AUSA M-50 x 4 Workshop Manual
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AUSA M-50 x 4 Workshop Manual

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

  • Page 4: Table Of Contents

    Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS TROUBLESHOOTING......................03-02-1 COOLING SYSTEM ......................03-02-1 MAGNETO SYSTEM ......................03-02-2 LUBRICATION........................03-02-4 CYLINDER AND HEAD ...................... 03-02-6 CRANKSHAFT AND BALANCER SHAFT................03-02-7 GEARBOX .......................... 03-02-7 REWIND STARTER ......................03-02-9 CVT .............................
  • Page 5 Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) COOLING FAN........................03-05-11 TEMPERATURE SENDER ....................03-05-12 REWIND STARTER ......................... 03-06-1 GENERAL..........................03-06-2 REWIND STARTER......................03-06-2 STARTING PULLEY......................03-06-5 MAGNETO SYSTEM ......................03-07-1 GENERAL..........................03-07-2 MAGNETO HOUSING COVER................... 03-07-2 OIL SEAL..........................03-07-4 STATOR ..........................
  • Page 6 Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) CRANKSHAFT/BALANCER SHAFT ..................03-10-1 CRANKCASE ........................03-10-1 CRANKSHAFT/BALANCER SHAFT .................. 03-10-2 GENERAL ........................... 03-10-3 CRANKSHAFT LOCKING PROCEDURE................03-10-3 TIMING CHAIN ........................03-10-4 TIMING CHAIN GUIDE ...................... 03-10-5 CRANKCASE ........................03-10-5 BALANCER SHAFT ......................03-10-9 CRANKSHAFT........................

  • Page 8: Troubleshooting

    Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) TROUBLESHOOTING The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. This section pertains to engine mechanical components only. Some related problems can come from other systems such as ignition system, fuel system, etc.

  • Page 9: Magneto System

    Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) HIGH ENGINE OPERATING TEMPERATURE. SYMPTOM CONDITION NORMAL USE. Test/Inspection 10. Check cooling fan and connection. a. Fan motor faulty. Replace. b. Wire harness is brittle or hard (no connection). Replace. 11. Check cylinder head and/or cylinder base gasket. a.
  • Page 10 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM NO SPARK. CONDITION NORMAL USE. Test/Inspection 4. Check spark plug electrode condition. a. Gap is too big. Readjust gap (refer to TECHNICAL DATA). b. Spark plug condition is bad. Diagnose spark plug condition and replace it (refer to IGNITION SYSTEM). 5.

  • Page 11: Lubrication

    Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) LUBRICATION SYMPTOM LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION. CONDITION NORMAL USE. Test/Inspection 1. Check oil level and search for leakage on crankcase and/or defective seals. a. Crankcase is leaking due to damage. Rebuild engine with new crankcase and gasket parts. Use a high quality oil (refer to TECHNICAL DATA).
  • Page 12 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION. CONDITION NORMAL USE. Test/Inspection 8. Check oil orifice(s) on the oil pump suction side. a. Oil orifice(s) is (are) clogged. Clean from contamination. Replace oil and oil filter if necessary (refer to MAINTENANCE or LUBRICATION).

  • Page 13: Cylinder And Head

    Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) CYLINDER AND HEAD SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATION IN IDLE SPEED. CONDITION NORMAL USE. Test/Inspection 1. Check operation of decompressor located on camshaft. a. Decompressor shaft stucks and/or torsion spring is damaged. Replace spring and/or decompressor mechanism. Loose camshaft gear.

  • Page 14: Crankshaft And Balancer Shaft

    Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) CRANKSHAFT AND BALANCER SHAFT SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATIONS. CONDITION NORMAL USE. Test/Inspection 1. Check for possible plain bearing failure. a. Oil pressure is out of specified values. Replace damaged parts (refer to LUBRICATION). b.
  • Page 15 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM GEAR INDICATION FAILS. CONDITION NORMAL USE. Test/Inspection 1. Check wire harness connector pins (gear indicator) and/or electronical system. a. Connector pins are corroded and/or damaged. Clean connector and/or replace wire harness if damaged. b.

  • Page 16: Rewind Starter

    Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM GEAR(S) IS (ARE) HARD TO SHIFT. CONDITION NORMAL USE. Test/Inspection 4. Check transmission lever and connecting rod. a. Ball joint and/or ball joint nut is (are) loose. Retighten or replace the ball joint. 5.

  • Page 17: Cvt

    Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM THE ATV ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED. CONDITION NORMAL USE. Test/Inspection 1. Check drive belt condition. a. Belt is too narrow (drive belt engagement is higher in drive pulley). Replace belt if width is less than specified (refer to CVT and/or TECHNICAL DATA). 2.
  • Page 18 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM ENGINE MAXIMUM RPM IS TOO HIGH AND TOP SPEED IS NOT REACHED. CONDITION NORMAL USE. Test/Inspection 1. Check items 1 to 3 of THE ATV ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED. 2. Check drive/driven pulley spring tension. a.
  • Page 19 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM DRIVE PULLEY NOISE WHEN ACCELERATING/DECELERATING. CONDITION NORMAL USE. Test/Inspection 1. Check items 1 to 5 of DRIVE PULLEY NOISE IN IDLE SPEED. 2. Check if belt runs in dry conditions. a. Drive pulley area is wet/contaminated due to water/dirt intrusion. Clean driven pulley area and/or drain water out of CVT cover.
  • Page 20 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM VIBRATIONS ORIGINATING FROM DRIVEN PULLEY. CONDITION NORMAL USE. Test/Inspection 1. Check fixed and sliding half bushings on driven pulley. a. Excessive gap between bushings and CVT shaft, thus restraining sliding half movements. Replace fixed and/or sliding half of driven pulley, polish CVT shaft area with fine emery cloth and wipe clean with a cloth.
  • Page 21 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM BELT WORN EXCESSIVELY IN TOP WIDTH. CONDITION NORMAL USE. Test/Inspection 1. Check drive belt width. a. Considerable wear. Considerable Replace belt if narrower than specified (refer to CVT or TECHNICAL DATA). 2. Check drive belt identification number. a.

  • Page 22: Engine General

    Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) ENGINE GENERAL SYMPTOM ENGINE BACKFIRES. CONDITION NORMAL USE. Test/Inspection 1. Check spark plug and/or electrical system. a. Carbon accumulation caused by defective spark plug. Clean carbon accumulation and replace spark plug. b. Electrical system has failure. Replace defective part(s).
  • Page 23 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. Test/Inspection 3. Check fuel supply to engine intake. a. Fuel valve is switched off. Turn on fuel valve. b. Run out of fuel. Turn fuel valve to “RES” position and refill. c.
  • Page 24 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. Test/Inspection 7. Cracked or broken piston. a. Cracked or broken piston due to excessive piston/cylinder clearance or engine overreving. Replace piston. Check piston/cylinder clearance (refer to CYLINDER AND HEAD). 8.
  • Page 25 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH SYMPTOM MAXIMUM OPERATING RPM. CONDITION NORMAL USE. Test/Inspection 1. Check items of ENGINE SUDDENLY TURNS OFF. 2. Check air intake system. a. Air filter is clogged due to contamination. Replace air filter.
  • Page 26 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM STARTER TURNS, BUT ENGINE DOES NOT CRANK. CONDITION NORMAL USE. Test/Inspection 1. Check gear condition on electric starter. a. Worn and/or damaged starter gear. Replace electric starter and/or starter drive. 2. Check condition of starter pinion gear. a.

  • Page 28: Leak Test

    Section 03 ENGINE Subsection 03 (LEAK TEST) LEAK TEST GENERAL VERIFICATION Remove: – LH side panel Before performing the cylinder leak test, verify the – radiator cap following: – Inlet hose of CVT cover. – intake port/air filter contaminated (clogged) with dirt, sand, etc.
  • Page 29 Section 03 ENGINE Subsection 03 (LEAK TEST) Prepare Rotate crankshaft until piston is at TDC. To place piston at ignition TDC, it is possible to use two procedures. First possible procedure: – Remove CVT cover. Refer to CVT section. – Turn the drive pulley until piston is at TDC. Second possible procedure: –...

  • Page 30: Installation

    Section 03 ENGINE Subsection 03 (LEAK TEST) Note the amount of leaking or percentage (depending on tester). LEAKAGE ENGINE PERCENTAGE CONDITION 0% to 7% Excellent condition. Fair condition; 8% to 15% proceed with tune up or adjustment. Poor condition; engine will run and 16% to 30% performance might be down in some cases.

  • Page 32: Water Pump

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) COOLING SYSTEM WATER PUMP 03-05-1 VMR2004_128_03_05A.FM...

  • Page 33: Cooling System

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) COOLING SYSTEM 03-05-2 VMR2004_128_03_05A.FM...

  • Page 34: General

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded views. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure.

  • Page 35: Draining The System

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) DRAINING THE SYSTEM System Capacity Refer to TECHNICAL DATA. WARNING Coolant Replacement Procedure Never drain or refill cooling system when en- gine is hot. WARNING To drain cooling system, partially unscrew cooling To avoid potential burns, do not remove the drain plug no.

  • Page 36: Thermostat

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) With vehicle on a flat surface, engine cold, refill ra- diator no. 13. When the coolant comes out by the thermostat housing hole, install the bleeding screw and remove the hose pincher. Install the pressure cap.

  • Page 37: Water Temperature Switch

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) WATER TEMPERATURE SWITCH Remove: – radiator outlet hose no. 16 Removal – screws no. 1 and no. 2 retaining water pump NOTE: The temperature switch is located on the housing no. 3 top of cylinder head, on intake side. Install a hose pincher on both radiator hoses.

  • Page 38: Water Pump Impeller

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Installation Inspection The installation is the opposite of the removal pro- Check impeller for cracks or other damage. Replace cedure. impeller if damaged. CAUTION: To prevent leaking, take care that Installation the gasket is exactly in groove when you rein- stall the water pump housing.
  • Page 39 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) NOTE: The water pump gear is held by a needle pin no. 8 on the water pump shaft. 1. Water pump shaft with rotary seal 1. Water pump gear – needle pin no. 8 and thrust washer no. 9. 1.
  • Page 40 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) 1. Special area for oil seal removal 1. Oil seal for the water pump shaft Inspection 2. Oil seal pusher (P/N 529 035 757) 3. Handle for insertion jig (P/N 420 877 255) Inspect water pump gear for wear and damage on It is recommended to install the water pump shaft the snap mechanism to the needle pin.

  • Page 41: Pressure Cap

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) 1. Water pump shaft with rotary seal 2. Water pump ceramic seal installer (P/N 529 035 766) NOTE: For installation use the torque values in the 1. Radiator inlet hose exploded view. Ensure to use multi-purpose grease for oil seal no.

  • Page 42: Coolant Tank

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Removal Remove: – LH inner fender (refer to BODY) – coolant tank support bolt no. 19 1. Radiator mounting bolts Unplug temperature sender connector no. 18 – overflow hose no. 12 then remove the radiator no. 13. –...

  • Page 43: Temperature Sender

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) TEMPERATURE SENDER Test Remove temperature sender no. 18, see below for procedure. Put the temperature sender in water and heat wa- ter. Using a multimeter, check the resistance from temperature sender. Temperature sender should open when water temperature reaches the follow- ing degree.
  • Page 44 Section 03 ENGINE Subsection 07 (MAGNETO SYSTEM) MAGNETO SYSTEM 03-07-1 VMR2004_130_03_07A.FM...

  • Page 45: General

    Section 03 ENGINE Subsection 07 (MAGNETO SYSTEM) GENERAL The engine removal is necessary to work on mag- neto components except for the CPS (Crankshaft Position Sensor) and oil seal. Always perform the electric tests before removing or installing whatever component. During assembly/installation, use the torque values and service products as in the exploded views.
  • Page 46 Section 03 ENGINE Subsection 07 (MAGNETO SYSTEM) For installation, reverse the removal procedure. However, pay attention to the following. IMPORTANT: When beginning the application of the crankcase sealant, the assembly and the first torquing should be done within 10 minutes. It is suggested to have all you need on hand to save time.

  • Page 47: Oil Seal

    Section 03 ENGINE Subsection 07 (MAGNETO SYSTEM) NOTE: Do not use Loctite Primer N with this seal- ant. The sealant curing time is similar to the Loc- tite 518 without using the Primer N, which is 4 to 24 hours. CAUTION: Apply Loctite 5910 all around the crankcase MAG slit surface except the areas de- scribed below.

  • Page 48: Stator

    Section 03 ENGINE Subsection 07 (MAGNETO SYSTEM) Installation CAUTION: Use the oil seal protector (P/N 529 035 935) to avoid damaging the oil seal during With Magneto Housing Cover Removed installation. Using the oil seal installer (P/N 529 035 759) and the inserting jig handle (P/N 420 877 650), install STATOR the oil seal in its location.

  • Page 49: Cps (Crankshaft Position Sensor)

    Section 03 ENGINE Subsection 07 (MAGNETO SYSTEM) Inspection NOTE: There is only one position for the stator (notch in the magneto housing cover). Check the CPS condition and replace it if necessary. To test the sensor refer to IGNITION SYSTEM. Installation For installation, reverse the removal procedure.

  • Page 50: Lubrication System

    Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) LUBRICATION SYSTEM 03-08-1 VMR2004_131_03_08A.FM...

  • Page 51: General

    Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) GENERAL Prior to change the oil, ensure vehicle is on a level surface. Oil and oil filter must be replaced at the same time. Oil change and oil filter replacement should be done with a warm engine. WARNING The engine oil can be very hot.

  • Page 52: Oil Change

    Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) OIL CHANGE Removal Place a drain pan under the engine magnetic drain plug area. Clean the magnetic drain plug area. Unscrew magnetic drain plug no. 3 then remove dipstick no. 4. CAUTION: Pay attention not to lose the O-ring no.

  • Page 53: Oil Strainer

    Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) Inspection OIL STRAINER Check oil filter cover O-ring, change it if necessary. Removal Check and clean the oil filter inlet and outlet area Remove: for dirt and other contaminations. – engine oil (refer to OIL CHANGE) –...
  • Page 54 Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) – oil collector no. 8 and O-ring no. 7 – oil strainer no. 6. 1. Oil inlet to the oil pump 2. Oil return from the oil pressure regulator system 3. Oil return from the engine oil circulation Installation 1.

  • Page 55: Engine Oil Pressure Regulator

    Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) ENGINE OIL PRESSURE Inspection REGULATOR Inspect valve piston for scoring or other damages. Check compression spring for free length. The oil pressure regulator is located on the engine MAG side (behind magneto housing cover). COMPRESSION SPRING FREE LENGTH NEW NOMINAL 64 mm (2.519 in)
  • Page 56 Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1. Dowel pins – oil pump gear no. 25 1. Intermediate gear 2. Pin NOTE: Oil pump gear is snapped on needle pin. This needle pin passes through the oil pump shaft. – screws no. 26 Use screwdrivers to remove this gear.
  • Page 57 Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1. Oil pump shaft assembly 2. Oil pump housing 1. Oil pump gear Inspection 2. Dowel pins 3. Suction side of the oil pump 4. Outlet from the engine oil pressure regulator valve Inspect oil pump shaft assembly, housing and cov- er for marks or other damages.
  • Page 58 Section 03 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1. Outer rotor 1. Oil pump outer rotor surface 2. Inner rotor 2. Dial indicator Difference between pump housing and outer rotor OUTER AND INNER ROTOR CLEARANCE should not exceed 0.1 mm (.004 in). If so, replace mm (in) replace the complete oil pump assembly.

  • Page 60: Cylinder And Head

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) CYLINDER AND HEAD NOTE: For cylinder head, cylinder and piston removal, it is not necessary to remove engine from vehicle. 400 engine type only 35 33 procedure inside 03-09-1 VMR2004_132_03_09A.FM...
  • Page 61 Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) 03-09-2 VMR2004_132_03_09A.FM...

  • Page 62: General

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) GENERAL Intake port/air filter contaminated (clogged) with dirt, sand, etc. (leads to worn valves, piston rings NOTE: When diagnosing an engine problem, always and finally to leak of power). perform a cylinder leak test. This will help pin-point a CAUTION: In case of piston rings and/or valve problem.

  • Page 63: Valve Cover

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) VALVE COVER Installation For installation, reverse the removal procedure. Removal Install the valve cover screws in a criss-cross se- Remove: quence. – valve cover screws no. 1 VALVE ADJUSTMENT Lock crankshaft at the TDC compression position (refer to CRANKSHAFT/BALANCER SHAFT, see CRANKSHAFT LOCKING PROCEDURE).

  • Page 64: Chain Tensioner

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) CHAIN TENSIONER Installation For installation, reverse the removal procedure. Removal However, pay attention to the following. Screw the plunger until it touches the chain guide. WARNING Install a spring end in plunger groove and the other Chain tensioner is spring loaded.

  • Page 65: Decompressor

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) DECOMPRESSOR 330 Engines This engine is not equipped with a decompressor system. Therefore parts no. 5 to no. 8 are not present and camshaft screw no. 4 is shorter. 1. Camshaft screw 2.
  • Page 66 Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) DECOMPRESSOR SHAFT MEASUREMENT A NEW MINIMUM 5.578 mm (.219 in) NEW MAXIMUM 5.590 mm (.220 in) SERVICE LIMIT 5.450 mm (.215 in) DECOMPRESSOR SHAFT MEASUREMENT B NEW MINIMUM 5.300 mm (.210 in) NEW MAXIMUM 5.350 mm (.211 in) SERVICE LIMIT...

  • Page 67: Camshaft Timing Gear

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) CAMSHAFT TIMING GEAR Installation For installation, reverse the removal procedure. Removal Pay attention to the following details. Remove: Clean mating surface and threads of camshaft pri- or to assemble camshaft timing gear. –...

  • Page 68: Rocker Arm

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) CAUTION: Crankshaft and camshaft must be locked on TDC position to place camshaft timing gear and timing chain in the proper position. Double-check position of timing gear with cam- shaft locking tool (P/N 529 035 926) 1.
  • Page 69 Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) – thrust washers no. 16. Check adjustment screws for free movement, cracks and/or excessive play. CAUTION: Pay attention not to lose thrust wash- ers or drop them into the timing chain compart- ment.

  • Page 70: Timing Chain

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) – Push in rocker arm shaft no. 11 until its chamfer NOTE: Before removing cylinder head, blow out reaches the end of rocker arm bore. remaining coolant by air pressure. During cylinder head removal, the remaining coolant in cylinder head could overflow into the engine and a little quantity of coolant could drop into the engine.
  • Page 71 Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) Installation Pull up cylinder head no. 29. Remove: For installation, reverse the removal procedure. Pay attention to the following details. – chain guide no. 30 Ensure dowel pins are in place. – gasket no. 31 (discard). Install a new gasket no.

  • Page 72: Camshaft

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) CAMSHAFT Inspection Check each lobe and bearing journal of camshaft Removal for scoring, scuffing, cracks or other signs of wear. The camshaft can be removed with the cylinder Measure camshaft bearing journal diameter and head installed.

  • Page 73: Valve Spring

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) Measure clearance between both ends of cam- shaft and cylinder head. 1. Camshaft retaining plate position 2. Slot retaining camshaft 3. Direction of movement For other parts, refer to proper installation proce- dure.
  • Page 74 Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) Inspection Check valve spring for visible damages. If so, replace valve spring. Check valve spring for free length and straightness. 1. Valve spring compressor clamp (P/N 529 035 724) 2. Valve spring compressor cup (P/N 529 035 725) 3.

  • Page 75: Valve

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) VALVE Inspection Valve Stem Seal Removal Inspection of valve stem seals is not needed because Remove valve spring. new seals should always be installed whenever cylinder head is removed. Push valve stem then pull valves no. 36 (intake) and no.
  • Page 76 Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) Ensure to seat valves properly. Apply some lapping VALVE STEM DIAMETER compound to valve face and work valve on its seat with a lapping tool (see VALVE GUIDE PROCE- NEW MINIMUM DURE below). EXHAUST 4.956 mm (.1951 in) Measure valve face contact width.

  • Page 77: Valve Guide Procedure

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) Installation For installation, reverse the removal procedure. Pay attention to the following details. CAUTION: Make sure the thrust washer no. 39 is installed before installing valve stem seal no. 38. Apply engine oil on valve stem and install it. CAUTION: Be careful when valve stem is passed through sealing lips of valve stem seal.

  • Page 78: Cylinder

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) CAUTION: Push valve guide no. 40 in the cold NOTE: Ensure to turn reamer in the right direc- cylinder head as per following illustration. tion. Use cutting oil and make brakes to clean reamer/valve guide from metal shavings.
  • Page 79 Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) Pull cylinder no. 41. CYLINDER TAPER IN DIAMETER Discard cylinder gasket no. 42. NEW MAXIMUM 0.038 mm (.0015 in) SERVICE LIMIT 0.090 mm (.004 in) Distance between measurements should not ex- ceed the service limit mentioned above. Cylinder Out of Round Measure cylinder diameter in piston axis direction from top of cylinder.

  • Page 80: Piston

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) Remove one piston circlip no. 43 and discard it. 1. Piston circlip 1. Timing chain 2. Piston ring compressor tool NOTE: The removal of both piston circlips is not 3. Piston necessary to remove piston pin. 4.
  • Page 81 Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) Inspection Piston Inspect piston for scoring, cracking or other dam- ages. Replace piston and piston rings if necessary. Using a micrometer, measure piston at 8 mm (.315 in) perpendicularly (90°) to piston pin. 1.
  • Page 82 Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) NOTE: Make sure used piston is not worn. See PISTON MEASUREMENT above. If clearance exceeds specified tolerance, replace cylinder. NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the micrometer, otherwise the reading will be false.

  • Page 83: Piston Rings

    Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) CAUTION: Always replace disassembled pis- ton circlip(s) by new ones. Place a rag on cylin- der base to avoid dropping the circlip inside the engine. – Place circlip no. 43 in sleeve as per following illustration.
  • Page 84 Section 03 ENGINE Subsection 09 (CYLINDER AND HEAD) Install the oil scraper ring first, then the lower com- pression ring with the word “N and TOP “ facing up, then the upper compression ring with the word “N and TOP“ facing up. 1.

  • Page 86: Crankshaft/Balancer Shaft

    Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) CRANKSHAFT/BALANCER SHAFT CRANKCASE 03-10-1 VMR2004_133_03_10A.FM...

  • Page 87: Crankshaft/Balancer Shaft

    Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) CRANKSHAFT/BALANCER SHAFT 03-10-2 VMR2004_133_03_10A.FM...

  • Page 88: General

    Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) GENERAL Use a screwdriver to check if groove in crankshaft is aligned with the hole. During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure.

  • Page 89: Timing Chain

    Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) CHAIN TENSIONER PLUNGER PROTRUSION 18.5 mm to 20 mm SERVICE LIMIT (.71 in to .79 in) If protrusion exceeds service limit, replace timing chain, camshaft timing gear, chain guide and chain tensioner guide at the same time. Check timing chain on camshaft timing gear for ex- cessive radial play.

  • Page 90: Timing Chain Guide

    Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) TIMING CHAIN GUIDE CRANKCASE To reach the balancer shaft and the crankshaft, it Removal is necessary to separate the crankcase. Remove: The procedures to remove, inspect and install the – engine from vehicle balancer shaft and the crankshaft are explain fur- (refer to REMOVAL AND INSTALLATION) ther in this section.
  • Page 91 Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) If measurement is out of specification, inspect NOTE: Hit with a soft hammer to ease lifting crank- butting faces of crankshaft and crankcase (MAG/ case MAG. PTO side) for excessive wear. Remove balancer shaft and crankshaft (see BAL- Remove: ANCER SHAFT and CRANKSHAFT above).
  • Page 92 Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) PUSH PLAIN BEARINGS OUTSIDE 1. PTO plain bearing without groove 1. Plain bearing remover/installer 2. Oil bore 2. Plain bearing 3. Split of the plain bearing halves 3. Crankcase PTO 4. Cylinder base direction A.
  • Page 93 Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) 1. Crankcase support PTO (P/N 529 035 754) 2. Crankcase PTO side 1. Mark on crankcase and oil bore position NOTE: Mark oil bore position on crankcase to align 2. Split between bearing halves new plain bearing with crankcase thrust surface.

  • Page 94: Balancer Shaft

    Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) Install a new oil seal no. 11 with the crankshaft oil seal installer (P/N 529 035 760). 1. Crankshaft 2. Balancer shaft 3. Connecting rod 4. Rotate crankshaft for balancer shaft removal 5. Groove for fixation at TDC 1.

  • Page 95: Crankshaft

    Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) CRANKSHAFT Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between Removal butting face of connecting rod and crankshaft coun- terweight. If the distance exceeds specified toler- Remove: ance, replace the crankshaft. –...
  • Page 96 Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) A. Piston pin diameter in the area of the bushing CONNECTING ROD SMALL END DIAMETER MINIMUM (new) 20.010 mm (.7878 in) MAXIMUM (new) 20.020 mm (.7882 in) SERVICE LIMIT 20.060 mm (.7898 in) PISTON PIN DIAMETER MINIMUM (new) 19.996 mm (.7872 in)
  • Page 97 Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) CONNECTING ROD BIG END DIAMETER CRANKSHAFT MAG/PTO DIAMETER SERVICE LIMIT 40.100 mm (1.579 in) MINIMUM (new) 42.024 mm (1.6545 in) MAXIMUM (new) 42.040 mm (1.6551 in) CONNECTING ROD BIG END CLEARANCE SERVICE LIMIT 42.000 mm (1.6535 in) SERVICE LIMIT 0.09 mm (.0035 in)
  • Page 98 Section 03 ENGINE Subsection 10 (CRANKSHAFT/BALANCER SHAFT) CAUTION: Failure to strictly follow this proce- dure may cause screw to loosen and lead to engine damage. The bushing tapered end must be against the counterweight. Besides, as the “crankpin” screw has been stretched from the previous installation, it is very important to use a new screw at assembly.

  • Page 100: Gearbox

    Section 03 ENGINE Subsection 11 (GEARBOX) GEARBOX OUTPUT SHAFT AND TRANSMISSION Different gear transmission between Outlander 400 and 330 03-11-1 VMR2004_134_03_11A.FM...

  • Page 101: Crankcase

    Section 03 ENGINE Subsection 11 (GEARBOX) CRANKCASE 03-11-2 VMR2004_134_03_11A.FM...

  • Page 102: General

    Section 03 ENGINE Subsection 11 (GEARBOX) GENERAL To remove gearbox, the engine removal is necessary. During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure.
  • Page 103 Section 03 ENGINE Subsection 11 (GEARBOX) – bearing cover screws no. 30 CAUTION: Use a soft hammer to remove output shaft from crankcase MAG side. – O-ring no. 4 and bearing no. 5 NOTE: Both bearings on output shaft have a tran- sition fit.
  • Page 104 Section 03 ENGINE Subsection 11 (GEARBOX) 1. Shim 1. Soft hammer 2. Output shaft gear 2. Push output shaft as per following illustration. Inspection Check output shaft for cracks and other visible dam- ages. CAUTION: Always replace output shaft no. 1 and bevel gear shaft no.

  • Page 105: Crankcase

    Section 03 ENGINE Subsection 11 (GEARBOX) 4. Remove output shaft again and rebuild it with proper shim. 5. Take measured thickness and choose shim as per the following table. MEASURED THICKNESS SHIM THICKNESS 0.79 to 0.88 mm 0.70 mm (.0311 to .0346 in) (.0276 in) 0.89 to 0.98 mm 0.80 mm...
  • Page 106 Section 03 ENGINE Subsection 11 (GEARBOX) – screws retaining crankcase housing. POSITION FOR BIG FLAT SCREWDRIVER Inspection NOTE: To check some parts, it is recommended to remove all components in both crankcase halves. 1. 14 screws M6 x 45 2. 2 screws M6 x 85 Clean crankcase from contaminations and blow 3.
  • Page 107 Section 03 ENGINE Subsection 11 (GEARBOX) To remove bevel gear needle bearing no. 36 and Ball bearings no. 38 and no. 45 can be easily re- main shaft needle bearing no. 37, use a punch. moved with a suitable pusher from outside in. The oil seals no.
  • Page 108 Section 03 ENGINE Subsection 11 (GEARBOX) Bearing Installation Procedure Unless otherwise instructed, never use hammer to install ball bearings, needle bearings or plain bearings. Use press machine only. WARNING Clean oil, outside and inside, from housing. Install plain bearings no. 40 and no. 41 with the proper plain bearing installer (refer to CRANKSHAFT/ BALANCER SHAFT).
  • Page 109 Section 03 ENGINE Subsection 11 (GEARBOX) Install new oil seals with the proper installer. OIL SEAL INSTALLER Crankshaft oil seal 529 035 760 Balancer shaft oil seal 529 035 933 Main shaft oil seal 529 035 934 1. Main shaft oil seal PTO side 2.
  • Page 110 Section 03 ENGINE Subsection 11 (GEARBOX) CAUTION: Do not use Loctite 515 or 518 to seal crankcase. Do not use Loctite Primer N with the Loctite 5910. Using these products or non silicone- based sealant over a previously sealed crankcase with Loctite 5910 will lead to poor adhesion and possibly a leaking crankcase.

  • Page 111: Gearbox

    Section 03 ENGINE Subsection 11 (GEARBOX) GEARBOX – shift fork shaft no. 11 General The only difference between gearbox of the Out- lander 400 to 330 is the transmission ratio of gears no. 22 and no. 29 (high range gear). During and after gearbox disassembly, inspect the condition of each part closely.
  • Page 112 Section 03 ENGINE Subsection 11 (GEARBOX) – gear selection no. 22, thrust washer no. 23, re- verse gear no. 25, needle bearing no. 24 and shim no. 26 – distance sleeve no. 14, thrust washer no. 15, in- termediate gear no. 16, needle bearing no. 17 and intermediate gear shaft no.
  • Page 113 Section 03 ENGINE Subsection 11 (GEARBOX) Replace isolating washer no. 10 if there are signs of wear or visible damages. 1. Main gear 2. Caliper A. Gap for engagement of shift fork Check main shaft for wear. 1. Track for the low/reverse gear shift fork MAINSHAFT 2.
  • Page 114 Section 03 ENGINE Subsection 11 (GEARBOX) Install: – intermediate gear shaft no. 18, needle bearing no. 17, intermediate gear no. 16, thrust washer no. 15 and distance sleeve no. 14 – shim no. 26, needle bearing no. 24, reverse gear no. 25, thrust washer no. 23 and gear se- lection no.
  • Page 115 Section 03 ENGINE Subsection 11 (GEARBOX) Bevel Gear Adjustment Insert a flat screwdriver in the slot of index lever no. 8. Turn screwdriver counterclockwise and in- Use following course of calculation to adjust bevel stall shift drum on park position as per the follow- gear in place between crankcase PTO and MAG.
  • Page 116 Section 03 ENGINE Subsection 11 (GEARBOX) 03-11-17 VMR2004_134_03_11A.FM...
  • Page 117 Section 03 ENGINE Subsection 11 (GEARBOX) Measure shim on MAG side: • C = Distance between butting face (MAG side) to mating surface of crankcase MAG. NOTE: Clean mating surface of crankcase before measurement. Refer to crankcase assembly pro- cedure. •...
  • Page 118 Section 03 ENGINE Subsection 11 (GEARBOX) Measure shim on PTO side: NOTE: Clean mating surfaces of crankcase before measurement. Refer to crankcase assembly pro- cedure. • F = Distance between mating surface (crank- case PTO) to ball bearing inner race. •...
  • Page 119 Section 03 ENGINE Subsection 11 (GEARBOX) Example Installation For installation, reverse the removal procedure. LETTER MEASUREMENT 1 Pay attention to the following details. 2 mm (.0787 in) CAUTION: Don’t forget thrust washer no. 15 and no. 22. 37.760 mm (1.487 in) First install intermediate gear then main shaft and 34.040 mm (1.340 in) afterward the bevel gear.

  • Page 120: Shifting Indicator Switch

    Section 03 ENGINE Subsection 11 (GEARBOX) SHIFTING INDICATOR SWITCH Test Prior to remove parts from vehicle and/or engine perform general test as per following procedure: – Unplug connector from vehicle wire harness. 1. Blue wire for contact to parking gear 2.

  • Page 121: Starter Drive Pinion

    Section 03 ENGINE Subsection 11 (GEARBOX) Inspection NOTE: The alligator clip is recommended. Replace wire harness no. 54 if damaged, brittle, Check if starter drive pinion is free of movement. hard or otherwise damaged. NOTE: Centrifugal weights avoid disengaging of If the shifting indicator switch and its harness are the pinion while starting the engine.

  • Page 122: Cvt

    Section 03 ENGINE Subsection 12 (CVT) NOTE: This is a lubrication free system except drive pulley one-way clutch. 35 32 4 31 03-12-1 VMR2004_135_03_12A.FM...

  • Page 123: General

    Section 03 ENGINE Subsection 12 (CVT) GENERAL CAUTION: These pulleys have metric threads. Do not use imperial thread puller. Always tight- NOTE: For a better understanding, the following en puller by hand to ensure that the drive pulley illustrations are taken with engine out of vehicle. has the same type of threads (metric vs impe- To perform the following instructions, it is not nec- rial) before tightening completely.

  • Page 124: Drive Pulley

    Section 03 ENGINE Subsection 12 (CVT) Screw tool in the threaded hole of driven pulley and tighten to open the pulley. 1. Drive belt A. Belt width Installation For installation, reverse the removal procedure. Pay attention to following details. 1. Driven pulley expander The maximum drive belt life span is obtained when 2.
  • Page 125 Section 03 ENGINE Subsection 12 (CVT) Removal of Drive Pulley Remove belt no. 4. NOTE: To remove drive pulley, two procedures can be followed. WARNING Drive pulley screw has a left-hand thread. First possible procedure: – Remove the spark plug (refer to CYLINDER AND HEAD).
  • Page 126 Section 03 ENGINE Subsection 12 (CVT) Disassembly of Drive Pulley Remove drive pulley screw no. 5, spring washer no. 6 and thrust washer no. 7. Governor Cup Carefully lift governor cup no. 10 until slider shoes no. 11 come at their highest position into guides. Sliding Half Unscrew lock nut no.
  • Page 127 Section 03 ENGINE Subsection 12 (CVT) Pull one-way clutch no. 15 slowly until the half of WARNING spring sleeves no. 16 is visible. This procedure must be performed in a well- ventilated area. CAUTION: To avoid damage, make sure clean- er does not contact the crankshaft seal.
  • Page 128 Section 03 ENGINE Subsection 12 (CVT) Roller Check each roller no. 19 for roundness of external diameter. NOTE: Replace governor cup if the roller does not move freely. Measure the roller diameter. If a roller is out of spec- ification, replace governor cup. ROLLER DIAMETER MINIMUM (new) 13.70 mm (.539 in)
  • Page 129 Section 03 ENGINE Subsection 12 (CVT) Measure centrifugal lever pivot bolt bores. Replace sliding half if bores are out of specification or dam- aged. 1. Bushing on governor cup side A. Centrifugal lever pivot bolt bore diameter A. Bore diameter of bushing CENTRIFUGAL LEVER PIVOT BOLT BORE SLIDING HALF LARGE BUSHING DIAMETER...
  • Page 130 Section 03 ENGINE Subsection 12 (CVT) Check for any marks on fixed half plate. Replace if Measure length of spring sleeve no. 16 and check necessary. if edges on top of the spring sleeve are excessive- ly worn. If out of specifications, replace both Check ring gear teeth for excessive wear or other spring sleeves and springs at the same time.

  • Page 131: Driven Pulley

    Section 03 ENGINE Subsection 12 (CVT) 1. Clutch holding tool (P/N 529 006 400) 2. Drive pulley removal/installation area 1. Clutch holding tool (P/N 529 035 771) DRIVEN PULLEY 2. Driven pulley fixed half Second possible procedure: Removal of Driven Pulley –...
  • Page 132 Section 03 ENGINE Subsection 12 (CVT) Disassembly of Driven Pulley CAUTION: To avoid damage, make sure clean- er does not contact the countershaft seal. Fixed Half Remove retaining ring no. 23 and lift torque gear no. 24. NOTE: The following procedure is not necessary except if ball bearing or shaft must be removed.
  • Page 133 Section 03 ENGINE Subsection 12 (CVT) BUSHING BORE DIAMETER Check cam no. 29 for visible damage and wear limit MAXIMUM (new) 30.000 mm (1.181 in) with a caliper. MAXIMUM (new) 30.020 mm (1.182 in) SERVICE LIMIT 30.200 mm (1.189 in) Fixed Half Check ball bearing for free play and smooth oper- ation.
  • Page 134 Section 03 ENGINE Subsection 12 (CVT) Spring Measure spring free length and squareness. If spring is out of specification, replace by a new. SPRING FREE LENGTH SERVICE LIMIT 164 mm (6.457 in) CLUTCH SPRING SQUARENESS SERVICE LIMIT 3.8 mm (.150 in) Assembly of Driven Pulley For installation, reverse the removal procedure.
  • Page 135 Section 03 ENGINE Subsection 12 (CVT) Installation of Driven Pulley Place spring no. 33 behind sliding half then align driven pulley with cam. For installation, reverse the removal procedure. Pay attention to the following details. Install sliding half no. 30 into fixed half no. 31. Place O-ring no.
  • Page 136 Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR) CARBURETOR 04-03-1 VMR2004_137_04_03A.FM...
  • Page 137 Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR) GENERAL Unscrew choke cable then remove the choke plunger from the throttle body. Before performing any job on the fuel system, al- NOTE: Take care not to drop the choke plunger. If ways turn fuel valve to OFF position and discon- so, check plunger for damages and replace if nec- nect BLACK (-) cable from battery.
  • Page 138 Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR) Installation Refer to following photos for proper float level gauge positioning and to TECHNICAL DATA for To install carburetor on engine, inverse removal proper level. procedure. Pay attention to the following details: – Inspect throttle and choke cable housing prior to installation.
  • Page 139 Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR) Align carburetor notch with the flange recess. Idle Speed Preliminary Adjustment Adjust throttle screw to 1-1/2 turn or so that throt- tle valve closes bypass hole by half, as shown in the next photo. TYPICAL Carburetor notch aligned with the flange recess Install air filter box.
  • Page 140 Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR) Diaphragm Installation Carefully replace diaphragm in its original position. Make sure spring is located properly in carburetor cover before screwing. 1. Release tension on throttle lever 2. Cable end bushing Separate cable end bushing from throttle cable THROTTLE CABLE end, as shown in the next photo.
  • Page 141 Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR) Loosen throttle cable nut, as shown in the next photo. 1. Cable protector 2. Throttle cable adjuster 3. Lock nut 4. Throttle lever housing 1. Loosen this nut Screw in the throttle cable adjuster. Pull cable out from carburetor.
  • Page 142 Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR) Insert the needle of lubricant can in the end of throt- tle cable adjuster. WARNING Always wear eye protection and gloves when lubricating cables. NOTE: Place a rag around cable adjuster to prevent lubricant splash.

  • Page 143: Choke Cable

    Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR) With the transmission lever on PARK position, start engine. Check if the throttle cable is adjusted cor- rectly by turning handlebar fully right then fully left. If the engine RPM increase, readjust the throttle lever free play.
  • Page 144 Section 05 ELECTRICAL Subsection 03 (CHARGING SYSTEM) CHARGING SYSTEM TESTING PROCEDURE DYNAMIC TEST Current Test NOTE: First, ensure that battery is in good condi- tion prior to performing the following test using a Proceed as follows: current inductive ammeter such as Snap-on MT –...
  • Page 145 Section 05 ELECTRICAL Subsection 03 (CHARGING SYSTEM) Stator STATIC TEST: INSULATION With the stator leads disconnected, insert either STATIC TEST: CONTINUITY meter test probe onto AC-1 and ground the other 1. Disconnect the magneto wiring harness connec- meter test probe to the engine or the stator iron tor.

  • Page 146: Technical Data

    Section 11 TECHNICAL DATA Subsection 01 (SI METRIC INFORMATION GUIDE) TECHNICAL DATA SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length ..............meter ............. mass ..............kilogram ..........force ..............newton ........... liquid ..............liter ............temperature ............Celsius ........... °C pressure ..............
  • Page 148 Section 11 TECHNICAL DATA Subsection 03 (OUTLANDER 400) OUTLANDER 400 OUTLANDER 400 H.O. VEHICLE MODEL 2 X 4 4 X 4 ENGINE BOMBARDIER-ROTAX, 4-stroke, Engine type Over Head Camshaft (OHC), liquid cooled Electric start and manual rewind starter. Starting system Start in any gear (with brakes applied) Number of cylinder(s) Number of valves...
  • Page 149 Section 11 TECHNICAL DATA Subsection 03 (OUTLANDER 400) OUTLANDER 400 H.O. VEHICLE MODEL 2 X 4 4 X 4 ENGINE Upper compression ring mm (in) 0.2 (.008) Lower compression ring New minimum mm (in) 0.2 (.008) Oil scraper ring mm (in) 0.2 (.008) Piston ring end gap Upper compression ring...
  • Page 150 Section 11 TECHNICAL DATA Subsection 03 (OUTLANDER 400) OUTLANDER 400 H.O. VEHICLE MODEL 2 X 4 4 X 4 ENGINE MAG side Wear limit mm (in) 42.070 (1.6563) Crankcase plain bearing PTO side Wear limit mm (in) 42.070 (1.6563) MAG/PTO side Crankshaft radial clearance Service limit mm (in)
  • Page 151 Section 11 TECHNICAL DATA Subsection 03 (OUTLANDER 400) OUTLANDER 400 H.O. VEHICLE MODEL 2 X 4 4 X 4 ELECTRICAL Magneto/generator 400 W @ 6000 RPM Ignition system type C.D.I. (Capacitive Discharge Ignition) Ignition timing Not adjustable Quantity Spark plug Make and type NGK DCPR8E mm (in)
  • Page 152 Section 11 TECHNICAL DATA Subsection 03 (OUTLANDER 400) OUTLANDER 400 H.O. VEHICLE MODEL 2 X 4 4 X 4 LUBRICATION Oil pressure switch operation 30 to 60 kPa (4.35 to 8.70 PSI) Engine oil pressure (min.) 350 kPa (51 PSI) DRIVE TRAIN CVT (Continuously Variable Transmission).
  • Page 153 Section 11 TECHNICAL DATA Subsection 03 (OUTLANDER 400) OUTLANDER 400 H.O. SERVICE PRODUCT VEHICLE MODEL 2 X 4 4 X 4 TORQUE • ENGINE Lower engine mounting bracket 23 N•m (17 lbf•ft) Lower engine mounting bolts 48 N•m (35 lbf•ft) Upper engine support Spark plug 20 N•m (15 lbf•ft)
  • Page 154 Section 11 TECHNICAL DATA Subsection 03 (OUTLANDER 400) OUTLANDER 400 H.O. SERVICE PRODUCT VEHICLE MODEL 2 X 4 4 X 4 TORQUE • CRANKSHAFT 10 N•m (89 lbf•in) Crankcase housing screw 25 N•m (18 lbf•ft) None Connecting rod 20 N•m (15 lbf•ft) + 70° rotation Crankshaft locking access screw 25 N•m (18 lbf•ft) •...

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