BOMBARDIER DS 650 Shop Manual

Category
Motorcycles
Type
Shop Manual

This manual is also suitable for

Shop Manual
2004
DS 650
TM
DS 650
TM
BAJA
DS 650
TM
BAJA X
Legal deposit:
National Library of Quebec
2
nd
trimester 2003
National Library of Canada 2003
All rights reserved. No parts of this manual may be reproduced in any
form without the prior written permission of Bombardier Inc.
©
Bombardier Inc. 2003
Technical Publications
Bombardier Inc.
Valcourt (Québec) Canada
Printed in Canada
®
Registered trademarks of Bombardier Inc. and its subsidiaries.
This document contains the trademarks of the following companies:
Kimtowels
®
is a trademark of Kimberly-Clark
Loctite
®
is a trademark of Loctite Corporation
Molykote
®
is a trademark of Dow Corning Corporation
Snap-on
®
is a trademark of Snap-on Tools Corporation
VMR2004_001_00_02A.FM I
SECTION SUBSECTION PAGE
SAFETY NOTICE ................................................................................................................................... III
INTRODUCTION .................................................................................................................................. IV
01 SERVICE TOOLS AND
SERVICE PRODUCTS
01 – Table of contents...................................................................... 01-01-1
02 – Service tools............................................................................. 01-02-1
03 – Service products....................................................................... 01-03-1
02 MAINTENANCE 01 – Table of contents...................................................................... 02-01-1
02 – Maintenance chart.................................................................... 02-02-1
03 – Maintenance/lubrication ........................................................... 02-03-1
04 – Storage/preseason preparation ................................................ 02-04-1
03 ENGINE 01 – Table of contents...................................................................... 03-01-1
02 – Troubleshooting........................................................................ 03-02-1
03 – Leak test................................................................................... 03-03-1
04 – Removal and installation........................................................... 03-04-1
05 – Cooling system......................................................................... 03-05-1
06 – Magneto system ...................................................................... 03-06-1
07 – Lubrication system................................................................... 03-07-1
08 – Cylinder and head..................................................................... 03-08-1
09 – Crankshaft/balancer shaft......................................................... 03-09-1
10 – Clutch ....................................................................................... 03-10-1
11 – Transmission ............................................................................ 03-11-1
04 FUEL SYSTEM 01 – Table of contents...................................................................... 04-01-1
02 – Fuel circuit................................................................................ 04-02-1
03 – Carburetor and air intake silencer............................................. 04-03-1
05 ELECTRICAL 01 – Table of contents...................................................................... 05-01-1
02 – Overview.................................................................................. 05-02-1
03 – Charging system ...................................................................... 05-03-1
04 – Starting system ........................................................................ 05-04-1
05 – Ignition system......................................................................... 05-05-1
06 – Accessories .............................................................................. 05-06-1
06 DRIVE TRAIN 01 – Table of contents...................................................................... 06-01-1
02 – Front drive ................................................................................ 06-02-1
03 – Rear axle .................................................................................. 06-03-1
07 STEERING SYSTEM 01 – Table of contents...................................................................... 07-01-1
02 – Steering system ....................................................................... 07-02-1
08 SUSPENSION 01 – Table of contents...................................................................... 08-01-1
02 – Front suspension...................................................................... 08-02-1
03 – Rear suspension....................................................................... 08-03-1
09 BRAKES 01 – Table of contents...................................................................... 09-01-1
02 – Hydraulic brakes....................................................................... 09-02-1
TABLE OF CONTENTS
II VMR2004_001_00_02A.FM
10 BODY/FRAME 01 Table of contents ..................................................................... 10-01-1
02 Body......................................................................................... 10-02-1
03 Frame....................................................................................... 10-03-1
11 TECHNICAL DATA 01 SI metric information guide...................................................... 11-01-1
02 Engine and vehicle................................................................... 11-02-1
12 WIRING DIAGRAMS 01 Wiring diagrams....................................................................... 12-01-1
SECTION SUBSECTION PAGE
TABLE OF CONTENTS
VMR2004_001_00_02A.FM III
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair 2004 ATVs.
This edition was primarily published to be used by ATV mechanic technicians who are already familiar
with all service procedures relating to Bombardier made vehicles. Mechanic technicians should attend
continuous training courses given by Bombardier Training Department.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This Shop Manual uses technical terms which may be slightly different from the ones used in Parts
Catalog.
It is understood that this manual may be translated into another language. In the event of any discrepancy,
the english version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at its time of writing.
Service and Warranty Bulletins may be published to update the content of this manual. Make sure to read
and understand these. It does not include dealer modifications, whether authorized or not by Bombardier,
after manufacturing the product.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those mentioned in this document.
This manual emphasizes particular information denoted by the wording and symbols:
CAUTION: Denotes an instruction which, if not followed, may damage the ATV and/or components.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
However, Bombardier disclaims liability for all damages and/or injuries resulting from the improper use
of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled
professional mechanic. It is understood that certain modifications may render use of the vehicle illegal
under existing federal, provincial and state regulations.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in serious injury
or death.
WARNING
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking
tab, elastic stop nut, self-locking fasteners, etc.) must be installed or replaced with new ones,
where specified. If the efficiency of a locking device is impaired, it must be renewed.
SAFETY NOTICE
IV VMR2004_001_00_02A.FM
INTRODUCTION 0
This Shop Manual covers the following Bombardier
made 2004 ATVs:
2004 Models
TYPICAL
1. Model number
VEHICLE AND ENGINE SERIAL
NUMBER LOCATION
TYPICAL
1. Vehicle
2. Engine
DS 650
TM
.....................................................7717
DS 650
TM
Baja..............................................7718
DS 650
TM
Baja X ..........................................7995
DS 650
TM
Intl ...............................................7719
DS 650
TM
Baja Intl .......................................7720
DS 650
TM
Baja X Intl....................................7997
1
V02A0PA
1
2
V02A0QA
INTRODUCTION
VMR2004_001_00_02A.FM V
ARRANGEMENT OF THE
MANUAL
The manual is divided into 12 major sections:
Each section is divided in various subsections, and
again, each subsection has one or more divisions.
LIST OF ABBREVIATIONS USED
IN THIS MANUAL
01 SERVICE TOOLS AND SERVICE PRODUCTS
02 MAINTENANCE
03 ENGINE
04 FUEL SYSTEM
05 ELECTRICAL
06 DRIVE TRAIN
07 STEERING SYSTEM
08 SUSPENSION
09 BRAKES
10 BODY/FRAME
11 TECHNICAL DATA
12 WIRING DIAGRAMS
Aampere
amp ampere
Ah ampere-hour
AC alternate current
BDC bottom dead center
BTDC before top dead center
°C degree Celsius
cm centimeter
cm² square centimeter
cm³ cubic centimeter
DC direct current
°F degree Fahrenheit
fl. oz fluid ounce
ft foot
GRD ground
hal. halogen
I.D. inside diameter
IDI induction discharge ignition
imp. oz imperial ounce
in inch
in² square inch
in³ cubic inch
k kilo (thousand)
kg kilogram
km/h kilometer per hour
kPa kilo pascal
Lliter
lb pound
lbf pound (force)
LH left hand
m meter
MAG magneto
Max. maximum
Min. minimum
mL milliliter
mm millimeter
MPH mile per hour
Nnewton
N.A. not applicable
no. number
00.0 continuity
O.L. overload (open circuit)
O.D. outside diameter
OPT optional
oz ounce
P/N part number
PSI pound per square inch
PTO power take off
RPM revolution per minute
Sp. Gr. specific gravity
TDC top dead center
U.S. oz ounce (United States)
Vvolt
Vac volt (alternative current)
INTRODUCTION
VI VMR2004_001_00_02A.FM
Section 03 ENGINE
Subsection 05 (CYLINDER AND HEAD)
VMR2000_007_03-05A.FM 03-05-1
CYLINDER AND HEAD
CYLINDER AND HEAD
9
12
4
8
21
22
23
27
V02C0ES
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
33 Nm
(24 lbfft)
10 Nm
(89 lbfin)
Loctite 243
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
60 Nm
(44 lbfft)
Engine oil
Page heading
indicates section
and subsection
detailed.
Bold face number
indicates special
procedure
concerning this
part.
Tightening torque
nearby fastener. In this
case, nut must be
torqued to
10 Nm or 89 lbfin.
This Shop Manual uses technical terms wich may be
slightly different from the ones in the parts catalog.
Exploded view
assists you in
identifying parts and
related positions.
TYPICAL PAGE
V02A0TS
Illustration
number for
publishing
process.
Subsection title
indicates
beginning of the
subsection.
Drop represents a
liquid product to
be applied to
a surface.
Page numbering system:
03: ENGINE section
05: CYLINDER AND HEAD
subsection
1: First page of this subsection
CAUTION: Pay attention to
torque specifi
cations. Some
of these are in
lbf
ft
instead
of lbf
in
. Use appropriate
torque wrench.
Document
number for
publishing
process.
INTRODUCTION
VMR2004_001_00_02A.FM VII
TYPICAL PAGE
Subtitle indicates
main procedure
to be carried-out.
Reference to look
up a certain section
and subsection.
In this case it
concerns
carburetor and air
intake silencer.
Bold face number
following part name
refers to exploded
view at beginning of
subsection.
Call-outs for
above illustration.
V02A0UT
2
V02C18A
5 413
V02C19A
1
V02C05A
Call-out
Section 03 ENGINE
Subsection 02 (REMOVAL AND INSTALLATION)
VMR2000_004_03_02.FM
03-02-3
footrest (refer to BODY)
engine pinion
no. 2
(refer to
Engine Pinion
sec-
tion)
RH SIDE OF ENGINE
1. Exhaust pipes
2. Radiator inlet hose
3. Oil line
4. Brake pedal
5. Footrest
carburetor and carburetor adaptor (refer to CAR-
BURETOR AND AIR INTAKE SILENCER)
gearshift pedal
no. 9
.
Unscrew neutral switch connector.
Removal
Remove the upper support bracket
no. 10
com-
pletely.
Install engine lifting tool (P/N 529 035 610) then,
install a hoist.
Remove:
upper engine support bolt
no. 11
lower bolts
no. 12
retaining the engine support
no. 13
on either side, then, remove supports
front lower mounting bolt
no. 14
rear lower mounting bolt
no. 15
rear upper mounting bolt
no. 16
.
Remove engine from vehicle.
Installation
For installation, reverse the removal procedure,
paying attention to the following details.
Reattach cables, hoses, wiring harness, etc.
Adjust clutch cable.
Bleed rear brake.
Before to start the engine, remove oil filter.
Unfasten pressure bleeding screw.
BEHIND OIL FILTER
1. Bleeding screw
Unscrew and remove one spark plug.
Turn engine using starter until oil emerges in filter
chamber.
Tighten pressure bleeding screw.
Install oil filter.
This operation activated the oil pump. Check if ve-
hicle runs correctly.
2
V02C18A
5 413
V02C19A
1
V02C05A
Call-out
INTRODUCTION
VIII VMR2004_001_00_02A.FM
GENERAL INFORMATION
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. Bombardier Inc. however, main-
tains a policy of continuous improvement of its
products without imposing upon itself any obliga-
tion to install them on products previously manu-
factured.
Due to late changes, there may be some differences
between the manufactured product and the descrip-
tion and/or specifications in this document.
Bombardier Inc. reserves the right at any time to dis-
continue or change specifications, designs, features,
models or equipment without incurring obligation.
ILLUSTRATIONS AND
PROCEDURES
Illustrations and photos show the typical construc-
tion of the different assemblies and, in all cases,
may not reproduce the full detail or exact shape of
the parts shown, however, they represent parts
that have the same or a similar function.
CAUTION: Most components in the vehicles are
built with parts dimensioned in the metric sys-
tem. Most fasteners are metric and must not be
replaced by customary fasteners or vice- versa.
Mismatched or incorrect fasteners could cause
damage to the vehicle or possible personal injury.
As many of the procedures in this manual are in-
terrelated, we suggest, that before undertaking
any task, you read and thoroughly understand the
entire section or subsection concerning the proce-
dure.
A number of procedures throughout the book re-
quire the use of special tools. Before starting any
procedure, be sure that you have on hand all re-
quired tools, or approved equivalents.
The use of RIGHT and LEFT indications in the text,
always refers to driving position (sitting on the ve-
hicle).
1. Left
2. Right
SELF-LOCKING FASTENERS
PROCEDURE
The following describes the most common appli-
cation procedures when working with self-locking
fasteners.
Use a metal brush or a screwtap to clean the hole
properly then use a solvent (Methyl-Chloride), let
it sit during 30 minutes and wipe off. The solvent
ensures the adhesive works properly.
LOCTITE APPLICATION
PROCEDURE
The following describes the most common appli-
cation procedures when working with Loctite
products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.
V02L02A
21
INTRODUCTION
VMR2004_001_00_02A.FM IX
Threadlocker
Uncovered Holes (bolts and nuts)
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.
2. Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
3. Choose proper strength Loctite threadlocker.
4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.
Blind Holes
1. On threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.
2. Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
4. Apply several drops along the threaded hole and
at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
Stud in Blind Holes
1. On threads
2. On threads and in the hole
3. Onto nut threads
1. Clean threads (stud and hole) with solvent.
2. Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
3. Put several drops of proper strength Loctite
threadlocker on female threads and in hole.
4. Apply several drops of proper strength Loctite
on stud threads.
5. Install stud.
6. Install cover, etc.
7. Apply drops of proper strength Loctite on un-
covered threads.
8. Tighten nuts as required.
A00A3LA
1
2
A00A3MA
1
2
A00A5RA
2
1
3
INTRODUCTION
X VMR2004_001_00_02A.FM
Adjusting Screw
1. Apply here
2. Plunger
1. Adjust screw to proper setting.
2. Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232°C (450°F)).
Mounting on Shaft
Mounting with a Press
1. Bearing
2. Proper strength Loctite
3. Shaft
Standard
1. Clean shaft external part and element internal
part.
2. Apply a strip of proper strength Loctite on shaft
circumference at insert or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
3. DO NOT use anti-seize Loctite or any similar
product.
4. No curing period is required.
Mounting in Tandem
1. Apply retaining compound on internal element
bore.
2. Continue to assemble as shown above.
Case-In Components
Metallic Gaskets
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket
diameter.
2. Spray housing and gasket with Loctite Primer N
(P/N 293 800 041).
3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.
4. Install according to standard procedure.
5. Wipe off surplus.
6. Allow it to cure for 30 minutes.
NOTE: Normally used on worn-out housings to
prevent leaking or sliding.
It is generally not necessary to remove gasket
compound applied on outer gasket diameter.
A00A3PA
1
2
A00A3UA
1
2
3
A00A3VA
1
INTRODUCTION
VMR2004_001_00_02A.FM XI
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in exploded views and text. When they are not specified refer to
following tables. The tables also give the metric conversion.
In order to avoid a poor assembling, tighten screws and bolts in accordance with the following procedure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply the half of the recommended torque value.
CAUTION: Be sure to use the proper tightening torque for the proper strength grade.
NOTE: When possible, always apply torque on the nut.
3. Torque at the recommended torque value.
NOTE: Always torque screws, bolts and/or nuts in a criss-cross sequence.
WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices (ex.: locking tab, elastic stop nut, self-locking fasteners, etc.) must be installed or
replaced with new ones where specified. If the efficiency of a locking device is impaired, it must
be renewed.
TIGHTENING
TORQUE
STRENGTH GRADE
GRADE 5.8 GRADE 8.8 GRADE 10.9 GRADE 12.9
DIMENSION
M4
1.5 to 2 Nm
(13 to 18 lbfin)
2.5 to 3 Nm
(22 to 27 lbfin)
3.5 to 4 Nm
(31 to 35 lbfin)
4 to 5 Nm
(35 to 44 lbfin)
M5
3 to 3.5 Nm
(27 to 31 lbfin)
4.5 to 5.5 Nm
(40 to 47 lbfin)
7 to 8.5 Nm
(62 to 75 lbfin)
8 to 10 Nm
(71 to 89 lbfin)
M6
6.5 to 8.5 Nm
(58 to 75 lbfin)
8 to 12 Nm
(71 to 106 lbfin)
10.5 to 15 Nm
(93 to 133 lbfin)
16 Nm (12 lbfft)
M8 15 Nm (11 lbfft) 24.5 Nm (18 lbfft) 31.5 Nm (23 lbfft) 40 Nm (30 lbfft)
M10 29 Nm (21 lbfft) 48 Nm (35 lbfft) 61 Nm (45 lbfft) 72.5 Nm (53 lbfft)
M12 52 Nm (38 lbfft) 85 Nm (63 lbfft) 105 Nm (77 lbfft) 127.5 Nm (94 lbfft)
M14 85 Nm (63 lbfft) 135 Nm (100 lbfft) 170 Nm (125 lbfft) 200 Nm (148 lbfft)
INTRODUCTION
We would be pleased if you could
communicate to Bombardier any sug-
gestions you may have concerning
our publications.
Bombardier SERVICE PUBLICATIONS REPORT
Publication title and year ________________________ Page______
Machine___________________ Report of error
Suggestion
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________
City and State/Prov. ________________________ Date___________
Zip code/Postal code ________________________________________
Bombardier SERVICE PUBLICATIONS REPORT
Publication title and year ________________________ Page______
Machine___________________ Report of error
Suggestion
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________
City and State/Prov. ________________________ Date___________
Zip code/Postal code ________________________________________
Bombardier SERVICE PUBLICATIONS REPORT
Publication title and year ________________________ Page______
Machine___________________ Report of error
Suggestion
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________
City and State/Prov. ________________________ Date___________
Zip code/Postal code ________________________________________
AFFIX
PROPER
POSTAGE
AFFIX
PROPER
POSTAGE
AFFIX
PROPER
POSTAGE
Technical Publications
After Sales Service
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After Sales Service
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Technical Publications
After Sales Service
565 de la Montagne Street
Valcourt, Québec, Canada J0E 2L0
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 01 (TABLE OF CONTENTS)
VMR2004_033_01_01ATOC.FM 01-01-1
TABLE OF CONTENTS 0
SERVICE TOOLS.................................................................................................................... 01-02-1
SERVICE PRODUCTS ............................................................................................................ 01-03-1
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
VMR2004_002_01_02A.FM 01-02-1
SERVICE TOOLS 0
This is a list of tools to properly service ATV vehicles. If you need to replace or add to your tool inventory,
these items can be ordered through the regular parts channel.
Following mention points out new tool:
NEW
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
01-02-2 VMR2004_002_01_02A.FM
All Models
MANDATORY
Small Hose Pincher
295 000 076
Large Hose Pincher
529 032 500
Fuel System Pressure Tester
529 033 100
All Models
RECOMMENDED
Low Speed Screw Adjuster
529 035 732
Float Level Gauge
529 035 520
Carburetor Kit
404 112 000
1234
All Models
RECOMMENDED
Valve Spring Compressor
529 035 724
Insertion Jig Handle
420 877 650
Vacuum/Pressure Pump
529 021 800
Leak Down Tester
529 035 661
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
VMR2004_002_01_02A.FM 01-02-3
All Models
RECOMMENDED
Multimeter
529 035 868
Oil Pressure Adapter
529 035 652
Oil Pressure Gauge
529 035 709
Connection Tool
529 035 714
All Models
RECOMMENDED
Terminal Remover
Snap-On TT660-4
Shock Tool
529 035 636
Handle Grip Insertion Tool
529 035 897
Crimp Plier
529 035 730
NEW
NEW
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BOMBARDIER DS 650 Shop Manual

Category
Motorcycles
Type
Shop Manual
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