BOMBARDIER TRAXTER AUTOSHIFT 2002 - User Manual

This document is a Shop Manual for the 2002 Bombardier Traxter ATV, covering the Autoshift, XL, and XT models. It is identified by part number 704 100 013. The manual provides comprehensive information for servicing and maintaining these vehicles.

Function Description:

The manual serves as a technical guide for mechanics and owners to perform maintenance, troubleshooting, and repair procedures on the specified 2002 Bombardier Traxter ATV models. It details various systems and components of the vehicle, offering step-by-step instructions and illustrations to facilitate proper service. The content is structured to cover all major aspects of the ATV, from basic maintenance to complex engine and electrical system repairs.

Important Technical Specifications:

The manual covers the following 2002 Bombardier Traxter models:

• TRAXTER® AUTOSHIFT (Red): 7453
• TRAXTER® AUTOSHIFT (Green): 7454
• TRAXTER® AUTOSHIFT (Yellow): 7475
• TRAXTER® XL (Green): 7458
• TRAXTER® XT (Green): 7446
• TRAXTER® XT (Yellow): 7452
• TRAXTER® AUTOSHIFT INTL (Red): 7495
• TRAXTER® AUTOSHIFT INTL (Green): 7496
• TRAXTER® AUTOSHIFT INTL (Yellow): 7497
• TRAXTER® XL INTL (Green): 7577
• TRAXTER® XT INTL (Green): 7493
• TRAXTER® XT INTL (Yellow): 7494

The manual includes a "TECHNICAL DATA" section (Section 11) which provides SI metric information and detailed specifications for the engine and vehicle. It also features a "LIST OF ABBREVIATIONS USED IN THIS MANUAL" to clarify technical terms and units of measurement, such as N•m for Newton-meter, lbf•in for pound-force inch, and lbf•ft for pound-force foot, along with common abbreviations like BDC (bottom dead center), TDC (top dead center), and RPM (revolutions per minute).

A critical aspect of the technical specifications is the inclusion of tightening torques for various fasteners. The manual provides a table for standard bolt and nut sizes (M4, M5, M6, M8, M10, M12, M14) with corresponding torque values in N•m, lbf•in, and lbf•ft. These values are specified for 8.8 grade bolts and nuts. For instance:

• M4: 2 N•m (18 lbf•in)
• M5: 4 N•m (35 lbf•in)
• M6: 10 N•m (89 lbf•in)
• M8: 23 N•m (17 lbf•ft)
• M10: 48 N•m (35 lbf•ft)
• M12: 80 N•m (59 lbf•ft)
• M14: 135 N•m (100 lbf•ft)

The manual emphasizes the use of metric fasteners and warns against replacing them with customary fasteners to prevent damage or injury.

Usage Features:

The manual is organized into 12 major sections, each covering a specific system or aspect of the ATV:

1. SERVICE TOOLS AND SERVICE PRODUCTS
2. MAINTENANCE
3. ENGINE
4. FUEL SYSTEM
5. ELECTRICAL
6. DRIVE TRAIN
7. STEERING/CONTROL SYSTEMS
8. SUSPENSION
9. BRAKES
10. BODY/FRAME
11. TECHNICAL DATA
12. WIRING DIAGRAMS

Each section is further divided into subsections and divisions, making it easy to navigate and locate specific information. The manual includes "TYPICAL PAGE" examples to explain its layout, showing how procedures, exploded views, call-outs, and cross-references are presented. This structure helps users understand how to interpret the information effectively.

Safety is a key feature, with a dedicated "SAFETY NOTICE" section outlining important warnings and precautions. The manual uses specific terminology and symbols to highlight potential hazards (WARNING, CAUTION, NOTE). For example, a "WARNING" indicates an instruction that, if not followed, could cause serious personal injury or death.

The manual also provides detailed procedures for using self-locking fasteners and applying Loctite products, including instructions for cleaning threads, applying primer, and selecting the correct strength of threadlocker. This ensures proper assembly and prevents loosening of components.

Maintenance Features:

The "MAINTENANCE" section (Section 02) includes a maintenance chart and detailed procedures for lubrication, storage, and pre-season preparation. The "WHAT'S NEW" section highlights updates and new procedures for the 2002 models, such as:

• Updated service tools and products lines.
• New maintenance chart and procedures for flipped over and ATV immersion.
• Complete new sections for troubleshooting and leak tests.
• Updated removal and installation procedures.
• Procedure to test the temperature sender in the cooling system.
• Completely reviewed magneto system section.
• Procedure to remove the oil pump in the lubrication system.
• Crankshaft locking bolt installation and camshaft removal procedure for the crankshaft/balancer shaft.
• New THROTTLE CABLE section for the carburetor and fuel pump.
• New spark plug symbol chart for the ignition system.
• Shifting valve cleaning procedure for the electric shift system.
• Procedure for hourmeter removal, test, and installation on XL models.
• Shimming procedures for inner differentials in front drive and rear axle.
• Toe-out adjustment procedure for steering/controls system.
• New brakes for all models.
• Technical data updates for all models.
• New wiring diagrams for all models.

The manual emphasizes the importance of following specific tightening torque procedures to ensure proper assembly and prevent damage. It recommends manually screwing in all fasteners, then applying half the recommended torque, and finally torquing to the full value in a criss-cross sequence.

The "Bombardier SERVICE PUBLICATIONS REPORT" forms included at the end of the manual allow users to provide feedback, report errors, or suggest improvements, indicating a commitment to continuous improvement of the documentation.