BOMBARDIER Traxter 7401 Datasheet

I

SECTION SUBSECTION PAGE

SAFETY NOTICE ................................................................................................................................... III

WHAT’S NEW ....................................................................................................................................... IV

INTRODUCTION .................................................................................................................................. V

01 SERVICE TOOLS AND

SERVICE PRODUCTS

01 – Table of contents...................................................................... 01-01-1

02 – Service tools............................................................................. 01-02-1

03 – Service products....................................................................... 01-03-1

02 MAINTENANCE 01 – Table of contents...................................................................... 02-01-1

02 – Maintenance chart.................................................................... 02-02-1

03 – Maintenance and lubrication .................................................... 02-03-1

04 – Storage and pre-season preparation......................................... 02-04-1

03 ENGINE 01 – Table of contents...................................................................... 03-01-1

02 – Removal and installation........................................................... 03-02-1

03 – Cooling system......................................................................... 03-03-1

04 – Rewind starter.......................................................................... 03-04-1

04 FUEL SYSTEM 01 – Table of contents...................................................................... 04-01-1

02 – Fuel circuit ................................................................................ 04-02-1

03 – Carburetor and fuel pump ........................................................ 04-03-1

04 – Air intake silencer..................................................................... 04-04-1

05 ELECTRICAL 01 – Table of contents...................................................................... 05-01-1

02 – Overview.................................................................................. 05-02-1

03 – Charging system ...................................................................... 05-03-1

04 – Starting system ........................................................................ 05-04-1

05 – Ignition system......................................................................... 05-05-1

06 – Electric shift system................................................................. 05-06-1

07 – Instruments and accessories ................................................... 05-07-1

06 DRIVE TRAIN 01 – Table of contents...................................................................... 06-01-1

02 – Front differential ....................................................................... 06-02-1

03 – Rear axle................................................................................... 06-03-1

07 STEERING/CONTROL

SYSTEM

01 – Table of contents...................................................................... 07-01-1

02 – Steering/control systems ......................................................... 07-02-1

08 SUSPENSION 01 – Table of contents...................................................................... 08-01-1

02 – Front suspension...................................................................... 08-02-1

03 – Rear suspension....................................................................... 08-03-1

09 BRAKES 01 – Table of contents...................................................................... 09-01-1

02 – Hydraulic brakes ....................................................................... 09-02-1

TABLE OF CONTENTS

II

10 BODY/FRAME 01 – Table of contents ..................................................................... 10-01-1

02 – Body......................................................................................... 10-02-1

03 – Frame....................................................................................... 10-03-1

11 TECHNICAL DATA 01 – SI metric information guide...................................................... 11-01-1

02 – Engine and vehicle ................................................................... 11-02-1

12 WIRING DIAGRAM 01 – Wiring diagram......................................................................... 12-01-1

SECTION SUBSECTION PAGE

TABLE OF CONTENTS

V

INTRODUCTION

This

Shop Manual

covers the following Bombar-

dier made 1999 ATV:

Models

1. Model number

VEHICLE AND ENGINE SERIAL

NUMBER LOCATION

1. Engine

2. Vehicle

TRAXTER* (Canada) ................................ 7400

TRAXTER* (Canada) ................................ 7413

TRAXTER* (Canada) ................................ 7415

TRAXTER* (Canada) ................................ 7417

TRAXTER* (U.S.)...................................... 7401

TRAXTER* (U.S.)..................................... 7414

TRAXTER* (U.S.)..................................... 7416

TRAXTER* (U.S.)..................................... 7418

*Trademark of Bombardier Inc.

V01A17A

1

V01A16A

1

2

INTRODUCTION

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VI

Serial Number Meaning

10 11 12 13 14 15 16 17987654321

SECTION 1 SECTION 2 SECTION 3 SECTION 4

321

SECTION 1

Class

Make

Manufacturer

87654

SECTION 2

Factory use

Engine type II

Engine type I

Product line

Type of drive

9

SECTION 3

Check digit

10 11 12 13 14 15 16 17

SECTION 4

Number sequentially assigned by the manufacturer

in the production process

Plant of manufacture

Model year

V01A0PS

INTRODUCTION

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VII

ARRANGEMENT OF THE

MANUAL

The manual is divided into 12 major sections:

01 SERVICE TOOLS AND SERVICE PRODUCTS

02 MAINTENANCE

03 ENGINE

04 FUEL SYSTEM

05 ELECTRICAL

06 DRIVE TRAIN

07 STEERING/CONTROL SYSTEMS

08 SUSPENSION

09 BRAKES

10 BODY/FRAME

11 TECHNICAL DATA

12 WIRING DIAGRAM

Each section is divided in various subsections, and

again, each subsection has one or more division.

LIST OF ABBREVIATIONS USED

IN THIS MANUAL

A ampere

amp ampere

A•h ampere-hour

AC alternate current

BDC bottom dead center

BTDC before top dead center

°C degree Celsius

cm centimeter

cm² square centimeter

cm³ cubic centimeter

DC direct current

°F degree Fahrenheit

fl. oz fluid ounce

ft foot

GRD ground

hal. halogen

I.D. inside diameter

IDI induction discharge ignition

imp. oz imperial ounce

in inch

in² square inch

in³ cubic inch

k kilo (thousand)

kg kilogram

km/h kilometer per hour

kPa kilo pascal

L liter

lb pound

lbf pound (force)

lbf/in² pound per square inch

LH left hand

m meter

MAG magneto

Max. maximum

Min. minimum

mL milliliter

mm millimeter

MPEM multi-purpose electronic module

MPH mile per hour

N newton

N.A. not applicable

no. number

00.0 continuity

0.L overload (open circuit)

O.D. outside diameter

OPT optional

oz ounce

P/N part number

PSI pound per square inch

PTO power take off

RPM revolution per minute

Sp. Gr. specific gravity

TDC top dead center

U.S. oz ounce (United States)

V volt

Vac volt (alternative current)

INTRODUCTION

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VIII

V01C15S

10

8

7

10

9

7

11

10

8

9

7

9

14

7

8

10

19

15

30

2

32

4

31

32

26

1

28

27

25

24

25

24

23

6

3

17

13

12

29

11

16

21

20

22

18

17

5

Therma Lube

grease

Therma Lube

grease

Therma Lube

grease

12

48 Nm

(35 lbfft)

48 Nm

(35 lbfft)

24 Nm

(17 lbfft)

24 Nm

(17 lbfft)

10 Nm

(97 lbfin)

24 Nm

(17 lbfft)

48 Nm

(35 lbfft)

10 Nm

(97 lbfin)

03 02 1

Section 03 ENGINE

Subsection 02 (REMOVAL AND INSTALLATION)

REMOVAL AND INSTALLATION

Page heading

indicates section

and subsection

detailed.

Bold face number

indicates special

procedure

concerning this

part.

Tightening torque

nearby fastener. In this

case, nut must be

torqued to

48 Nm or 35 lbfft.

This Shop Manual uses technical terms wich may be

slightly different from the ones in the parts catalog.

Exploded view

assists you in

identifying parts and

related positions.

TYPICAL PAGE

V01A0QS

Illustration

number for

publishing

process.

Subsection title

indicates

beginning of the

subsection.

Drop represents a

liquid product to

be applied to

a surface.

Page numbering system:

03: ENGINE section

02: REMOVAL AND INSTALLATION

subsection

1: First page of this subsection

CAUTION: Pay attention to

torque specifi

cations. Some

of these are in

lbfin instead

of lbfft. Use appro

priate torque

wrench.

INTRODUCTION

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Section 03 ENGINE

Subsection 02 (REMOVAL AND INSTALLATION)

03 02 2

1 Shifting valve

2 GBPS (Gear Box Pos tion Sensor)

3 Magneto/Trigger plug

4 Engine coolant hose

Place the vehicle on jackstands and place the shifter

no. 1

on park position

Remove front wheels

Drain engine oil and engine coolant

Remove seat, front and rear fenders, inner fend-

ers, side panels, steering cover, shifter guide cov-

er and skid plate Refer to the section 09-02 BODY

Disconnect BLACK negative cable from battery,

then RED positive cable

Front Part Preparation

Remove fuel tank and fuel valve Refer to the sec-

tion 03-02 FUEL CIRCUIT

Disconnect the interlock cable

no. 2

under shifter

lever

Remove seat pivot bar and unplug the clutching

and clutch modulator valves connector

Remove the STPS (Sub Transmission Position Sen-

sor)

ROD REMOVAL section

Remove front propeller shaft Refer to the section

05-02 FRONT DIFFERENTIAL

Unplug the VSS (Vehicle Speed Sensor), located

under engine drive shaft

Engine Preparation

Unplug spark plug cables

Unplug oil pressure sensor

Remove radiator inlet hose

Remove breather` hose

Unplug the temperature sensor

WARNING

Always disconnect battery or starter cables

exactly in the specified order, BLACK nega-

tive cable first. It is recommended to discon-

nect electrical connections prior to discon-

necting fuel lines.

2

V01C0DA

431 6

5

1

3

V01C0EA

24

Vehicle Preparation

2 STPS (Sub Transmission Position Sensor)

3 VSS (Vehicle Speed Sensor)

4 Shifting engine rod

5 Oil pressure sensor

6 Engine coolant hose

1 Clutching and clutch modulator valves connector

Remove exhaust pipe

no. 5

Refer to the EXHAUST

SYSTEM section

Remove shifting rod

no. 3

Refer to the SHIFTING

ENGINE REMOVAL

m

TYPICAL PAGE

Title indicates

main procedure

to be carried out.

Reference to look

up a certain section

and subsection.

In this case it

concerns

exhaust system.

Bold face number

following part

name refers to

exploded view

at beginning of

subsection.

Call outs for

above illustration.

V01A0RS

INTRODUCTION

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X

GENERAL INFORMATION

The information and component/system descrip-

tions contained in this manual are correct at time

of publication. Bombardier Inc. however, main-

tains a policy of continuous improvement of its

products without imposing upon itself any obliga-

tion to install them on products previously manu-

factured.

Due to late changes, it may have some differences

between the manufactured product and the descrip-

tion and/or specifications in this document.

Bombardier Inc. reserves the right at any time to

discontinue or change specifications, designs,

features, models or equipment without incurring

obligation.

ILLUSTRATIONS AND

PROCEDURES

Illustrations and photos show the typical construc-

tion of the different assemblies and, in all cases,

may not reproduce the full detail or exact shape of

the parts shown, however, they represent parts

which have the same or a similar function.

CAUTION: Most components of those vehicles

are built with parts dimensioned in the metric

system. Most fasteners are metric and must

not be replaced by customary fasteners or vice-

versa. Mismatched or incorrect fasteners could

cause damage to the vehicle or possible per-

sonal injury.

As many of the procedures in this manual are in-

terrelated, we suggest, that before undertaking

any task, you read and thoroughly understand the

entire section or subsection in which the proce-

dure is contained.

A number of procedures throughout the book re-

quire the use of special tools. Before commencing

any procedure, be sure that you have on hand all

the tools required, or approved equivalents.

The use of RIGHT and LEFT indications in the text,

always refers to driving position (when sitting on

vehicle).

1. Left

2. Right

1

2

V01L25A

INTRODUCTION

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XI

TIGHTENING TORQUES

Tighten fasteners to torque mentioned in explod-

ed views and text. When they are not specified

refer to following table.The table also gives the

metric conversion.

N•m FASTENER SIZE (8.8) Lbf•in

19

2M418

327

4M535

544

653

762

871

980

10 M6 89

11 97

12 106

13 115

14 124

15 133

16 142

17 150

18 159

19 168

N•m FASTENER SIZE (8.8) Lbf•ft

20 15

21 15

22 16

23 M8 17

24 18

25 18

26 19

27 20

28 21

29 21

30 22

31 23

32 24

33 24

34 25

35 26

36 27

37 27

38 28

39 29

40 30

41 30

42 31

43 32

44 32

45 33

46 34

47 35

48 M10 35

49 36

50 37

51 38

52 38

53 39

54 40

55 41

56 41

57 42

58 43

59 44

60 44

61 45

62 46

63 46

64 47

INTRODUCTION

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XII

TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS

N•m FASTENER SIZE (8.8) Lbf•ft

65 48

66 49

67 49

68 50

69 51

70 52

71 52

72 53

73 54

74 55

75 55

76 56

77 57

78 58

79 58

80 M12 59

81 60

82 60

83 61

84 62

85 63

86 63

87 64

88 65

89 66

90 66

91 67

92 68

93 69

94 69

95 70

96 71

97 72

98 72

99 73

100 74

101 74

102 75

103 76

104 77

105 77

106 78

107 79

108 80

N•m FASTENER SIZE (8.8) Lbf•ft

109 80

110 81

111 82

112 83

113 83

114 84

115 85

116 86

117 86

118 87

119 88

120 89

121 89

122 90

123 91

124 91

125 92

126 93

127 94

128 94

129 95

130 96

131 97

132 97

133 98

134 99

135 M14 100

136 100

137 101

138 102

139 103

140 103

141 104

142 105

143 105

144 106

145 107

146 108

147 108

148 109

149 110

150 111

INTRODUCTION

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01-01-1

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS

Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

SERVICE TOOLS 01-02-1

ENGINE — MANDATORY SERVICE TOOLS ................................................................... 01-02-2

ENGINE — RECOMMENDED SERVICE TOOLS .............................................................. 01-02-3

ELECTRICAL — MANDATORY SERVICE TOOLS ........................................................... 01-02-5

ELECTRICAL — RECOMMENDED SERVICE TOOLS ...................................................... 01-02-6

SUSPENSION — MANDATORY SERVICE TOOLS ......................................................... 01-02-7

SUSPENSION — RECOMMENDED SERVICE TOOLS .................................................... 01-02-8

DRIVE — MANDATORY SERVICE TOOLS ...................................................................... 01-02-9

DRIVE — RECOMMENDED SERVICE TOOLS ................................................................. 01-02-10

VEHICLE — MANDATORY SERVICE TOOLS .................................................................. 01-02-11

VEHICLE — RECOMMENDED SERVICE TOOLS ............................................................. 01-02-12

SERVICE PRODUCTS ............................................................................................................ 01-03-1

MANDATORY SERVICE PRODUCTS ............................................................................... 01-03-1

RECOMMENDED SERVICE PRODUCTS ......................................................................... 01-03-2

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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS

Subsection 02 (SERVICE TOOLS)

01-02-1

SERVICE TOOLS

This is a list of tools to properly service ATV vehicle. If you need to replace or add to your tool inventory

these items can be ordered through the regular parts channel.

Following mention points out new tool:

NEW

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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS

Subsection 02 (SERVICE TOOLS)

01-02-2

ENGINE — MANDATORY SERVICE TOOLS

Lifting bar

(P/N 529 035 610)

V01B094

Small hose pincher

(P/N 529 009 900)

A01B2I4

Large hose pincher

(P/N 529 032 500)

F01B234

NEW

Magneto puller

(P/N 529 035 547)

F01B294

Fuel and oil system leak tester kit

(P/N 529 033 100)

A01B5E4

46 mm socket for crankshaft

(P/N 529 035 648)

V01B0A4

NEW

Spanner tool for clutch basket

(P/N 529 035 647)

V01B0B4

Crankshaft locking bolt

(P/N 529 035 645)

V01B0C4

Crankshaft protector

(P/N 290 876 557)

V01B0D4

NEW

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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS

Subsection 02 (SERVICE TOOLS)

01-02-3

ENGINE — RECOMMENDED SERVICE TOOLS

Sub-transmission positioner

(P/N 529 035 651)

V01B0E4

Oil pressure gauge (1 to 8 bar)

(P/N 529 035 652)

V01B0K4

Lifting ring

(P/N 529 035 644)

V01B0F4

Choke nut tool

(P/N 529 035 660)

V01B0G4

NEW

Ring compressor

Not sold by Bombardier

Snap-on

RCW60

V01B0H4

Carburetor tool kit

(P/N 529 035 660)

A00B2F4

Float level gauge

(P/N 529 035 520)

A00B4N4

Digital/induction type tachometer

(P/N 529 014 500)

F01B1G4

NEW

1234

Handle for insertion jig

(P/N 420 877 650)

A00C3V4

Exhaust spring installer/remover

(P/N 529 035 400)

A01B584

Valve spring compressor

Not sold by Bombardier

Snap-on

CF811

V01B0I4

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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS

Subsection 02 (SERVICE TOOLS)

01-02-4

ENGINE — RECOMMENDED SERVICE TOOLS (continued)

Engine stand

(P/N 529 035 646)

V01B0J4

NEW

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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS

Subsection 02 (SERVICE TOOLS)

01-02-5

ELECTRICAL — MANDATORY SERVICE TOOLS

Six-pin magneto harness

(P/N 529 035 654)

F01B284

T-Harness for diagnoses of

solenoids

(P/N 529 035 653)

V01B0L4

Jumper for self-diagnoses

(P/N 529 035 605)

V01B0M4

NEW

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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS

Subsection 02 (SERVICE TOOLS)

01-02-6

ELECTRICAL — RECOMMENDED SERVICE TOOLS

Crimping tool

(P/N 295 100 164)

F00B0E4

Terminal remover

Not sold by Bombardier

Snap-on

TT 600-4

F01B1J4

Multimeter

(P/N 529 022 000)

F01B1O4

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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS

Subsection 02 (SERVICE TOOLS)

01-02-7

SUSPENSION — MANDATORY SERVICE TOOLS

Front suspension space bar

(P/N 529 035 611)

V01B0N4

NEW

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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS

Subsection 02 (SERVICE TOOLS)

01-02-8

SUSPENSION — RECOMMENDED SERVICE TOOLS

Shock spring removal kit

(P/N 529 027 100)

Replacement clevis pin:

(P/N 414 528 400)

A01B4O4

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Section 01 SERVICE TOOLS AND SERVICE PRODUCTS

Subsection 02 (SERVICE TOOLS)

01-02-9

DRIVE — MANDATORY SERVICE TOOLS

Pliers

(P/N 295 000 069)

Oetiker 1090

F01D184

Pliers

(P/N 295 000 054)

Caillau

F01B1T4

Hub puller

(P/N 529 035 612)

V01B0O4

NEW

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