BRP BOMBARDIER DS250 2006 Install guide

C M Y CM MY CY CMY K
2006-2019

2006 -2019
Shop Manual
DS 250

TABLEOFCONTENTS
SAFETY NOTICE................................................................................... VII
INTRODUCTION .................................................................................. VIII
GENERAL INFORMATION........................................................................................ VIII
VEHICLE SERIAL NUMBER LOCATION........................................................................ VIII
ENGINE SERIAL NUMBER LOCATION......................................................................... VIII
ARRANGEMENT OF THE MANUAL, ILLUSTRATIONS AND PROCEDURES ............................ VIII
SELF-LOCKING FASTENERS PROCEDURE .................................................................... XII
LOCTITE®APPLICATION PROCEDURE ......................................................................... XII
TIGHTENING TORQUES ......................................................................................... XVI
01 MAINTENANCE
01 – MAINTENANCE CHART....................................................................................... 1
NOISE EMISSION CONTROL SYSTEM REGULATION ............................................................ 1
MAINTENANCE CHART .............................................................................................. 2
02 – PRESEASON PREPARATION................................................................................. 5
03 – STORAGE PROCEDURES..................................................................................... 7
FUEL SYSTEM......................................................................................................... 7
ENGINE ................................................................................................................ 7
ELECTRICAL SYSTEM................................................................................................ 7
COOLING SYSTEM ................................................................................................... 7
CVT TRANSMISSION................................................................................................. 8
VEHICLE ............................................................................................................... 8
04 – SPECIAL PROCEDURES..................................................................................... 11
ATV IMMERSION .................................................................................................... 11
02 TROUBLESHOOTING
01 – TROUBLESHOOTING CHART.............................................................................. 13
COOLING SYSTEM .......................................................................................... 13
ELECTRICAL SYSTEM....................................................................................... 13
LUBRICATION SYSTEM..................................................................................... 14
CYLINDER HEAD............................................................................................. 15
CRANKSHAFT ................................................................................................ 16
GEARBOX ..................................................................................................... 16
CVT............................................................................................................. 17
ENGINE GENERAL........................................................................................... 19
STARTING SYSTEM ......................................................................................... 21
03 ENGINE
01 – ENGINE REMOVAL AND INSTALLATION................................................................ 23
GENERAL............................................................................................................. 23
REMOVAL ............................................................................................................ 23
INSPECTION.......................................................................................................... 27
INSTALLATION ....................................................................................................... 27
02 – ENGINE LEAK TEST ......................................................................................... 29
GENERAL............................................................................................................. 29
PROCEDURES........................................................................................................ 29
03 – AIR INTAKE SYSTEM........................................................................................ 33
GENERAL...................................................................................................... 34
PROCEDURES ................................................................................................ 34
AIR FILTER............................................................................................................ 34
AIR FILTER HOUSING ............................................................................................... 34
AIR INJECTION VALVE FILTER...................................................................................... 35
04 – EXHAUST SYSTEM.......................................................................................... 37
GENERAL...................................................................................................... 38
PROCEDURES ................................................................................................ 38
I

TABLE OF CONTENTS
MUFFLER............................................................................................................. 38
EXHAUST PIPE....................................................................................................... 38
SPARK ARRESTER................................................................................................... 39
05 – LUBRICATION SYSTEM..................................................................................... 41
GENERAL............................................................................................................. 43
ENGINE OIL .......................................................................................................... 43
ENGINE OIL PRESSURE............................................................................................. 45
ENGINE OIL PRESSURE RELIEF VALVE ........................................................................... 45
OIL PUMP ............................................................................................................ 45
06 – COOLING SYSTEM .......................................................................................... 49
GENERAL...................................................................................................... 52
COOLING SYSTEM INSPECTION ......................................................................... 52
LEAK INDICATOR HOLE............................................................................................. 52
COOLING SYSTEM LEAK TEST..................................................................................... 52
PROCEDURES ................................................................................................ 53
ENGINE COOLANT .................................................................................................. 53
RADIATOR CAP ...................................................................................................... 54
THERMOSTAT........................................................................................................ 54
THERMO-SWITCH................................................................................................... 55
WATER PUMP........................................................................................................ 55
COOLING FAN MOTOR ............................................................................................. 58
RADIATOR............................................................................................................ 59
07 – MAGNETO AND STARTER DRIVE......................................................................... 61
GENERAL...................................................................................................... 62
PROCEDURES ................................................................................................ 62
MAGNETO COVER................................................................................................... 62
TRIGGER COIL ....................................................................................................... 64
STATOR ............................................................................................................... 64
CRANKSHAFT END BEARING ...................................................................................... 64
FLYWHEEL ........................................................................................................... 65
STARTER REDUCTION GEAR....................................................................................... 66
STARTING CLUTCH GEAR .......................................................................................... 67
08 – CYLINDER HEAD............................................................................................. 69
GENERAL............................................................................................................. 70
VALVE CLEARANCE ADJUSTMENT ................................................................................ 70
CYLINDER HEAD REMOVAL........................................................................................ 71
CYLINDER HEAD DISASSEMBLY .................................................................................. 74
CLEANING............................................................................................................ 75
PARTS INSPECTION ................................................................................................. 75
CYLINDER HEAD ASSEMBLY ...................................................................................... 79
CYLINDER HEAD INSTALLATION .................................................................................. 80
09 – PISTON AND CYLINDER.................................................................................... 83
GENERAL............................................................................................................. 84
DISASSEMBLY ....................................................................................................... 84
INSPECTION.......................................................................................................... 85
ASSEMBLY ........................................................................................................... 88
10 – CRANKSHAFT AND CRANKCASE......................................................................... 91
GENERAL............................................................................................................. 92
CRANKCASE DISASSEMBLY ....................................................................................... 92
INSPECTION.......................................................................................................... 94
CRANKCASE ASSEMBLY ........................................................................................... 96
11 – GEARBOX..................................................................................................... 99
GENERAL........................................................................................................... 101
GEARBOX OIL LEVEL ............................................................................................. 101
GEARBOX OIL CHANGE .......................................................................................... 101
GEARBOX SWITCH................................................................................................ 102
II

TABLEOFCONTENTS
OIL SEAL REPLACEMENT ........................................................................................ 102
GEARBOX DISASSEMBLY ........................................................................................ 103
GEARBOX INSPECTION........................................................................................... 106
GEARBOX ASSEMBLY ............................................................................................ 107
04 FUEL SYSTEM
01 – CARBURETOR AND FUEL TANK ......................................................................... 111
GENERAL..................................................................................................... 114
PROCEDURES ............................................................................................... 114
CARBURETOR...................................................................................................... 114
FUEL FILTER........................................................................................................ 117
FUEL VALVE ........................................................................................................ 117
FUEL TANK ......................................................................................................... 118
THROTTLE CABLE................................................................................................. 119
CHOKE CABLE..................................................................................................... 120
05 ELECTRICAL SYSTEM
01 – CHARGING SYSTEM ....................................................................................... 123
GENERAL..................................................................................................... 123
PROCEDURES ............................................................................................... 123
VOLTAGE REGULATOR/ RECTIFIER.............................................................................. 123
STATOR ............................................................................................................. 124
BATTERY............................................................................................................ 125
02 – IGNITION SYSTEM ......................................................................................... 129
GENERAL..................................................................................................... 129
TROUBLESHOOTING....................................................................................... 130
REPAIR PROCEDURES ..................................................................................... 130
FUSES............................................................................................................... 131
SPARK PLUG ....................................................................................................... 131
BATTERY............................................................................................................ 132
IGNITION SWITCH................................................................................................. 132
ENGINE STOP SWITCH ........................................................................................... 134
TRIGGER COIL ..................................................................................................... 134
IGNITION COIL..................................................................................................... 136
IGNITION MODULE................................................................................................ 137
SHIFT GEAR CONTROL MODULE ............................................................................... 139
OVERRIDE SWITCH ............................................................................................... 140
ADJUSTMENT............................................................................................... 141
IGNITION TIMING.................................................................................................. 141
03 – STARTING SYSTEM ........................................................................................ 143
GENERAL..................................................................................................... 143
TESTING PROCEDURES................................................................................... 144
FUSES............................................................................................................... 144
BATTERY............................................................................................................ 144
IGNITION SWITCH................................................................................................. 144
ENGINE STOP SWITCH ........................................................................................... 144
START SWITCH .................................................................................................... 144
STARTING SOLENOID............................................................................................. 145
ELECTRICAL CABLES OR CONNECTIONS...................................................................... 146
ELECTRIC STARTER............................................................................................... 146
SHIFT GEAR CONTROL MODULE ............................................................................... 146
PART REPLACEMENT ...................................................................................... 146
ELECTRIC STARTER............................................................................................... 146
04 – LIGHTS AND ACCESSORIES.............................................................................. 149
GENERAL..................................................................................................... 149
PROCEDURES ............................................................................................... 150
III

TABLE OF CONTENTS
FUSES............................................................................................................... 150
HEADLAMP......................................................................................................... 150
TURN SIGNAL LIGHTS ............................................................................................ 155
POSITION LIGHT................................................................................................... 160
PILOT LAMPS...................................................................................................... 161
TAILLIGHT .......................................................................................................... 165
HORN ............................................................................................................... 165
12-VOLT POWER OUTLET ........................................................................................ 166
06 TRANSMISSION
01 – CONTINUOUSLY VARIABLE TRANSMISSION (CVT)................................................. 169
GENERAL..................................................................................................... 171
PROCEDURES ............................................................................................... 171
DRIVE BELT......................................................................................................... 171
CVT COVER......................................................................................................... 171
CVT COVER BEARING............................................................................................. 172
DRIVE PULLEY..................................................................................................... 172
DRIVEN PULLEY ................................................................................................... 176
07 STEERING AND FRONT SUSPENSION
01 – STEERING AND FRONT SUSPENSION ................................................................. 179
GENERAL..................................................................................................... 181
PROCEDURES ............................................................................................... 181
HANDLEBAR GRIP................................................................................................. 181
MULTIFUNCTION SWITCH........................................................................................ 181
AUXILIARY MULTIFUNCTION SWITCH.......................................................................... 182
THROTTLE LEVER ................................................................................................. 183
MASTER CYLINDER............................................................................................... 184
HANDLEBAR ....................................................................................................... 184
TIE-ROD............................................................................................................. 185
STEERING COLUMN .............................................................................................. 186
STEERING COLUMN BEARING................................................................................... 187
FRONT WHEEL HUB .............................................................................................. 188
WHEEL BEARING.................................................................................................. 188
KNUCKLE........................................................................................................... 189
SHOCK ABSORBER AND SPRING ............................................................................... 189
LOWER A-ARM .................................................................................................... 190
UPPER A-ARM ..................................................................................................... 192
ADJUSTMENT............................................................................................... 193
STEERING ALIGNMENT........................................................................................... 193
08 REAR SUSPENSION AND AXLE
01 – REAR SUSPENSION AND AXLE.......................................................................... 195
GENERAL..................................................................................................... 197
PROCEDURES ............................................................................................... 197
REAR SHOCK....................................................................................................... 197
DRIVE CHAIN....................................................................................................... 198
ENGINE SPROCKET ............................................................................................... 200
AXLE SPROCKET................................................................................................... 200
WHEEL HUB........................................................................................................ 201
BRAKE DISC HUB.................................................................................................. 201
REAR AXLE......................................................................................................... 202
SPROCKET HUB ................................................................................................... 203
CHAIN TENSIONER................................................................................................ 203
SWING ARM........................................................................................................ 205
IV

TABLEOFCONTENTS
09 BRAKING SYSTEM
01 – FRONT AND REAR BRAKES............................................................................... 209
ALL MODELS EXCEPT EUROPEAN MODELS.......................................................... 210
GENERAL..................................................................................................... 212
MAINTENANCE ............................................................................................. 212
BRAKE FLUID ...................................................................................................... 212
PROCEDURES ............................................................................................... 215
CALIPERS........................................................................................................... 215
BRAKE PADS....................................................................................................... 216
MASTER CYLINDERS OF BRAKE LEVERS ...................................................................... 217
REAR BRAKE PEDAL .............................................................................................. 218
MASTER CYLINDER OF REAR BRAKE PEDAL.................................................................. 219
PRESSURE CONTROL VALVE..................................................................................... 220
BRAKE DISCS ...................................................................................................... 220
BRAKE HOSES..................................................................................................... 221
BRAKE LIGHT SWITCHES......................................................................................... 221
EUROPEAN MODELS ...................................................................................... 223
GENERAL..................................................................................................... 225
MAINTENANCE ............................................................................................. 225
BRAKE FLUID ...................................................................................................... 225
PROCEDURES ............................................................................................... 226
PARKING BRAKE (CABLE AND LEVER).......................................................................... 226
CALIPERS........................................................................................................... 227
BRAKE PADS....................................................................................................... 228
MASTER-CYLINDERS OF BRAKE LEVERS ...................................................................... 230
REAR BRAKE PEDAL .............................................................................................. 231
MASTER CYLINDER OF REAR BRAKE PEDAL.................................................................. 232
FRONT BRAKE PRESSURE CONTROL VALVE .................................................................. 232
REAR BRAKE PRESSURE CONTROL VALVE .................................................................... 233
BRAKE DISCS ...................................................................................................... 233
BRAKE HOSES..................................................................................................... 234
BRAKE LIGHT SWITCHES......................................................................................... 234
10 BODY/FRAME
01 – BODY.......................................................................................................... 237
PARTS REPLACEMENT..................................................................................... 239
DECAL .............................................................................................................. 239
SEAT................................................................................................................. 239
SEAT LATCH........................................................................................................ 239
FUEL TANK COVER................................................................................................ 240
FRONT COVER..................................................................................................... 240
RADIATOR SHIELD ................................................................................................ 241
FRONT FENDER.................................................................................................... 242
REAR FENDER ..................................................................................................... 244
FOOTREST.......................................................................................................... 245
CLEANING.................................................................................................... 246
SEAT................................................................................................................. 246
PLASTIC............................................................................................................. 246
REPAIR........................................................................................................ 246
PLASTIC REPAIR................................................................................................... 246
02 – FRAME........................................................................................................ 247
GENERAL..................................................................................................... 249
PROCEDURES ............................................................................................... 249
FRONT BUMPER................................................................................................... 249
FOOTPEG........................................................................................................... 249
FOOTREST SUPPORT............................................................................................. 250
V

TABLE OF CONTENTS
REAR FRAME EXTENSION........................................................................................ 250
FRONT FENDER SUPPORT ....................................................................................... 251
REAR FENDER SUPPORT......................................................................................... 251
11 TECHNICAL SPECIFICATIONS
01 – DS 250 ........................................................................................................ 253
12 WIRING DIAGRAMS
01 – WIRING DIAGRAMS........................................................................................ 261
WIRE COLORS..................................................................................................... 261
CONNECTORS ..................................................................................................... 261
VI

SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair the DS 250™ ATVs as
describe in the model list in the INTRODUCTION.
This edition was primarily published to be used by mechanical technicians who are already familiar with
all service procedures relating to BRP products. Mechanical technicians should attend training courses
given by BRP Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This Vehicle Shop Manual uses technical terms which may be slightly different from the ones used in the
PARTS CATALOG.
It is understood that this manual may be translated into another language. In the event of any discrepan-
cy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser-
vice 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 BRP, 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 BRP parts is most strongly recommended when considering replacement of any component.
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 for which it was designed.
WARNING
Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair
procedures.
This manual emphasizes particular information denoted by the wording and symbols:
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including pos-
sibility of death.
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 BRP. However, BRP 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.
vmr2006-060 VII

INTRODUCTION
INTRODUCTION
GENERAL INFORMATION
This Shop Manual covers the following 2006 ATV
models:
MODEL MODEL
NUMBER
DS 250 CE
(European Community models) 3J6B
DS 250 (North America and
International models) 3J6C
The use of RIGHT and LEFT indications in the text,
always refers to driving position (sitting on the ve-
hicle).
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. BRP, however, maintains a policy
of continuous improvement of its products with-
out imposing upon itself any obligation to install
them on products previously manufactured.
Due to late changes, it may have some differences
between the manufactured product and the de-
scription and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
VEHICLE SERIAL NUMBER
LOCATION
1
2
vmo2006-014-004_a
1. V.I.N. (Vehicle Identification Number)
2. Model number
ENGINE SERIAL NUMBER
LOCATION
vmo2006-014-005_a
E.I.N. (ENGINE IDENTIFICATION NUMBER)
ARRANGEMENT OF THE
MANUAL, ILLUSTRATIONS
AND PROCEDURES
The manual is divided into many major sections as
you can see in the main table of contents at the
beginning of the manual.
Each section is divided in various subsections, and
again, each subsection has one or more division.
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
that have the same or a similar function.
CAUTION: Most components in the 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
personal injury.
VIII vmr2006-060

INTRODUCTION
As many of the procedures in this manual are inter-
related, we suggest, that before undertaking any
task, you read and thoroughly understand the en-
tire section or subsection concerning the proce-
dure.
A number of procedures throughout the book re-
quire the use of special tools. Before starting any
procedure, be sure that you have on hand all re-
quired tools, or approved equivalents.
vmr2006-060 IX

INTRODUCTION
Section 03 ENGINE
Subsection 05 (CYLINDER AND HEAD)
31
CYLINDER AND HEAD
CYLINDER AND HEAD
9
12
4
8
21
22
23
27
V02C0ES
10 Nm
(8 lbfin)
10 Nm
(8 lbfin)
33 Nm
(24 lbfft)
10 Nm
(8 lbfin)
Loctite 243
10 Nm
(8 lbfin)
10 Nm
(8 lbfin)
60 Nm
(44 lbfft)
Engine oil
Page heading
indicates section
and subsection
detailed.
Bold face number
indicates special
procedure
concerning this
part.
Tightening torque
nearby fastener. In this
case, nut must be
torqued to
10 N m or 89 lbf in.
This Shop Manual uses technical terms wich may be
slightly different from the ones in the parts catalog.
Exploded view
assists you in
identifying parts and
related positions.
TYPICAL PAGE
V00A2NS
Illustration
number for
publishing
process.
Subsection title
indicates
beginning of the
subsection.
Drop represents a
liquid product to be
applied to a surface.
Page number
CAUTION: Pay attention
to torque specifi
cations.
Some of these are in
lbf ft instead of lbf in .
Use appropriate
torque wrench.
Xvmr2006-060

INTRODUCTION
BEARING
1. Ball bearing
Inspection
Ball bearing no. 10 must rotate freely. Othewise,
replace it.
Removal
 Heat up the magneto housing cover to about
Installation
For installation also heat the magneto housing
up to about 100oC (212oF) to put ball bearing in
place.
Place new ball bearing in freezer for 10 minutes
approximately.
Reinstall other removed parts in the reverse order.
STATOR AND TRIGGER COIL
Removal
Remove.
 magneto housing cover no. 7
100oC (212oF) for an easy ball bearing removal.
 screw no. 11 and 12
 stator with trigger coil no. 13.
1. Stator
2. Stator screws
3. Trigger coil
4. Trigger coil screws
Inspection
Check stator and trigger coil condition. If damaged
replace the faulty part.
For electrical inspection, refer to CHARGING SYS-
TEM for the stator and IGNITION SYSTEM for the
trigger coil.
TYPICAL PAGE
Title indicates
main procedure
to be carried-out.
Bold face number
following part
name refers to
exploded view
at beginning of
subsection.
V00A2OS
m
Section 03 ENGINE
Subsection 06 (MAGNETO SYSTEM)
82
Call-outs for
above illustration.
Reference to look
up a certain section
and subsection.
In this case it
concerns
IGNITION SYSTEM.
1
R610motr12A
4
1
R610motr20A
43
2
Subtitle indicates
main procedure
to be carried-out.
vmr2006-060 XI

INTRODUCTION
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 screw tap to clean the
hole properly then use a solvent, 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 ap-
plication procedures when working with Loctite
products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this SHOP MANUAL.
Threadlocker
Uncovered Holes (bolts and nuts)
A00A3LA
1
2
1. Apply here
2. Do not apply
– Clean threads (bolt and nut) with solvent.
– Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
– Choose proper strength Loctite threadlocker.
– Fit bolt in the hole.
– Apply a few drops of threadlocker at proposed
tightened nut engagement area.
– Position nut and tighten as required.
Blind Holes
A00A3MA
1
2
1. On threads
2. On threads and at the bottom of hole
– Clean threads (bolt and hole) with solvent.
– Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
– Choose proper strength Loctite threadlocker.
– Apply several drops along the threaded hole and
at the bottom of the hole.
– Apply several drops on bolt threads.
– Tighten as required.
Stud in Blind Holes
A00A5RA
2
13
1. On threads
2. On threads and in the hole
3. Onto nut threads
– Clean threads (stud and hole) with solvent.
– Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
–Putseveral drops of proper strength Loctite
threadlocker on female threads and in hole.
– Apply several drops of proper strength Loctite
on stud threads.
– Install stud.
–In
stall cover, etc.
XII vmr2006-060

INTRODUCTION
– Apply drops of proper strength Loctite on un-
covered threads.
– Tighten nuts as required.
Preassembled Parts
A00A3OA
1
2
1. Apply here
2. Do not apply
– Clean bolts and nuts with solvent.
– Assemble components.
– Tighten nuts.
– Apply drops of proper strength Loctite on
bolt/nut contact surfaces.
– Avoid touching metal with tip of flask.
NOTE: For preventive maintenance on exist-
ing equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces.
Adjusting Screw
A00A3PA
12
1. Applyhere
2. Plunger
– Adjust screw to proper setting.
– Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces.
–Avo
id touching metal with tip of flask.
NOTE: if it is difficult to readjust, heat screw with
a soldering iron (232°C (450°F)).
Stripped Thread Repair
A00A3QA
5
8
6
7
1
2
3
4
1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tapes
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker
Standard Thread Repair
– Follow instructions on Loctite FORM-A-
THREAD 81668 package.
– if a plate is used to align bolt:
a. Apply release agent on mating surfaces.
b. Put waxed paper or similar film on the sur-
faces.
– Twist bolt when inserting it to improve thread
conformation.
NOTE: NOT intended for engine stud repairs.
Repair of Small Holes/Fine Threads
Option 1: Enlarge damaged hole, then follow
STANDARD THREAD REPAIR procedure.
Option 2: Apply FORM-A-THREAD on the screw
and insert in damaged hole.
Permanent Stud Installation (light duty)
– Use a stud or thread on desired length.
– DO NOT apply release agent on stud.
– Do a STANDARD THREAD REPAIR.
– Allow to cure for 30 minutes.
– Assemble.
vmr2006-060 XIII

INTRODUCTION
Gasket Compound
A00A3SA
2
1
13
1
1. Proper strength Loctite
2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
(P/N 293 800 038) on both sides of gasket
3. Loctite Primer N only
– Remove old gasket and other contaminants
with Loctite Chisel remover (P/N 413 708 500).
Use a mechanical mean if necessary.
NOTE: Avoid grinding.
–Cleanbo
th mating surfaces with solvent.
– Spray Loctite Primer N on both mating surfaces
and on both sides of gasket. Allow to dry 1 or
2 minutes.
– Apply Gasket Eliminator 518 (P/N 293 800 038)
on both sides of gasket, using a clean applicator.
– Place gasket on mating surfaces and assemble
immediately.
NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite in the hole and on
threads. Tighten.
If holes are sunken, apply proper strength Loctite
on bolt threads.
– Tighten as usual.
MountingonShaft
Mounting with a Press
A00A3UA
1
2
3
1. Bearing
2. Proper strength Loctite
3. Shaft
– Clean shaft external part and element internal
part.
– 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.
– DO NOT use antiseize Loctite or any similar
product.
–Nocuring
period is required.
Mounting in Tandem
1. Apply retaining compound on internal element
bore.
2. Continue to assemble as shown above.
Case-in Components
Metallic Gaskets
A00A3VA 1
1. Proper strength Loctite
– Clean inner housing diameter and outer gasket
diameter.
– Spray housing and gasket with Loctite Primer N
(P/N 293 800 041).
– Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
XIV vmr2006-060

INTRODUCTION
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.
– Install according to standard procedure.
– Wipe off surplus.
– 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.
vmr2006-060 XV

INTRODUCTION
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in exploded views and/or text, When they are not specified, refer
to following table.
WARNING
Torque wrench tightening specifications must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic stop nuts, 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.
In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the following pro-
cedure:
– Manually screw all screws, bolts and/or nuts.
– Apply the half of the recommended torque value.
CAUTION: Be sure to use the proper tightening torque for the proper strength grade.
NOTE: When possible, always apply torque on the nut.
– Torque to the recommended torque value.
NOTE: Always torque screws, bolts and/or nuts in a criss-cross sequence.
A00A8BS
Property
class
and
head
markings
Property
class
and
nut
markings
5
5
10
10
10
10
12
12
4.8
4.8
4.8
8.8
8.8
8.8
.8
.8
.8
10.
10.
10.
12.
12.
12.
12.
FASTENER GRADE/TORQUE
FASTENER
SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
M4 1.5–2N•m
(13 – 18 lbf•in)2.5–3N•m (22 – 27 lbf•in)3.5–4N•m (31 – 35 lbf•in)4–5N•m (35 –44 lbf•in)
M5 3–3.5N•m
(27 – 31 lbf•in)4.5 – 5.5 N•m (40 – 47 lbf•in)7–8.5N•m (62 – 75 lbf•in)8–10N•m (71 – 89 lbf•in)
M6 6.5 – 8.5 N•m
(58 – 75 lbf•in)8–12N•m (71 – 106 lbf•in)10.5 – 15 N•m (93–133lbf•in)16 N•m (142 lbf•in)
M8 15 N•m (11 lbf•ft) 24.5 N•m (18 lbf•ft) 31.5 N•m (23 lbf•ft) 40 N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 72.5 N•m (53 lbf•ft)
M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 127.5 N•m (94 lbf•ft)
M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)
XVI vmr2006-060

Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)
MAINTENANCE CHART
NOISE EMISSION CONTROL SYSTEM REGULATION
Tampering with noise control system is prohibited!
U.S. Federal law and Canadian provincial laws may prohibit the following acts or the causing there of:
1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair
or replacement of any device or element of design incorporated into any new vehicle for the purpose
of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or,
2. The use of the vehicle after such device or element of design has been removed or rendered inoper-
ative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1. Removal or alteration or the puncturing of the muffler or any engine component which conducts re-
moval of engine exhaust gases.
2. Removal or alteration or the puncturing of any part of the intake system.
3. Replacing any moving parts of the vehicle or parts of the exhaust or intake system, with parts other
than those specified by the manufacturer.
4. Lack of proper maintenance.
vmr2006-061 1