving.
If the caliper is being removed for replacement, re-
move bolt retaining the Banjo fitting and its seal- BRAKE PADS
ing washers. Remove the caliper from the vehicle
and discard sealing washers. Removal
Catch spilled fluid with a rag. Attach the brake Loosen pad pins.
hose in a position to prevent the fluid from flowing
out.
Rear Caliper
If the caliper is not being removed from the vehicle
as during brake pad replacement, unscrew caliper
bolts and hang the caliper with a piece of wire.
CAUTION: Do not let the caliper hang by the
hose and do not stretch or twist the hose.
If the caliper is being removed for replacement,
remove Banjo fitting and its sealing washers. Re-
move parking brake cable from caliper and un- vmr2006-085-044_a
screw caliper bolts. Remove the caliper from the 1. Pad pins
vehicle and discard sealing washers. 2. Caliper
vmr2006-085-043_a
228 vmr2006-085
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
vmr2006-085-018_a
vmr2006-085-040_a
1. Adjusting bolt
2. Lock nut
3. Caliper brake lever
vmr2006-085-019_a
vmr2006-085 229
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
MASTER-CYLINDERS OF
BRAKE LEVERS
Removal
Master Cylinder of LH Rear Brake Lever
Drain the rear brake lever circuit. Refer to BRAKE
FLUID REPLACEMENT in this section.
Remove banjo fitting and the sealing washers.
Unplug brake light switch connectors. Note posi-
tion of wires for reinstallation. vmr2006-085-032_a
vmr2006-085-020_a
Installation
Master Cylinders of Front or Rear Brake Levers
For installation, reverse the removal procedure.
However, pay attention to the following.
Install the master cylinder holder with the arrow in
the proper position.
vmr2006-085-038_a
230 vmr2006-085
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
WARNING
Bleed rear brake lever and rear brake pedal
circuits before riding vehicle.
vmr2006-085-024_a
vmr2006-085-026_a
vmr2006-085-023_a
vmr2006-085-027_a
Installation
The installation is the reverse of the removal pro-
cedure.
vmr2006-085 231
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
Installation
For installation, reverse the removal procedure.
Refill and bleed the rear brake pedal circuit.
vmr2006-085-024_a
WARNING
Then, remove pin to separate yoke and rear brake Bleed rear brake pedal circuit before riding
pedal. vehicle.
232 vmr2006-085
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
Installation
The installation is the reverse of the removal pro-
cedure.
Refill and bleed braking system.
WARNING
Bleed braking system before riding vehicle.
BRAKE DISCS
vmr2006-085-045_a
WARNING
DISC MINIMUM THICKNESS
Front and rear 2 mm (5/64 in)
Bleed braking system before riding vehicle.
Replace disc if not within specifications.
CAUTION: Brake discs should never be ma-
REAR BRAKE PRESSURE chined.
CONTROL VALVE Turn the brake disc and check warpage.
Removal
MAXIMUM DISC WARPAGE
Remove rear fender. Refer to BODY.
Front
Disconnect the four (4) brake hoses. Discard seal- 0.1 mm (1/32 in)
ing washers and catch spilled fluid with a rag. Rear
Unscrew bolts securing pressure control valve to
frame. Removal
Front Brake Disc
Remove caliper. Refer to CALIPER in this section.
Remove front wheel hub. Refer to STEERING
AND FRONT SUSPENSION.
Unscrew brake disc screws. Heat up brake disc
around screws to facilitate removal.
Rear Brake Disc
Remove brake hub. Refer to REAR SUSPENSION
AND AXLE.
Unscrew brake disc screws. Heat up brake disc
vmr2006-085-046_a
around screws to facilitate removal.
1. From LH rear brake lever
2. From rear master cylinder
3. From the front brake pressure control valve
4. Toward rear caliper
5. Pressure control valve bolts
vmr2006-085 233
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
Installation
The installation is the reverse of removal proce-
dure. However, pay attention to the following de-
tails.
Torque brake disc screws in accordance with the
following table.
Installation
Install the new hose.
Make sure the piece will not rub against any other
vmr2006-085-030_a
part.
REAR BRAKE PEDAL
When there is a Banjo fitting securing the hoses 1. Brake pedal switch connector
to the calipers, pressure control valve or to mas-
ter cylinders, always replace sealing washers with
new ones.
234 vmr2006-085
Section 09 BRAKING SYSTEM
Subsection 01 (FRONT AND REAR BRAKES)
vmr2006-085-020_a
vmr2006-085-033_a
vmr2006-085-032_a
SWITCH
SWITCH WIRES/PINS RESISTANCE
POSITION
Installation
If brake pedal switch is defective, replace with a
new one. For installation, reverse the removal procedure.
If a brake lever switch is defective, replace brake
lever.
Removal
Front and Rear Brake Levers
The brake light switches on brake levers are not
available in spare parts. Replace brake levers.
vmr2006-085 235
Section 10 BODY/FRAME
Subsection 01 (BODY)
BODY
BODY
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
vmr2006-086-001_a
vmr2006-086 237
Section 10 BODY/FRAME
Subsection 01 (BODY)
SEAT
4 Nm
(35 lbfin) 10 Nm
(89 lbfin)
4 Nm
(35 lbfin)
vmr2006-086-002_a
238 vmr2006-086
Section 10 BODY/FRAME
Subsection 01 (BODY)
PARTS REPLACEMENT
DECAL
To remove a decal; heat old decal with a heat gun
and peel off slowly.
Using isopropyl alcohol, clean the surface and dry
thoroughly.
Apply liquid soap to new decal and carefully po-
sition the decal. Using a sponge or a squeegee,
remove the air bubbles and surplus water work-
ing from the center toward the edges. Allow to
air dry. vmo2006-014-018_a
SEAT LATCH
Removal
Remove seat.
Unscrew seat latch bolts.
vmo2006-014-016_a
TYPICAL
Installation
Insert seat tab into frame hook.
vmr2006-086-029_a
1. Seat latch
2. Seat latch bolts
Installation
The installation is the reverse of the removal pro-
cedure.
vmr2006-086 239
Section 10 BODY/FRAME
Subsection 01 (BODY)
vmr2006-086-006_a
vmr2006-086-003_a
Remove seat.
Unscrew bolt securing fuel tank cover and front
fender to frame. vmr2006-086-007
vmr2006-086-004
vmr2006-086-008_a
Installation
The installation is the reverse of removal proce-
dure.
vmr2006-086-005
240 vmr2006-086
Section 10 BODY/FRAME
Subsection 01 (BODY)
vmr2006-086-013_a
RADIATOR SHIELD
Removal
Remove front cover. See procedures above.
Unscrew bolt near radiator cap.
vmr2006-086-017
vmr2006-086-010
vmr2006-086-011_a
vmr2006-086-012_a
vmr2006-071-003_a
vmr2006-086 241
Section 10 BODY/FRAME
Subsection 01 (BODY)
vmr2006-086-011_a
vmr2006-071-004_a
Installation
The installation is the reverse of the removal pro-
cedure.
vmr2006-086-013_a
vmr2006-086-010
vmr2006-086-014_a
242 vmr2006-086
Section 10 BODY/FRAME
Subsection 01 (BODY)
vmr2006-086-015_a vmr2006-086-018
Remove shifter handle. Remove CVT air inlet hose from the front fender.
vmr2006-086-016
vmr2006-086-019_a
Remove screw joining front and rear side panels 1. CVT air inlet hose
(one on each side). 2. Radiator cap
vmr2006-086-017
1. Power outlet
vmr2006-086 243
Section 10 BODY/FRAME
Subsection 01 (BODY)
vmr2006-086-014_a
vmr2006-086-021
Unscrew bolts holding front fender and rear fender
to frame.
Carefully, remove the front fender.
vmr2006-086-015_a
vmr2006-086-022
REAR FENDER
Removal
Remove seat and fuel tank cover. See procedures
above.
Remove screws at the bottom of rear fender (one
vmr2006-086-017
on each side).
Using a flat screwdriver, unlock and separate front
fender and rear fender.
vmr2006-086-023_a
vmr2006-086-018
vmr2006-086-024_a vmr2006-086-027_a
Remove battery retaining plate and battery. Refer 1. Starting solenoid connectors
2. BLACK wire on solenoid
to CHARGING SYSTEM.
Remove starting solenoid from vehicle.
Unlatch the fuse box from fender.
Slide fuse box and wires through the fender open-
ing.
Disconnect rear light.
Lift rear fender and remove it.
Installation
vmr2006-086-025_a
The installation is the reverse of removal proce-
1. Battery
dure.
2. Battery retaining plate
FOOTREST
Remove bolts securing rear fender to frame.
Removal
Remove screws retaining footrest to its support.
vmr2006-086-026_a
vmr2006-086-028_a
vmr2006-086 245
Section 10 BODY/FRAME
Subsection 01 (BODY)
CLEANING
SEAT
It is recommended to clean the seat with a solu-
tion of warm soapy water, using a soft clean cloth.
CAUTION: Avoid use of harsh detergents such
as strong soaps, degreasing solvents, abrasive
cleaners, paint thinners, etc. that may cause
damage to the seat cover.
PLASTIC
Clean the vehicle thoroughly, removing all dirt and
grease accumulation.
To clean use a soft clean cloth and either soapy
water or isopropyl alcohol.
To remove grease, oil or glue use isopropyl alco-
hol.
CAUTION: Do not apply isopropyl alcohol or
acetone directly on decals.
CAUTION: The following products must not be
used to clean or wax any of the plastic compo-
nents used on the vehicles:
– gasoline
– brake fluid
– kerosene
– diesel fuel
– lighter fluid
– varsol
– naphtha
– acetone
– strong detergents
– abrasive cleaners
– waxes containing an abrasive or a cleaning
agent in their formula.
Apply wax without abrasive agent on glossy finish
only. Protect the vehicle with a cover to prevent
dust accumulation during storage.
CAUTION: If for some reason the vehicle has
to be stored outside, it is preferable to cover it
with an opaque tarpaulin. This will prevent the
sun rays from affecting the plastic components
and the vehicle finish.
REPAIR
PLASTIC REPAIR
No plastic part on the vehicle is repairable.
Change all defective parts.
246 vmr2006-086
Section 10 BODY/FRAME
Subsection 02 (FRAME)
FRAME
SERVICE PRODUCTS
Description Part Number Page
XP-S Lube ............................................................................. 293 600 016 ......................................... 249
12 Nm
(106 lbfin)
12 Nm
(106 lbfin)
12 Nm
(106 lbfin)
12 Nm
(106 lbfin)
12 Nm
(106 lbfin)
12 Nm
(106 lbfin)
27 Nm 12 Nm
(20 lbfft) (106 lbfin)
27 Nm
(20 lbfft)
vmr2006-087-014_a
vmr2006-087 247
Section 10 BODY/FRAME
Subsection 02 (FRAME)
4 Nm
(35 lbfin)
12 Nm
(106 lbfin) 4 Nm
(35 lbfin)
27 Nm
(20 lbfft)
12 Nm
(106 lbfin) 27 Nm
(20 lbfft)
12 Nm
(106 lbfin)
27 Nm 27 Nm
(20 lbfft) (20 lbfft)
vmr2006-087-015_a
248 vmr2006-087
Section 10 BODY/FRAME
Subsection 02 (FRAME)
GENERAL PROCEDURES
During assembly/installation, use the torque val-
ues and service products as in the exploded FRONT BUMPER
views.
Removal
WARNING Remove bolts that attach front bumper to the
Torque wrench tightening specifications frame. Two (2) on each sides.
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin,
etc.) must be installed or replaced with new
ones where specified. If the efficiency of
a locking device is impaired, it must be re-
newed.
Touch up all metal spots where paint has been Pull bumper forward to remove it.
scratched off. Spray all bare metal parts of vehicle
with metal protector such as XP-S Lube (P/N 293 Installation
600 016).
The installation is the reverse of the removal pro-
Welding cedure.
NOTE: Install all bolts before torquing them.
WARNING
Welding should be performed by a profes- FOOTPEG
sional solder and limited to areas that are not
safety related, such as steering, footrests, Removal
suspension, etc. Remove the both screws holding footpeg to
footrest.
– electric welding
– amperage: 70 - 110 A
– voltage: 20 - 24 V
– rod: E-7014 (3/32 in).
CAUTION: Before performing electrical weld-
ing anywhere on the vehicle, unplug the
electronic module connector. Also unplug the
BLACK (-) cable from the battery and the volt-
age regulator. This will protect the electronic
module and battery against damage caused
by flowing current when welding.
vmr2006-087-002_a
NOTE: Install the ground as close as possible to
the repair area.
Installation
CAUTION: If welding is to be done near plastic
material, it is recommended to remove the part For installation, reverse the removal procedure.
from the area or to protect it with aluminum foil
to prevent damage.
vmr2006-087 249
Section 10 BODY/FRAME
Subsection 02 (FRAME)
vmr2006-087-003_a
vmr2006-087-004_a
vmr2006-087-005_a
1. LH footrest
2. Bottom screw of rear fender
250 vmr2006-087
Section 10 BODY/FRAME
Subsection 02 (FRAME)
vmr2006-087-010_a
1. Retaining screw
vmr2006-087-008_a
2. Retaining bolt
LEFT SIDE SHOWN
1. Rear frame extension bolts Remove nuts retaining the support to the frame.
Installation
To install the rear frame extension, reverse the
removal procedure.
vmr2006-087-012_a
Installation
Reverse the removal procedure.
vmr2006-087-009_a
vmr2006-087 251
Section 10 BODY/FRAME
Subsection 02 (FRAME)
vmr2006-087-013_a
Installation
The installation is the reverse of the removal pro-
cedure.
252 vmr2006-087
Section 11 TECHNICAL SPECIFICATIONS
Subsection 01 (DS 250)
DS 250
DS 250
VEHICLE MODEL
NORTH AMERICA MODEL EUROPEAN MODEL
ENGINE
4-stroke, Single Over Head Camshaft (SOHC),
Engine type
liquid cooled
Starting system Electric
Number of cylinder(s) 1
Number of valves 4 valves with mechanical adjustment
Bore Standard mm (in) 71 (2.8)
Stroke mm (in) 63 (2.5)
Displacement cm3 (in3) 249.4 (15.22)
Compression ratio 10.6:1
Air filter type Sponge wet type
Type Single output
Exhaust system USDA Forest Service
Spark arrester —
approved
Intake mm (in) 0.08 to 0.12 (.0031 to .0047)
Valve clearance
Exhaust mm (in) 0.13 to 0.17 (.0051 to .0067)
New mm (in) 4.975 to 4.990 (.1968 to .1973)
Intake Service
mm (in) 4.900 (.1980)
Valve stem outer limit
diameter New mm (in) 4.950 to 4.975 (.1968 to .1973)
Exhaust Service
mm (in) 4.900 (.1980)
limit
New mm (in) 5.00 to 5.012 (.1968 to .1973)
Valve guide internal diameter Service
mm (in) 5.030 (.1980)
limit
New mm (in) 0.010 to 0.050 (.0004 to .0015)
Clearance Intake
Wear limit mm (in) 0.080 (.0032)
between valve
stem and guide Exhaust New mm (in) 0.025 to 0.062 (.0010 to .0024)
Wear limit mm (in) 0.100 (.0039)
New mm (in) 38.7 (1.525)
Inner Service
Valve spring free mm (in) 35.2 (1.389)
limit
length New mm (in) 40.4 (1.590)
Outer Service
mm (in) 36.9 (1.453)
limit
Valve seat width mm (in) 1.6 (.063)
New mm (in) 70.430 to 70.480 (2.7728 to 2.7748)
Piston measurement
Wear limit mm (in) 70.380 (2.7709)
New
mm (in) 0.010 to 0.040 (.0004 to .0016)
Piston/cylinder clearance nominal
Wear limit mm (in) 0.100 (.0039)
vmr2006-088 253
Section 11 TECHNICAL SPECIFICATIONS
Subsection 01 (DS 250)
DS 250
VEHICLE MODEL
NORTH AMERICA MODEL EUROPEAN MODEL
ENGINE (con'd)
New
mm (in) 17.002 to 17.008 (.6694 to .6696)
Piston pin hole diameter nominal
Wear limit mm (in) 17.020 (.6701)
New mm (in) 16.994 to 17.000 (.6691 to .6693)
Piston pin diameter
Wear limit mm (in) 16.960 (.6677)
New mm (in) 0.002 to 0.014 (.0001 to .0006)
Piston pin bore clearance
Wear limit mm (in) 0.020 (.0008)
1st Upper compression ring
Piston ring type 2nd Lower compression ring
3rd Oil scraper ring
Upper New mm (in) 0.15 to 0.30 (.006 to .012)
compression
ring Wear limit mm (in) 0.50 (.06)
Piston ring end Lower New mm (in) 0.30 to 0.45 (.012 to .018)
gap compression Wear limit
ring mm (in) 0.65 (.026)
Oil scraper
ring New mm (in) 0.15 to 0.30 (.006 to .012)
New mm (in) 0.015 to 0.050 (.0006 to .0020)
Piston/ring groove clearance
Wear limit mm (in) 0.090 (.0035)
New mm (in) 11.982 to 12.000 (.4717 to .4724)
Rocker arm bore diameter
Wear limit mm (in) 12.080 (.4756)
New mm (in) 11.966 to 11.984 (.4711 to .4718)
Rocker arm shaft diameter
Wear limit mm (in) 11.936 (.4699)
Cylinder head warpage Wear limit mm (in) 0.050 (.002)
Cylinder warpage Wear limit mm (in) 0.050 (.002)
New mm (in) 70.995 to 71.015 (2.7951 to 2.7959)
Cylinder bore
Wear limit mm (in) 71.100 (2.7992)
New mm (in) 34.880 (1.3732)
Intake
Wear limit mm (in) 34.860 (1.3724)
Cam lobe
New mm (in) 34.740 (1.3677)
Exhaust
Wear limit mm (in) 34.725 (1.3671)
Crankshaft deflection Wear limit mm (in) 0.100 (.0039)
Crankshaft MAG side New mm (in) 35.008 to 35.021 (1.3783 to 1.3788)
journal diameter PTO side New mm (in) 30.006 to 30.019 (1.1813 to 1.1818)
Connecting rod big end New mm (in) 41.003 to 41.011 (1.6143 to 1.6146)
diameter Wear limit mm (in) 41.021 (1.6150)
Connecting rod big end New mm (in) 0.100 to 0.400 (.0039 to .0157)
clearance Wear limit mm (in) 0.600 (.0236)
254 vmr2006-088
Section 11 TECHNICAL SPECIFICATIONS
Subsection 01 (DS 250)
DS 250
VEHICLE MODEL
NORTH AMERICA MODEL EUROPEAN MODEL
ENGINE (con'd)
Connecting rod big end axial New mm (in) 0.00 to 0.008 (.000 to .0003)
play Wear limit mm (in) 0.050 (.002)
Connecting rod small end New mm (in) 17.016 to 17.034 (.6699 to .6706)
diameter Wear limit mm (in) 17.064 (.6718)
Starting clutch gear inner New mm (in) 25.026 to 25.045 (.9853 to .9860)
diameter Wear limit mm (in) 25.050 (.9862)
Starting clutch gear outer New mm (in) 42.192 to 42.208 (1.6611 to 1.6617)
diameter Wear limit mm (in) 42.100 (1.6575)
ELECTRICAL
Magneto/generator 338 W @ 5000 RPM
Ignition system type CDI (Capacitor Discharge Ignition)
Ignition timing Not adjustable
Quantity 1
Spark plug Make and type NGK CR8E
Gap mm (in) 0.8 (.03)
Trigger coil 445.5 to 544.5
Battery charging coil 0.315 to 0.385
Primary 0.189 to 0.231 @ 20°C (68°F)
Ignition coil 6.54 to 9.66 @ 20°C (68°F) with spark plug cap
Secondary k 2.79 to 3.41 @ 20°C (68°F) without spark plug cap
Forward 8450 ± 1500
Engine RPM limiter
Reverse 4000
Type Dry type battery
Battery Voltage 12 volts
Nominal rating 10 A•h
Headlamp 2 x 31.5 W 2 x 35 W
Taillight 1 x 5/21 W
Turn signal light N.A. 4 x 21 W
Temperature 1.7 W 1.7 W
Neutral Pilot 1.7 W 1.7 W
Reverse Pilot 1.7 W 1.7 W
Indicator lamps
Forward — 1.7 W
High beam — 1.7 W
Turn pilot — 1.2 W
Fan 10 A
Headlamp 15 A
Fuses
Other lights 15 A
Main fuse 30 A
vmr2006-088 255
Section 11 TECHNICAL SPECIFICATIONS
Subsection 01 (DS 250)
DS 250
VEHICLE MODEL
NORTH AMERICA MODEL EUROPEAN MODEL
CARBURETION
Type KEHIN with manual choke
Carburetor
Model PTG-23
Idle engine speed RPM 1700 ± 100
Main jet 105 110
Pilot jet 35 35
Needle jet 2.6 2.6
Jet needle NB5G NB5E
Clip position 4 2
Choke plunger position Variable
Throttle cable 1 to 3 mm (.039 to .118 in)
Adjustment Preliminary pilot screw
2 turns
turn
Float level 14.8 mm (.5827 in)
Type Regular unleaded gasoline
87 (Ron + Mon)/2
Fuel inside North America
Octane no. 91 RON
91 RON outside North
America
LUBRICATION
Type Forced circulation and splashing
Oil filter No oil filter on this engine
Clearance between inner and New mm (in) 0.15 (.006)
outer rotors Wear limit mm (in) 0.20 (.008)
Clearance between outer rotor New mm (in) 0.15 to 0.20 (.006 to .008)
and pump body Wear limit mm (in) 0.25 (.0098)
Clearance between inner rotor New mm (in) 0.04 to 0.09 (.0016 to .0035)
side face and pump body Wear limit mm (in) 0.12 (.0047)
TRANSMISSION
CVT (Continuously Variable Transmission)
Transmission type
HI range, neutral and reverse
New mm (in) 11.982 to 12.000 (.4717 to .4724)
Shift fork shaft diameter
Wear limit mm (in) 11.970 (.4713)
New mm (in) 12.016 to 12.043 (.4731 to .4741)
Shift fork bore diameter
Wear limit mm (in) 12.010 (.4728)
New mm (in) 5.930 to 6.000 (.2335 to .2362)
Shift fork claw thickness
Wear limit mm (in) 5.730 (.2256)
256 vmr2006-088
Section 11 TECHNICAL SPECIFICATIONS
Subsection 01 (DS 250)
DS 250
VEHICLE MODEL
NORTH AMERICA MODEL EUROPEAN MODEL
CVT
New mm (in) 24.000 (.9449)
Belt width
Wear limit mm (in) 22.50 (.8858)
• Drive Pulley
New mm (in) 29.946 to 29.980 (1.1790 to 1.1803)
Sliding sheave spacer diameter
Wear limit mm (in) 29.926 (1.1782)
Inner diameter of sliding sheave New mm (in) 30.000 to 30.040 (1.1811 to 1.1827)
bushing Wear limit mm (in) 30.060 (1.1835)
New mm (in) 19.500 to 20.000 (.7677 to .7874)
Outside diameter of roller
Wear limit mm (in) 19.000 (.7480)
• Driven Pulley
Centrifugal clutch lining New mm (in) 6.000 (.2362)
thickness Wear limit mm (in) 3.000 (.1181)
New mm (in) 144.850 to 145.150 (5.7027 to 5.7146)
Clutch drum inner diameter
Wear limit mm (in) 145.450 (5.7264)
New mm (in) 102.400 (4.0315)
Spring free length
Wear limit mm (in) 97.400 (3.8346)
Fixed sheave shaft outside New mm (in) 40.950 to 40.990 (1.6122 to 1.6138)
diameter Wear limit mm (in) 40.930 (1.6114)
New mm (in) 41.000 to 41.050 (1.6142 to 1.6161)
Sliding sheave inside diameter
Wear limit mm (in) 41.070 (1.6169)
COOLING
BRP premixed coolant or ethyl glycol/water mix
Coolant (50% coolant, 50% distilled water). Use coolant
specifically designed for aluminum engines
Fan (thermostatic switch) Opening temperature 98°C ± 3°C (208°F ± 37°F)
Engine thermostat Opening temperature 82°C to 95°C (180°F to 203°F)
Radiator cap opening pressure 90 kPa (13 PSI)
DRIVE TRAIN
Rear axle Chain driven/solid axle
Rear axle ratio 2.53:1
STEERING
Turning radius 3.5 m (138 in) at low speed
Total toe (vehicle on ground) mm (in) 3 (.118), each side (showroom position)
Camber angle 0.7° (not adjustable)
Tie-rod total length mm (in) 332 (13.071)
vmr2006-088 257
Section 11 TECHNICAL SPECIFICATIONS
Subsection 01 (DS 250)
DS 250
VEHICLE MODEL
NORTH AMERICA MODEL EUROPEAN MODEL
SUSPENSION
• FRONT
Suspension type Independent suspension — double A-arms
Suspension travel mm (in) 125 (5)
Qty 2
Shock absorber
Type Oil
Spring free length mm (in) 246.3 (9.7)
Front preload adjustment —
• REAR
Suspension type Rigid swing arm
Suspension travel mm (in) 167 (6.6)
Qty 1
Shock absorber
Type Oil
Spring free length mm (in) 310.5 (12.2)
Rear preload adjustment 5 settings
BRAKES
Qty 2, discs
Front brake
Type Hydraulic
Qty 1, disc
Rear brake
Type Hydraulic
Parking brake Brake lever lock on RH Separate RH lock lever
brake lever on handlebar
Caliper Floating
Lining material Organic
Minimum pad thickness mm (in) 2.0 (.0787)
New mm (in) 3.5 (.1378)
Minimum brake disk thickness
Wear limit mm (in) 2.0 (.0787)
Maximum brake disk warpage mm (in) 0.1 (.0039) maximum
TIRES AND WHEELS
• TIRE
Recommended 34 kPa (5 PSI)
Front
Minimum 26 kPa (3.8 PSI)
Pressure
Recommended 34 kPa (5 PSI)
Rear
Minimum 26 kPa (3.8 PSI)
Front 22 x 7 – 10
Size
Rear 20 x 11 – 9
• WHEELS
Front 10 x 5.5
Size
Rear 9 x 8
258 vmr2006-088
Section 11 TECHNICAL SPECIFICATIONS
Subsection 01 (DS 250)
DS 250
VEHICLE MODEL
NORTH AMERICA MODEL EUROPEAN MODEL
CAPACITIES
• LIQUID
Fuel tank 12 L (3.2 U.S. gal)
Fuel tank reserve 2.8 L (2.96 U.S. quarts)
Replacement: 1.2 L (1.27 U.S. quarts)
Capacity
Disassembly: 1.4 L (1.48 U.S. quarts)
Engine
Refer to the oil viscosity chart in the
Recommended
LUBRICATION SYSTEM section
Replacement: 800 mL (27 U.S. oz)
Capacity
Disassembly: 900 mL (30.4 U.S. oz)
Gearbox XP-S chaincase oil (P/N 413 801 900) or
Recommended XP-S synthetic chaincase oil (P/N 413 803 300)
or 85W-140
Cooling system 1.2 L (1.27 U.S. quarts)
• BODY
150 kg (330 lb) includes operator, all other loads
Total vehicle load allowed
and added accessories
DIMENSIONS
Dry weight kg (lb) 219 (483)
Overall length m (in) 1.890 (74.4)
Overall width m (in) 1.055 (41.5)
Overall height m (in) 1.115 (43.9)
Seat height m (in) 813 (32)
Wheel base m (in) 1.180 (46.5)
Front mm (in) 810 (32)
Wheel Track
Rear mm (in) 805 (31.7)
Ground clearance (center of vehicle) mm (in) 150 (5.9)
Rear rigid axle ground clearance mm (in) 220 (8.7)
vmr2006-088 259
Section 12 WIRING DIAGRAMS
Subsection 01 (WIRING DIAGRAMS)
WIRING DIAGRAMS
SERVICE PRODUCTS
Description Part Number Page
dielectric grease .................................................................. 293 550 004 ......................................... 261
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.
XX/XX
XX/XX
vmr2006-089-001
CONNECTORS
To release and disconnect a connector, proceed as
follows.
vmr2006-089-002_a
WARNING
Ensure all terminals are properly crimped on
the wires and all connectors are properly fas-
tened.
vmr2006-089 261
C M Y CM MY CY CMY K