Upload
bapal1986
View
217
Download
0
Tags:
Embed Size (px)
DESCRIPTION
manual de PDI brp
Citation preview
Printed in Canada (vbl2000-006a.fm MD)®*Trademarks of Bombardier Inc. and/or its subsidiaries.©2000 Bombardier Inc. All rights reserved.
2000-1 Page 1 of 18
This bulletin must be used in conjunction with the check list enclosed in the bag with the Operator’sGuide and the Safety Handbook. Make sure that predelivery check list is completed and signed.
NOTE: The information and components/system descriptions contained in this document are correct atthe time of publication. Bombardier however, maintains a policy of continuous improvement of its prod-ucts without imposing upon itself any obligation to install them on products previously manufactured.Due to late changes, there might be some differences between the manufactured product and the de-scriptions and/or specifications in this document. Bombardier reserves the right at any time to discontinueor change specifications, designs, features, models or equipment without incurring obligation.The illustrations in this document show the typical construction of the different assemblies and may notreproduce the full detail or exact shape of the parts. However, they represent parts that have the sameor similar function.The content of this bulletin is designed as a guideline only. All mechanics performing predeliveryprocedures should have attended the current model-year service training. Further information orinquiries should be directed to your distributor service representative and/or specific Shop Manualsections. Please complete the Predelivery Check List for each vehicle and retain a customer-signedcopy. Make sure the customer receives the Operator’s Guide, Safety Handbook, Predelivery CheckList signed copy and video.
No. 2000-1REVISION 1
Date: February 25, 2000 SUBJECT: Predelivery Inspection
YEAR MODEL MODEL NUMBER SERIAL NUMBER
2000 Traxter*7415/7416/7417/74187405/7406/7407/7408 All
WARNING
To obtain warranty coverage, predelivery procedures must be performed by an authorized BombardierATV dealer. Apply all necessary torques as indicated.
FO
R A
PP
RO
VA
L O
NLY
FO
R
Page 2 of 18 2000-1
UNCRATING
Carefully lay the crate on its bottom.CAUTION: Allowing the crate to drop may causeserious damage to the vehicle.Remove all screws retaining cover to crate base.Assisted by another person, lift crate cover over.
CAUTION: Do not tip cover toward front of ve-hicle. Remove straps and hooks retaining vehi-cle. The vehicle is retained in front by thebumper and in rear by the frame extension.
To remove, charge and install battery in vehicle,refer to next section.Fill the fuel tank and check all liquid levels (brake,cooling, etc.).Move vehicle of the crate base.
PARTS INSTALLATIONBATTERY
Battery RemovalRemove seat.Remove the holding straps.Remove battery from vehicle.Place battery on a level surface (other than ce-ment).
Activation of a New BatteryA new battery is factory fresh dry charged. Forstorage purposes, it is fitted with a temporary seal-ing tube.Do not remove the sealing tube or loosen batterycaps unless activation is desired.In case of accidental premature removal of capsor sealing tube, battery should be given a fullcharge.Perform the following operations:1. Remove the sealing tube from the vent elbow.
Install vent tube (included in the battery kit) tobattery elbow.
1. Battery electrolyte
2. Remove caps and fill battery to UPPER LEVELline with electrolyte (specific gravity: 1.260 at20°C (68°F)).
WARNING
Torque wrench tightening specificationsmust be strictly adhered to. Locking devices(e.g. lock tabs, elastic nuts) must be installedor replaced by new ones, where specified.Fasteners with locking agent must be re-placed by new ones. If the efficiency of a lock-ing devices is impaired, it must be renewed.
WARNING
No one should be standing in front of or inback of the vehicle while straps are being cut.
WARNING
Failure to remove the sealing tube could re-sult in an explosion.
WARNING
Electrolyte is poisonous and dangerous. Avoidcontact with eyes, skin and clothing. Wearprotective eyewear and a suitable pair of non-absorbent gloves when handling the battery.
A17E0FA
1
2000-1 Page 3 of 18
3. Allow the battery to stand for 30 minutes MIN-IMUM so that electrolyte soaks through batterycells.
4. Allow gas bubbles to escape by lightly shakingbattery by hand.
5. Readjust the electrolyte level to the UPPERLEVEL line.
6. Connect a 2 A battery charger for 10 to 20 hoursas per following 1, 2 and 3 sequence.
CAUTION: If charging rate rises higher than 2.4A reduce it immediately. If cell temperature ris-es higher than 50°C (122°F) (if the casing feelshot) discontinue charging temporarily or re-duce the charging rate.
7. Disconnect battery charger as per following 1,2 and 3 sequence.
8. Test battery state of charge. Use a hydrometer.
1. Specific gravity 1.260
9. Let battery settle for 1 hour.10. Allow gas bubbles to escape by lightly shaking
battery.11. Readjust electrolyte level.12. Reinstall caps and clean any electrolyte spill-
age using a solution of baking soda and water.
1. Baking soda
CAUTION: Do not allow cleaning solution to en-ter battery interior since it will destroy the elec-trolyte.
WARNING
Never charge battery while installed on vehicle.
WARNING
Gases given off by a battery being charged arehighly explosive. Always charge in a well ven-tilated area. Keep battery away from sparks oropen flames. Always turn battery charger offprior to disconnecting cables. Otherwise aspark will occur and battery might explode.
Page 4 of 18 2000-1
Battery InstallationPlace the battery in the engine compartment ontothe battery support.Install the vent tube.Secure RED positive cable to battery post.
1. Cable between battery and strap
Apply dielectric grease (P/N 293 550 004) on bat-tery posts.Cover battery positive post with rubber boot.
LIQUIDSLIQUID LEVEL
Engine Oil LevelWith vehicle on a level surface and engine not run-ning, check the engine oil with the dipstick. Refillif necessary.CAUTION: Do not overfill. Operating the engine/transmission with an improper level may se-verely damage engine/transmission. Wipe offany spillage.SAE 10W40 is recommended for general use. Al-ways use 4-stroke mineral-based engine oil thatmeets or exceeds the requirements for API ser-vice classification SF, SG or SH.Other viscosity should be used if the average tem-perature is outside the range of the recommendedoil. See the Operator’s Guide.CAUTION: The same oil lubricates both engineand transmission. Do not use synthetic or semi-synthetic oil. They affect the clutching calibra-tion.CAUTION: For proper operation of the clutch-ing system, do not use special oil additives. Donot use unrecommended types of oil.
LH SIDE OF ENGINE1. Dipstick2. Filler cap
Brake FluidWith vehicle on a level surface, check brake fluidin reservoirs for proper level. It should be to theMAX. mark.Add fluid as required. Do not overfill.Clean filler cap before removing.
WARNING
Connect RED positive cable first then nega-tive cable. Always connect RED positive cablefirst.
WARNING
Place the RED positive cable between hold-ing straps and battery to avoid cable beingcaught in shock absorber.
2000-1 Page 5 of 18
CAUTION: Use only DOT 4 brake fluid from asealed container.
FRONT BRAKE FLUID RESERVOIR
REAR BRAKE FLUID RESERVOIR
Coolant LevelCheck the coolant level and refill if necessary witha solution of 60% antifreeze and 40% water.
FRONT DIFFERENTIAL
Oil LevelClean filler plug prior to checking oil level.With vehicle on a level surface, check the oil levelby removing filler cap. Oil level must be 32 mm(1-1/4 in) below filler plug.Add oil if necessary (refer to specifications at theend of this bulletin).
REAR AXLE
Oil LevelLift back of vehicle and secure in place. Place theswing arm to the horizontal position.Clean filler plug prior to check oil level, check theoil level by removing filler cap. Oil level must reachthe lower edge.Add oil if necessary (refer to specifications at theend of this bulletin).
Page 6 of 18 2000-1
TIRES AND WHEELSCheck pressure when tires are “cold” before us-ing the vehicle. Tire pressure changes with tem-perature and altitude. Recheck pressure if one ofthese conditions has changed.
For your convenience, a pressure gauge is sup-plied in tool box.
ADJUSTMENTSIMPORTANT: All adjustments have already been performed at factory. It is only necessary to val-idate them. However, if readjustment is needed, the following procedures should be used.
BRAKE PEDALPlace a shim between brake pedal lever andswitch nut. The tickness of the shim must be 2mm (5/64 in).Adjust push rod to eliminate free play betweenbrake pedal lever and master cylinder.When a light pressure is felt, torque push rod nutto 4.5 N•m(39 lbf•in).Remove the shim and press the brake pedal lever.Check for a light play in the system.
1. Push rod jam nut2. Brake pedal return spring
BRAKE CABLE
While holding rod with locking pliers, turn the ad-justment nut until stopper comes in contact withthe brake pedal lever.Unscrew adjustment nut approximately 1/4 turn tomake sure there is no tension on brake cable.
1. Adjustment nut2. Stopper3. Maximum 1 mm (1/32 in) gap
WARNING
Underpressure may cause tire to deflate androtate on wheel. Overpressure may burst thetire. Always follow recommended pressure.Since tires are low-pressure type, a manualpump should be used.
TIRE PRESSURE FRONT REAR
RECOMMENDED 38 kPa(5.5 Psi)
35 kPa(5 Psi)
MINIMUM 35 kPa(5 Psi)
31 kPa(4.5 Psi)
WARNING
Adjust brake pedal prior to adjusting brakecable. If brake pedal is not correctly adjusted,the parking device will not function properly.
2000-1 Page 7 of 18
INTERLOCK CABLEAdjust cable so that the pin end from interlock ca-ble is flush with the shifter lever plate. Use theinterlock adjustment as per following photos.
1. Interlock pin end2. Shifter lever plate
Torque nut and jam nut.
1. Interlock adjustment2. Jam nut3. Nut
BRAKE LIGHT SWITCH
Front Brake Light SwitchThe front brake switch is located on the mastercylinder and cannot be adjusted. Check that switchis securely installed and operational.
Rear Brake Light SwitchDepress brake pedal and check for brake light toturn on. The rear brake light switch cannot be ad-justed.
SUSPENSION
InspectionInspect shock absorber for oil leaks and fastenersfor tightness.
Spring Preload AdjustmentAdjust spring preload by turning adjusting camwith the wrench in vehicle tool box.Turn the adjusting cams clockwise for a firmer rideand rought road condition or when carrying cargoor pulling a trailer.Turn the adjusting cams counterclockwise for alight load and a smooth road condition.
1. Adjusting cam2. Smooth adjustment3. Hard adjustment
WARNING
Left and right adjusting cams must alwaysbe set at the same position. Never adjust oneadjusting cam only. Uneven adjustment cancause poor handling and loss of stability,which could lead to an accident.
Page 8 of 18 2000-1
CARBURETOR ADJUSTMENTSModels 7415/7416/7417/7418
BOTTOM VIEW1. Idle speed screw2. Pilot screw3. Drain plug and screw
Models 7405/7406/7407/7408
BOTTOM VIEW1. Idle speed screw2. Pilot screw3. Drain plug and screw
All Models
Pilot Screw AdjustmentNOTE: Pilot screw is factory pre-set. Adjustmentis not necessary unless carburetor is overhauledor replaced.Warm-up engine to operating temperature.NOTE: Engine must run for a minimum of 20 min-utes at idle speed to reach normal operating tem-perature. Set idle speed to specification, using idle speedscrew.Connect RPM gauge. If you are using Bombardiertool (P/N 529 014 500), turn RPM gauge wire, 4 to5 turns around spark plug cable. Note that there isa spark at each crankshaft turn.Turn pilot screw clockwise till engine RPM speeddecreases and then counterclockwise till engineRPM speed decreases then set screw position ex-actly between these two settings.If idle speed changes after pilot screw adjustment,readjust engine RPM by the idle speed screw.CAUTION: Failure to do so will result in a toohigh engine idle speed and a difficulty to shiftthe sub-transmission caused by centrifugalclutch engagement.Refer to TECHNICAL DATA for the specifications.
2000-1 Page 9 of 18
Models 7415/7416/7417/7418
EnrichnerRemove top cover from carburetor. Detach diaphragm from carburetor body, then pull out throttle slide.With enrichner lever at fully closed position, enrichner plunger must be fully closed. With lever halfway,plunger must be opened to specifications and with lever completely opened, plunger must be opened.See next photos for proper enrichner lever and plunger positioning.
FULLY CLOSED POSITION1. Plunger end must be here
HALFWAY POSITION1. Plunger end must be hereA. Opening to specification
FULLY OPENED POSITION1. Plunger end must be here
Page 10 of 18 2000-1
Plunger AdjustmentTo adjust plunger use cable adjuster, as shown inthe next photo.
USE CABLE ADJUSTER TO ADJUST PLUNGER1. Enrichner plunger
NOTE: For proper adjustment at halfway position,use a drill bit with a diameter of the opening spec-ification (refer to TECHNICAL DATA).
Models 7405/7406/7407/7408
On these models, the enrichner is not adjustablebecause it is fully variable.
All Models
Diaphragm InstallationCarefully replace diaphragm in its original position.NOTE: On models 7415/7416/7417/7418, checkand place the indexation lob correctly.Make sure spring is located properly in carburetorcover before screwing.
Throttle
Before adjusting the throttle cable, adjust idlespeed (preliminary adjustment) and enrichner.On the carburetor, loosen the lock nut and adjustthe throttle cable.Make sure the throttle lever, at the full position,doesn’t press against carburetor body.
TYPICAL — THROTTLE LEVER AT THE FULL POSITION A. 1 mm (1/32 in) gap
Retorque lock nut.
WARNING
Ensure the key is turned OFF, prior to per-forming the throttle cable adjustment.
2000-1 Page 11 of 18
TOE-OUTPlace the vehicle on the level surface.Check that handlebar is horizontal.Use a long rule and check if the rear and frontwheels are aligned.Adjust alignment with the tie-rod.Adjust toe-out to 17 mm ± 4 mm (43/64 in ±5/32 in).
Measuring ProcedureNOTE: Before measuring toe-out, ensure tirepressure is correct.Place vehicle on a level surface.Raise front end of vehicle and release slowly.Move rear portion of front wheels toward the in-side of vehicle.Place handle bar straight ahead.Mark both front tire thread center at 254 mm(10 in) from the ground.Measure the width A between the marks.Measure the width B between the marks.Calculate the toe-out as per following formula:Toe-out = A - B
Toe-out should be 17 mm ± 4 mm (43/64 in ±5/32 in).If toe-out is incorrect, adjust it.
Adjustment ProcedureMark both tie-rod ends. This reference point willbe needed during adjustment.Loosen tie-rod end lock nuts; adjust both tie-rods.
Move rear portion of front wheels toward the in-side of the vehicle.Adjust both tie-rods until the specified toe-out isobtained. The important is to keep the length ofthe tie-rods the same.Tighten tie-rods and lock nuts of both tie-rod ends.Torque specification for lock nuts is 32-36 N•m(24-27 lbf•ft).Adjust tie-rod ends so that A and B are equal.NOTE: After setting toe-out to specification, runthe vehicle slowly for some distance with bothhands lightly holding handlebar and check thathandlebar responds correctly. If not, turn eitherleft or right tie-rod within toe-out specification.
WARNING
Ensure that both tie-rods are turned the sameamount of turns. If not, vehicle will drift rightor left even though handlebar is positionedstraight. This may lead to mishandling and/oraccident.
Page 12 of 18 2000-1
GENERAL INFORMATIONSComplete Predelivery Check List.Test run vehicle.Clean vehicle.To clean the entire vehicle, use only flannel clothesor Kimtowels® wipers no. 58-380 from Kimberly-Clark.CAUTION: It is necessary to use flannel clothsor Kimtowels wipers on vehicle to avoid dam-aging further surfaces to clean.To clean the entire vehicle, including metallic partswith a thick coat of grease, use Endust® by BristolMyers, available at hardware stores or supermar-kets.CAUTION: Do not apply isopropyl alcohol orsolvent directly on decals.To clean the entire vehicle, including metallic partswith a thin coat of grease, use Simple Green®
from Sunshine Makers Inc., available at hardwarestores or at automotive parts retailer.For vinyl and plastic parts, use Vinyl & Plastic Clean-er (P/N 413 711 200 (6 x 1 L)).CAUTION: Never clean plastic parts with strongdetergent, degreasing agent, paint thinner, ac-etone, products containing chlorine, etc.Give Operator’s Guide (P/N 704 000 005), SafetyHandbook (P/N 704 200 013) and Videocassette tocustomer. Ask the customer to sign the Predeliv-ery Check List.
2000-1 Page 13 of 18
TECHNICAL DATAENGINE TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Engine type BOMBARDIER-ROTAX 511, longitudinal mount, liquid cooled
Lubrication type Wet sump with replaceable oil filter
Oil filter BOMBARDIER-ROTAX
Air filter type Cleanable synthetic panelette
Exhaust typeType Nelson, stainless steel
Spark arrester USDA approved
Starting system Electric and manual
Number of cylinders 1
Number of valves 2 valves with hydraulic lifters (no adjustment)
Decompressor type Automatic
Bore Standard 89 mm (3.5 in)
Stroke 80 mm (3.15 in)
Displacement 498 cm3 (30.4 in3)
Compression ratio 9:1 on models 7415/7416/7417/7418,9.75:1 on models 7405/7406/7407/7408
Maximum HP RPM ± 100 RPM 6000
ELECTRICAL TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Magneto/generator 40 W @ 6000 RPM
Ignition system type I.D.I. (Inductive Discharge Ignition)
Spark plugMake and type NGK DR8 EA
Gap 0.65 mm (.026 in)
Trigger coil 190 to 300 ΩBattery charging coil 0.4 ± 0.1 Ω
Ignition coilPrimary 0.4 to 0.9 Ω @ 20°C
Secondary Not measurable
Engine RPM limiter 7500
Battery
Type Electrolyte battery type
Voltage 12 volts
Nominal rating 19 (21 optional) A•h
Power starter output 0.6 kW
Fuse
Ignition 15 A
Accessories 15 A
Solenoids 15 A
Fan 15 A
MPEM 20 A
Charging system 30 A
Page 14 of 18 2000-1
CARBURETION TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
CarburetorType Mikuni Constant depressure type with manual choke and ECS
(Enricher Coating System)
ModelBST34-232 on models 7415/7416/7417/7418,BSR 33-12 on models 7405/7406/7407/7408
Fuel pumpType Mikuni
Model External (vacuum-operated)
Idle engine speed ± 100 RPM 1100
Needle jet 0-7M (850) on models 7415/7416/7417/7418,0-8 (826) on models 7405/7406/7407/7408
Jet needle 5 GBF61-2 on models 7415/7416/7417/7418,5 FEY1-3 on models 7405/7406/7407/7408
Clip position number Middle
Enrichner plunger position Opening halfway 2.5 ± 0.5 mm (0.098 ± 0.039 in) on models 7415/7416/7417/7418,variable on models 7405/7406/7407/7408
Adjustment
Throttle cable 0.5 mm (0.02 in)
Preliminary pilot screw turn 2.25 turns on models 7415/7416/7417/7418,2 turns on models 7405/7406/7407/7408
Float level± 0.5 mm 10.6 on models 7415/7416/7417/7418,
10 on models 7405/7406/7407/7408
± 0.020 in 0.417 on models 7415/7416/7417/7418,0.39 on models 7405/7406/7407/7408
FuelType Regular unleaded gasoline
Octane no. 87 (Ron + Mon)/2
COOLING TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Fan Thermostatic
Fan thermostatOpening temperature 96°C (205°F)
Closing temperature 102°C (221°F)
Engine thermostatOpening temperature 85°C (185°F)
Closing temperature 75°C (167°F)
Cap opening pressure 90 kPa (13 PSi)
DRIVE TRAIN TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Transmission type
Type Dual range (HI-LO) with park, neutral and reverse
Speeds 5
Model Electronically controlled hydraulic shift
Normal oil operating pressure of engine
Minimum 101 kPa (14.7 PSi)
Maximum 608 kPa (88 PSi)
Operating pressure for shifting and clutching 810 kPa (118 PSi)
Clutch type 1 centrifugal and 1 multi-disc hydraulically controlled
Engagement RPM ± 100 1600
Front differential Shaft driven/single Auto-lock differential (pump driven)
Front differential ratio 3.6:1
Rear axle Shaft driven/solid axle
Rear axle ratio 3.6:1
STEERING/CONTROL TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Turning radius 3.3 m (11 ft)
Total toe-out (vehicle on ground) 17 mm ± 4 mm (43/64 in ± 5/32 in)
Camber angle 0°
Tie rod maximum length unengaged± 5 20 mm
± 0.197 0.787 in
2000-1 Page 15 of 18
SUSPENSION TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Front
Suspension type Independent suspension — double A arm
Suspension travel 178 mm (7 in)
Shock absorberQty 2
Type Oil
Spring free length 270 mm (11 in)
Spring color code Silver-Blue-Black
Front preload adjustment type N.A.
Rear
Suspension type Rigid swing arm
Suspension travel 191 mm (7.5 in)
Shock absorberQty 2
Type Oil
Spring free length 355 mm (14 in)
Spring color code Green-White-Black
Rear preload adjustment type 3 Positions
BRAKE TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Front brakeQty 2
Type Brembo hydraulic
Rear brakeQty 1
Type Brembo hydraulic
Parking device Transmission brake and brake lever lock on LH brake lever
Lining material Metallic
Minimum pad thickness 1 mm (0.04 in)
Minimum brake disc thighness 4.7 mm (0.18 in)
Maximum brake disc warpage 0.25 mm (0.01 in)
Caliper Fixed
TIRES AND WHEELS TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Tires
Pressure
FrontRecommended 38 kPa (5.5 PSi)
Minimum 35 kPa (5 PSi)
RearRecommended 35 kPa (5 PSi)
Minimum 31 kPa (4.5 PSi)
Minimum tire thread depth 4 mm (0.16 in)
SizeFront 635 x 203 x 305 mm (25 x 8 x 12 in)
Rear 635 x 254 x 305 mm (25 x 10 x 12 in)
Wheels
SizeFront 305 x 165 mm (12 x 6.5 in)
Rear 305 x 203 mm (12 x 8 in)
Page 16 of 18 2000-1
DIMENSION TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Overall length 2071 mm (81.5 in)
Overall width 1194 mm (47 in)
Overall height 1143 mm (45 in)
Dry weight 340 kg (755 lb)
Wheel base 1296 mm (51 in)
Wheel trackFront 992 mm (39 in)
Rear 940 mm (37 in)
Front and under engine ground clearance 244 mm (9.6 in)
Rear differential ground clearance 188 mm (7.4 in)
CAPACITIES TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Liquid
Fuel tank 20 L (5.7 U.S. gal)
Fuel tank reserve 6 L (1.6 U.S. gal)
Engine/transmission oilCapacity 3 L (0.8 U.S. gal)
Recommended SAE 10W40, 4 stroke mineral based oil SH or SJ
Differential oil
FrontCapacity 650 mL (22 U.S. oz.)
Recommended Synthetic polyolester oil 75W90 (API GL5)
RearCapacity 300 mL (10 U.S. oz.)
Recommended Synthetic polyolester oil 75W90 (API GL5)
CV joint grease TEXACO, HTBJ grease (M3014), ONLY
Propeller shaft grease SHELL, Alvania EP-2 ONLY
Hydraulic brakesCapacity 250 mL (8.5 U.S. oz)
Recommended Brake fluid DOT 4 ONLY
Cooling system 2.5 L (0.7 U.S. gal)
Ethylene-glycol concentration 60%
Body and Frame
Weight distribution Front/rear 49/51
Front storage tray 10 kg (22 lb)
RackFront 40 kg (90 lb)
Rear (including tongue weight) 80 kg (175 lb)
Total vehicle load allowed 220 kg (485 lb)
Gross vehicle weight rating 540 kg (1200 lb)
Towing 500 kg (1100 lb)
Tongue 14 kg (30 lb)
2000-1 Page 17 of 18
MATERIALS TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Material Color
Frame Steel Black
Front/rear rack Steel Black
Front bumper Steel Silver
Front/rear fender High density polyethylene Green/Red
Fuel tank cover High density polyethylene Black
Steering cover High density polyethylene Black
Storage compartment cover High density polyethylene Black
Front/rear facia High density polyethylene Black
Side panel High density polyethylene Black
Mudguard Low density polyethylene Black
Seat cover Thermoformed vinyl Black
TIGHTENING TORQUES TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
EN
GIN
E
Engine support 24 N•m (17 lbf•ft)
Engine mount 48 N•m (35 lbf•ft)
Spark plug 22 N•m (16 lbf•ft)
Rewind starter 5 N•m (44 lbf•in)
Rear solenoid block 5 N•m (44 lbf•in)
Magneto 10 N•m (89 lbf•in)
Starter 10 N•m (89 lbf•in)
Starter RED (+) cable 6 N•m (53 lbf•in)
STPS (Sub-Transmission Position Sensor) 3 N•m (27 lbf•in)
GBPS (Gear Box Position Sensor) 3 N•m (27 lbf•in)
CO
OLI
NG
Radiator mount screw/nut 10 N•m (89 lbf•in)
Temperature sensor Engine unit 17 N•mRadiator unit 11 N•m
(150 lbf•in)(97 lbf•in)
Water pump 10 N•m (89 lbf•in
Fan mounting screws 4 N•m (35 lbf•in)
EX
HA
US
T
Exhaust nut 11N•m (97 lbf•in)
Heat shield screws 10 N•m (89 lbf•in)
FUE
L
Carburetor mounting clamp 0.6 N•m (5.4 lbf•in)
DR
IVE
TR
AIN
Front wheel hub nut 140 N•m (103 lbf•ft) (MINIMUM)
Front differentialFront 48 N•m (35 lbf•ft)
Rear 48 N•m (35 lbf•ft)
Rear differential socket screws 48 N•m (35 lbf•ft)
Propeller shaft screwEngine side 34 N•m (25 lbf•ft)
Differential side 42 N•m (31 lbf•ft)
WARNING
Apply all necessary torques as indicated. Specified torques must be adhered to.
Page 18 of 18 2000-1
TIGHTENING TORQUES TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)W
HE
EL
Wheel nuts 73 N•m (54 lbf•ft)
ST
EE
RIN
G/
CO
NT
RO
L
Upper/lower arm lock nut 75 N•m (55 lbf•ft)
Tie rod ends 75 N•m (55 lbf•ft)
Steering arm (castel nut) 75 N•m (55 lbf•ft)
Steering column support screws 24 N•m (17 lbf•ft)
Handlebar screws 24 N•m (17 lbf•ft)
Flanged bearing bolts 19 N•m (14 lbf•ft)
SU
SP
EN
SIO
N
Shock absorber bolt 48 N•m (35 lbf•ft)
Front upper A-arm 67 N•m (49 lbf•ft)
Front lower A-arm 67 N•m (49 lbf•ft)
Rear swing arm RH pivot 147 N•m (108 lbf•ft)
Rear swing arm LH pivot 11 N•m (97 lbf•in)
Rear swing arm LH nut 147 N•m (108 lbf•ft)
Rear swing arm hexagonal screws 48 N•m (35 lbf•ft)
BR
AK
E Caliper brake screws 24 N•m (17 lbf•ft)
Brake disc screws 34 N•m (25 lbf•ft)
BO
DY
/FR
AM
E
Front bumper 24 N•m (17 lbf•ft)
Front rackFront 15 N•m (133 lbf•in)
Rear 15 N•m (133 lbf•in)
Rear rackUpper 15 N•m (133 lbf•in)
Lower 15 N•m (133 lbf•in)
Rear frame extension 48 N•m (35 lbf•ft)
Front differential support 24 N•m (17 lbf•ft)
Seat pivot bar 24 N•m (17 lbf•ft)
Winch plate support 24 N•m (17 lbf•ft)
Footrest 24 N•m (17 lbf•ft)
Removable brace 24 N•m (17 lbf•ft)
Skid plate 15 N•m (133 lbf•in)
Headlight adjustment 0.6 N•m (5.4 lbf•in)
WARNING
Apply all necessary torques as indicated. Specified torques must be adhered to.