BOMBARDIER Traxter 7401 Datasheet

Category
Offroad Vehicle
Type
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
25
24
25
25
24
23
6
3
3
17
13
12
29
11
16
21
21
21
20
20
20
22
18
17
5
Therma Lube
grease
Therma Lube
grease
Therma Lube
grease
12
48 Nî‚•m
(35 lbfî‚•ft)
48 Nî‚•m
(35 lbfî‚•ft)
24 Nî‚•m
(17 lbfî‚•ft)
24 Nî‚•m
(17 lbfî‚•ft)
10 Nî‚•m
(97 lbfî‚•in)
24 Nî‚•m
(17 lbfî‚•ft)
48 Nî‚•m
(35 lbfî‚•ft)
10 Nî‚•m
(97 lbfî‚•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 Nî‚•m or 35 lbfî‚•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
lbfî‚•in instead
of lbfî‚•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
NEW
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
NEW
NEW
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
NEW
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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BOMBARDIER Traxter 7401 Datasheet

Category
Offroad Vehicle
Type
Datasheet

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