FOR APPROVAL ONLYFOR

No. 2000-1
REVISION 1
SUBJECT: Predelivery Inspection

Date: February 25, 2000

YEAR

MODEL

MODEL NUMBER

SERIAL NUMBER

2000

Traxter*

7415/7416/7417/7418
7405/7406/7407/7408

All

This bulletin must be used in conjunction with the check list enclosed in the bag with the Operators
Guide and the Safety Handbook. Make sure that predelivery check list is completed and signed.

WARNING
To obtain warranty coverage, predelivery procedures must be performed by an authorized Bombardier
ATV dealer. Apply all necessary torques as indicated.
NOTE: The information and components/system descriptions contained in this document are correct at
the time of publication. Bombardier 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 might be some differences between the manufactured product and the descriptions and/or specifications in this document. Bombardier reserves the right at any time to discontinue
or 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 not
reproduce the full detail or exact shape of the parts. However, they represent parts that have the same
or similar function.
The content of this bulletin is designed as a guideline only. All mechanics performing predelivery
procedures should have attended the current model-year service training. Further information or
inquiries should be directed to your distributor service representative and/or specific Shop Manual
sections. Please complete the Predelivery Check List for each vehicle and retain a customer-signed
copy. Make sure the customer receives the Operators Guide, Safety Handbook, Predelivery Check
List signed copy and video.

Printed in Canada (vbl2000-006a.fm MD)

*Trademarks of Bombardier Inc. and/or its subsidiaries.
2000 Bombardier Inc. All rights reserved.

2000-1

Page 1 of 18

UNCRATING
CAUTION: Do not tip cover toward front of vehicle. Remove straps and hooks retaining vehicle. The vehicle is retained in front by the
bumper and in rear by the frame extension.

WARNING
Torque wrench tightening specifications
must be strictly adhered to. Locking devices
(e.g. lock tabs, elastic nuts) must be installed
or replaced by new ones, where specified.
Fasteners with locking agent must be replaced by new ones. If the efficiency of a locking devices is impaired, it must be renewed.

WARNING
No one should be standing in front of or in
back of the vehicle while straps are being cut.

Carefully lay the crate on its bottom.

CAUTION: Allowing the crate to drop may cause
serious damage to the vehicle.
Remove all screws retaining cover to crate base.
Assisted by another person, lift crate cover over.

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 INSTALLATION
BATTERY
Battery Removal
Remove seat.
Remove the holding straps.
Remove battery from vehicle.
Place battery on a level surface (other than cement).

Activation of a New Battery

A new battery is factory fresh dry charged. For
storage purposes, it is fitted with a temporary sealing tube.
Do not remove the sealing tube or loosen battery
caps unless activation is desired.
In case of accidental premature removal of caps
or sealing tube, battery should be given a full
charge.
Perform the following operations:
1. Remove the sealing tube from the vent elbow.
Install vent tube (included in the battery kit) to
battery elbow.

A17E0FA

1. Battery electrolyte

2. Remove caps and fill battery to UPPER LEVEL

line with electrolyte (specific gravity: 1.260 at
20C (68F)).

WARNING
Failure to remove the sealing tube could result in an explosion.

Page 2 of 18

2000-1

WARNING
Electrolyte is poisonous and dangerous. Avoid
contact with eyes, skin and clothing. Wear
protective eyewear and a suitable pair of nonabsorbent gloves when handling the battery.

7. Disconnect battery charger as per following 1,

2 and 3 sequence.

3. Allow the battery to stand for 30 minutes MINIMUM so that electrolyte soaks through battery
cells.
4. Allow gas bubbles to escape by lightly shaking
battery by hand.

1
2

A17E0IB

8. Test battery state of charge. Use a hydrometer.

A17E0HA

5. Readjust the electrolyte level to the UPPER

LEVEL line.
6. Connect a 2 A battery charger for 10 to 20 hours
as per following 1, 2 and 3 sequence.

3
2

A17E0JA

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 spillage using a solution of baking soda and water.

A17E0IA

WARNING
Never charge battery while installed on vehicle.
CAUTION: If charging rate rises higher than 2.4
A reduce it immediately. If cell temperature rises higher than 50C (122F) (if the casing feels
hot) discontinue charging temporarily or reduce the charging rate.

WARNING
Gases given off by a battery being charged are
highly explosive. Always charge in a well ventilated area. Keep battery away from sparks or
open flames. Always turn battery charger off
prior to disconnecting cables. Otherwise a
spark will occur and battery might explode.

A17E0LA

1. Baking soda

CAUTION: Do not allow cleaning solution to enter battery interior since it will destroy the electrolyte.

2000-1

Page 3 of 18

Battery Installation
Place the battery in the engine compartment onto
the battery support.
Install the vent tube.
Secure RED positive cable to battery post.

WARNING
Connect RED positive cable first then negative cable. Always connect RED positive cable
first.

WARNING

V01G05A

Place the RED positive cable between holding straps and battery to avoid cable being
caught in shock absorber.

1. Cable between battery and strap

Apply dielectric grease (P/N 293 550 004) on battery posts.

Cover battery positive post with rubber boot.

LIQUIDS
LIQUID LEVEL

Engine Oil Level

With vehicle on a level surface and engine not running, check the engine oil with the dipstick. Refill
if necessary.
CAUTION: Do not overfill. Operating the engine/
transmission with an improper level may severely damage engine/transmission. Wipe off
any spillage.
SAE 10W40 is recommended for general use. Always use 4-stroke mineral-based engine oil that
meets or exceeds the requirements for API service classification SF, SG or SH.
Other viscosity should be used if the average temperature is outside the range of the recommended
oil. See the Operators Guide.
CAUTION: The same oil lubricates both engine
and transmission. Do not use synthetic or semisynthetic oil. They affect the clutching calibration.
CAUTION: For proper operation of the clutching system, do not use special oil additives. Do
not use unrecommended types of oil.

Page 4 of 18

V01C02A

LH SIDE OF ENGINE
1. Dipstick
2. Filler cap

Brake Fluid
With vehicle on a level surface, check brake fluid
in reservoirs for proper level. It should be to the
MAX. mark.
Add fluid as required. Do not overfill.
Clean filler cap before removing.

2000-1

CAUTION: Use only DOT 4 brake fluid from a

sealed container.

Coolant Level
Check the coolant level and refill if necessary with
a solution of 60% antifreeze and 40% water.

MIN

V01K04A

FRONT BRAKE FLUID RESERVOIR

V01L0LA

FRONT DIFFERENTIAL
Oil Level
Clean filler plug prior to checking oil level.
With vehicle on a level surface, check the oil level
by removing filler cap. Oil level must be 32 mm
(1-1/4 in) below filler plug.
Add oil if necessary (refer to specifications at the
end of this bulletin).

REAR AXLE
V01K03A

REAR BRAKE FLUID RESERVOIR

Oil Level
Lift back of vehicle and secure in place. Place the
swing arm to the horizontal position.
Clean filler plug prior to check oil level, check the
oil level by removing filler cap. Oil level must reach
the lower edge.
Add oil if necessary (refer to specifications at the
end of this bulletin).

2000-1

Page 5 of 18

TIRES AND WHEELS

Check pressure when tires are cold before using the vehicle. Tire pressure changes with temperature and altitude. Recheck pressure if one of
these conditions has changed.

For your convenience, a pressure gauge is supplied in tool box.

WARNING
Underpressure may cause tire to deflate and
rotate on wheel. Overpressure may burst the
tire. Always follow recommended pressure.
Since tires are low-pressure type, a manual
pump 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)

ADJUSTMENTS
IMPORTANT: All adjustments have already been performed at factory. It is only necessary to validate them. However, if readjustment is needed, the following procedures should be used.

BRAKE PEDAL

BRAKE CABLE

Place a shim between brake pedal lever and

switch nut. The tickness of the shim must be 2
mm (5/64 in).
Adjust push rod to eliminate free play between
brake pedal lever and master cylinder.
When a light pressure is felt, torque push rod nut
to 4.5 Nm(39 lbfin).
Remove the shim and press the brake pedal lever.
Check for a light play in the system.

WARNING
Adjust brake pedal prior to adjusting brake
cable. If brake pedal is not correctly adjusted,
the parking device will not function properly.
While holding rod with locking pliers, turn the adjustment nut until stopper comes in contact with
the brake pedal lever.
Unscrew adjustment nut approximately 1/4 turn to
make sure there is no tension on brake cable.
1

V01K0YA

1. Push rod jam nut

2. Brake pedal return spring

Page 6 of 18

V01K0ZA

1. Adjustment nut
2. Stopper
3. Maximum 1 mm (1/32 in) gap

2000-1

INTERLOCK CABLE

Rear Brake Light Switch

Adjust cable so that the pin end from interlock cable is flush with the shifter lever plate. Use the
interlock adjustment as per following photos.

Depress brake pedal and check for brake light to

turn on. The rear brake light switch cannot be adjusted.

SUSPENSION
Inspection
Inspect shock absorber for oil leaks and fasteners
for tightness.

WARNING

V01E04A

Left and right adjusting cams must always

be set at the same position. Never adjust one
adjusting cam only. Uneven adjustment can
cause poor handling and loss of stability,
which could lead to an accident.

1. Interlock pin end

2. Shifter lever plate

Spring Preload Adjustment

Adjust spring preload by turning adjusting cam
with the wrench in vehicle tool box.
Turn the adjusting cams clockwise for a firmer ride
and rought road condition or when carrying cargo
or pulling a trailer.
Turn the adjusting cams counterclockwise for a
light load and a smooth road condition.

Torque nut and jam nut.

2 3 1

V01K10A

1. Interlock adjustment
2. Jam nut
3. Nut

BRAKE LIGHT SWITCH

V01J0MA

Front Brake Light Switch

The front brake switch is located on the master
cylinder and cannot be adjusted. Check that switch
is securely installed and operational.

1. Adjusting cam
2. Smooth adjustment
3. Hard adjustment

2000-1

Page 7 of 18

CARBURETOR ADJUSTMENTS

All Models

Models 7415/7416/7417/7418

Pilot Screw Adjustment

2
V01F0HA

BOTTOM VIEW
1. Idle speed screw
2. Pilot screw
3. Drain plug and screw

Models 7405/7406/7407/7408
2

NOTE: Pilot screw is factory pre-set. Adjustment

is not necessary unless carburetor is overhauled
or replaced.
Warm-up engine to operating temperature.
NOTE: Engine must run for a minimum of 20 minutes at idle speed to reach normal operating temperature.
Set idle speed to specification, using idle speed
screw.
Connect RPM gauge. If you are using Bombardier
tool (P/N 529 014 500), turn RPM gauge wire, 4 to
5 turns around spark plug cable. Note that there is
a spark at each crankshaft turn.
Turn pilot screw clockwise till engine RPM speed
decreases and then counterclockwise till engine
RPM speed decreases then set screw position exactly 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 too
high engine idle speed and a difficulty to shift
the sub-transmission caused by centrifugal
clutch engagement.
Refer to TECHNICAL DATA for the specifications.

V01F0YA

BOTTOM VIEW
1. Idle speed screw
2. Pilot screw
3. Drain plug and screw

Page 8 of 18

2000-1

Models 7415/7416/7417/7418

Enrichner
Remove 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.

V01F0JS

FULLY CLOSED POSITION

1. Plunger end must be here

1
A

V01F0KT

HALFWAY POSITION
1. Plunger end must be here
A. Opening to specification

V01F0LS

FULLY OPENED POSITION

1. Plunger end must be here

2000-1

Page 9 of 18

Plunger Adjustment

Throttle

WARNING

To adjust plunger use cable adjuster, as shown in

the next photo.

Ensure the key is turned OFF, prior to performing the throttle cable adjustment.
Before adjusting the throttle cable, adjust idle
speed (preliminary adjustment) and enrichner.
On the carburetor, loosen the lock nut and adjust
the throttle cable.
Make sure the throttle lever, at the full position,
doesnt press against carburetor body.

V01F0MA

USE CABLE ADJUSTER TO ADJUST PLUNGER

1. Enrichner plunger

NOTE: For proper adjustment at halfway position,

use a drill bit with a diameter of the opening specification (refer to TECHNICAL DATA).
Models 7405/7406/7407/7408
On these models, the enrichner is not adjustable
because it is fully variable.
All Models
Diaphragm Installation
Carefully replace diaphragm in its original position.
NOTE: On models 7415/7416/7417/7418, check
and place the indexation lob correctly.
Make sure spring is located properly in carburetor
cover before screwing.

Page 10 of 18

V01F0RA

TYPICAL THROTTLE LEVER AT THE FULL POSITION

A. 1 mm (1/32 in) gap

Retorque lock nut.

2000-1

TOE-OUT

Adjustment Procedure

Place the vehicle on the level surface.

Check that handlebar is horizontal.
Use a long rule and check if the rear and front
wheels are aligned.
Adjust alignment with the tie-rod.
Adjust toe-out to 17 mm 4 mm (43/64 in
5/32 in).

Mark both tie-rod ends. This reference point will

be needed during adjustment.
Loosen tie-rod end lock nuts; adjust both tie-rods.

WARNING
Ensure that both tie-rods are turned the same
amount of turns. If not, vehicle will drift right
or left even though handlebar is positioned
straight. This may lead to mishandling and/or
accident.

Measuring Procedure
NOTE: Before measuring toe-out, ensure tire
pressure is correct.
Place vehicle on a level surface.
Raise front end of vehicle and release slowly.
Move rear portion of front wheels toward the inside 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

Move rear portion of front wheels toward the inside of the vehicle.
Adjust both tie-rods until the specified toe-out is
obtained. The important is to keep the length of
the tie-rods the same.
Tighten tie-rods and lock nuts of both tie-rod ends.
Torque specification for lock nuts is 32-36 Nm
(24-27 lbfft).
Adjust tie-rod ends so that A and B are equal.
NOTE: After setting toe-out to specification, run
the vehicle slowly for some distance with both
hands lightly holding handlebar and check that
handlebar responds correctly. If not, turn either
left or right tie-rod within toe-out specification.

FRONT
A
V01I19A

Toe-out should be 17 mm 4 mm (43/64 in

5/32 in).
If toe-out is incorrect, adjust it.

2000-1

Page 11 of 18

GENERAL INFORMATIONS
Complete Predelivery Check List.
Test run vehicle.
Clean vehicle.
To clean the entire vehicle, use only flannel clothes
or Kimtowels wipers no. 58-380 from KimberlyClark.
CAUTION: It is necessary to use flannel cloths
or Kimtowels wipers on vehicle to avoid damaging further surfaces to clean.
To clean the entire vehicle, including metallic parts
with a thick coat of grease, use Endust by Bristol
Myers, available at hardware stores or supermarkets.
CAUTION: Do not apply isopropyl alcohol or
solvent directly on decals.
To clean the entire vehicle, including metallic parts
with a thin coat of grease, use Simple Green
from Sunshine Makers Inc., available at hardware
stores or at automotive parts retailer.
For vinyl and plastic parts, use Vinyl & Plastic Cleaner (P/N 413 711 200 (6 x 1 L)).
CAUTION: Never clean plastic parts with strong
detergent, degreasing agent, paint thinner, acetone, products containing chlorine, etc.
Give Operators Guide (P/N 704 000 005), Safety
Handbook (P/N 704 200 013) and Videocassette to
customer. Ask the customer to sign the Predelivery Check List.

Page 12 of 18

2000-1

TECHNICAL DATA
ENGINE

TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)

Engine type

BOMBARDIER-ROTAX 511, longitudinal mount, liquid cooled

Lubrication type

Wet sump with replaceable oil filter

Oil filter

BOMBARDIER-ROTAX

Air filter type

Exhaust type

Cleanable synthetic panelette

Type

Nelson, stainless steel

Spark arrester

USDA approved

Starting system

Electric and manual

Number of cylinders

Number of valves

2 valves with hydraulic lifters (no adjustment)

Decompressor type
Bore

Automatic
Standard

89 mm (3.5 in)

Stroke

80 mm (3.15 in)
498 cm3 (30.4 in3)

Displacement

9:1 on models 7415/7416/7417/7418,

9.75:1 on models 7405/7406/7407/7408

Compression ratio
Maximum HP RPM

100 RPM

ELECTRICAL

6000
TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)

Magneto/generator

40 W @ 6000 RPM

Ignition system type

I.D.I. (Inductive Discharge Ignition)

Spark plug

Make and type

NGK DR8 EA

Gap

0.65 mm (.026 in)

190 to 300

Trigger coil

0.4 0.1

Battery charging coil

Ignition coil

0.4 to 0.9 @ 20C

Primary
Secondary

Not measurable

Engine RPM limiter

7500
Type

Battery

Electrolyte battery type

Voltage

12 volts

Nominal rating

19 (21 optional) Ah

Power starter output

Fuse

0.6 kW

Ignition

15 A

Accessories

15 A

Solenoids

15 A

Fan

15 A

MPEM

20 A

Charging system

30 A

2000-1

Page 13 of 18

CARBURETION

TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Mikuni Constant depressure type with manual choke and ECS
(Enricher Coating System)

Type
Carburetor

BST34-232 on models 7415/7416/7417/7418,

BSR 33-12 on models 7405/7406/7407/7408

Model
Fuel pump

Type

Mikuni

Model

Idle engine speed

External (vacuum-operated)
100 RPM

1100

Needle jet

0-7M (850) on models 7415/7416/7417/7418,

0-8 (826) on models 7405/7406/7407/7408

Jet needle

5 GBF61-2 on models 7415/7416/7417/7418,

5 FEY1-3 on models 7405/7406/7407/7408

Clip position number

Enrichner plunger position

Middle
Opening halfway

2.5 0.5 mm (0.098 0.039 in) on models 7415/7416/7417/7418,

variable on models 7405/7406/7407/7408

Throttle cable

0.5 mm (0.02 in)

2.25 turns on models 7415/7416/7417/7418,
2 turns on models 7405/7406/7407/7408

Preliminary pilot screw turn

Adjustment

0.5 mm

10.6 on models 7415/7416/7417/7418,

10 on models 7405/7406/7407/7408

0.020 in

0.417 on models 7415/7416/7417/7418,

0.39 on models 7405/7406/7407/7408

Float level

Fuel

Type

Regular unleaded gasoline

Octane no.

87 (Ron + Mon)/2

COOLING

TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)

Fan
Fan thermostat
Engine thermostat

Thermostatic
Opening temperature

96C (205F)

Closing temperature

102C (221F)

Opening temperature

85C (185F)

Closing temperature

75C (167F)

Cap opening pressure

90 kPa (13 PSi)

DRIVE TRAIN

TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Type

Transmission type

Normal oil operating

pressure of engine

Dual range (HI-LO) with park, neutral and reverse

Speeds

Model

Electronically controlled hydraulic shift

Minimum

101 kPa (14.7 PSi)

Maximum

608 kPa (88 PSi)

Operating pressure for shifting and clutching

810 kPa (118 PSi)

Clutch type
Engagement RPM

1 centrifugal and 1 multi-disc hydraulically controlled

100

Front differential

1600
Shaft driven/single Auto-lock differential (pump driven)

Front differential ratio

3.6:1

Rear axle

Shaft driven/solid axle

Rear axle ratio

3.6:1

STEERING/CONTROL

TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)

Turning radius

3.3 m (11 ft)

Total toe-out (vehicle on ground)

17 mm 4 mm (43/64 in 5/32 in)

Camber angle
Tie rod maximum length unengaged

Page 14 of 18

0
5

20 mm

0.197

0.787 in

2000-1

SUSPENSION

TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)

Front
Suspension type

Independent suspension double A arm

Suspension travel

178 mm (7 in)

Shock absorber

Qty

Type

Oil

Spring free length

270 mm (11 in)

Spring color code

Silver-Blue-Black

Front preload adjustment type

N.A.

Rear
Suspension type

Rigid swing arm

Suspension travel

191 mm (7.5 in)

Shock absorber

Qty

Type

Oil

Spring free length

355 mm (14 in)

Spring color code

Green-White-Black

Rear preload adjustment type

3 Positions

BRAKE

TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)

Front brake
Rear brake

Qty

Type

Brembo hydraulic

Qty

Type

Parking device

Brembo hydraulic
Transmission brake and brake lever lock on LH brake lever

Lining material

Metallic

Minimum pad thickness

1 mm (0.04 in)

Minimum brake disc thighness

4.7 mm (0.18 in)

Maximum brake disc warpage

0.25 mm (0.01 in)

Caliper

Fixed
TRAXTER (7405/ 7406/7407/7408/7415/ 7416/7417/7418)

TIRES AND WHEELS

Tires
Front
Pressure
Rear

Recommended

38 kPa (5.5 PSi)

Minimum

35 kPa (5 PSi)

Recommended

35 kPa (5 PSi)
31 kPa (4.5 PSi)

Minimum

Minimum tire thread depth

Size

4 mm (0.16 in)

Front

635 x 203 x 305 mm (25 x 8 x 12 in)

Rear

635 x 254 x 305 mm (25 x 10 x 12 in)

Front

305 x 165 mm (12 x 6.5 in)

Rear

305 x 203 mm (12 x 8 in)

Wheels
Size

2000-1

Page 15 of 18

DIMENSION

TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)

Overall length

2071 mm (81.5 in)

Overall width

1194 mm (47 in)

Overall height

1143 mm (45 in)

Dry weight

340 kg (755 lb)

Wheel base

1296 mm (51 in)

Wheel track

Front

992 mm (39 in)

Rear

940 mm (37 in)

Front and under engine ground clearance

244 mm (9.6 in)

Rear differential ground clearance

188 mm (7.4 in)

CAPACITIES

TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)

Liquid
Fuel tank

20 L (5.7 U.S. gal)

Fuel tank reserve

6 L (1.6 U.S. gal)

Capacity

Engine/transmission oil

3 L (0.8 U.S. gal)

Recommended
Front

Differential oil
Rear

SAE 10W40, 4 stroke mineral based oil SH or SJ

Capacity

650 mL (22 U.S. oz.)

Recommended

Synthetic polyolester oil 75W90 (API GL5)

Capacity

300 mL (10 U.S. oz.)

Recommended

Synthetic polyolester oil 75W90 (API GL5)

CV joint grease

TEXACO, HTBJ grease (M3014), ONLY

Propeller shaft grease

SHELL, Alvania EP-2 ONLY

Capacity

Hydraulic brakes

250 mL (8.5 U.S. oz)

Recommended

Brake fluid DOT 4 ONLY

Cooling system

2.5 L (0.7 U.S. gal)

Ethylene-glycol concentration

60%

Body and Frame

Weight distribution

Front/rear

49/51

Front storage tray

Rack

10 kg (22 lb)
Front

40 kg (90 lb)

Rear (including tongue weight)

80 kg (175 lb)

Total vehicle load allowed

220 kg (485 lb)

Gross vehicle weight rating

540 kg (1200 lb)

Towing

500 kg (1100 lb)

Tongue

14 kg (30 lb)

Page 16 of 18

2000-1

MATERIALS

TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)
Material

Color

Frame

Steel

Black

Front/rear rack

Steel

Black

Front bumper
Front/rear fender

Steel

Silver

High density polyethylene

Green/Red

Fuel tank cover

High density polyethylene

Black

Steering cover

High density polyethylene

Black

Storage compartment cover

High density polyethylene

Black

Front/rear facia

High density polyethylene

Black

Side panel

High density polyethylene

Black

Mudguard

Low density polyethylene

Black

Seat cover

Thermoformed vinyl

Black

TIGHTENING TORQUES

TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)

WARNING

ENGINE

Apply all necessary torques as indicated. Specified torques must be adhered to.
Engine support

24 Nm (17 lbfft)

Engine mount

48 Nm (35 lbfft)

Spark plug

22 Nm (16 lbfft)

Rewind starter

5 Nm (44 lbfin)

Rear solenoid block

5 Nm (44 lbfin)

Magneto

10 Nm (89 lbfin)

Starter

10 Nm (89 lbfin)

Starter RED (+) cable

6 Nm (53 lbfin)

STPS (Sub-Transmission Position Sensor)

3 Nm (27 lbfin)

GBPS (Gear Box Position Sensor)

3 Nm (27 lbfin)

DRIVE TRAIN

FUEL EXHAUST

COOLING

Radiator mount screw/nut

10 Nm (89 lbfin)
Engine unit 17 Nm (150 lbfin)
Radiator unit 11 Nm (97 lbfin)

Temperature sensor

10 Nm (89 lbfin

Water pump
Fan mounting screws

4 Nm (35 lbfin)

Exhaust nut

11Nm (97 lbfin)

Heat shield screws

10 Nm (89 lbfin)

Carburetor mounting clamp

0.6 Nm (5.4 lbfin)

Front wheel hub nut

140 Nm (103 lbfft) (MINIMUM)

Front

48 Nm (35 lbfft)

Rear

48 Nm (35 lbfft)

Front differential
Rear differential socket screws
Propeller shaft screw

48 Nm (35 lbfft)
Engine side

34 Nm (25 lbfft)

Differential
side

42 Nm (31 lbfft)

2000-1

Page 17 of 18

TIGHTENING TORQUES

TRAXTER (7405/7406/7407/7408/7415/7416/7417/7418)

WARNING

BRAKE

SUSPENSION

STEERING/
CONTROL

WHEEL

Apply all necessary torques as indicated. Specified torques must be adhered to.

Wheel nuts
Upper/lower arm lock nut

75 Nm (55 lbfft)

Tie rod ends

75 Nm (55 lbfft)

Steering arm (castel nut)

75 Nm (55 lbfft)

Steering column support screws

24 Nm (17 lbfft)

Handlebar screws

24 Nm (17 lbfft)

Flanged bearing bolts

19 Nm (14 lbfft)

Shock absorber bolt

48 Nm (35 lbfft)

Front upper A-arm

67 Nm (49 lbfft)

Front lower A-arm

67 Nm (49 lbfft)

Rear swing arm RH pivot

147 Nm (108 lbfft)

Rear swing arm LH pivot

11 Nm (97 lbfin)

Rear swing arm LH nut

147 Nm (108 lbfft)

Rear swing arm hexagonal screws

48 Nm (35 lbfft)

Caliper brake screws

24 Nm (17 lbfft)

Brake disc screws

34 Nm (25 lbfft)

Front bumper

24 Nm (17 lbfft)

Front rack
Rear rack
BODY/FRAME

73 Nm (54 lbfft)

Front

15 Nm (133 lbfin)

Rear

15 Nm (133 lbfin)

Upper

15 Nm (133 lbfin)

Lower

15 Nm (133 lbfin)

Rear frame extension

48 Nm (35 lbfft)

Front differential support

24 Nm (17 lbfft)

Seat pivot bar

24 Nm (17 lbfft)

Winch plate support

24 Nm (17 lbfft)

Footrest

24 Nm (17 lbfft)

Removable brace

24 Nm (17 lbfft)

Skid plate

15 Nm (133 lbfin)

Headlight adjustment

Page 18 of 18

0.6 Nm (5.4 lbfin)

2000-1