This bulletin must be used in conjunction with the check list enclosed in the bag with the Operator’sGuide and the Safety Handbook. Make sure that predelivery check list is completed and signed.
NOTE: The information and components/system descriptions contained in this document are correct atthe time of publication. Bombardier however, maintains a policy of continuous improvement of its prod-ucts without imposing upon itself any obligation to install them on products previously manufactured.Due to late changes, there might be some differences between the manufactured product and the de-scriptions and/or specifications in this document. Bombardier reserves the right at any time to discontinueor change specifications, designs, features, models or equipment without incurring obligation.The illustrations in this document show the typical construction of the different assemblies and may notreproduce the full detail or exact shape of the parts. However, they represent parts that have the sameor similar function.The content of this bulletin is designed as a guideline only. All mechanics performing predeliveryprocedures should have attended the current model-year service training. Further information orinquiries should be directed to your distributor service representative and/or specific Shop Manualsections. Please complete the Predelivery Check List for each vehicle and retain a customer-signedcopy. Make sure the customer receives the Operator’s Guide, Safety Handbook, Predelivery CheckList signed copy and video.
No. 2000-1REVISION 1
Date: February 25, 2000 SUBJECT: Predelivery Inspection
YEAR MODEL MODEL NUMBER SERIAL NUMBER
2000 Traxter*7415/7416/7417/74187405/7406/7407/7408 All
WARNING
To obtain warranty coverage, predelivery procedures must be performed by an authorized BombardierATV dealer. Apply all necessary torques as indicated.
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UNCRATING
Carefully lay the crate on its bottom.CAUTION: Allowing the crate to drop may causeserious damage to the vehicle.Remove all screws retaining cover to crate base.Assisted by another person, lift crate cover over.
CAUTION: Do not tip cover toward front of ve-hicle. Remove straps and hooks retaining vehi-cle. The vehicle is retained in front by thebumper and in rear by the frame extension.
To remove, charge and install battery in vehicle,refer to next section.Fill the fuel tank and check all liquid levels (brake,cooling, etc.).Move vehicle of the crate base.
PARTS INSTALLATIONBATTERY
Battery RemovalRemove seat.Remove the holding straps.Remove battery from vehicle.Place battery on a level surface (other than ce-ment).
Activation of a New BatteryA new battery is factory fresh dry charged. Forstorage purposes, it is fitted with a temporary seal-ing tube.Do not remove the sealing tube or loosen batterycaps unless activation is desired.In case of accidental premature removal of capsor sealing tube, battery should be given a fullcharge.Perform the following operations:1. Remove the sealing tube from the vent elbow.
Install vent tube (included in the battery kit) tobattery elbow.
1. Battery electrolyte
2. Remove caps and fill battery to UPPER LEVELline with electrolyte (specific gravity: 1.260 at20°C (68°F)).
WARNING
Torque wrench tightening specificationsmust be strictly adhered to. Locking devices(e.g. lock tabs, elastic nuts) must be installedor replaced by new ones, where specified.Fasteners with locking agent must be re-placed by new ones. If the efficiency of a lock-ing devices is impaired, it must be renewed.
WARNING
No one should be standing in front of or inback of the vehicle while straps are being cut.
WARNING
Failure to remove the sealing tube could re-sult in an explosion.
WARNING
Electrolyte is poisonous and dangerous. Avoidcontact with eyes, skin and clothing. Wearprotective eyewear and a suitable pair of non-absorbent gloves when handling the battery.
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2000-1 Page 3 of 18
3. Allow the battery to stand for 30 minutes MIN-IMUM so that electrolyte soaks through batterycells.
4. Allow gas bubbles to escape by lightly shakingbattery by hand.
5. Readjust the electrolyte level to the UPPERLEVEL line.
6. Connect a 2 A battery charger for 10 to 20 hoursas per following 1, 2 and 3 sequence.
CAUTION: If charging rate rises higher than 2.4A reduce it immediately. If cell temperature ris-es higher than 50°C (122°F) (if the casing feelshot) discontinue charging temporarily or re-duce the charging rate.
7. Disconnect battery charger as per following 1,2 and 3 sequence.
8. Test battery state of charge. Use a hydrometer.
1. Specific gravity 1.260
9. Let battery settle for 1 hour.10. Allow gas bubbles to escape by lightly shaking
battery.11. Readjust electrolyte level.12. Reinstall caps and clean any electrolyte spill-
age using a solution of baking soda and water.
1. Baking soda
CAUTION: Do not allow cleaning solution to en-ter battery interior since it will destroy the elec-trolyte.
WARNING
Never charge battery while installed on vehicle.
WARNING
Gases given off by a battery being charged arehighly explosive. Always charge in a well ven-tilated area. Keep battery away from sparks oropen flames. Always turn battery charger offprior to disconnecting cables. Otherwise aspark will occur and battery might explode.
Page 4 of 18 2000-1
Battery InstallationPlace the battery in the engine compartment ontothe battery support.Install the vent tube.Secure RED positive cable to battery post.
1. Cable between battery and strap
Apply dielectric grease (P/N 293 550 004) on bat-tery posts.Cover battery positive post with rubber boot.
LIQUIDSLIQUID LEVEL
Engine Oil LevelWith vehicle on a level surface and engine not run-ning, check the engine oil with the dipstick. Refillif necessary.CAUTION: Do not overfill. Operating the engine/transmission with an improper level may se-verely damage engine/transmission. Wipe offany spillage.SAE 10W40 is recommended for general use. Al-ways use 4-stroke mineral-based engine oil thatmeets or exceeds the requirements for API ser-vice classification SF, SG or SH.Other viscosity should be used if the average tem-perature is outside the range of the recommendedoil. See the Operator’s Guide.CAUTION: The same oil lubricates both engineand transmission. Do not use synthetic or semi-synthetic oil. They affect the clutching calibra-tion.CAUTION: For proper operation of the clutch-ing system, do not use special oil additives. Donot use unrecommended types of oil.
LH SIDE OF ENGINE1. Dipstick2. Filler cap
Brake FluidWith vehicle on a level surface, check brake fluidin reservoirs for proper level. It should be to theMAX. mark.Add fluid as required. Do not overfill.Clean filler cap before removing.
WARNING
Connect RED positive cable first then nega-tive cable. Always connect RED positive cablefirst.
WARNING
Place the RED positive cable between hold-ing straps and battery to avoid cable beingcaught in shock absorber.
2000-1 Page 5 of 18
CAUTION: Use only DOT 4 brake fluid from asealed container.
FRONT BRAKE FLUID RESERVOIR
REAR BRAKE FLUID RESERVOIR
Coolant LevelCheck the coolant level and refill if necessary witha solution of 60% antifreeze and 40% water.
FRONT DIFFERENTIAL
Oil LevelClean filler plug prior to checking oil level.With vehicle on a level surface, check the oil levelby removing filler cap. Oil level must be 32 mm(1-1/4 in) below filler plug.Add oil if necessary (refer to specifications at theend of this bulletin).
REAR AXLE
Oil LevelLift back of vehicle and secure in place. Place theswing arm to the horizontal position.Clean filler plug prior to check oil level, check theoil level by removing filler cap. Oil level must reachthe lower edge.Add oil if necessary (refer to specifications at theend of this bulletin).
Page 6 of 18 2000-1
TIRES AND WHEELSCheck pressure when tires are “cold” before us-ing the vehicle. Tire pressure changes with tem-perature and altitude. Recheck pressure if one ofthese conditions has changed.
For your convenience, a pressure gauge is sup-plied in tool box.
ADJUSTMENTSIMPORTANT: All adjustments have already been performed at factory. It is only necessary to val-idate them. However, if readjustment is needed, the following procedures should be used.
BRAKE PEDALPlace a shim between brake pedal lever andswitch nut. The tickness of the shim must be 2mm (5/64 in).Adjust push rod to eliminate free play betweenbrake pedal lever and master cylinder.When a light pressure is felt, torque push rod nutto 4.5 N•m(39 lbf•in).Remove the shim and press the brake pedal lever.Check for a light play in the system.
1. Push rod jam nut2. Brake pedal return spring
BRAKE CABLE
While holding rod with locking pliers, turn the ad-justment nut until stopper comes in contact withthe brake pedal lever.Unscrew adjustment nut approximately 1/4 turn tomake sure there is no tension on brake cable.
1. Adjustment nut2. Stopper3. Maximum 1 mm (1/32 in) gap
WARNING
Underpressure may cause tire to deflate androtate on wheel. Overpressure may burst thetire. Always follow recommended pressure.Since tires are low-pressure type, a manualpump should be used.
TIRE PRESSURE FRONT REAR
RECOMMENDED 38 kPa(5.5 Psi)
35 kPa(5 Psi)
MINIMUM 35 kPa(5 Psi)
31 kPa(4.5 Psi)
WARNING
Adjust brake pedal prior to adjusting brakecable. If brake pedal is not correctly adjusted,the parking device will not function properly.
2000-1 Page 7 of 18
INTERLOCK CABLEAdjust cable so that the pin end from interlock ca-ble is flush with the shifter lever plate. Use theinterlock adjustment as per following photos.
1. Interlock pin end2. Shifter lever plate
Torque nut and jam nut.
1. Interlock adjustment2. Jam nut3. Nut
BRAKE LIGHT SWITCH
Front Brake Light SwitchThe front brake switch is located on the mastercylinder and cannot be adjusted. Check that switchis securely installed and operational.
Rear Brake Light SwitchDepress brake pedal and check for brake light toturn on. The rear brake light switch cannot be ad-justed.
SUSPENSION
InspectionInspect shock absorber for oil leaks and fastenersfor tightness.
Spring Preload AdjustmentAdjust spring preload by turning adjusting camwith the wrench in vehicle tool box.Turn the adjusting cams clockwise for a firmer rideand rought road condition or when carrying cargoor pulling a trailer.Turn the adjusting cams counterclockwise for alight load and a smooth road condition.
1. Adjusting cam2. Smooth adjustment3. Hard adjustment
WARNING
Left and right adjusting cams must alwaysbe set at the same position. Never adjust oneadjusting cam only. Uneven adjustment cancause poor handling and loss of stability,which could lead to an accident.
Page 8 of 18 2000-1
CARBURETOR ADJUSTMENTSModels 7415/7416/7417/7418
BOTTOM VIEW1. Idle speed screw2. Pilot screw3. Drain plug and screw
Models 7405/7406/7407/7408
BOTTOM VIEW1. Idle speed screw2. Pilot screw3. Drain plug and screw
All Models
Pilot Screw AdjustmentNOTE: Pilot screw is factory pre-set. Adjustmentis not necessary unless carburetor is overhauledor replaced.Warm-up engine to operating temperature.NOTE: Engine must run for a minimum of 20 min-utes at idle speed to reach normal operating tem-perature. Set idle speed to specification, using idle speedscrew.Connect RPM gauge. If you are using Bombardiertool (P/N 529 014 500), turn RPM gauge wire, 4 to5 turns around spark plug cable. Note that there isa spark at each crankshaft turn.Turn pilot screw clockwise till engine RPM speeddecreases and then counterclockwise till engineRPM speed decreases then set screw position ex-actly between these two settings.If idle speed changes after pilot screw adjustment,readjust engine RPM by the idle speed screw.CAUTION: Failure to do so will result in a toohigh engine idle speed and a difficulty to shiftthe sub-transmission caused by centrifugalclutch engagement.Refer to TECHNICAL DATA for the specifications.
2000-1 Page 9 of 18
Models 7415/7416/7417/7418
EnrichnerRemove top cover from carburetor. Detach diaphragm from carburetor body, then pull out throttle slide.With enrichner lever at fully closed position, enrichner plunger must be fully closed. With lever halfway,plunger must be opened to specifications and with lever completely opened, plunger must be opened.See next photos for proper enrichner lever and plunger positioning.
FULLY CLOSED POSITION1. Plunger end must be here
HALFWAY POSITION1. Plunger end must be hereA. Opening to specification
FULLY OPENED POSITION1. Plunger end must be here
Page 10 of 18 2000-1
Plunger AdjustmentTo adjust plunger use cable adjuster, as shown inthe next photo.
USE CABLE ADJUSTER TO ADJUST PLUNGER1. Enrichner plunger
NOTE: For proper adjustment at halfway position,use a drill bit with a diameter of the opening spec-ification (refer to TECHNICAL DATA).
Models 7405/7406/7407/7408
On these models, the enrichner is not adjustablebecause it is fully variable.
All Models
Diaphragm InstallationCarefully replace diaphragm in its original position.NOTE: On models 7415/7416/7417/7418, checkand place the indexation lob correctly.Make sure spring is located properly in carburetorcover before screwing.
Throttle
Before adjusting the throttle cable, adjust idlespeed (preliminary adjustment) and enrichner.On the carburetor, loosen the lock nut and adjustthe throttle cable.Make sure the throttle lever, at the full position,doesn’t press against carburetor body.
TYPICAL — THROTTLE LEVER AT THE FULL POSITION A. 1 mm (1/32 in) gap
Retorque lock nut.
WARNING
Ensure the key is turned OFF, prior to per-forming the throttle cable adjustment.
2000-1 Page 11 of 18
TOE-OUTPlace the vehicle on the level surface.Check that handlebar is horizontal.Use a long rule and check if the rear and frontwheels are aligned.Adjust alignment with the tie-rod.Adjust toe-out to 17 mm ± 4 mm (43/64 in ±5/32 in).
Measuring ProcedureNOTE: Before measuring toe-out, ensure tirepressure is correct.Place vehicle on a level surface.Raise front end of vehicle and release slowly.Move rear portion of front wheels toward the in-side of vehicle.Place handle bar straight ahead.Mark both front tire thread center at 254 mm(10 in) from the ground.Measure the width A between the marks.Measure the width B between the marks.Calculate the toe-out as per following formula:Toe-out = A - B
Toe-out should be 17 mm ± 4 mm (43/64 in ±5/32 in).If toe-out is incorrect, adjust it.
Adjustment ProcedureMark both tie-rod ends. This reference point willbe needed during adjustment.Loosen tie-rod end lock nuts; adjust both tie-rods.
Move rear portion of front wheels toward the in-side of the vehicle.Adjust both tie-rods until the specified toe-out isobtained. The important is to keep the length ofthe tie-rods the same.Tighten tie-rods and lock nuts of both tie-rod ends.Torque specification for lock nuts is 32-36 N•m(24-27 lbf•ft).Adjust tie-rod ends so that A and B are equal.NOTE: After setting toe-out to specification, runthe vehicle slowly for some distance with bothhands lightly holding handlebar and check thathandlebar responds correctly. If not, turn eitherleft or right tie-rod within toe-out specification.
WARNING
Ensure that both tie-rods are turned the sameamount of turns. If not, vehicle will drift rightor left even though handlebar is positionedstraight. This may lead to mishandling and/oraccident.
Page 12 of 18 2000-1
GENERAL INFORMATIONSComplete Predelivery Check List.Test run vehicle.Clean vehicle.To clean the entire vehicle, use only flannel clothesor Kimtowels® wipers no. 58-380 from Kimberly-Clark.CAUTION: It is necessary to use flannel clothsor Kimtowels wipers on vehicle to avoid dam-aging further surfaces to clean.To clean the entire vehicle, including metallic partswith a thick coat of grease, use Endust® by BristolMyers, available at hardware stores or supermar-kets.CAUTION: Do not apply isopropyl alcohol orsolvent directly on decals.To clean the entire vehicle, including metallic partswith a thin coat of grease, use Simple Green®
from Sunshine Makers Inc., available at hardwarestores or at automotive parts retailer.For vinyl and plastic parts, use Vinyl & Plastic Clean-er (P/N 413 711 200 (6 x 1 L)).CAUTION: Never clean plastic parts with strongdetergent, degreasing agent, paint thinner, ac-etone, products containing chlorine, etc.Give Operator’s Guide (P/N 704 000 005), SafetyHandbook (P/N 704 200 013) and Videocassette tocustomer. Ask the customer to sign the Predeliv-ery Check List.
