Can-Am DS 450 2008 Install guide

2008
Shop Manual
DS 450™
DS 450™ X

Legal deposit:
National Library of Quebec
National Library of Canada 2007
All rights reserved. No parts of this manual may be reproduced in any form without the prior written
permission of Bombardier Recreational Products Inc. (BRP)
©Bombardier Recreational Products Inc. (BRP) 2007
Printed in Canada
Technical Publications
Bombardier Recreational Products Inc. (BRP)
Valcourt (Quebec) Canada
®™ Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
* Trademarks of Bombardier Inc., used under license.
Can-Am™ Rotax®
DS 450™ XP-S™
This document contains the trademarks of the following companies:
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

TABLE OF CONTENTS
SAFETY NOTICE.................................................................................. VIII
INTRODUCTION ................................................................................... IX
GENERAL INFORMATION......................................................................................... IX
VEHICLE INFORMATION .......................................................................................... IX
ENGINE EMISSIONS INFORMATION ............................................................................ X
SELF-LOCKING FASTENERS PROCEDURE ..................................................................... X
LOCTITE®APPLICATION PROCEDURE .......................................................................... X
TIGHTENING TORQUES ......................................................................................... XIV
MANUAL INFORMATION ........................................................................................ XV
01 MAINTENANCE
01 – MAINTENANCE CHART....................................................................................... 1
02 – PRESEASON PREPARATION................................................................................. 5
03 – STORAGE PROCEDURE....................................................................................... 7
FUEL SYSTEM......................................................................................................... 7
ENGINE ................................................................................................................ 7
ELECTRICAL SYSTEM................................................................................................ 7
COOLING SYSTEM ................................................................................................... 7
VEHICLE ............................................................................................................... 7
04 – SPECIAL PROCEDURES....................................................................................... 9
TURN OVER ........................................................................................................... 9
ATV IMMERSION ..................................................................................................... 9
02 TROUBLESHOOTING
01 – TECHNICAL GUIDELINES (ENGINE)...................................................................... 11
COOLING SYSTEM .................................................................................................. 11
LUBRICATION SYSTEM ............................................................................................. 11
CLUTCH............................................................................................................... 12
CYLINDER HEAD AND CYLINDER ................................................................................. 13
CRANKSHAFT AND BALANCER SHAFT ........................................................................... 13
GEARBOX............................................................................................................. 14
02 – DIAGNOSTIC FLOW CHART................................................................................ 15
FUEL SYSTEM........................................................................................................ 15
03 ENGINE
01 – ENGINE REMOVAL AND INSTALLATION................................................................ 17
GENERAL...................................................................................................... 18
PROCEDURES ................................................................................................ 18
ENGINE ............................................................................................................... 18
02 – AIR INTAKE SYSTEM........................................................................................ 25
GENERAL...................................................................................................... 26
PROCEDURES ................................................................................................ 26
AIR FILTER............................................................................................................ 26
AIR FILTER HOUSING ............................................................................................... 26
03 – EXHAUST SYSTEM.......................................................................................... 29
GENERAL...................................................................................................... 30
PROCEDURES ................................................................................................ 30
MUFFLER............................................................................................................. 30
EXHAUST PIPE....................................................................................................... 31
SPARK ARRESTER................................................................................................... 32
HEAT SHIELD......................................................................................................... 32
04 – LUBRICATION SYSTEM..................................................................................... 33
GENERAL...................................................................................................... 36
MAINTENANCE .............................................................................................. 36
ENGINE OIL .......................................................................................................... 36
I

TABLE OF CONTENTS
OIL FILTER............................................................................................................ 37
OIL TANK STRAINER ................................................................................................ 38
INSPECTION .................................................................................................. 39
ENGINE OIL PRESSURE............................................................................................. 39
PROCEDURES ................................................................................................ 40
OIL TANK ............................................................................................................. 40
OIL HOSE CONNECTOR ............................................................................................ 41
ENGINE OIL PRESSURE REGULATOR............................................................................. 42
OIL PRESSURE PUMP............................................................................................... 43
ENGINE OIL STRAINER ............................................................................................. 46
OIL SUCTION PUMP................................................................................................. 47
OIL NOZZLE.......................................................................................................... 48
OIL TUBE ............................................................................................................. 48
05 – COOLING SYSTEM .......................................................................................... 51
GENERAL...................................................................................................... 54
INSPECTION .................................................................................................. 54
COOLING SYSTEM LEAK TEST..................................................................................... 54
MAINTENANCE .............................................................................................. 55
COOLANT REPLACEMENT ......................................................................................... 55
PROCEDURES ................................................................................................ 57
COOLANT TANK CAP................................................................................................ 57
COOLANT TANK ..................................................................................................... 57
RADIATOR............................................................................................................ 58
COOLING FAN........................................................................................................ 59
THERMOSTAT........................................................................................................ 60
COOLANT TEMPERATURE SENSOR (CTS)........................................................................ 60
WATER PUMP HOUSING ........................................................................................... 61
WATER PUMP IMPELLER........................................................................................... 62
WATER PUMP SHAFT, BEARING AND SEALS.................................................................... 62
06 – MAGNETO/STARTER ....................................................................................... 67
GENERAL...................................................................................................... 69
PROCEDURES ................................................................................................ 69
MAGNETO COVER................................................................................................... 69
CRANKSHAFT POSITION SENSOR (CPS).......................................................................... 71
STATOR............................................................................................................... 71
ROTOR................................................................................................................ 76
SPRAG CLUTCH...................................................................................................... 78
SPRAG CLUTCH GEAR.............................................................................................. 79
STARTER DRIVE GEARS ............................................................................................ 79
STARTER.............................................................................................................. 80
07 – CYLINDER HEAD/CYLINDER............................................................................... 85
GENERAL...................................................................................................... 89
MAINTENANCE .............................................................................................. 89
VALVE CLEARANCE.................................................................................................. 89
INSPECTION .................................................................................................. 90
CYLINDER LEAK TEST............................................................................................... 90
PROCEDURES ................................................................................................ 91
VALVE COVER........................................................................................................ 91
TIMING CHAIN TENSIONER........................................................................................ 94
CAMSHAFT TIMING GEAR.......................................................................................... 94
CAMSHAFT........................................................................................................... 97
VALVE LIFTER BUCKET.............................................................................................. 99
CYLINDER HEAD................................................................................................... 100
VALVE SPRINGS.................................................................................................... 102
VALVE ............................................................................................................... 103
VALVE GUIDE....................................................................................................... 106
II

TABLE OF CONTENTS
CYLINDER .......................................................................................................... 107
PISTON.............................................................................................................. 108
PISTON RINGS..................................................................................................... 111
PISTON PIN......................................................................................................... 112
08 – CRANKCASE/CRANKSHAFT.............................................................................. 115
GENERAL..................................................................................................... 117
PROCEDURES ............................................................................................... 117
MAIN SHAFT OIL SEAL ........................................................................................... 117
PRIMARY DRIVE GEAR............................................................................................ 118
TIMING CHAIN AND CHAIN TENSIONER GUIDE............................................................... 118
TIMING CHAIN DRIVE GEARS.................................................................................... 119
CRANKCASE........................................................................................................ 121
BALANCER SHAFT................................................................................................. 126
CRANKSHAFT...................................................................................................... 127
09 – CLUTCH....................................................................................................... 131
GENERAL..................................................................................................... 134
MAINTENANCE ............................................................................................. 134
CLUTCH ADJUSTMENT........................................................................................... 134
PROCEDURES ............................................................................................... 136
CLUTCH RELEASE COVER........................................................................................ 136
CLUTCH CABLE.................................................................................................... 139
CLUTCH LEVER.................................................................................................... 139
RETAINING PLATE AND CLUTCH SPRING ...................................................................... 140
CLUTCH............................................................................................................. 141
CLUTCH COVER ................................................................................................... 144
CLUTCH DRUM.................................................................................................... 146
10 – GEARBOX .................................................................................................... 149
GENERAL..................................................................................................... 152
PROCEDURES ............................................................................................... 152
NEUTRAL INDICATOR SWITCH .................................................................................. 152
SHIFTING MECHANISM........................................................................................... 152
GEARBOX........................................................................................................... 155
04 ENGINE MANAGEMENT SYSTEM
01 – OVERVIEW................................................................................................... 161
SYSTEM DESCRIPTION.................................................................................... 164
CONTROLLER AREA NETWORK (CAN).......................................................................... 164
ENGINE CONTROL MODULE (ECM)............................................................................. 164
POWER DISTRIBUTION........................................................................................... 165
02 – COMMUNICATION TOOLS/B.U.D.S. SOFTWARE..................................................... 167
MULTI-PURPOSE INTERFACE-2 (MPI-2)......................................................................... 167
B.U.D.S. SOFTWARE .............................................................................................. 168
03 – MONITORING SYSTEM/FAULT CODES................................................................. 171
MONITORING SYSTEM ........................................................................................... 171
FAULT CODES...................................................................................................... 171
FAULT CODE TABLE............................................................................................... 173
05 FUEL SYSTEM
01 – ELECTRONIC FUEL INJECTION (EFI) .................................................................... 179
GENERAL..................................................................................................... 179
SYSTEM DESCRIPTION ........................................................................................... 179
GENERAL RECOMMENDATIONS................................................................................ 180
BASIC ADJUSTMENTS .................................................................................... 182
IDLE SPEED ........................................................................................................ 182
CLOSED THROTTLE AND IDLE ACTUATOR RESET ............................................................ 182
PROCEDURES ............................................................................................... 183
III

TABLE OF CONTENTS
ENGINE CONTROL MODULE (ECM)............................................................................. 183
FUEL INJECTOR ................................................................................................... 191
FUEL RAIL .......................................................................................................... 193
THROTTLE BODY.................................................................................................. 195
THROTTLE POSITION SENSOR (TPS)............................................................................ 198
IDLE AIRCONTROL VALVE ....................................................................................... 200
CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 201
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS) ......................................................... 203
AMBIENT AIR PRESSURE AND TEMPERATURE SENSOR (AAPTS) .......................................... 205
COOLANT TEMPERATURE SENSOR (CTS)...................................................................... 209
02 – FUEL TANK/FUEL PUMP .................................................................................. 211
GENERAL..................................................................................................... 213
INSPECTION ................................................................................................. 213
FUEL TANK LEAK TEST............................................................................................ 213
FUEL PUMP PRESSURE TEST.................................................................................... 214
PROCEDURES ............................................................................................... 216
FUEL HOSE AND OETIKER CLAMPS ............................................................................ 216
FUEL PUMP ........................................................................................................ 216
FUEL TANK ......................................................................................................... 222
06 ELECTRICAL SYSTEM
01 – IGNITION SYSTEM ......................................................................................... 225
GENERAL..................................................................................................... 225
IGNITION SYSTEM DESCRIPTION ............................................................................... 225
IGNITION SYSTEM OPERATION.................................................................................. 225
TROUBLESHOOTING....................................................................................... 225
IGNITION SYSTEM TESTING...................................................................................... 225
PROCEDURES ............................................................................................... 227
IGNITION SWITCH................................................................................................. 227
ENGINE STOP SWITCH ........................................................................................... 229
IGNITION COIL..................................................................................................... 232
SPARK PLUG ....................................................................................................... 236
02 – CHARGING SYSTEM ....................................................................................... 239
GENERAL..................................................................................................... 239
SYSTEM DESCRIPTION ........................................................................................... 239
PROCEDURES ............................................................................................... 240
VOLTAGE REGULATOR/RECTIFIER .............................................................................. 240
BATTERY............................................................................................................ 243
ELECTRICAL SYSTEM MAIN GROUNDS ........................................................................ 246
03 – STARTING SYSTEM ........................................................................................ 247
GENERAL..................................................................................................... 247
TROUBLESHOOTING....................................................................................... 247
PROCEDURES ............................................................................................... 248
STARTER SOLENOID.............................................................................................. 248
START BUTTON.................................................................................................... 253
CLUTCH SWITCH.................................................................................................. 255
04 – LIGHTS........................................................................................................ 257
GENERAL..................................................................................................... 257
LIGHTS SYSTEM DESCRIPTION.................................................................................. 257
LIGHTS SYSTEM OPERATION ..... ..... .. ....... ..... ........ ............ .. ..... ........ ............ ....... ..... . 257
TROUBLESHOOTING....................................................................................... 257
LIGHTS SYSTEM TESTING........................................................................................ 257
PROCEDURES ............................................................................................... 257
HEADLIGHT POWER REGULATOR .............................................................................. 257
HEADLIGHTS....................................................................................................... 259
HEADLIGHT SWITCH.............................................................................................. 261
IV

TABLE OF CONTENTS
TAILLIGHT/BRAKE LIGHT ......................................................................................... 262
NEUTRAL INDICATOR LIGHT (GREEN) .......................................................................... 263
CHECK ENGINE INDICATOR LIGHT (YELLOW) ................................................................. 265
LOW FUEL LEVEL INDICATOR LIGHT (YELLOW) .............................................................. 266
07 DRIVE SYSTEM
01 – DRIVE CHAIN/REAR AXLE ................................................................................ 271
GENERAL..................................................................................................... 273
PROCEDURES ............................................................................................... 273
DRIVE CHAIN....................................................................................................... 273
FRONT SPROCKET ................................................................................................ 276
REAR SPROCKET .................................................................................................. 277
REAR AXLE......................................................................................................... 278
REAR SPROCKET HUB............................................................................................ 280
CHAIN TENSIONER................................................................................................ 281
08 CHASSIS
01 – WHEELS/TIRES.............................................................................................. 283
GENERAL..................................................................................................... 284
MAINTENANCE ............................................................................................. 284
TIRE PRESSURE ................................................................................................... 284
PROCEDURES ............................................................................................... 284
TIRE ................................................................................................................. 284
WHEEL.............................................................................................................. 285
FRONT WHEEL HUB .............................................................................................. 285
REAR WHEEL HUB ................................................................................................ 287
WHEEL BEARING.................................................................................................. 289
02 – STEERING.................................................................................................... 291
GENERAL..................................................................................................... 293
ADJUSTMENT............................................................................................... 293
STEERING ALIGNMENT........................................................................................... 293
PROCEDURES ............................................................................................... 294
HANDLEBAR GRIP................................................................................................. 294
MULTIFUNCTION SWITCH........................................................................................ 294
THROTTLE LEVER ................................................................................................. 295
THROTTLE CABLE................................................................................................. 295
HANDLEBAR ....................................................................................................... 298
STEERING COLUMN .............................................................................................. 299
TIE-ROD............................................................................................................. 301
KNUCKLE........................................................................................................... 302
03 – FRONT SUSPENSION...................................................................................... 305
GENERAL..................................................................................................... 307
ADJUSTMENTS............................................................................................. 307
FACTORY SETTINGS............................................................................................... 307
ADJUSTING SUSPENSION........................................................................................ 308
MAINTENANCE ............................................................................................. 309
LUBRICATION...................................................................................................... 309
PROCEDURES ............................................................................................... 310
SHOCK ABSORBER................................................................................................ 310
UPPER SUSPENSION ARM ....................................................................................... 311
UPPER BALL JOINT ............................................................................................... 312
LOWER SUSPENSION ARM...................................................................................... 313
LOWER BALL JOINT .............................................................................................. 314
04 – REAR SUSPENSION........................................................................................ 317
GENERAL..................................................................................................... 319
ADJUSTMENTS............................................................................................. 319
V

TABLE OF CONTENTS
FACTORY SETTINGS............................................................................................... 319
ADJUSTING SUSPENSION........................................................................................ 319
MAINTENANCE ............................................................................................. 320
LUBRICATION...................................................................................................... 320
PROCEDURES ............................................................................................... 321
SHOCK ABSORBER................................................................................................ 321
SPRING ............................................................................................................. 322
SWING ARM........................................................................................................ 323
BELL CRANK LEVER............................................................................................... 325
PIVOT ARM......................................................................................................... 326
05 – BRAKES....................................................................................................... 329
GENERAL..................................................................................................... 332
SYSTEM DESCRIPTION ........................................................................................... 332
MAINTENANCE ............................................................................................. 332
BRAKE FLUID ...................................................................................................... 332
PROCEDURES ............................................................................................... 334
CALIPER ............................................................................................................ 334
BRAKE PADS ....................................................................................................... 336
BRAKE DISC........................................................................................................ 338
BRAKE LEVER...................................................................................................... 339
FRONT MASTER CYLINDER...................................................................................... 340
REAR MASTER CYLINDER........................................................................................ 340
BRAKE PEDAL...................................................................................................... 342
BRAKE DISC HUB.................................................................................................. 344
REAR CALIPER BRACKET......................................................................................... 344
FRONT BRAKE LIGHT SWITCH................................................................................... 345
REAR BRAKE LIGHT SWITCH .................................................................................... 346
FLEXIBLE BRAKE HOSE........................................................................................... 347
06 – BODY.......................................................................................................... 351
GENERAL..................................................................................................... 354
PROCEDURES ............................................................................................... 354
DECALS............................................................................................................. 354
SEAT................................................................................................................. 354
ACCESS COVER.................................................................................................... 356
CONSOLE........................................................................................................... 356
FRONT BUMPER................................................................................................... 356
FRONT BODY ASSEMBLY ........................................................................................ 356
FRONT FENDER.................................................................................................... 358
FRONT GRILLE..................................................................................................... 358
SIDE PANELS....................................................................................................... 358
FRONT FASCIA..................................................................................................... 359
FOOTREST.......................................................................................................... 359
FOOTREST SUPPORT............................................................................................. 359
REAR FENDER ..................................................................................................... 359
REAR BUMPER .................................................................................................... 360
ENGINE SKID PLATE............................................................................................... 360
NERF BAR .......................................................................................................... 361
07 – FRAME........................................................................................................ 363
GENERAL..................................................................................................... 364
PROCEDURES ............................................................................................... 364
FRAME.............................................................................................................. 364
REAR FRAME EXTENSION........................................................................................ 364
REAR ENGINE SUPPORTS........................................................................................ 365
FOOTPEG........................................................................................................... 365
SIDE MEMBER..................................................................................................... 366
LOWER SUSPENSION ARMATTACHMENTS................................................................... 367
VI

TABLE OF CONTENTS
09 TECHNICAL SPECIFICATIONS
01 – DS 450/DS 450 X............................................................................................ 369
10 WIRING DIAGRAM
01 – DS 450/DS 450 X............................................................................................ 377
WIRING DIAGRAM................................................................................................. 377
VII

SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair 2008 Can-Am 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 B.R.P.T.I.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
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.
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.
VIII vmr2008-002

INTRODUCTION
INTRODUCTION
GENERAL INFORMATION
This shop manual covers the following BRP made 2008 Can-Am ATVs.
MODEL COLOR ENGINE MODEL NUMBER
DS 450 EFI Yellow/Black 449 3F8A, 3F8B, 3F8C
DS 450 EFI X Black 449 3G8A, 3G8B, 3G8C
The information and component/system descrip-
tions contained in this manual are correct at time
of writing. BRP 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, there may be some differ-
ences between the manufactured product and the
description 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 INFORMATION
Model Number
MFD. DATE FAB:
12/2003
2BPS1234X2V000123
1234
MODEL:
VIN / NIV:
MANUFACTURED BY:
FABRIQUÉ PAR:
MADE IN/FABRIQUÉ AU:
XXXXX
TYPE: ATV / VTT
2
1
vmo2008-011-094_a
TYPICAL — VEHICLE IDENTIFICATION NUMBER LABEL
1. Serial number
2. Model number
Vehicle Identification Number (V.I.N.)
vmo2008-011-026_a
TYPICAL
1. Vehicle Identification Number (V.I.N.)
Engine Identification Number (E.I.N.)
vmo2008-011-026_b
1. Engine Identification Number (E.I.N.)
vmr2008-002 IX

INTRODUCTION
ENGINE EMISSIONS
INFORMATION
Manufacturer's Responsibility
Manufacturers of ATVs engines must determine
the exhaust emission levels for each engine horse-
power family and certify these engines with the
United States of America Environmental Protec-
tion Agency (EPA). An emissions control informa-
tion label, showing emission levels and engine
specifications, must be placed on each vehicle at
the time of manufacture.
Dealer Responsibility
When performing service on ATVs that carry an
emissions control information label, adjustments
must be kept within published factory specifica-
tions.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sion levels to exceed their predetermined factory
specifications.
Exceptions include manufacturer's prescribed
changes, such as altitude adjustments for exam-
ple.
Owner Responsibility
The owner/operator is required to have engine
maintenance performed to maintain emission
levels within prescribed certification standards.
The owner/operator is not to, and should not al-
low anyone to modify the engine in any manner
that would alter the horsepower or allow emis-
sions levels to exceed their predetermined factory
specifications.
EPA Emission Regulations
Some ATVs manufactured by BRP are certified
to the EPA as conforming to the requirements
of the regulations for the control of air pollution
from new ATV engines. This certification is con-
tingent on certain adjustments being set to factory
standards. For this reason, the factory procedure
for servicing the product must be strictly followed
and, whenever practicable, returned to the origi-
nal intent of the design.
The responsibilities listed above are general and
in no way a complete listing of the rules and regu-
lations pertaining to the EPA requirements on ex-
haust emissions for ATVs products. For more de-
tailed information on this subject, you may contact
the following locations:
FORALLCOURIERSERVICES:
U.S. Environmental Protection Agency
Office of Transportation and Air Quality
1310 L Street NW
Washington D.C. 20005
REGULAR US POSTAL MAIL:
1200 Pennsylvania Ave. NW
Mail Code 6403J
Washington D.C. 20460
INTERNET: http://www.epa.gov/otaq/
E-MAIL: [e-mail]
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 manual.
Xvmr2008-002

INTRODUCTION
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
1
2
lmr2007-040-004_a
1. On screw threads
2. On hole threads
Clean threads (screw and hole) with solvent.
Apply Loctite Primer N (P/N 293 800 041) on
threads (screw and nut) and allow to dry for 30
seconds.
Choose proper strength Loctite threadlocker.
Apply 2 or 3 drops along the threaded hole.
NOTE: To avoid a hydro lock situation, do not apply
too much Loctite.
Apply several drops on screw threads.
Tighten as required.
Stud in Blind Holes
2
13
lmr2007-040-005_a
1. On stud threads
2. On hole threads
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.
Put 2 or 3 drops of proper strength Loctite thread-
locker along the threaded hole.
NOTE: To avoid a hydro lock situation, do not apply
too much Loctite.
Apply several drops of proper strength Loctite on
stud threads.
Install stud.
Install cover, etc.
Apply drops of proper strength Loctite on uncov-
ered threads.
Tighten nuts as required.
Preassembled Parts
A00A3OA
1
2
1. Apply here
2. Do not apply
Clean bolts and nuts with solvent.
vmr2008-002 XI

INTRODUCTION
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. Apply here
2. Plunger
Adjust screw to proper setting.
Apply drops of proper strength Loctite threadlock-
er on screw/body contact surfaces.
Avoid 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. Tape
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:
– Apply release agent on mating surfaces.
– Put waxed paper or similar film on the surfaces.
Twist bolt when inserting it to improve thread con-
formation.
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.
Gasket Compound
21
1
3
1
lmr2007-040-006_a
1. Proper strength Loctite
2. Loctite Primer N (P/N 293 800 041) and Loctite 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.
Cleanbothmatingsurfaceswithsolvent.
XII vmr2008-002

INTRODUCTION
Spray Loctite Primer N on both mating surfaces
and on both sides of gasket. Allow to dry 1 or 2
minutes.
Apply Loctite 518 (P/N 293 800 038) on both sides
of gasket, using a clean applicator.
Place gasket on mating surfaces and assemble im-
mediately.
NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite on the threads of
hole. Tighten.
If holes are sunken, apply proper strength Loctite
on bolt threads.
Tighten as usual.
Mounting on Shaft
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
whenappliedonshaft.
DO NOT use antiseize Loctite or any similar prod-
uct.
No curing period is required.
Mounting in Tandem
Apply retaining compound on internal element
bore.
Continue to assemble as shown above.
Case-In Components
Metallic Gaskets
A00A3VA 1
1. Proper strength Loctite
Clean inner housing diameter and outer gasket di-
ameter.
Spray housing and gasket with Loctite Primer N
(P/N 293 800 041).
Apply a strip of proper strength Loctite on leading
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.
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.
vmr2008-002 XIII

INTRODUCTION
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in explod-
ed views and/or text. When they are not speci-
fied, refer to following table.
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced
with new ones.
In order to avoid a poor assembling, tighten
screws, bolts or nuts in accordance with the
following procedure:
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
8
8
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•mN•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 – 133 lbf•in)16 N•m (142 lbf•in)
M8 15 N•m (133 lbf•in) 25 N•m (18 lbf•ft) 32 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) 73 N•m (53 lbf•ft)
M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 128 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)
XIV vmr2008-002

INTRODUCTION
MANUAL INFORMATION
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.
The illustrations show the typical construction 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 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.
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 in which the procedure
is contained.
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.
The use of RIGHT and LEFT indications in the text,
always refers to the driving position (sitting on the
vehicle).
vmr2008-002-001_a
TYPICAL
1. Left
2. Right
This manual uses technical terms which may be
different from the ones of the
PARTS CATALOGS .
When ordering parts always refer to the specific
model
PARTS CATALOGS .
vmr2008-002 XV

INTRODUCTION
Section 06 ENGINE
Subsection 01 (MAGNETO)
MAGNETO
Models
55
mmr2008-001
XXX0000
Model
Loctite 243
5 Nm
(44 lbfin)
1
NEW
Page heading
indicates section
and subsection.
Exploded view assists
you in identifying parts
and their related
positions.
TYPICAL PAGE
Illustration number
for publishing process.
Subsection title
Indicates applicable
models.
Document number for
publishing process.
Bold face number
is used to identify
a part referred to
the text.
Drop represents a
service product
to be applied.
Dotted box contains
parts applicable to a
specific model.
Page number
Specific tor ue applicable to this installation.
CAUTION: Pay attention to torque specifi
cations.
Some of these are in
lbf  in instead of lbf  ft.
Use appro
priate torque wrench.
NEW indicates that the
part must be replaced
with a new one.
Typical_iso_2008_en
XVI vmr2008-002

INTRODUCTION
TYPICAL PAGE
Subsection 0 (MAGNETO SYSTEM)
GENERAL
NOTE: The following procedures can be done
without removing the engine.
During assembly/installation, use the tor ue val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to the
SELF-LOCKING FASTENERS
and
LOC-
TITE APPLICATION
sections at the beginning of
this manual for complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones.
PROCEDURES
MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
a clean cloth.
Magneto Flywheel Removal
Remove muffler, refer to the EXHAUST S STEM
section.
Remove acoustic panel.
Remove rewind starter.
Remove starting pulley no. 2.
TYPICAL
NOTE: To remove starting pulley bolts, hold mag-
neto flywheel with a socket as shown.
TYPICAL
Models
Remove the connecting flange retaining the
rewind starter to the engine housing.
Section 03 ENGINE
1. Starting pulley
1
Subsection 0 (MAGNETO SYSTEM)
GENERAL
NOTE: The following procedures can be done
without removing the engine.
During assembly/installation, use the tor ue val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to the
SELF-LOCKING FASTENERS
and
LOC-
TITE APPLICATION
sections at the beginning of
this manual for complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones.
PROCEDURES
MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
a clean cloth.
Magneto Flywheel Removal
Remove muffler, refer to the EXHAUST S STEM
section.
Remove acoustic panel.
Remove rewind starter.
Remove starting pulley no. 2.
TYPICAL
NOTE: To remove starting pulley bolts, hold mag-
neto flywheel with a socket as shown.
TYPICAL
Models
Remove the connecting flange retaining the
rewind starter to the engine housing.
Section 03 ENGINE
1. Starting pulley
1
Indicates component
procedures apply to.
Reference to a
specific section
or subsection.
Call-outs pertaining
to above illustration.
Italic bold face type-
setting indicates a
procedure applicable
to a specific
model(s).
TYPICAL
indicates a general
view which may
not represent exact
details.
Illustration always
follows text to which
it applies.
Indicates specific
procedure to be
carried out.
Bold face number following part
name refers to exploded view
at beginning of subsection.
mmr2007-016-002
Tittle in bold
indicates category
of information to be
carried out.
mmr2008-001 57
typical_txt_2008_en
vmr2008-002 XVII