2004 Bombardier DS650 DS 650 Baja Service & Repair Manual

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

IV VMR2004_001_00_02A.FM INTRODUCTION 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      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 A ampere 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 L liter lb pound lbf pound (force) LH left hand m meter MAG magneto Max. maximum Min. minimum mL milliliter mm millimeter MPH mile per hour N newton 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) V volt Vac volt (alternative current) INTRODUCTION

VI VMR2004_001_00_02A.FM                                                                                            INTRODUCTION

VMR2004_001_00_02A.FM VII                                                                                                                                                 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 obligation to install them on products previously manufactured. Due to late changes, there may be some differences between the manufactured product and the description 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 system. 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 procedure. 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 required tools, or approved equivalents. The use of RIGHT and LEFT indications in the text, always refers to driving position (sitting on the vehicle). 1. Left 2. Right SELF-LOCKING FASTENERS PROCEDURE The following describes the most common application 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 application procedures when working with Loctite products. NOTE: Always use proper strength Loctite product as recommended in this Shop Manual.    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 uncovered threads. 8. Tighten nuts as required. A00A3LA 1 2        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 threadlocker 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.    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 N•m (13 to 18 lbf•in) 2.5 to 3 N•m (22 to 27 lbf•in) 3.5 to 4 N•m (31 to 35 lbf•in) 4 to 5 N•m (35 to 44 lbf•in) M5 3 to 3.5 N•m (27 to 31 lbf•in) 4.5 to 5.5 N•m (40 to 47 lbf•in) 7 to 8.5 N•m (62 to 75 lbf•in) 8 to 10 N•m (71 to 89 lbf•in) M6 6.5 to 8.5 N•m (58 to 75 lbf•in) 8 to 12 N•m (71 to 106 lbf•in) 10.5 to 15 N•m (93 to 133 lbf•in) 16 N•m (12 lbf•ft) M8 15 N•m (11 lbf•ft) 24.5 N•m (18 lbf•ft) 31.5 N•m (23 lbf•ft) 40 N•m (30 lbf•ft) M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 72.5 N•m (53 lbf•ft) M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 127.5 N•m (94 lbf•ft) M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft) INTRODUCTION

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2004 Bombardier DS650 DS 650 Baja Service & Repair Manual

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