BOMBARDIER traxter max series Manual

vmo2005 traxter max ang.FH8 Fri Jul 09 10:20:19 2004 Page 1
C M Y CM MY CY CMY K

This Operator’s Guide utilizes the following symbols to emphasize particular in-
formation:
The Safety Alert Symbol indicates a potential personal injury hazard.
WARNING Indicates a potentially hazardous situation which, if not
avoided, could result in serious injury or death.
CAUTION: Denotes an instruction which, if not followed, could severely
damage vehicle components.
WARNING
YOUR VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rollover
can occur quickly, even during routine maneuvers such as turning and driv-
ing on hills or over obstacles, if you fail to take proper precautions.
For your safety, understand and follow all the warnings contained in this
Operator's Guide and the labels on your vehicle. Failure to follow these
warnings can result in SEVERE INJURY OR DEATH!
Keep this Operator's Guide with the vehicle at all times.
WARNING
Disregarding any of the safety precautions and instructions contained in this
Operator’s Guide, Safety Videocassette and on-product labels could cause
injury including the possibility of death!
All safety documentation should remain with the vehicle at the time of sale.
All content of the Safety Information section should be interpreted by the reader
as a warning which, if not followed, may result in injury including the possibility
of death.
In Canada, products are distributed by Bombardier Recreational Products Inc.
(BRP)
In USA, products are distributed by Bombardier Motor Corporation of America.
The following trademarks are the property of Bombardier Recreational Prod-
ucts Inc.:
Traxter®Rotax®
Printed in Canada. (vmo2005-007 AP)
®™Trademarks of Bombardier Recreational Products Inc. or its affiliates.
©2004 Bombardier Recreational Products Inc. All rights reserved.
* Bombardier and the sprocket design are trademarks of Bombardier Inc., used under license.

FOREWORD
Congratulations on your purchase of
a new Bombardier*recreational vehi-
cle. It is backed by the BRP warranty
and a network of authorized Bom-
bardier ATV dealers ready to provide
the parts, service or accessories you
may require.
Your dealer is committed to your satis-
faction. He has taken training to per-
form the initial set-up and inspection
of your vehicle as well as completed
the final adjustment before you took
possession. At delivery, your dealer
would have explained the vehicle for
the operation, maintenance and safety
features of the vehicle. We trust you
have taken full advantage of this! If
you need more complete servicing in-
formation, please ask your dealer.
Atdelivery,youwerealsoinformedof
the warranty coverage and completed
the Warranty Registration Form which
is to be sent to us for processing. In
the near future you should be receiv-
ing a warranty card which will confirm
our receipt of the registration as well
as be used for warranty or recall pur-
poses.
You are invited to contact our cus-
tomer assistance center should you
experience problems which cannot be
resolved by an authorized Bombardier
ATV dealer.
It is understood that this guide may be
translated into another language. In
the event of any discrepancy, the Eng-
lish version shall prevail. Throughout
this document the masculine is used
to denote the masculine or feminine.
The information and components/sys-
tem descriptions contained in this
document are correct at the time of
publication. Bombardier Recreational
Products Inc., however, maintains a
policy of continuous improvement of
its products without imposing upon
itself any obligation to install them
on products previously manufactured.
Due to late changes, some differ-
ences between the manufactured
product and the descriptions and/or
specifications in this guide may occur.
BRP reserves the right at any time to
discontinue or change specifications,
designs, features, models or equip-
ment without incurring any obligation
upon itself.
The illustrations in this document
show the typical construction of the
different assemblies and may not re-
produce the full detail or exact shape
of the parts. However, they represent
parts that have the same or similar
function.
The use of RIGHT and LEFT indica-
tions in the text always refers to driv-
ing position (when sitting on vehicle).
Specifications are given in the SI met-
ric system with the SAE U.S. equiva-
lent in parenthesis. Where precise ac-
curacy is not required, some conver-
sions are rounded off for easier use.
We recommend genuine Bombardier
products for replacement parts and ac-
cessories. They have been especially
designed for your vehicle and man-
ufactured to meet BRP's demanding
standards.
A Shop Manual can be obtained for
complete service and maintenance in-
formation and more repair information.
______________________ 1

TABLE OF CONTENTS
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious in-
jury or death.
NOTICE................................................................................ 7
INTRODUCTION ..................................................................... 8
SAFETY INFORMATION
SPECIAL SAFETY MESSAGES .................................................... 11
OPERATION WARNINGS........................................................... 14
SAFETY WARNING.................................................................. 43
Pre-Operation Check ............................................................ 44
Clothing........................................................................... 45
Carrying Loads/Passenger ...................................................... 46
Hauling a Trailer .................................................................. 46
Working with your Vehicle...................................................... 46
Recreational Riding .............................................................. 47
Environment...................................................................... 47
Design Limitation ................................................................ 47
Off-Highway Operation.......................................................... 48
General Operating and Safety Precautions.................................... 48
Uphill Driving ..................................................................... 49
Downhill Driving.................................................................. 49
Side Hilling........................................................................ 49
Drop-Off .......................................................................... 49
Riding Techniques ............................................................... 50
Routine Maintenance............................................................ 57
HANG TAG ........................................................................... 58
LOCATION OF THE IMPORTANT LABELS....................................... 59
SAFETY TRAINING
INTRODUCTION ..................................................................... 64
Objective.......................................................................... 64
Sections Covered................................................................ 64
Time Required.................................................................... 64
2_______________________

SECTION I – GENERAL SAFETY INFORMATION............................... 65
SECTION II – BOMBARDIER 2-UP VEHICLE SAFETY VIDEOCASSETTE ... 67
SECTION III – OPERATOR'S GUIDE REVIEW.................................... 69
SECTION IV – HANDS-ON RIDING ............................................... 70
DRIVING MANEUVER LIST........................................................ 71
INSTRUCTOR'S CHECK LIST ...................................................... 75
VEHICLE INFORMATION
HOW TO IDENTIFY YOUR ATV.................................................... 80
Engine and Vehicle Identification Number Location.......................... 80
Compliance Label................................................................ 82
EMISSION REQUIREMENTS ...................................................... 83
CONTROLS/INSTRUMENTS/EQUIPMENT ..................................... 84
1) Throttle Lever ................................................................. 88
2) Front Brake Lever............................................................. 88
3) Rear Brake Lever.............................................................. 88
4) Brake Lever Lock ............................................................. 89
5) Transmission Lever ........................................................... 89
6) Multi-Function Switch ........................................................ 91
7) Indicator Lights Cluster....................................................... 94
8) Speedometer.................................................................. 95
9) Rear Passenger's Grab Handles............................................. 97
10) Ignition Switch............................................................... 97
11) Choke Knob Lever........................................................... 98
12) Auxiliary Headlamp ................. .... ............................ ......... 99
13) Fuel Tank Cap................................................................ 99
14) Fuel Gauge................................................................... 99
15) Fuel Valve .................................................................... 99
16) Rear Brake Pedal ............................................................100
17) Rewind Starter Handle......................................................101
18) Footpeg.......................................................................101
19) Storage Compartment ......................................................101
20) Tool Box ......................................................................102
21) Seat Latch....................................................................102
22) Cargo Racks..................................................................103
23) Air Duct.......................................................................103
24) Trailer Hitch ..................................................................103
25) Radiator Cap .................................................................104
26) 12-Volt Power Outlet........................................................104
27) Fuses .........................................................................104
28) Winch (if so equipped) ......................................................104
29) Winch Control Switch (if so equipped) ....................................105
30) Fairlead (if so equipped) ....................................................105
______________________ 3

LIQUIDS...............................................................................106
Fuel................................................................................106
Engine/Transmission Oil.........................................................106
Engine Coolant...................................................................108
Brake Fluid........................................................................109
Battery ...........................................................................111
BREAK-IN PERIOD...................................................................112
Engine.............................................................................112
Belt................................................................................112
10-Hour Inspection ..............................................................112
PRE-OPERATION CHECK...........................................................113
OPERATING INSTRUCTIONS......................................................114
General............................................................................114
Initial Cold Starting...............................................................114
Warm Engine Starting...........................................................115
Emergency Manual Starting ....................................................115
Stopping the Engine.............................................................116
Shifting the Transmission .......................................................116
Winch Operation.................................................................117
SPECIAL PROCEDURES ............................................................118
Flooded Engine...................................................................118
Engine Overheat.................................................................118
Turn Over .........................................................................118
ATV Immersion...................................................................118
Post-Operation Care.............................................................119
Emergency Shifter...............................................................119
Storage and Preseason Preparation............................................120
CARGO AND TRANSPORTATION.................................................121
Cargo..............................................................................121
Hauling a Trailer ..................................................................122
Transportation....................................................................122
MAINTENANCE INFORMATION
MAINTENANCE CHART ............................................................126
MAINTENANCE......................................................................129
Engine/Transmission.............................................................129
Carburetor ........................................................................133
Air Intake System................................................................134
Electrical ..........................................................................135
Drive Train ........................................................................139
Steering System .................................................................141
Suspension.......................................................................142
Brake..............................................................................144
Body/Frame ......................................................................144
4_______________________

TROUBLESHOOTING...............................................................146
SPECIFICATIONS ....................................................................150
INTERNATIONAL METRIC INFORMATION GUIDE.............................160
WARRANTY
BRP LIMITED WARRANTY NORTH AMERICA: 2005 BOMBARDIER†ATV . 162
BRP INTERNATIONAL LIMITED WARRANTY: 2005 BOMBARDIER†ATV ..166
PRIVACY OBLIGATION/DISCLAIMER............................................170
CHANGE OF ADDRESS/OWNERSHIP ...........................................171
______________________ 5

NOTICE
This Operator's Guide has been pre-
pared to acquaint the owner/operator
of a new vehicle with the various ve-
hicle controls, maintenance and safe
operating instructions. It is indispens-
able for the proper use of the product.
This Operator's Guide uses the follow-
ing symbols.
WARNING
Indicates a potentially hazardous
situation which, if not avoided,
couldresultinseriousinjuryor
death.
CAUTION: Denotes an instruc-
tion which, if not followed, could
severely damage vehicle compo-
nents.
NOTE: Indicates supplementary infor-
mation needed to fully complete an in-
struction.
Although the mere reading of such in-
formation does not eliminate the haz-
ard, the understanding and application
of the information will promote the
correct use of this vehicle.
To fully appreciate the pleasures, en-
joyment and excitement of using this
vehicle, there are some basic rules
that MUST be observed and followed
by any user.
______________________ 7

INTRODUCTION
Your dealer should have provided you
with some basic information on the
particular controls and features of
your new vehicle. Please take the
time to study this Operator's Guide
and all on-product warning labels as
well as the Safety Videocassette that
came with this vehicle. They more
completely describe what you should
know about this vehicle before riding
it.
Whether you are a new user or an ex-
perienced rider, it is important for your
personal safety as well as passenger
safety that you know the controls and
features of this vehicle. Equally impor-
tant is knowing how to properly ride.
Irrespective of your age, experience or
state regulations, it is always prudent
for you or any other person who may
ride your vehicle, to take an approved
safe riding course. Please check with
your dealer or local authorities for avail-
ability in your area. If you are a com-
pletely new rider, this should be done
before your first ride. Your instructor
should be able to provide advice on lo-
cal conditions and safe riding practices
particular to the area.
Riding conditions vary from place
to place. Each is subject to weather
conditions which may radically change
from time to time and from season to
season. Riding on sand is different
than riding on snow or through forests
or marshes. Each location may re-
quire a greater degree of awareness
and skill may not be suitable with a
passenger. Show good judgement.
Always proceed with caution. Please
do not take any unnecessary risks that
could leave you or your passenger
stranded or possibly injured.
The vehicle handling, stability and
braking distance may be affected
when riding with a passenger. Safely
reduce speed when riding with a pas-
senger. Allow greater distance for
braking.
The contents of this Operator's Guide
provide riding information which has
been proven reliable by other users.
They are not intended as a definitive
means of avoiding accidents. How
you apply this information, coupled
with your mental and physical condi-
tion, the particular terrain hazard and
your risk acceptance level will have
an effect on your riding experience.
Have fun…and ride responsibly.
This Operator's Guide has been pre-
pared to acquaint the owner/operator
of a new vehicle with the various ve-
hicle controls, maintenance and safe
operating instructions. They are indis-
pensable for the proper use of the
product.
We would be pleased to receive any
comments on the content and format
of this Operator's Guide, the Safety
Videocassette or on-product warnings
labels.
8_______________________

SAFETY
INFORMATION
____________ SAFETY INFORMATION ____________ 9

WARNING
Operator:
•A person under 16 years old should never operate this vehicle.
•Never carry more than one passenger on this vehicle.
•Passenger must be seated on the designated passenger's seat and hold on
to the grab handles at all times.
•The operator is responsible for the safety of the passenger. In doubt, dis-
embark him before executing any maneuver.
•The vehicle handling, stability and braking distance may be affected when
riding with a passenger. Safely reduce speed when riding with a passenger.
Allow greater distance for braking.
•Always practice the maneuvers described in this Operator's Guide without
and with passenger.
•Inform the passenger concerning the basic rules for a safe ride.
Passenger:
•The passenger should be 12 years old or more and must be capable of
keeping his feet on footrests and his hands on grab handles at all times
when he is seated on this vehicle.
•Passenger should always hold on to rear passenger grab handles. Never
hold on to the operator.
•Passenger should pay attention to vehicle and operator movements.
•Passenger should always wear the appropriate protective gear, including
an approved helmet with a rigid chin guard.
•Passenger should always keep hands and feet in the proper place during
operation.
•Never get up during vehicle operation. An excessive movement could
cause loss of control.
•Failure to follow the recommendations here could cause changes in ve-
hicle handling which could lead to an accident resulting in severe injuries
including the possibility of death for the passenger and/or the operator.
10 ___________ SAFETY INFORMATION ___________

SPECIAL SAFETY MESSAGES
THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
This vehicle handles differently from other vehicles including motorcycles and
cars. A collision or rollover can occur quickly, even during routine maneuvers
such as turning and driving on hills or over obstacles, if you fail to take proper
precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this Operator's Guide and all on-product warnings labels carefully and
follow the operating procedures described. Watch and pay attention to the
Safety Videocassette before operation.
Never operate this vehicle without proper instruction. Take a training course.
All operators should receive training from a certified instructor. See your au-
thorized Bombardier ATV dealer for more informations.
Always follow this age recommendation: A person under 16 years old should
never operate this vehicle.
Never carry more than one passenger on this vehicle. This passenger should
be 12 years old or more and must be capable of keeping his feet on footrests
and his hands on grab handles at all times when he is seated.
The vehicle handling, stability and braking distance may be affected when rid-
ing with a passenger. Safely reduce speed when riding with a passenger.
Allow greater distance for braking.
Never operate this vehicle on any paved surfaces, including sidewalks, drive-
ways, parking lots and streets.
Never operate this vehicle on any public street, road or highway, even a dirt or
gravel one.
Never take place on this vehicle without wearing an approved helmet that fits
properly. The operator and the passenger should also wear eye protection
(goggles or face shield), gloves, boots, long sleeved shirt or jacket, and long
pants. The passenger should have an approved helmet including a rigid chin
guard.
Never consume alcohol or drugs before or while riding this vehicle.
Never operate at excessive speeds. Always go at a speed that is proper for
the terrain, visibility, and operating conditions, and your experience.
Never attempt wheelies, jumps, or other stunts.
Always inspect your vehicle each time you use it to make sure it is in safe op-
erating condition. Always follow the inspection and maintenance procedures
and schedules described in this Operator's Guide.
The operator and the passenger must always keep both hands on the han-
dlebars or grab handles and both feet on the footrests of the vehicle during
operation.
Always go slowly and be extra careful when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating this vehicle.
Always keep in mind that you are carrying a passenger.
____________ SAFETY INFORMATION ___________ 11

Never operate on excessively rough, slippery or loose terrain until you have
learned and practiced the skills necessary to control this vehicle on such ter-
rain. Always be especially cautious on these kinds of terrain. Always keep in
mind that you are carrying a passenger.
Always follow proper procedures for turning as described further in this Oper-
ator's Guide. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speed. Carrying a passenger may affect the
stability and the handling of the vehicle.
Never operate this vehicle on hills too steep for the vehicle or for your abilities.
Do not forget, the operator is responsible for the safety of the passenger. In
doubt, disembark him before climbing hill. Always remember that the vehicle
handling, stability and braking distance may be affected when riding with a
passenger.
Always follow proper procedures for climbing hills as described further in this
Operator's Guide. Check the terrain carefully before you start up any hill.
Never climb hills with excessively slippery or loose surfaces. Shift operator
and passenger weight forward. Never open the throttle suddenly or make
sudden gear changes. Never go over the top of any hill at high speed. Always
keep in mind that you are carrying a passenger.
Always follow proper procedures for going down hills and for braking on hills as
described further in this Operator's Guide. Check the terrain carefully before
you start down any hill. Shift operator and passenger weight backward. Never
go down a hill at high speed. Avoid going down a hill at an angle that would
cause the vehicle to lean sharply to one side. Go straight down the hill where
possible. Always keep in mind that you are carrying a passenger.
Always follow proper procedures for crossing the side of a hill as described
further in this Operator's Guide. Avoid hills with excessively slippery or loose
surfaces. Shift operator and passenger weight to the uphill side of the vehi-
cle. Never attempt to turn the vehicle around on any hill until you have mas-
tered the turning technique described in this Operator's Guide on level ground.
Avoid crossing the side of a steep hill if possible. Always keep in mind that
you are carrying a passenger.
Always use proper procedures if you stall or roll backwards when climbing a
hill. To avoid stalling, use proper gear and maintain a steady speed when climb-
ing a hill. If you stall or roll backwards, follow the special procedure for braking
described in this Operator's Guide. First, disembark the passenger then the
operator. Dismount on the uphill side or to a side if pointed straight uphill. Turn
the vehicle around and remount, following the procedure described further in
this Operator's Guide.
Always check for obstacles before operating in a new area. Never attempt to
operate over large obstacles, such as large rocks or fallen trees. Always follow
proper procedures when operating over obstacles as described further in this
Operator's Guide. Do not forget, the operator is responsible for the safety of
the passenger. In doubt, disembark him to get through the obstacles.
12 ___________ SAFETY INFORMATION ___________

Always be careful when skidding or sliding. Never attempt with a passenger;
overturn or passenger ejection may occur. Learn to safely control skidding or
sliding by practicing at low speeds and on level smooth terrain. On extremely
slippery surfaces, such as ice, go slowly and be very cautious in order to reduce
the chance of skidding out of control.
Never operate this vehicle in fast flowing water or in water deeper than that
specified in this Operator's Guide. Remember that wet brakes may have re-
duced stopping ability. Test your brakes after leaving water. If necessary,
apply them several times to let friction dry out the pads. The vehicle braking
distance may be affected when riding with a passenger. Safely reduce speed
when riding with a passenger. Allow greater distance for braking.
Always be sure there are no obstacles or people behind the vehicle when you
operate in reverse. When it is safe to proceed in reverse, go slowly. Take
account that the passenger can obstruct your view.
Always use the size and type tires specified further in this Operator's Guide.
Always maintain proper tire pressure as described further in this Operator's
Guide.
Never modify this vehicle through improper installation or use of accessories.
Only use BRP's approved accessories. Do not install passenger's seats or use
the racks to carry more than one passenger.
Never exceed the stated load limits for this vehicle including operator and pas-
senger, all other loads and added accessories. Cargo should be properly dis-
tributed and securely attached. Reduce speed and follow instructions in this
manual for carrying cargo or pulling a trailer. Allow greater distance for braking.
Do not forget, the operator is responsible for the safety of the passenger. If in
doubt, disembark him. Always practice the maneuvers described in this Oper-
ator's Guide without and with passenger. Always remember that the vehicle
handling, stability and braking distance may be affected when riding with a
passenger. Safely reduce speed when riding with a passenger. Allow greater
distance for braking. In some situations, this vehicle can be used easily with
the operator alone but not necessarily with a passenger. Use your common
sense.
____________ SAFETY INFORMATION ___________ 13

OPERATION WARNINGS
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious in-
jury or death.
NOTE: The following illustrations are general representations only. Your model
may differ.
WARNING
V00A0AQ
POTENTIAL HAZARD
Operating this vehicle without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does not know
how to operate this vehicle properly in different situations and on different
types of terrain with or without passenger.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the training
course offered by BRP. They should then regularly practice the skills
learned in the course and the operating techniques described in this
Operator's Guide.
14 ___________ SAFETY INFORMATION ___________

WARNING
V00A1AQ
POTENTIAL HAZARD
Failure to follow the age recommendations for this vehicle.
WHAT CAN HAPPEN
A lack of respect for this age recommendation can lead to severe injury or
death of the child.
Even though a child may be within the age group for which this vehicle is
recommended, he may not have the skills, abilities, or judgment needed
to operate this vehicle safely and may be involved in a serious accident.
HOW TO AVOID THE HAZARD
No one under 16 should operate this vehicle.
____________ SAFETY INFORMATION ___________ 15

WARNING
V00A1BQ
POTENTIAL HAZARD
Failure to follow the age recommendations for the passenger.
WHAT CAN HAPPEN
A child, under 12, may not have the ability needed to ride safely and may
be involved in a serious accident.
HOW TO AVOID THE HAZARD
No one under 12 should be riding on this vehicle.
WARNING
POTENTIAL HAZARD
Failure to respect the physical limitations of the passenger.
WHAT CAN HAPPEN
A passenger that cannot completely lean his feet on footrests can be
ejected when riding on uneven terrain.
HOW TO AVOID THE HAZARD
The passenger must be capable of keeping his feet on the footrests and his
hands on grab handles at all time when he is seated on the vehicle.
16 ___________ SAFETY INFORMATION ___________

WARNING
V00A1CQ
POTENTIAL HAZARD
Carrying more than one passenger on this vehicle.
WHAT CAN HAPPEN
Carrying more than one passenger reduces your ability to balance and con-
trol this vehicle.
Could cause an accident, resulting in harm to you and/or your passengers.
HOW TO AVOID THE HAZARD
Never carry more than one passenger. Even with a long seat that provides
unrestricted operator movement, the vehicle is not designed nor intended
to carry more than one (1) operator and one (1) passenger. The passenger
must use the designated passenger's seat when he is seated on the vehicle.
____________ SAFETY INFORMATION ___________ 17

WARNING
V00A2DQ
POTENTIAL HAZARD
Allowing passenger to sit in a location other than the designated passen-
ger's seat.
WHAT CAN HAPPEN
Passenger seated in a location other than designated passenger's seat
could:
–impair vehicle stability which could lead to a loss of control
–suffer injury from impact on hard surfaces.
Could cause an accident, resulting in harm to you and/or your passenger.
HOW TO AVOID THE HAZARD
Passenger must always remain seated on designated passenger's seat with
feet firmly planted on footrests and always hold on to the grab handles.
18 ___________ SAFETY INFORMATION ___________

WARNING
V00A1DQ
POTENTIAL HAZARD
Operating this vehicle on paved surfaces.
WHAT CAN HAPPEN
The tires are designed for off-road use only, not for use on pavement.
Paved surfaces may seriously affect handling and control of the vehicle,
and may cause the vehicle to go out of control.
HOW TO AVOID THE HAZARD
Never operate this vehicle on any paved surfaces, including sidewalks,
driveways, parking lots and streets.
____________ SAFETY INFORMATION ___________ 19