AUSA M-50 x 4, Workshop Manual

Page 1: ...1 AUSA M 50 x 4 ROTAX ENGINE WORKSHOP MANUAL ...

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Page 4: ...PREPARATION AND TEST 03 03 1 INSTALLATION 03 03 3 REMOVAL AND INSTALLATION 03 04 1 GENERAL 03 04 3 ENGINE REMOVAL 03 04 3 ENGINE INSTALLATION 03 04 8 ANTI VIBRATION SYSTEM 03 04 9 EXHAUST SYSTEM 03 04 9 SHIFTING SYSTEM 03 04 10 COOLING SYSTEM 03 05 1 WATER PUMP 03 05 1 COOLING SYSTEM 03 05 2 GENERAL 03 05 3 COOLING SYSTEM LEAK TEST 03 05 3 INSPECTION 03 05 3 DRAINING THE SYSTEM 03 05 4 COOLANT REP...

Page 5: ... GENERAL 03 08 2 ENGINE OIL PRESSURE TEST 03 08 2 OIL CHANGE 03 08 3 OIL FILTER 03 08 3 OIL STRAINER 03 08 4 ENGINE OIL PRESSURE REGULATOR 03 08 6 OIL PUMP 03 08 6 CYLINDER AND HEAD 03 09 1 GENERAL 03 09 3 SPARK PLUG 03 09 3 THERMOSTAT 03 09 3 VALVE COVER 03 09 4 VALVE ADJUSTMENT 03 09 4 CHAIN TENSIONER 03 09 5 CHAIN TENSIONER HOUSING 03 09 5 DECOMPRESSOR 03 09 6 CAMSHAFT TIMING GEAR 03 09 8 ROCKE...

Page 6: ...NG CHAIN 03 10 4 TIMING CHAIN GUIDE 03 10 5 CRANKCASE 03 10 5 BALANCER SHAFT 03 10 9 CRANKSHAFT 03 10 10 GEARBOX 03 11 1 OUTPUT SHAFT AND TRANSMISSION 03 11 1 CRANKCASE 03 11 2 GENERAL 03 11 3 OIL SEALS 03 11 3 OUTPUT SHAFT 03 11 3 CRANKCASE 03 11 6 GEARBOX 03 11 12 SHIFTING INDICATOR SWITCH 03 11 21 STARTER DRIVE PINION 03 11 22 CVT 03 12 1 GENERAL 03 12 2 BELT REPLACEMENT 03 12 2 DRIVE PULLEY 03...

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Page 8: ...stat defective Replace 4 Check gasket s underneath water pump cover a Leakage in water pump cover area Retighten screws and or replace gasket 5 Check leak indicator hole water pump housing area MAG side if coolant leaks a Coolant leaking from leak indicator hole means a damaged rotary seal inside mag neto cover Replace both rotary seal and oil seal refer to COOLING SYSTEM and MAGNETO SYSTEM 6 Chec...

Page 9: ...ant supply Replace worn out and or broken gear s refer to LUBRICATION MAGNETO SYSTEM 13 Check radiator fan switch and fuse 20A a Faulty fan switch and or faulty fuse Replace defective part s 14 Check radiator condition for leakage a Radiator cracked or deformed Replace radiator 15 Check mud dust in radiator fins a Radiator fin obstructed hard air cooling Clean radiator fins 16 Check if water pump ...

Page 10: ...k CPS crankshaft position sensor for damage and or electrical failure a Sensor shows electrical failure and or damages Replace CPS b Connector is corroded Clean and reconnect c Resistance value is out of specification refer to TECHNICAL DATA Replace CPS 8 Check wire harness for cracks or other damages a Harness shows electrical failure and or other damages Replace wire harness and or damaged wire ...

Page 11: ...amination a Oil filter clogged Replace oil filter and oil at the same time Use a high quality oil refer to TECHNICAL DATA 3 Check oil pressure regulator valve spring function a Valve spring damaged valve always open Replace spring b 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 a Plug is loosed and...

Page 12: ...er to CRANKSHAFT SYMPTOM OIL CONTAMINATION WHITE APPEARANCE CONDITION NORMAL USE Test Inspection 1 Check leak indicator hole water pump housing area MAG side if water and oil leaks a Leakage of oil water mixture from leak indicator hole means damaged oil seal and rotary seal inside magneto cover on water pump shaft Replace both rotary seal and oil seal and refill with recommended oil and or coolan...

Page 13: ...NDITION NORMAL USE Test Inspection 1 Check items 1 and 2 of UNUSUAL ENGINE NOISE AND OR VIBRATION IN IDLE SPEED 2 Check noise coming from cylinder head area a Check valve clearance Readjust valve clearance and or replace defective part s b Chain guide worn out Replace chain guide c Stretched chain and or worn out sprocket Replace chain and sprocket at the same time d Sprocket screw got loose Retig...

Page 14: ...nd plain bearing MAG PTO at the same time refer to CRANKSHAFT 2 Check ball bearing s on balancer shaft end s a Ball bearing s do es not move freely Replace bearing s 3 Check that mark on balancer shaft is aligned with crankshaft position mark a Mark on balancer shaft and crankshaft are not aligned Readjust position of balancer shaft and crankshaft refer to CRANKSHAFT BALANCER SHAFT SYMPTOM UNUSUAL...

Page 15: ...RE HARD TO SHIFT CONDITION NORMAL USE Test Inspection 1 Check shift shaft spline and or shift forks for wear and or damages a Shift shaft is worn out and or shows damaged splines Replace shift shaft b Shift drum track s and or splines is are worn out or damaged Replace shift drum and damaged part s c Shift fork s is are worn out and or engagement pins are damaged Replace shift fork s d Shift fork ...

Page 16: ...he spring 6 Check for any mud intrusion s a CVT parts dirty Clean all CVT parts SYMPTOM REWIND STARTER ROPE DOES NOT REWIND CONDITION NORMAL USE Test Inspection 1 Check rewind spring a Broken spring Replace spring refer to REWIND STARTER SYMPTOM REWIND STARTER PAWL DOES NOT ENGAGE CONDITION NORMAL USE Test Inspection 1 Check stop spring a Broken stop spring Replace 2 Check pawl and pawl lock a Paw...

Page 17: ...kit 3 Check drive pulley sliding half for free axial movement a Sliding half is stuck refer to CVT Replace damaged part s 4 Check condition of drive driven pulley spring a Drive pulley spring tension is too smooth and or damaged refer to CVT Replace spring b Driven pulley spring tension is too stiff refer to CVT Replace spring 5 Check carburator adjustment and or high altitude calibration a Carbur...

Page 18: ... Replace all slider shoes at the same time slider shoes kit 2 Check driven pulley sliding mechanism between driven pulley outer and inner half a Mechanism is stucked and or damaged Replace driven pulley assembly 3 Check roller s and or levers for wear located on sliding half of drive pulley a Roller s on governor cup is are worn out and or damaged refer to CVT Replace governor cup assembly b Lever...

Page 19: ...n pulley sliding half for wear a Torque gear out of wear limit and or damaged Replace torque gear refer to CVT 6 Check for foreign particles in CVT area stones dirt etc a Small particles damaged belt and or pulley surface s Clean system and replace damaged parts refer to CVT SYMPTOM VIBRATIONS ORIGINATING FROM DRIVE PULLEY CONDITION NORMAL USE Test Inspection 1 Check tightening torque of drive pul...

Page 20: ...cks to sliding half pulley bushing Clean system and or replace sliding half pulley c One way clutch does not operate properly Clean system and or replace damaged part s 2 Check driven pulley spring tension a Driven pulley spring tension is too weak and or broken Replace b Driven pulley cam is worn or damaged Replace SYMPTOM BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE CONDITION NORMAL USE Te...

Page 21: ...on A00DOEY 1 Check drive belt identification number a Excessive belt speed Using unspecified type of belt Replace belt with proper type of belt refer to TECHNICAL DATA 2 Check if pulley halves are clean a Oil on pulley surfaces Clean pulley surfaces with fine emery cloth and wipe clean using Pulley Flange Cleaner P N 413 711 809 and a cloth b Drive driven pulley halves are damaged through stones i...

Page 22: ... gasket 4 Check intake valve s for leaking a Intake valve s is are leaking Repair or replace valve s 5 Check if fuel supply is insufficient at high RPM a Fuel line is contaminated and or bent engine gets lean Clean and or replace defective part s 6 Check carburation a Faulty carburetor settings Adjust carburetor SYMPTOM ENGINE SUDDENLY TURNS OFF CONDITION NORMAL USE Test Inspection 1 Check spark p...

Page 23: ...ocedure Check for possible piston seizure a Damaged head gasket and or seal and or leaking inlet exhaust valve s Replace and or repair defective parts 5 Piston seizure piston ring s damaged and or cylinder shows grooves a Spark plug heat range is too low Replace damaged parts and install spark plug with appropriate heat range refer to TECHNICAL DATA b Compression ratio is too high Install genuine ...

Page 24: ...ing damages the cylinder head valve s rocker arm s piston Replace defective part s and do the valve adjustment 10 Check for water intrusion through intake system into combustion chamber a Water in intake system and or combustion chamber Replace defective part s SYMPTOM ENGINE TURNS OVER BUT FAILS TO START CONDITION NORMAL USE Test Inspection 1 Check items of ENGINE DOES NOT START NO SPARK AT SPARK...

Page 25: ...et exhaust valve s Replace and or repair defective parts b Worn piston and or piston ring s Replace refer to CYLINDER AND HEAD 6 Check for water in fuel wrong fuel a There is water in fuel or wrong fuel Drain fuel system search for leakage and refill it with appropriate fuel 7 Check drive belt CVT condition a Worn belt Replace belt if width is less than specified refer to CVT SYMPTOM HIGH ENGINE O...

Page 26: ...ion 1 Verify spark plug condition a Defective improperly set worn out fouled Identify source of problem and correct Replace spark plug 2 Verify condition of ignition coil and resistance with an ohmmeter a Mechanically damaged part Vibration problem Electrically damaged part Replace ignition coil 3 Verify condition of CPS and resistance with an ohmmeter and connector condi tion a Defective CPS Corr...

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Page 28: ...aft refer to COOLING SYSTEM coolant escaping from water pump housing means damaged gasket s and or loosened screws refer to COOLING SYSTEM NOTE For all the checkpoints mentioned above see the appropriate engine section to diagnose and repair the engine LEAK TEST PROCEDURE PREPARATION AND TEST NOTE The following procedures should be done with a cold engine Disconnect battery Remove LH side panel ra...

Page 29: ...6 refer to CYLINDER AND HEAD CAUTION When removing camshaft screw al ways lock camshaft using locking tool P N 529 035 926 to avoid stretching the timing chain 1 Camshaft locking tool Second possible procedure Using crankshaft locking bolt P N 529 035 617 for crankshaft fixation at TDC refer to CRANKSHAFT see CRANKSHAFT LOCKING PROCEDURE 1 Vehicle front side 2 Position for crankshaft locking bolt ...

Page 30: ...screws refer to CYLINDER AND HEAD air escaping into crankcase area means exces sively worn cylinder and or broken piston rings NOTE For all the checkpoints mentioned above see the appropriate engine section to diagnose and repair the engine INSTALLATION NOTE At reassembly use the torque values and Loctite products from the exploded views refer to particular engine sections For installation reverse...

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Page 32: ...ENGINE Subsection 05 COOLING SYSTEM VMR2004_128_03_05A FM 03 05 1 COOLING SYSTEM 0 WATER PUMP 4 10 N m 89 lbf in 2 1 3 2 5 N m 22 lbf in Right hand thread 5 Engine oil Multi purpose grease 10 9 8 6 7 R400motr131S ...

Page 33: ...ENGINE Subsection 05 COOLING SYSTEM 03 05 2 VMR2004_128_03_05A FM COOLING SYSTEM V07C1RS 12 17 17 10 N m 89 lbf in 13 15 5 5 N m 49 lbf in 19 21 7 N m 62 lbf in 16 20 14 21 7 N m 62 lbf in 18 18 N m 159 lbf in 11 ...

Page 34: ... plug Check all hoses radiator no 13 and cylinder base for coolant leaks Spray a soap water solution and look for air bubbles INSPECTION Check general condition of hoses and clamp tight ness Check the leak indicator hole if there is oil or water NOTE Flowing water indicates a damaged rotary seal no 5 Oil out of the leak indicator hole indi cates a non working oil seal no 10 1 Leak indicator hole W...

Page 35: ...th 50 anti freeze and 50 water Do not use tap water straight antifreeze or straight water in the sys tem Tap water contains minerals and impuri ties which build up in the system During cold weather straight water causes the system to freeze while straight antifreeze thickens and does not have the same efficiency Always use ethylene glycol antifreeze containing corrosion inhibitors specifically rec...

Page 36: ...n centration freezing point with proper tester THERMOSTAT The thermostat is a single action type Removal NOTE The thermostat is located on the top of cyl inder head on intake side Install a hose pincher on both radiator hoses Remove bleeding screw on thermostat cover thermostat housing screws and pull thermostat cover 1 Thermostat cover 2 2 screws thermostat with gasket out of the hole 1 Thermosta...

Page 37: ...F Replace coolant temperature switch if necessary Installation For installation reverse the removal procedure CAUTION Never use the gasket ring a second time Always install a new one Torque temperature switch to 16 N m 142 lbf in Check coolant level in radiator and coolant tank and top up if necessary WATER PUMP HOUSING It is located on the engine MAG side Removal Drain cooling system Remove radia...

Page 38: ...ht hand threads Remove by turn ing counterclockwise and install by turning clockwise Inspection Check impeller for cracks or other damage Replace impeller if damaged Installation The installation is the opposite of the removal pro cedure Pay attention to the following detail CAUTION Be careful not to damage impeller wings during installation WATER PUMP SHAFT Removal Remove water pump housing no 3 ...

Page 39: ...p shaft always replace rotary seal with water pump shaft no 5 and oil seal no 10 behind rotary seal 1 Water pump shaft with rotary seal 1 Oil seal behind the rotary seal 2 Rotary seal bore Extract the water pump shaft with rotary seal no 5 together with oil seal no 10 from inside magneto housing cover with a pusher CAUTION Be carefulnot to damage the surface of the rotary seal bore in magneto hous...

Page 40: ...o the following NOTE Never use oil in the press fit area of the oil seal and rotary seal Push water pump shaft oil seal in place by using the oil seal pusher P N 529 035 757 1 Oil seal for the water pump shaft 2 Oil seal pusher P N 529 035 757 3 Handle for insertion jig P N 420 877 255 It is recommended to install the water pump shaft assembly using the water pump ceramic seal in staller P N 529 0...

Page 41: ...il in water pump shaft bore shaft Tighten screws in the following sequence PRESSURE CAP Check if radiator cap no 11 pressurizes the sys tem If not install a new 110 kPa 16 PSI cap do not exceed this pressure RADIATOR Removal Drain cooling system Remove front facia and both inner fenders refer to BODY radiator inlet no 14 and radiator outlet no 16 hoses 1 Radiator inlet hose 1 Radiator outlet hose ...

Page 42: ...C 212 230 F and pressure rise in the system If the limiting system working pressure cap is reached 110 kPa 16 PSI the pressure relief valve in the pressure cap is lifted from its seat and allows coolant to flow through the overflow hose into the overflow coolant tank no 15 Removal Remove LH inner fender refer to BODY coolant tank support bolt no 19 overflow hose no 12 coolant tank no 15 Empty cool...

Page 43: ...follow ing degree Change temperature sender if resistance does not change when water temperature is equal or over specification Removal Drain coolant Remove the LH inner fender refer to BODY Unplug temperature sender connector 1 Temperature sender connector Unscrew temperature sender no 18 Installation The installation is the reverse of the removal pro cedure pay attention to the following details...

Page 44: ...0 N m 89 lbf in 10 N m 89 lbf in 10 N m 89 lbf in 10 N m 89 lbf in 10 N m 89 lbf in 25 N m 18 lbf ft 30 N m 22 lbf ft 25 N m 18 lbf ft 1 3 4 5 6 7 8 9 11 12 14 10 15 Loctite 5910 Loctite 5910 Loctite 243 180 N m 133 lbf ft Multi purpose grease 5 Multi purpose grease Loctite 243 25 N m 18 lbf ft 2 Multi purpose grease 13 Anti seize lubricant ...

Page 45: ...move rewind starter refer to REWIND STARTER water pump cover refer to COOLING SYSTEM electric starter screws no 1 screws no 2 holding output shaft cover in place NOTE Only remove the two front screws no 2 To ease lifting the magneto cover it is recommend ed to loosen the screws behind 1 Unscrew these screws 2 Remove these screws screws nos 3 4 and 5 1 Gasket ring 2 Screw M6 3 CPS Crankshaft Positi...

Page 46: ... unlike the Drei Bond sealing compound using a finger will not affect the adhesion Use the silicone based Loctite 5910 P N 293 800 081 on mating surfaces NOTE The sealant curing time is similar to the Loctite 518 without using the Primer N CAUTION Do not use Loctite 515 or 518 to seal crankcase Do not use Loctite Primer N with the Loctite 5910 Using these products or non silicone based sealant ove...

Page 47: ... Magneto housing cover 3 Crankshaft MAG side Refer to the following illustration for proper instal lation of screws CAUTION Never use the gasket ring on screw no 4 a second time Always install a new one 1 Screws M6 x 45 2 Screws M6 x 45 with sealing ring 3 Screws M8 x 65 Tightening sequence for screws on magneto hous ing cover is as per following illustration OIL SEAL Remove rewind starter refer t...

Page 48: ...on Without Magneto Housing Cover Removed Using a suitable tube with the proper diameter install the oil seal as per following illustration 1 Oil seal 2 Oil seal protector 3 Tube CAUTION Use the oil seal protector P N 529 035 935 to avoid damaging the oil seal during installation STATOR Removal Remove magneto housing cover no 6 screws nos 8 and 9 stator no 11 1 Stator 2 Stator screws 3 Holding stri...

Page 49: ...lation reverse the removal procedure ROTOR Removal Lock crankshaft with locking bolt P N 529 035 617 Refer to CRANKSHAFT BALANCER SHAFT Remove magneto housing cover no 6 nut no 12 retaining rotor no 14 serrated washer no 13 1 Nut 2 Serrated washer 3 Rotor Install magneto puller P N 529 035 748 and crank shaft protector P N 420 876 557 then remove rotor NOTE Use grease to place protector on crank s...

Page 50: ...1 LUBRICATION SYSTEM 0 R400motr108S 30 N m 22 lbf ft 10 N m 89 lbf in 4 Engine oil Engine oil 5 10 N m 89 lbf in 26 27 Multi purpose grease 23 21 22 17 15 Engine oil 24 16 2 3 25 18 19 20 12 N m 106 lbf in 12 13 14 Loctite 243 10 N m 89 lbf in 6 7 8 9 10 11 Engine oil Engine oil 1 ...

Page 51: ...nder head exhaust side mounted on the crankcase MAG side and install the oil pres sure gauge P N 529 035 652 1 Oil pressure switch 2 Electrical starter NOTE Oil pressure switch works between 30 kPa 4 PSI and 60 kPa 9 PSI The engine oil pressure should be within the follow ing values If the engine oil pressure is out of specifications check the points described in TROUBLESHOOTING section To install...

Page 52: ...tion Clean the magnetic drain plug from metal shav ings and dirt Presence of debris gives an indica tion of failure inside the engine Check engine to correct the problem Change gasket ring on magnetic drain plug if dam aged Installation The installation is the reverse of removal proce dure CAUTION Never use the gasket ring no 2 a sec ond time Always replace by a new one 1 Magnetic drain plug 2 Gas...

Page 53: ...er seal of oil filter to ensure proper installation Install O ring on oil filter cover 1 O ring in place OIL STRAINER Removal Remove engine oil refer to OIL CHANGE air box refer to AIR INTAKE SILENCER disconnect unit bolts from engine exhaust support bolts upper engine support bolts Install the lifting engine tool P N 529 035 898 Remove front and rear engine mounting bolts front engine mounting br...

Page 54: ...nations 1 Oil inlet to the oil pump 2 Oil return from the oil pressure regulator system 3 Oil return from the engine oil circulation Installation For installation reverse the removal procedure Torque oil strainer cover screws as per following se quence Refill engine at the proper level with the recom mended oil Refer to TECHNICAL DATA for capacity Start engine and let idle for a few minutes Ensure...

Page 55: ...e present Clean bore and threads in the oil pump housing from metal shavings and other contaminations Installation For installation reverse the removal procedure OIL PUMP The oil pump is located on the engine MAG side refer to ENGINE OIL PRESSURE REGULATOR Removal Remove engine from vehicle refer to REMOVAL AND INSTALLATION water pump housing refer to COOLING SYSTEM magneto housing cover refer to ...

Page 56: ...emove oil pump system lift the dowel pins no 22 a bit The oil pump housing with oil pump shaft assembly will be easier to remove CAUTION Pay attention not to drop the dowel pins inside the engine 1 Oil pump system 1 Dowel pins oil pump gear no 25 NOTE Oil pump gear is snapped on needle pin This needle pin passes through the oil pump shaft Use screwdrivers to remove this gear 1 Flat screwdrivers 1 ...

Page 57: ...in support 1 Oil pump shaft assembly 2 Oil pump housing Inspection Inspect oil pump shaft assembly housing and cov er for marks or other damages Replace O ring no 27 if brittle or hard This O ring is located on the oil pump housing Check inner rotor for corrosion pin holes or other damages If so replace oil pump shaft assembly Ensure to also check oil pump housing and cover If damaged replace the ...

Page 58: ...or should not exceed 0 1 mm 004 in If so replace replace the complete oil pump assembly NOTE When the axial clearance of the oil pump shaft assembly increases the oil pressure de creases Check the inside of oil pump housing and its cover for scoring or other damages If so change the complete oil pump assembly Installation For installation reverse the removal procedure Tightening oil pump housing s...

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Page 60: ... 10 N m 89 lbf in 10 N m 89 lbf in 25 N m 18 lbf ft 10 N m 89 lbf in 0 4 N m 3 5 lbf in 4 5 N m 40 lbf in 8 N m 71 lbf in Loctite 243 Anti seize lubricant Engine oil Loctite243 Loctite 243 60 N m 44 lbf ft See procedure inside 3 2 5 6 7 8 9 16 11 12 13 14 34 35 33 38 16 39 19 40 17 22 18 21 20 23 27 37 36 29 31 32 28 10 25 24 16 11 15 13 14 34 35 33 38 39 16 4 30 26 400 engine type only 10 N m 89 ...

Page 61: ...Section 03 ENGINE Subsection 09 CYLINDER AND HEAD 03 09 2 VMR2004_132_03_09A FM Engine oil Engine oil R400motr50S 41 42 Engine oil 46 45 43 44 43 ...

Page 62: ...e cause and it will be easy to know which one among the springs is the cause to replace it if you grouped them at disassem bly Besides since used parts have matched togeth er during the engine operation they will keep their matched fit when you reassemble them together within their group Intake port air filter contaminated clogged with dirt sand etc leads to worn valves piston rings and finally to...

Page 63: ...VE ADJUSTMENT Lock crankshaft at the TDC compression position refer to CRANKSHAFT BALANCER SHAFT see CRANKSHAFT LOCKING PROCEDURE Remove valve cover refer to VALVE COVER above Hold adjusting screw no 14 and loosen locking nut no 13 Using feeler gauge check the valve clearance 1 Adjustment screws 2 Locking nuts 3 Feeler gauge NOTE Use mean value of exhaust intake to en sure a proper valve adjustmen...

Page 64: ...ing Screw the plunger until it touches the chain guide Install a spring end in plunger groove and the other in the plug groove Screw plug CAUTION Do not forget to place the O ring no 22 on chain tensioner plug CHAIN TENSIONER HOUSING Removal Remove chain tensioner screw no 19 chain tensioner housing no 20 with O ring no 23 1 Chain tensioner screw 2 Chain tensioner housing Inspection Check the hous...

Page 65: ...ver camshaft screw no 4 decompressor washer no 5 centrifugal weight no 6 together with torsion spring no 7 and spacer no 8 decompressor shaft no 9 1 Camshaft screw 2 Decompressor washer 3 Centrifugal weight Inspection Check decompressor shaft for service limit replace if out of specifications 1 Decompressor shaft 2 Groove for centrifugal weight A Measure here the bearing seat to cylinder head B Me...

Page 66: ...erly in the centrifugal weight location 1 Position of torsion spring end Engage the edge of centrifugal weight into the de compressor shaft groove then put the parts in place 1 Decompressor shaft groove 2 Centrifugal weight CAUTION Take care before and aftercoverinstal lation that the centrifugal system moves slides easily DECOMPRESSOR SHAFT MEASUREMENT A NEW MINIMUM 5 578 mm 219 in NEW MAXIMUM 5 ...

Page 67: ... worn or damaged replace it as a set camshaft timing gear and timing chain For crankshaft timing gear refer to CRANKSHAFT BALANCER SHAFT Installation For installation reverse the removal procedure Pay attention to the following details Clean mating surface and threads of camshaft pri or to assemble camshaft timing gear 1 Mating surface on camshaft 2 Threads for camshaft screw Camshaft timing gear ...

Page 68: ...ell as the camshaft locking tool Reinstall all other removed parts ROCKER ARM Removal Lock crankshaft at the TDC compression position refer to CRANKSHAFT BALANCER SHAFT see CRANKSHAFT LOCKING PROCEDURE Remove valve cover chain tensioner camshaft timing gear no 10 Allen screws no 25 and camshaft retaining plate no 26 1 Cylinder head 2 Allen screws 3 Camshaft retaining plate rocker arm shafts no 11 ...

Page 69: ...t cracks and or excessive play 1 Free movement of adjustment screw top Rocker Arm Shaft Checkforscored friction surfaces if so replace parts Measure rocker arm shaft diameter A Measure rocker arm shaft diameter here Any area worn excessively will require parts replacement Installation NOTE Use the same procedure for exhaust or in take rocker arm Apply engine oil on rocker arm shaft Install the roc...

Page 70: ...n coolant refer to COOLING SYSTEM NOTE Before removing cylinder head blow out remaining coolant by air pressure During cylinder head removal the remaining coolant in cylinder head could overflow into the engine and a little quantity of coolant could drop into the engine In this case the engine oil will be contaminated Disconnect spark plug wire temperature switch connectors Remove both side panels...

Page 71: ...nstallation For installation reverse the removal procedure Pay attention to the following details Ensure dowel pins are in place Install a new gasket no 31 First torque cylinder head screws no 27 in criss cross sequence to 20 N m 15 lbf ft then finish tightening by applying the recommended torque indicated in the exploded view Torque cylinder head screws no 28 with the rec ommended values in the e...

Page 72: ...ng journal of camshaft for scoring scuffing cracks or other signs of wear Measure camshaft bearing journal diameter and lobe height using a micrometer A Camshaft lobe exhaust valves B Camshaft lobe intake valves C Camshaft bearing journal MAG side D Camshaft bearing journal PTO side 1 R400motr65A 2 3 R400motr75A 1 3 2 CAMSHAFT LOBE EXHAUST VALVES NEW MINIMUM 32 027 mm 1 2609 in NEW MAXIMUM 32 047 ...

Page 73: ...ent For other parts refer to proper installation proce dure VALVE SPRING Removal Remove rocker arms see ROCKER ARM above cylinder head see CYLINDER HEAD above Compress valve spring no 33 use valve spring compressor clamp P N 529 035 724 and valve spring compressor cup P N 529 035 725 CAMSHAFT BORE MAG SIDE MEASURED IN DIAMETER NEW MINIMUM 35 000 mm 1 3780 in NEW MAXIMUM 35 025 mm 1 3789 in SERVICE...

Page 74: ...ing for visible damages If so replace valve spring Check valve spring for free length and straightness A Valve spring length Replace valves springs if not within specifications Installation For installation reverse the removal procedure Pay attention to the following details Colored area of the valve spring must be placed on top NOTE Valve cotter must be properly engaged in valve stem grooves 1 Po...

Page 75: ...stalled whenever cylinder head is removed Valve Inspect valve surface check for abnormal stem wear and bending If out of specification replace by a new one Valve Stem and Valve Guide Clearance Measure valve stem and valve guide in three places using a micrometer and a small bore gauge NOTE Clean valve guide to remove carbon depos its before measuring Change valve if valve stem is out of specificat...

Page 76: ...ith a lapping tool see VALVE GUIDE PROCE DURE below Measure valve face contact width NOTE The location of contact area should be in center of valve seat Measure valve seat width using a caliper If valve seat contact width is too wide or has dark spots replace the cylinder head A Valve face contact width B Valve seat contact width VALVE STEM DIAMETER NEW MINIMUM EXHAUST 4 956 mm 1951 in INTAKE 4 96...

Page 77: ...ew times CAUTION An improperly locked valve spring will cause engine damage VALVE GUIDE PROCEDURE Removal Remove cylinder head see CYLINDER HEAD above valve spring see VALVE SPRING above valves see VALVE above NOTE Clean valve guide area from contamination before removal Using valve guide remover P N 529 035 924 remove valve guide no 40 with a hammer 1 Valve guide remover 2 Valve guide Inspection ...

Page 78: ...Turn valve while pushing against cylinder head A Valve seat angle 45 NOTE Ensure to seat valves properly Apply marking paste to ease checking contact pattern Repeat procedure until valve seat valve face fits together CYLINDER Removal Lock crankshaft at TDC compression position re fer to CRANKSHAFT BALANCER SHAFT see CRANKSHAFT LOCKING PROCEDURE Using the camshaft locking tool P N 529 035 926 lock ...

Page 79: ...uld not ex ceed the service limit mentioned above Cylinder Out of Round Measure cylinder diameter in piston axis direction from top of cylinder Take another measurement 90 from first one and compare NOTE Take the same measuring points like de scribed in CYLINDER TAPER above A Perpendicular to crankshaft axis B Parallel to crankshaft axis CAUTION Always replace gasket no 42 before installing the cy...

Page 80: ...ion procedures PISTON Removal Remove cylinder head see CYLINDER HEAD above cylinder see CYLINDER above Place a rag under piston and in the area of timing chain compartment Remove one piston circlip no 43 and discard it 1 Piston circlip NOTE The removal of both piston circlips is not necessary to remove piston pin Push piston pin no 44 out of piston 1 Piston 2 Piston pin Detach piston no 45 from co...

Page 81: ...e dimension adjust a cylinder bore gauge to the micrometer dimen sion and set the indicator to 0 zero 1 Use the micrometer to set the cylinder bore gauge 2 Dial bore gauge TYPICAL 1 Indicator set to 0 zero Position the dial bore gauge 20 mm 787 in above cylinder base measuring perpendicularly 90 to piston pin axis Read the measurement on the cylinder bore gauge The result is the exact piston cylin...

Page 82: ... small end A Connecting rod small end diameter Replace crankshaft if diameter of connecting rod small end is out of specifications Refer to CRANKSHAFT BALANCER SHAFT for removal procedure Installation For installation reverse the removal procedure Pay attention to the following details Apply engine oil on the piston pin Insert piston pin into piston and connecting rod CAUTION Take care that piston...

Page 83: ... in place 3 Sleeve 4 Assembly jig 5 Direction to push circlip NOTE Take care that the hook of the piston circlip is positioned properly CORRECT POSITION OF THE PISTON CIRCLIP PISTON RINGS Removal Remove cylinder head cylinder piston pin Inspection Ring Piston Groove Clearance Using a feeler gauge measure each ring piston groove clearance If the clearance is too large the piston and the piston ring...

Page 84: ...ion ring with the word N and TOP facing up 1 Upper compression ring 2 Lower compression ring 3 Oil scraper ring CAUTION Ensure that top and second rings are not interchanged NOTE Use a ring expander to prevent breakage during installation The oil ring must be installed by hand Check that rings rotate smoothly after installation Space the piston ring end gaps 120 apart and do not align the gaps wit...

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Page 86: ... SHAFT VMR2004_133_03_10A FM 03 10 1 CRANKSHAFT BALANCER SHAFT 0 CRANKCASE R400motr15T 10 N m 89 lbf in 2 10 N m 89 lbf in 25 N m 18 lbf ft Loctite 5910 25 N m 18 lbf ft MAG PTO 5 1 Loctite 5910 9 10 9 10 Engine oil Multi purpose grease 11 Loctite 5331 ...

Page 87: ...n 03 ENGINE Subsection 10 CRANKSHAFT BALANCER SHAFT 03 10 2 VMR2004_133_03_10A FM CRANKSHAFT BALANCER SHAFT R400motr16S 20 N m 15 lbf ft Finish with 70 angle torque 8 7 3 Engine oil 4 6 Engine oil Engine oil ...

Page 88: ... and sealing washer no 2 1 Screw 2 Sealing washer 3 Output shaft on front side of vehicle Use a screwdriver to check if groove in crankshaft is aligned with the hole 1 Screwdriver Lock crankshaft with crankshaft locking bolt P N 529 035 617 1 Crankshaft locking bolt 2 Front output shaft area Install camshaft locking tool P N 529 035 926 NOTE At piston TDC the printed marks on the camshaft timing g...

Page 89: ...r and rollers condition 1 Timing chain If chain is excessively worn or damaged replace it as a set camshaft timing gear and timing chain Removal Remove engine from vehicle refer to REMOVAL AND INSTALLATION valve cover chain tensioner and camshaft tim ing gear refer to CYLINDER AND HEAD magneto cover and rotor refer to MAGNETO SYSTEM output shaft refer to GEARBOX If the chain is not changed note th...

Page 90: ... CRANKCASE To reach the balancer shaft and the crankshaft it is necessary to separate the crankcase The procedures to remove inspect and install the balancer shaft and the crankshaft are explain fur ther in this section For all gearbox parts refer to GEARBOX Removal Remove engine from vehicle refer to REMOVAL AND INSTALLATION magneto housing cover and rotor refer to MAGNETO SYSTEM NOTE Oil pump re...

Page 91: ...aft and crankshaft see BAL ANCER SHAFT and CRANKSHAFT above Inspection NOTE To check some parts it is recommended to remove all components in both crankcase housing Clean crankcase from contaminations and blow the oil supply lines with compressed air Check plain bearings no 9 and no 10 for scorings or other damages Measure plain bearing inside diameter Replace if the measurement is out of specific...

Page 92: ...ankcase hous ing damages may occur if this procedure is not performed correctly NOTE Always use a press for removal or installa tion of plain bearing halves Remove plain bearings no 9 and no 10 with the plain bearing remover installer P N 529 035 917 PUSH PLAIN BEARINGS OUTSIDE 1 Plain bearing remover installer 2 Plain bearing 3 Crankcase PTO To install the plain bearing turn the plain bearing rem...

Page 93: ...position 2 Split between bearing halves 3 Perpendicular axle to cylinder base 4 Crankcase MAG 1 Mark on crankcase and oil bore position 2 Split between bearing halves 3 Perpendicular axle to cylinder base 4 Crankcase PTO CAUTION Push plain bearings MAG PTO cor rectly in place to ensure oil supply to crankshaft oil bore and split between plain bearing halves PUSH PLAIN BEARINGS INSIDE 1 Plain beari...

Page 94: ...ng refer to CRANKCASE above Remove the crankshaft locking bolt Align the dot of crankshaft gear with the balancer shaft gear dot then remove balancer shaft no 4 1 Crankshaft 2 Balancer shaft 3 Connecting rod 4 Rotate crankshaft for balancer shaft removal 5 Groove for fixation at TDC Inspection Check balancer shaft and replace if damaged Check ball bearings on MAG and PTO side for ex cessive play a...

Page 95: ...od Big End Axial Play Using a feeler gauge measure distance between butting face of connecting rod and crankshaft coun terweight If the distance exceeds specified toler ance replace the crankshaft 1 Crankshaft 2 Feeler gauge Connecting Rod Piston Pin Clearance Measure piston pin Compare to inside diameter of connecting rod no 6 1 Bore gauge 2 Connecting rod 1 R400motr26A 2 2 R400motr27A 1 CONNECTI...

Page 96: ...alled 1 Connecting rod screw Measure crankpin Compare to inside diameter of connecting rod big end 1 Micrometer 2 Crankpin area for bushings To measure the connecting rod big end diameter use the OLD screws no 7 Install the OLD bushings no 8 as they were mount ed initially Do the torque procedure as described further A Connecting rod big end bushing CONNECTING ROD SMALL END DIAMETER MINIMUM new 20...

Page 97: ...shing of connecting rod big end 2 Split surface of the connecting rod 3 Nose of bushing in line with connecting rod groove Torque NEW connecting rod screws no 7 as per following procedure Install screws with half of recommended torque in the exploded view Do not apply any thread locker product Torque with the recommended values in the ex ploded view Finish tightening the screws with an additional ...

Page 98: ...d marks located in the gears After reinstalling of crankcase MAG measure axial clearance of crankshaft with a feeler gauge on the PTO side between PTO crankcase and crankshaft thrust surface CAUTION Install crankshaft locking bolt P N 529 035 617 right away to put crankshaft in TDC position before installing the camshaft and rockers refer to CYLINDER AND HEAD 1 Crankshaft locking bolt P N 529 035 ...

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Page 100: ...SHAFT AND TRANSMISSION R400tran31S Engine oil 3 2 4 1 5 4 Engine oil Engine oil 19 20 21 11 6 7 Engine oil 10 9 8 Loctite 243 10 N m 89 lbf in 24 23 Engine oil 12 13 27 29 Engine oil 17 26 25 15 14 18 Engine oil 28 Engine oil 22 Different gear transmission between Outlander 400 and 330 16 ...

Page 101: ...f ft 32 31 Multi purpose grease 59 25 N m 18 lbf ft 10 N m 89 lbf in Loctite 5910 25 N m 18 lbf ft 10 N m 89 lbf in 25 N m 18 lbf ft 35 34 33 25 N m 18 lbf ft Loctite 5910 10 N m 89 lbf in 39 40 Engine oil 41 45 43 44 38 42 36 37 10 N m 89 lbf in Loctite 243 54 58 56 57 55 46 47 Multi purpose grease 48 49 50 51 53 Loctite 243 8 N m 71 lbf in 52 Loctite 5331 Loctite 5910 Multi purpose grease ...

Page 102: ...ARBOX below Installation The installation is the reverse of removal procedure Pay attention to the following details Use a suitable ring to push oil seals in place CAUTION Oil seal must be installed with seal ing lip toward engine Measure output shaft axial clearance prior to re move output shaft no 1 This measure will indi cate if bevel gear adjustment is necessary 1 Output shaft 2 Dial indicator...

Page 103: ... Loctite 5910 magneto housing and rotor refer to MAGNETO SYSTEM output shaft CAUTION Use a soft hammer to remove output shaft from crankcase MAG side O ring no 4 and bearing no 5 NOTE Both bearings on output shaft have a tran sition fit 1 O ring 2 Bearing with writing to the outside O ring no 4 and bearing no 3 1 O ring 2 Bearing with writing to the outside shim no 2 2 R400motr196A 3 1 2 R400trans...

Page 104: ...tle hard or damaged Clean crankcase split surface and especially the bearing areas from metal particles or other con tamination Installation For installation reverse the removal procedure Pay attention to following details Adjust axial play as per following procedure 1 Use soft hammer to put bearing no 3 exactly in place against crankcase MAG side 1 Soft hammer 2 Push output shaft as per following...

Page 105: ...ings separation MEASURE AXIAL CLEARANCE OF BEVEL GEAR Remove cylinder head and cylinder timing chain drive and intermediate gear of water and oil pump 1 Timing chain 2 Intermediate gear 3 Drive gear MEASURED THICKNESS SHIM THICKNESS 0 79 to 0 88 mm 0311 to 0346 in 0 70 mm 0276 in 0 89 to 0 98 mm 0350 to 0386 in 0 80 mm 0315 in 0 99 to 1 08 mm 0390 to 0425 in 0 90 mm 0354 in 1 09 to 1 18mm 0429 to ...

Page 106: ...th compressed air Check bearings nos 38 no 42 no 43 and no 45 as well as needle bearings no 36 and no 37 for excessive play and smooth operation Replace if necessary Check plain bearings no 39 and no 40 for scor ings or other damages Measure plain bearing inside diameter Replace if the measurement is out of specification refer to CRANKSHAFT BALANCER SHAFT see CRANK CASE Bearing Removal Procedure C...

Page 107: ... bearing puller Ball bearings no 38 and no 45 can be easily re moved with a suitable pusher from outside in The oil seals no 46 no 49 no 60 and no 61 are removed easily with a flat screwdriver NOTE To remove oil seals no 34 no 49 no 60 and no 61 the engine removal disassembly is NOT necessary see OIL SEAL PROCEDURE above For ball bearing no 47 remove screw no 43 then push bearing from outside in w...

Page 108: ...earing installer 3 Insertion jig handle Install needle bearing no 36 using needle bearing installer P N 529 035 763 and insertion jig handle P N 420 877 650 1 Bevel gear needle bearing 2 Needle bearing installer 3 Insertion jig handle Install needle bearing no 46 using needle bearing installer P N 529 035 934 and insertion jig handle P N 420 877 650 1 Starter drive needle bearing PTO side 2 Needle...

Page 109: ...then make the final brushing per pendicularly 90 to the first pass cross hatch CAUTION Donot wipe with rags Use a new clean hand towel only IMPORTANT When beginning the application of the crankcase sealant the assembly and the first torquing should be done within 10 minutes It is sug gested to have all you need on hand to save time NOTE It is recommended to apply this specific sealant as described...

Page 110: ...roducts suppliers for printmak ing and roll the sealant to get a thin uniform coat on the plate spread as necessary When ready apply the sealant on crankcase mating surfaces Do not apply in excess as it will spread out inside crankcase NOTE Do not use Loctite Primer N with this seal ant The sealant curing time is similar to the Loc tite 518 without using the Primer N which is 4 to 24 hours CAUTION...

Page 111: ...or scoured shift fork worn or scoured shift fork shaft rounded engagement dogs and slots bent shift forks bent shift fork shaft worn shift fork engagement pins worn tracks on shift drum worn shift fork engagement groove worn splines on shafts and gears Removal Remove output shaft Separate crankcase Remove balancer shaft parking lever no 7 shift shaft no 6 1 Parking lever 2 Shift shaft shift fork s...

Page 112: ... 24 and shim no 26 distance sleeve no 14 thrust washer no 15 in termediate gear no 16 needle bearing no 17 and intermediate gear shaft no 18 NOTE It is not necessary to remove index lever no 8 Check index lever for visible damage and if it moves freely Replace if necessary Inspection Check both shift forks for visible damage wear or bent shift fork claws Measure the shift fork claw thickness 1 Mic...

Page 113: ... no 8 must have free move ment Measure the gap of shift fork engagement groove NOTE Both gears no 22 and no 27 have same gap width and same service limit 1 Main gear 2 Caliper A Gap for engagement of shift fork Check main shaft for wear 1 Mag side 2 PTO side Check bevel gear shaft GAP OF SHIFT FORK ENGAGEMENT GROOVE MINIMUM new 5 00 mm 197 in MAXIMUM new 5 10 mm 201 in SERVICE LIMIT 5 20 mm 205 in...

Page 114: ...te gear shaft no 18 needle bearing no 17 intermediate gear no 16 thrust washer no 15 and distance sleeve no 14 shim no 26 needle bearing no 24 reverse gear no 25 thrust washer no 23 and gear se lection no 22 main shaft with high range gear assembly O ring no 28 including distance sleeve on main shaft end PTO side CAUTION Place O ring no 28 including distance sleeve right away Chamfered bore of dis...

Page 115: ...ith mark in line to first tooth on shift drum 1 Mark on shift shaft 2 First tooth on shift drum Install parking lever no 7 Bevel Gear Adjustment Use following course of calculation to adjust bevel gear in place between crankcase PTO and MAG NOTE Only necessary if the output shaft axial clearance of the bevel gear is out of specification Measure following items and enter measurement in the followin...

Page 116: ...Section 03 ENGINE Subsection 11 GEARBOX VMR2004_134_03_11A FM 03 11 17 R400trans27S A C D E B G I J H F Output shaft mating surface Crankcase mating surface ...

Page 117: ... 2 Area of written number K to find out value B C Distance between butting face MAG side to mating surface of crankcase MAG 1 Depth gauge measurement C 2 Butting face inside of crankcase MAG D Theoretical shim thickness E Shim selected in accordance with D Use following course of calculation to get the the oretical thickness D for washer no 19 D B C A NOTE Take theoretical value D and choose shim ...

Page 118: ...rdance with I Use following course of calculation to get the the oretical thickness I for washer no 27 I F G H A E NOTE Take theoretical value I and choose shim J PTO side shim from the below table NOTE For example if the measured thickness is 1 53 mm 0602 in choose the shim 150 NOTE Bevel gear axial clearance of 0 02 to 0 11 mm 00079 to 00433 in is included in the above table 2 R400trans26A 1 3 1...

Page 119: ...would be 1 60 mm 0630 in In accordance with the appropriate table you need a shim number 140 Installation For installation reverse the removal procedure Pay attention to the following details CAUTION Don t forget thrust washer no 15 and no 22 First install intermediate gear then main shaft and afterward the bevel gear 1 Intermediate gear 2 Main shaft 3 Thrust washer after main gear on bevel gear 4...

Page 120: ...ting indicator switches To reach the shifting indicator switches remove CVT cover driven pulley Removal NOTE Clean area from dirt and belt dust before removing parts Remove screw no 57 protection sheet no 56 NOTE Clean area from dirt and belt dust before removing shifting indicator switch es 1 Blue wire for contact to parking gear 2 Brown wire for contact to reverse gear 3 Green yellow wire for co...

Page 121: ...no 50 no 52 and or spring no 49 during removal of starter pinion cover starter drive pinion cover no 51 starter drive pinion no 48 1 Starter drive pinion cover 2 Starter drive pinion 3 Screw 4 Shim 5 Shim 6 Spring Inspection Check if starter drive pinion is free of movement NOTE Centrifugal weights avoid disengaging of the pinion while starting the engine 1 Starter drive pinion 2 Starting position...

Page 122: ...lubrication free system except drive pulley one way clutch R400motr238S Anti seize lubricant 34 35 32 29 33 25 27 30 27 23 24 28 4 31 26 22 21 60 N m 44 lbf ft 3 2 1 7 N m 62 lbf in 100 N m 74 lbf ft 5 6 7 10 11 19 8 14 13 12 18 17 15 6 N m 44 lbf in Anti seize lubricant Degrease 16 9 20 ...

Page 123: ...T cover hoses Remove screws no 1 with mounted rubber bushings CVT cover no 2 and gasket no 3 1 CVT cover 2 Gasket 3 Intake for air cooling 4 Air outlet NOTE Remove the center top screw last This screw supports the cover during removal Open driven pulley with the driven pulley expand er P N 529 035 747 WARNING Torque wrench tightening specifications must strictly be adhered to Locking devices ex lo...

Page 124: ...lt width Installation For installation reverse the removal procedure Pay attention to following details The maximum drive belt life span is obtained when the drive belt has the proper rotation direction In stall it so the arrow printed on belt is pointing to wards the back of the vehicle NOTE Put a small amount of Loctite 5910 in the groove of CVT cover to ease installation of CVT cover with gaske...

Page 125: ...ockdrive pulleywithclutch holding tool P N 529 006 400 1 Clutch holding tool P N 529 006 400 2 Drive pulley sliding half 3 Area to place holding tool hook CAUTION Prior to removing the drive pulley mark sliding half and governor cup together to ensure correct reinstallation There are only 4 levers mounted out of 6 possible positions for the Outlander 400 execution On the Outlander 330 there are 3 ...

Page 126: ...pulley 1 Clutch puller 2 Fixed half Disassembly of Drive Pulley Governor Cup Carefully lift governor cup no 10 until slider shoes no 11 come at their highest position into guides Sliding Half Unscrew lock nut no 12 and remove centrifugal lever pivot bolt no 13 NOTE Outlander 400 shows 4 lever pivot bolt and Outlander 330 only 3 levers Remove centrifugal lever no 14 1 Lock nut 2 Centrifugal lever p...

Page 127: ...r does not contact the crankshaft seal Remove all hardened oil deposits that have baked on crankshaft and pulley tapered surfaces with coarse or medium steel wool and or sand paper no 600 CAUTION Do not use any other type of abrasive Reclean mounting surfaces with paper towel and cleaning solvent Wipe off the mounting surfaces with a clean dry paper towel CAUTION Mounting surfaces must be free of ...

Page 128: ...lock nuts no 12 if the contact surfaces show heavy visible wear 1 Contact surface to the roller Slider Shoe Check slider shoes no 11 for visible wear and re place if damaged NOTE If necessary use a screwdriver to remove slider shoes 1 Slider shoe Sliding Half Check sliding half for cracks and sliding contact surface for excessive wear Replace sliding half if necessary ROLLER DIAMETER MINIMUM new 1...

Page 129: ...ing Replace sliding half if bushings no 17 and or no 18 is are out of specification Visually inspect coatings Fixed Half Check fixed half contact surface to the governor cup for scorings and other damages If so replace fixed half 1 Visually check here CENTRIFUGAL LEVER PIVOT BOLT BORE DIAMETER MINIMUM new 6 113 mm 241 in MAXIMUM new 6 171 mm 243 in SERVICE LIMIT 6 300 mm 248 in SLIDING HALF SMALL ...

Page 130: ...rt slider shoes into governor cup to properly slide in guides Installation of Drive Pulley For installation reverse the removal procedure Pay attention to the following details Clean mounting surfaces as described in CLEAN ING above Install drive pulley on crankshaft extension Install spring washer no 6 with its concave side towards drive pulley then install drive pulley screw no 5 Install clutch ...

Page 131: ...arried out to re move driven pulley First possible procedure Block driven pulley fixed half with clutch holding tool P N 529 035 771 then remove the driven pulley bolt no 21 and the washer no 22 1 Clutch holding tool P N 529 035 771 2 Driven pulley fixed half Second possible procedure Block driven pulley with clutch holding tool P N 529 006 400 then remove the driven pul ley bolt no 21 and the was...

Page 132: ...loth Use pulley flange cleaner P N 413 711 809 to clean driven pulley Clean the CVT crankcase area from contamination Using a paper towel with cleaning solvent to clean main shaft end and the inside of the shaft no 25 CAUTION To avoid damage make sure clean er does not contact the countershaft seal 1 Main shaft support 2 Sealing lip of countershaft oil seal Inspection Sliding Half Check bushings n...

Page 133: ... a caliper A Measurement inside B Measurement outside Cam Check cam no 29 for visible damage and wear limit with a caliper 1 Contact surfaces for power train 2 Caliper A Width to be measured due to wear on contact surface 1 Caliper 2 Sliding half 3 Contact surface A Wear to be measured BUSHING BORE DIAMETER MAXIMUM new 30 000 mm 1 181 in MAXIMUM new 30 020 mm 1 182 in SERVICE LIMIT 30 200 mm 1 189...

Page 134: ...ng installation NOTE Place new ball bearing in a freezer for 10 min utes before installation Install ball bearing no 26 with the writing on top and push only on the outer ring 1 Ball bearing CAUTION Do not use a hammer use a press machine only 1 Shaft 2 Fixed half 3 Press machine Install torque gear no 24 then secure it with re taining ring no 23 1 Retaining ring 2 Torque gear SPRING FREE LENGTH S...

Page 135: ...then install cam no 29 NOTE Place cam retainer no 32 with printed mark ENGINE SIDE towards the engine 1 Sharp edge of cam retainer to engine side 2 Main shaft spline 3 Inscription Place spring no 33 behind sliding half then align driven pulley with cam 1 Cam 2 Spring 3 Driven pulley 4 Location for pushing during screw installation Push the driven pulley by hand Install the driven pulley screw no 2...

Page 136: ...Section 04 FUEL SYSTEM Subsection 03 CARBURETOR VMR2004_137_04_03A FM 04 03 1 CARBURETOR 0 V07F0ZS Harness assembly ...

Page 137: ...g and Inspection 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 cleaning Carburetor body and jets should be cleaned in a carburetor cleaner following manufacturer...

Page 138: ...e and choke cable housing prior to installation Reinstall throttle and choke cables at the same time adjust the throttle cable then install the side cover Refer to CARBURETOR ADJUST MENTS below in this section Reinstall carburetor on vehicle When reinstalling carburetor on vehicle pay atten tion to the following CAUTION The rubber flanges must be checked for cracks and or damage At assembly the ru...

Page 139: ...ase engine speed or counterclockwise to decrease it NOTE Use the digital induction tachometer P N 529 014 500 Turn tachometer wire around spark plug wire about 4 or 5 turns for the best measure CAUTION Do not attempt to set the idle speed by using the pilot screw Refer to TECHNICAL DATA for idle speed specifi cations Pilot Screw Adjustment NOTE The pilot screw is factory pre set Warm the engine to...

Page 140: ...ble routing Remove carburetor side cover Using thumb release tension on throttle lever With long nose pliers rotate cable end bushing so that cable aligns with throttle lever recess then lift cable end See next photo 1 Release tension on throttle lever 2 Cable end bushing Separate cable end bushing from throttle cable end as shown in the next photo Keep bushing REMOVE CABLE END BUSHING WARNING Ens...

Page 141: ...lever then open it 1 Remove these screws Separate housing Slide rubber protector back to expose throttle cable adjuster 1 Cable protector 2 Throttle cable adjuster 3 Lock nut 4 Throttle lever housing Screw in the throttle cable adjuster Remove inner housing protector 1 Inner housing protector throttle cable from housing Slide cable in clip slot and remove the end of cable from clip 1 V07F0BA V07I0...

Page 142: ...nt surplus in carburetor housing Spray lubricant inside throttle housing Reinstall carburetor cover and cable in throttle hous ing Adjust cable see below Installation For installation reverse the removal procedure Adjustment Slide rubber protector back to expose throttle ca ble adjuster Loosen lock nut then turn the adjuster to obtain correct throttle lever free play NOTE Measure throttle free pla...

Page 143: ...ve the LH side panel and the air filter box Unscrew choke plastic nut from carburetor Pull choke cable to remove choke plunger from car buretor Remove the choke plunger and its spring 1 Choke plunger 2 Choke plunger spring Handlebar Side Push the choke lever on FULL position Underneath multi function switch align the choke cable end with the lever slot then remove the cable Remove the retaining sp...

Page 144: ... amperes If not check magneto output prior to concluding that voltage regulator rectifier is faulty Voltage Test Proceed as follows Start engine Connect a multimeter to battery posts Set mul timeter to Vdc scale Bring engine to approximately 3500 RPM If multimeter reads over 15 1 0 5 volts voltage regulator rectifier is defective Replace it NOTE Whatever the voltmeter type used peak voltage or RMS...

Page 145: ...ith the stator leads disconnected insert either meter test probe onto AC 1 and ground the other meter test probe to the engine or the stator iron core and note the reading There should be no con tinuity infinity between the stator insulated coils and ground If there is a reading the stator coils and or the wiring from the coils is grounded and needs to be replaced repaired respectively TYPICAL DYN...

Page 146: ...sure torque speed meter kilogram newton liter Celsius kilo pascal newton meter kilometer per hour m kg N L C kPa N m km h PREFIXES PREFIX SYMBOL MEANING VALUE kilo centi milli micro k c m µ one thousand one hundredth one thousandth one millionth 1 000 0 01 0 001 0 000001 CONVERSION FACTORS TO CONVERT TO MULTIPLY BY in in in2 in3 ft oz lb lbf lbf in lbf ft lbf ft PSI lbf in2 imp oz imp oz imp gal i...

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Page 148: ...haust valve closing 10 00 ATDC Chain tensioner plunger protrusion Wear limit mm in 20 0 7874 Valve clearance Intake mm in 0 06 0024 to 0 14 0055 Exhaust mm in 0 11 0043 to 0 19 0075 Valve valve stem clearance Intake New minimum mm in 4 966 1955 New maximum mm in 4 980 1960 Wear limit mm in 4 930 1940 Exhaust New minimum mm in 4 956 1951 New maximum mm in 4 970 1957 Wear limit mm in 4 930 1940 Valv...

Page 149: ... Wear limit mm in 0 090 004 Cylinder out of round New maximum mm in 0 015 0006 Wear limit mm in 0 02 0008 Camshaft bearing journal PTO side New minimum mm in 21 959 8645 New maximum mm in 21 980 8654 Wear limit mm in 21 950 8642 Magneto side New minimum mm in 34 959 1 3763 New maximum mm in 34 975 1 3770 Wear limit mm in 34 950 1 3760 Camshaft bore PTO side New minimum mm in 22 000 8661 New maximu...

Page 150: ... limit mm in 13 20 519 Centrifugal lever pivot bolt diameter New minimum mm in 6 078 239 New maximum mm in 6 100 240 Service limit mm in 6 000 236 Centrifugal lever bore diameter Service limit mm in 6 200 244 Centrifugal lever pivot bolt bore diameter New minimum mm in 6 113 241 New maximum mm in 6 171 243 Service limit mm in 6 300 248 Drive pulley sliding half large bushing New minimum mm in 55 0...

Page 151: ...em 30 A CARBURETION Carburetor Type Mikuni constant depression type with manual choke and ECS Enrichner Coasting System Model BSR33 Fuel pump Type Mikuni Pulsation pump Model External vacuum operated Idle engine speed RPM 1300 100 Main jet 133 8 Pilot jet 32 5 Needle jet 826 P 4 Jet needle 5 FEY 1 Clip position number 3 Choke plunger position Variable choke Adjustment Throttle cable 0 5 mm 02 in P...

Page 152: ...d maximum length unengaged mm in 286 5 5 11 28 0 197 SUSPENSION FRONT Suspension type McPherson Strut Suspension travel mm in 178 7 Shock absorber Qty 2 Type Oil Spring free length mm in 354 14 Spring color code Blue Red Blue Front preload adjustment N A REAR Suspension type Trailing arms Suspension travel mm in 203 8 Shock absorber Qty 2 Type Oil Spring free length mm in 371 14 6 Spring color cod...

Page 153: ...9 lbf in None Thermostat housing 7 N m 62 lbf in Thermostat bleeding screw 5 N m 44 lbf in Temperature sensor 17 N m 151 lbf in Water pump housing 10 N m 89 lbf in Fan mount screw nut 7 N m 62 lbf in Temperature sender on radiator 11 N m 97 lbf in EXHAUST Exhaust nut 11 N m 97 lbf in None Heat shield screws 13 N m 115 lbf in Exhaust support 23 N m 17 lbf ft LUBRICATION Engine drain plug 30 N m 22 ...

Page 154: ... 90 N m 66 lbf ft Upper 90 N m 66 lbf ft Front propeller shaft screw Differential side 42 N m 31 lbf ft Rear propeller shaft screw Engine side 34 N m 26 lbf ft Differential side 42 N m 31 lbf ft Rear differential protector Hexagonal screw 2 5 N m 22 lbf in Differential oil drain plug Front rear 13 N m 115 lbf in Differential filler plug Front rear 13 N m 115 lbf in Differential housing Torx screw ...

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