BOMBARDIER TRAXTER AUTOSHIFT 2002 User manual

2002
Shop Manual
TRAXTER AUTOSHIFT
TRAXTER XL
TRAXTER XT

Legal deposit:
National Library of Quebec
2nd trimester 2002
National Library of Canada 2002
All rights reserved. No parts of this manual may be reproduced in any
form without the prior written permission of Bombardier Inc.
©Bombardier Inc. 2002
Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
Printed in Canada
This document contains the trademarks of the following companies:
Bombardier®is a trademark of Bombardier Inc. or its subsidiaries
Traxter®is a trademark of Bombardier Inc. or its subsidiaries
Rotax®is a trademark of Bombardier Inc. or its subsidiaries
Simple Green®is a trademark of Sunshine Markers Inc
Kimtowels®is a trademark of Kimberly-Clark
Loctite®is a trademark of Loctite Corporation
Molykote®is a trademark of Dow Corning Corporation
Snap-on®is a trademark of Snap-on Tools Corporation

VMR2002_036_00_02A.FM I
SECTION SUBSECTION PAGE
SAFETY NOTICE ................................................................................................................................... III
WHAT’S NEW ....................................................................................................................................... IV
INTRODUCTION .................................................................................................................................. VI
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/lubrication ........................................................... 02-03-1
04 – Storage/pre-season preparation ............................................... 02-04-1
03 ENGINE 01 – Table of contents...................................................................... 03-01-1
02 – Troubleshooting........................................................................ 03-02-1
03 – Leak test................................................................................... 03-03-1
04 – Removal and installation........................................................... 03-04-1
05 – Cooling system......................................................................... 03-05-1
06 – Rewind starter.......................................................................... 03-06-1
07 – Magneto system ...................................................................... 03-07-1
08 – Lubrication system ................................................................... 03-08-1
09 – Cylinder and head..................................................................... 03-09-1
10 – Crankshaft/balancer shaft......................................................... 03-10-1
11 – Clutch ....................................................................................... 03-11-1
12 – Transmission ............................................................................ 03-12-1
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 drive ................................................................................ 06-02-1
03 – Rear axle................................................................................... 06-03-1
07 STEERING/CONTROL
SYSTEMS
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
TABLE OF CONTENTS
SUPPLEMENT

II VMR2002_036_00_02A.FM
09 BRAKES 01 –Table of contents ..................................................................... 09-01-1
02 –Hydraulic brakes....................................................................... 09-02-1
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 DIAGRAMS 01 –Wiring diagrams ....................................................................... 12-01-1
SECTION SUBSECTION PAGE
TABLE OF CONTENTS

VMR2002_036_00_02A.FM III
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair 2002 ATVs.
This edition was primarily published to be used by ATV mechanical technicians who are already familiar
with all service procedures relating to Bombardier made vehicles. Mechanical technicians should attend
continuous training courses given by Bombardier Training Department.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This shop manual uses technical terms which may be slightly different from the ones used in parts catalog.
It is understood that this manual may be translated into another language. In the event of any discrepancy,
the english version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Service
and Warranty Bulletins may be published to update the content of this manual. Make sure to read and
understand these. It does not include dealer modifications, whether authorized or not by Bombardier,
after manufacturing the product.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those mentioned in this document.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab,
elastic stop nut, self-locking fasteners, etc.) must be installed or replaced with new ones, where specified.
If the efficiency of a locking device is impaired, it must be renewed.
This manual emphasizes particular information denoted by the wording and symbols:
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo-
nents.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
This information relates to the preparation and use of Bombardier ATV and has been utilized safely and
effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or injuries
resulting from the improper use of the contents. We strongly recommend that any services be carried
out and/or verified by a highly skilled professional mechanic. It is understood that certain modifications
may render use of the vehicle illegal under existing federal, provincial and state regulations.
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including
possibility of death.
SAFETY NOTICE

IV VMR2002_036_00_02A.FM
WHAT’S NEW 0
SERVICE TOOLS AND SERVICE PRODUCTS
• Update of service tools line.
• Update of service products line.
MAINTENANCE/LUBRICATION
• New maintenance chart.
• New procedure concerning flipped over and ATV immersion
TROUBLESHOOTING
• Complete new section.
LEAK TEST
• Complete new section.
REMOVAL AND INSTALLATION
• Update of removal and installation procedure.
COOLING SYSTEM
• Procedure to test the temperature sender.
MAGNETO SYSTEM
• This section has been completly reviewed.
LUBRICATION SYSTEM
• Procedure to remove oil pump.
CRANKSHAFT/BALANCER SHAFT
• Crankshaft locking bolt installation.
• Camshaft removal procedure.
CARBURETOR AND FUEL PUMP
• New THROTTLE CABLE section.
IGNITION SYSTEM
• New spark plug symbol chart.
ELECTRIC SHIFT SYSTEM
• Shifting valve cleaning procedure.
WHAT’S NEW

VMR2002_036_00_02A.FM V
INSTRUMENTS AND ACCESSORIES
•Procedure (removal, test and installation) concerning hourmeter on XL model.
FRONT DRIVE
•Shimming procedure for inner differential.
REAR AXLE
•Shimming procedure for inner differential.
STEERING/CONTROLS SYSTEM
•Toe-out adjustment procedure.
HYDRAULIC BRAKES
•New brakes for all models.
TECHNICAL DATA
•Technical data update for all models.
WIRING DIAGRAMS
•New wiring diagrams for all models.
WHAT’S NEW

VI VMR2002_036_00_02A.FM
INTRODUCTION 0
This Shop Manual covers the following Bombardier
made 2002 ATV:
Models
VEHICLE MODEL NUMBER
TYPICAL — VEHICLE SERIAL NUMBER LABEL
1. Model number
VEHICLE AND ENGINE SERIAL
NUMBER LOCATION
1. Engine
2. Vehicle
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 DIAGRAMS
Each section is divided in various subsections, and
again, each subsection has one or more division.
TRAXTER®AUTOSHIFT(Red)................. 7453
TRAXTER®AUTOSHIFT(Green) ............. 7454
TRAXTER®AUTOSHIFT(Yellow) ............ 7475
TRAXTER®XL(Green)............................ 7458
TRAXTER®XT(Green)............................ 7446
TRAXTER®XT(Yellow)........................... 7452
TRAXTER®AUTOSHIFT INTL(Red)........ 7495
TRAXTER®AUTOSHIFT INTL(Green) .... 7496
TRAXTER®AUTOSHIFT INTL(Yellow) ... 7497
TRAXTER®XL INTL(Green)................... 7577
TRAXTER®XT INTL(Green)................... 7493
TRAXTER®XT INTL(Yellow).................. 7494
1
V04M04A
2
1
V01A36A
INTRODUCTION

VMR2002_036_00_02A.FM VII
LIST OF ABBREVIATIONS USED
IN THIS MANUAL
Aampere
amp ampere
A•h ampere-hour
AC alternate current
BDC bottom dead center
BTDC before top dead center
°C degree Celsius
cm 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
k kilo (thousand)
kg kilogram
km/h kilometer per hour
kPa kilo pascal
Lliter
LH left hand
lb pound
lbf pound (force)
m meter
MAG magneto
Max. maximum
Min. minimum
mL milliliter
mm millimeter
MPH mile per hour
Nnewton
N.A. not applicable
no. number
00.0 continuity
0.L overload (open circuit)
O.D. outside diameter
OHC Over head camshaft
OPT optional
oz ounce
P/N part number
PSI pound per square inch
PTO power take off
RH Right hand
RPM revolution per minute
TDC top dead center
U.S. oz ounce (United States)
USFD U.S. Forest Service
Vvolt
Vac volt (alternative current)
INTRODUCTION

VIII VMR2002_036_00_02A.FM
Section 03 ENGINE
Subsection 04 (REMOVAL AND INSTALLATION)
VMR2002_043_03_04A.FM 03-04-1
REMOVAL AND INSTALLATION 0
All Models except XL
V01C2TS
17
6
16
17
6
9
18
17
6
17
7
5
10
S nthetic
grease
20
12
23 Nm
(17 lbfft)
11
48 Nm
(35 lbfft)
14
13
39
10 Nm
(89 lbfin)
2
41
3
40
41
35
1
37
36
23 Nm
(17 lbfft)
34
34
33
34
34
33
32
4
15 15
22 Nm
(16 lbfft)
29
38
18
22
7 Nm
(62 lbfin)
30
30
30
23
26
29
S nthetic
grease
S nthetic
grease 23 Nm
(17 lbfft)
48 Nm
(35 lbfft)
19
19
27
11 Nm
(97 lbfin)
23 Nm
(17 lbfft)
8
48 Nm
(35 lbfft)
23 Nm
(17 lbfft)
5
5
22 Nm
(16 lbfft)
21
31
31
10 Nm
(89 lbfin)
21
21
28
23 Nm
(17 lbfft)
10 Nm
(89 lbfin)
Loctite 243
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
Page heading
indicates section
and subsection
detailed.
Bold face number
indicates s ecial
rocedure
concerning this
art.
Tightening torque
nearby fastener. In this
case, nut must be
torqued to
48 Nm or 35 lbfft.
This Shop Manual uses technical terms wich may be
slightly different from the ones in the arts catalog.
Ex loded view
assists you in
identifying arts and
related ositions.
TYPICAL PAGE
V01A3CS
Illustration
number for
ublishing
rocess.
Subsection title
indicates
beginning of the
subsection.
Page numbering system:
03: ENGINE section
04: REMOVAL AND INSTALLATION
subsection
1: First age of this subsection
CAUTION: Pa attention to
torque specifi
cations. Some
of these are in
lbfin instead
of lbfft. Use appro
priate torque
wrench. Document
number for
ublishing
rocess.
Dro re resents a
liquid roduct to
be a lied to
a surface.
INTRODUCTION

VMR2002_036_00_02A.FM IX
Section 03 ENGINE
Subsection 04 (REMOVAL AND INSTALLATION)
VMR2002_043_03_04A.FM 03-04-3
ENGINE REMOVAL
Vehicle Preparation
Place the vehicle on jack stands and lace the shifter
no. 1 on NEUTRAL osition.
Remove seat then remove battery. Disconnect
BLACK (-) cable from battery, then RED (+) cable.
Drain engine oil and engine coolant by removing
drain lugs.
UNDER ENGINE
1. Engine oil plug
2. Engine coolant plug
Remove fuel tank cover, footrests, inner fenders and
skid late. Refer to BODY.
Front Part Preparation
Remove seat ivot bar and un lug solenoid(s) con-
nector.
Remove sub-transmission osition sensor.
NOTE: Do not un lug only, remove sensor com-
letely.
Remove shifting rod no. 2. Refer to Shifting Rod
Removal section.
Un lug vehicle s eed sensor.
Engine Preparation
Un lug s ark lug cables.
Un lug oil ressure sensor.
Remove exhaust i e no. 3. Refer to Exhaust S s-
tem section.
Remove radiator inlet hose.
Disconnect breather hose.
Un lug tem erature sensor.
On AUTO model, disconnect TPS connector.
1. Spark plug cable
2. Exhaust pipe
3. Radiator inlet hose
4. Breather hose
5. Temperature sensor
. TPS connector
Remove carburetor no. 4. Refer to CARBURETOR
AND FUEL PUMP.
WARNING
Alwa s disconnect batter or starter cables
exactl in the specified order, BLACK (-) cable
first. It is recommended to disconnect electri-
cal connections prior to disconnecting fuel
lines.
V01A0AC
1
2
1
V01C2VA 26 543
m
TYPICAL PAGE
Title indicates
main rocedure
to be carried-out.
Reference to look
u a certain section
and subsection.
In this case it
concerns
Carburetor
and fuel um .
Bold face number
following art
name refers to
ex loded view
at beginning of
subsection.
Call-outs for
above illustration.
V01A3DS
INTRODUCTION

XVMR2002_036_00_02A.FM
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 de-
scription 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
SELF-LOCKING FASTENERS
PROCEDURE
The following describes the most common appli-
cation procedures when working with self-locking
fasteners.
Use a metal brush or a screwtap to clean the hole
properly then use a solvent (Methyl-Chloride), let
act during 30 minutes and wipe off. The solvent
utilization is to ensure the adhesive works properly.
LOCTITE APPLICATION
PROCEDURE
The following describes the most common appli-
cation procedures when working with Loctite
products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.
12
V01L25A
INTRODUCTION

VMR2002_036_00_02A.FM XI
Threadlocker
Uncovered Holes (bolts and nuts)
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.
2. Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
3. Choose proper strength Loctite threadlocker.
4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.
Blind Holes
1. On threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.
2. Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30 sec-
onds.
3. Choose proper strength Loctite threadlocker.
4. Apply several drops along the threaded hole and
at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
Stud in Blind Holes
1. On threads
2. On threads and in the hole
3. Onto nut threads
1. Clean threads (stud and hole) with solvent.
2. Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
3. Put several drops of proper strength Loctite
threadlocker on female threads and in hole.
4. Apply several drops of proper strength Loctite
on stud threads.
5. Install stud.
6. Install cover, etc.
7. Apply drops of proper strength Loctite on un-
covered threads.
8. Tighten nuts as required.
A00A3LA
1
2
A00A3MA
1
2
A00A5RA
2
13
INTRODUCTION

XII VMR2002_036_00_02A.FM
Preassembled Parts
1. Apply here
2. Do not apply
1. Clean bolts and nuts with solvent.
2. Assemble components.
3. Tighten nuts.
4. Apply drops of proper strength Loctite on bolt/nut
contact surfaces.
5. Avoid touching metal with tip of flask.
NOTE: For preventive maintenance on existing
equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces.
Adjusting Screw
1. Apply here
2. Plunger
1. Adjust screw to proper setting.
2. Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232°C (450°F)).
Mounting on Shaft
Mounting with a Press
1. Bearing
2. Proper strength Loctite
3. Shaft
Standard
1. Clean shaft external part and element internal
part.
2. Apply a strip of proper strength Loctite on shaft
circumference at insert or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
3. DO NOT use anti-seize Loctite or any similar
product.
4. No curing period is required.
Mounting in Tandem
1. Apply retaining compound on internal element
bore.
2. Continue to assemble as shown above.
A00A3OA
1
2
A00A3PA
1
2
A00A3UA
1
2
3
INTRODUCTION

VMR2002_036_00_02A.FM XIII
Case-In Components
Metallic Gaskets
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket
diameter.
2. Spray housing and gasket with Loctite Primer N
(P/N 293 800 041).
3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.
4. Install according to standard procedure.
5. Wipe off surplus.
6. Allow it to cure for 30 minutes.
NOTE: Normally used on worn-out housings to
prevent leaking or sliding.
It is generally not necessary to remove gasket
compound applied on outer gasket diameter.
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.
In order to avoid a poor assembling, tighten
screws and bolts in accordance with the following
procedure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply the half of the recommended torque value.
3. Torque at the recommended torque value.
NOTE: Always torque screws, bolts and/or nuts in
a criss-cross sequence.
* TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS
A00A3VA 1BOLT OR NUT
SIZE
TIGHTENING TORQUE*
N•mlbf•in
M4 2 18
M5 4 35
M6 10 89
BOLT OR NUT
SIZE
TIGHTENING TORQUE*
N•mlbf•ft
M8 23 17
M10 48 35
M12 80 59
M14 135 100
INTRODUCTION

We would be pleased if you could
communicate to Bombardier any sug-
gestions you may have concerning
our publications.
✁
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Machine___________________ Report of error ❏Suggestion ❏
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____________________________________________________________
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Address ____________________________________________________
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Zip code/Postal code ________________________________________
Bombardier SERVICE PUBLICATIONS REPORT
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Machine___________________ Report of error ❏Suggestion ❏
____________________________________________________________
____________________________________________________________
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Address ____________________________________________________
City and State/Prov. ________________________ Date___________
Zip code/Postal code ________________________________________

AFFIX
PROPER
POSTAGE
AFFIX
PROPER
POSTAGE
AFFIX
PROPER
POSTAGE
Technical Publications
After Sales Service
565 de la Montagne Street
Valcourt, Québec, Canada J0E 2L0
Technical Publications
After Sales Service
565 de la Montagne Street
Valcourt, Québec, Canada J0E 2L0
Technical Publications
After Sales Service
565 de la Montagne Street
Valcourt, Québec, Canada J0E 2L0