2006-2015 Can-Am DS 250 OEM Service & Repair Manual

2006 -2015 Shop Manual DS 250

TABLE OF CONTENTS SAFETY NOTICE ................................................................................... VII INTRODUCTION .................................................................................. VIII GENERAL INFORMATION........................................................................................ VIII VEHICLE SERIAL NUMBER LOCATION ........................................................................ VIII ENGINE SERIAL NUMBER LOCATION ......................................................................... VIII ARRANGEMENT OF THE MANUAL, ILLUSTRATIONS AND PROCEDURES ............................ VIII SELF-LOCKING FASTENERS PROCEDURE .................................................................... XII LOCTITE ® APPLICATION PROCEDURE ......................................................................... XII TIGHTENING TORQUES ......................................................................................... XVI 01 MAINTENANCE 01 – MAINTENANCE CHART ....................................................................................... 1 NOISE EMISSION CONTROL SYSTEM REGULATION ............................................................ 1 MAINTENANCE CHART .............................................................................................. 2 02 – PRESEASON PREPARATION ................................................................................. 5 03 – STORAGE PROCEDURES ..................................................................................... 7 FUEL SYSTEM......................................................................................................... 7 ENGINE ................................................................................................................ 7 ELECTRICAL SYSTEM ................................................................................................ 7 COOLING SYSTEM ................................................................................................... 7 CVT TRANSMISSION ................................................................................................. 8 VEHICLE ............................................................................................................... 8 04 – SPECIAL PROCEDURES..................................................................................... 11 ATV IMMERSION .................................................................................................... 11 02 TROUBLESHOOTING 01 – TROUBLESHOOTING CHART .............................................................................. 13 COOLING SYSTEM .......................................................................................... 13 ELECTRICAL SYSTEM....................................................................................... 13 LUBRICATION SYSTEM..................................................................................... 14 CYLINDER HEAD ............................................................................................. 15 CRANKSHAFT ................................................................................................ 16 GEARBOX ..................................................................................................... 16 CVT ............................................................................................................. 17 ENGINE GENERAL ........................................................................................... 19 STARTING SYSTEM ......................................................................................... 21 03 ENGINE 01 – ENGINE REMOVAL AND INSTALLATION ................................................................ 23 GENERAL ............................................................................................................. 23 REMOVAL ............................................................................................................ 23 INSPECTION.......................................................................................................... 27 INSTALLATION ....................................................................................................... 27 02 – ENGINE LEAK TEST ......................................................................................... 29 GENERAL ............................................................................................................. 29 PROCEDURES........................................................................................................ 29 03 – AIR INTAKE SYSTEM ........................................................................................ 33 GENERAL ...................................................................................................... 34 PROCEDURES ................................................................................................ 34 AIR FILTER ............................................................................................................ 34 AIR FILTER HOUSING ............................................................................................... 34 AIR INJECTION VALVE FILTER ...................................................................................... 35 04 – EXHAUST SYSTEM.......................................................................................... 37 GENERAL ...................................................................................................... 38 PROCEDURES ................................................................................................ 38 I

TABLE OF CONTENTS MUFFLER ............................................................................................................. 38 EXHAUST PIPE ....................................................................................................... 38 SPARK ARRESTER ................................................................................................... 39 05 – LUBRICATION SYSTEM..................................................................................... 41 GENERAL ............................................................................................................. 43 ENGINE OIL .......................................................................................................... 43 ENGINE OIL PRESSURE............................................................................................. 45 ENGINE OIL PRESSURE RELIEF VALVE ........................................................................... 45 OIL PUMP ............................................................................................................ 45 06 – COOLING SYSTEM .......................................................................................... 49 GENERAL ...................................................................................................... 52 COOLING SYSTEM INSPECTION ......................................................................... 52 LEAK INDICATOR HOLE............................................................................................. 52 COOLING SYSTEM LEAK TEST..................................................................................... 52 PROCEDURES ................................................................................................ 53 ENGINE COOLANT .................................................................................................. 53 RADIATOR CAP ...................................................................................................... 54 THERMOSTAT ........................................................................................................ 54 THERMO-SWITCH ................................................................................................... 55 WATER PUMP ........................................................................................................ 55 COOLING FAN MOTOR ............................................................................................. 58 RADIATOR ............................................................................................................ 59 07 – MAGNETO AND STARTER DRIVE......................................................................... 61 GENERAL ...................................................................................................... 62 PROCEDURES ................................................................................................ 62 MAGNETO COVER................................................................................................... 62 TRIGGER COIL ....................................................................................................... 64 STATOR ............................................................................................................... 64 CRANKSHAFT END BEARING ...................................................................................... 64 FLYWHEEL ........................................................................................................... 65 STARTER REDUCTION GEAR ....................................................................................... 66 STARTING CLUTCH GEAR .......................................................................................... 67 08 – CYLINDER HEAD ............................................................................................. 69 GENERAL ............................................................................................................. 70 VALVE CLEARANCE ADJUSTMENT ................................................................................ 70 CYLINDER HEAD REMOVAL........................................................................................ 71 CYLINDER HEAD DISASSEMBLY .................................................................................. 74 CLEANING ............................................................................................................ 75 PARTS INSPECTION ................................................................................................. 75 CYLINDER HEAD ASSEMBLY ...................................................................................... 79 CYLINDER HEAD INSTALLATION .................................................................................. 80 09 – PISTON AND CYLINDER .................................................................................... 83 GENERAL ............................................................................................................. 84 DISASSEMBLY ....................................................................................................... 84 INSPECTION.......................................................................................................... 85 ASSEMBLY ........................................................................................................... 88 10 – CRANKSHAFT AND CRANKCASE......................................................................... 91 GENERAL ............................................................................................................. 92 CRANKCASE DISASSEMBLY ....................................................................................... 92 INSPECTION.......................................................................................................... 94 CRANKCASE ASSEMBLY ........................................................................................... 96 11 – GEARBOX ..................................................................................................... 99 GENERAL ........................................................................................................... 101 GEARBOX OIL LEVEL ............................................................................................. 101 GEARBOX OIL CHANGE .......................................................................................... 101 GEARBOX SWITCH ................................................................................................ 102 II

TABLE OF CONTENTS OIL SEAL REPLACEMENT ........................................................................................ 102 GEARBOX DISASSEMBLY ........................................................................................ 103 GEARBOX INSPECTION ........................................................................................... 106 GEARBOX ASSEMBLY ............................................................................................ 107 04 FUEL SYSTEM 01 – CARBURETOR AND FUEL TANK ......................................................................... 111 GENERAL ..................................................................................................... 114 PROCEDURES ............................................................................................... 114 CARBURETOR...................................................................................................... 114 FUEL FILTER........................................................................................................ 117 FUEL VALVE ........................................................................................................ 117 FUEL TANK ......................................................................................................... 118 THROTTLE CABLE ................................................................................................. 119 CHOKE CABLE ..................................................................................................... 120 05 ELECTRICAL SYSTEM 01 – CHARGING SYSTEM ....................................................................................... 123 GENERAL ..................................................................................................... 123 PROCEDURES ............................................................................................... 123 VOLTAGE REGULATOR/ RECTIFIER.............................................................................. 123 STATOR ............................................................................................................. 124 BATTERY ............................................................................................................ 125 02 – IGNITION SYSTEM ......................................................................................... 129 GENERAL ..................................................................................................... 129 TROUBLESHOOTING....................................................................................... 130 REPAIR PROCEDURES ..................................................................................... 130 FUSES............................................................................................................... 131 SPARK PLUG ....................................................................................................... 131 BATTERY ............................................................................................................ 132 IGNITION SWITCH ................................................................................................. 132 ENGINE STOP SWITCH ........................................................................................... 134 TRIGGER COIL ..................................................................................................... 134 IGNITION COIL ..................................................................................................... 136 IGNITION MODULE................................................................................................ 137 SHIFT GEAR CONTROL MODULE ............................................................................... 139 OVERRIDE SWITCH ............................................................................................... 140 ADJUSTMENT ............................................................................................... 141 IGNITION TIMING .................................................................................................. 141 03 – STARTING SYSTEM ........................................................................................ 143 GENERAL ..................................................................................................... 143 TESTING PROCEDURES ................................................................................... 144 FUSES............................................................................................................... 144 BATTERY ............................................................................................................ 144 IGNITION SWITCH ................................................................................................. 144 ENGINE STOP SWITCH ........................................................................................... 144 START SWITCH .................................................................................................... 144 STARTING SOLENOID ............................................................................................. 145 ELECTRICAL CABLES OR CONNECTIONS ...................................................................... 146 ELECTRIC STARTER ............................................................................................... 146 SHIFT GEAR CONTROL MODULE ............................................................................... 146 PART REPLACEMENT ...................................................................................... 146 ELECTRIC STARTER ............................................................................................... 146 04 – LIGHTS AND ACCESSORIES .............................................................................. 149 GENERAL ..................................................................................................... 149 PROCEDURES ............................................................................................... 150 III

TABLE OF CONTENTS FUSES............................................................................................................... 150 HEADLAMP......................................................................................................... 150 TURN SIGNAL LIGHTS ............................................................................................ 155 POSITION LIGHT ................................................................................................... 160 PILOT LAMPS ...................................................................................................... 161 TAILLIGHT .......................................................................................................... 165 HORN ............................................................................................................... 165 12-VOLT POWER OUTLET ........................................................................................ 166 06 TRANSMISSION 01 – CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ................................................. 169 GENERAL ..................................................................................................... 171 PROCEDURES ............................................................................................... 171 DRIVE BELT......................................................................................................... 171 CVT COVER......................................................................................................... 171 CVT COVER BEARING ............................................................................................. 172 DRIVE PULLEY ..................................................................................................... 172 DRIVEN PULLEY ................................................................................................... 176 07 STEERING AND FRONT SUSPENSION 01 – STEERING AND FRONT SUSPENSION ................................................................. 179 GENERAL ..................................................................................................... 181 PROCEDURES ............................................................................................... 181 HANDLEBAR GRIP ................................................................................................. 181 MULTIFUNCTION SWITCH........................................................................................ 181 AUXILIARY MULTIFUNCTION SWITCH .......................................................................... 182 THROTTLE LEVER ................................................................................................. 183 MASTER CYLINDER ............................................................................................... 184 HANDLEBAR ....................................................................................................... 184 TIE-ROD............................................................................................................. 185 STEERING COLUMN .............................................................................................. 186 STEERING COLUMN BEARING................................................................................... 187 FRONT WHEEL HUB .............................................................................................. 188 WHEEL BEARING .................................................................................................. 188 KNUCKLE ........................................................................................................... 189 SHOCK ABSORBER AND SPRING ............................................................................... 189 LOWER A-ARM .................................................................................................... 190 UPPER A-ARM ..................................................................................................... 192 ADJUSTMENT ............................................................................................... 193 STEERING ALIGNMENT ........................................................................................... 193 08 REAR SUSPENSION AND AXLE 01 – REAR SUSPENSION AND AXLE .......................................................................... 195 GENERAL ..................................................................................................... 197 PROCEDURES ............................................................................................... 197 REAR SHOCK....................................................................................................... 197 DRIVE CHAIN....................................................................................................... 198 ENGINE SPROCKET ............................................................................................... 200 AXLE SPROCKET................................................................................................... 200 WHEEL HUB........................................................................................................ 201 BRAKE DISC HUB.................................................................................................. 201 REAR AXLE ......................................................................................................... 202 SPROCKET HUB ................................................................................................... 203 CHAIN TENSIONER ................................................................................................ 203 SWING ARM........................................................................................................ 205 IV

TABLE OF CONTENTS 09 BRAKING SYSTEM 01 – FRONT AND REAR BRAKES............................................................................... 209 ALL MODELS EXCEPT EUROPEAN MODELS .......................................................... 210 GENERAL ..................................................................................................... 212 MAINTENANCE ............................................................................................. 212 BRAKE FLUID ...................................................................................................... 212 PROCEDURES ............................................................................................... 215 CALIPERS........................................................................................................... 215 BRAKE PADS ....................................................................................................... 216 MASTER CYLINDERS OF BRAKE LEVERS ...................................................................... 217 REAR BRAKE PEDAL .............................................................................................. 218 MASTER CYLINDER OF REAR BRAKE PEDAL .................................................................. 219 PRESSURE CONTROL VALVE..................................................................................... 220 BRAKE DISCS ...................................................................................................... 220 BRAKE HOSES ..................................................................................................... 221 BRAKE LIGHT SWITCHES......................................................................................... 221 EUROPEAN MODELS ...................................................................................... 223 GENERAL ..................................................................................................... 225 MAINTENANCE ............................................................................................. 225 BRAKE FLUID ...................................................................................................... 225 PROCEDURES ............................................................................................... 226 PARKING BRAKE (CABLE AND LEVER) .......................................................................... 226 CALIPERS........................................................................................................... 227 BRAKE PADS ....................................................................................................... 228 MASTER-CYLINDERS OF BRAKE LEVERS ...................................................................... 230 REAR BRAKE PEDAL .............................................................................................. 231 MASTER CYLINDER OF REAR BRAKE PEDAL .................................................................. 232 FRONT BRAKE PRESSURE CONTROL VALVE .................................................................. 232 REAR BRAKE PRESSURE CONTROL VALVE .................................................................... 233 BRAKE DISCS ...................................................................................................... 233 BRAKE HOSES ..................................................................................................... 234 BRAKE LIGHT SWITCHES......................................................................................... 234 10 BODY/FRAME 01 – BODY .......................................................................................................... 237 PARTS REPLACEMENT..................................................................................... 239 DECAL .............................................................................................................. 239 SEAT................................................................................................................. 239 SEAT LATCH ........................................................................................................ 239 FUEL TANK COVER ................................................................................................ 240 FRONT COVER ..................................................................................................... 240 RADIATOR SHIELD ................................................................................................ 241 FRONT FENDER.................................................................................................... 242 REAR FENDER ..................................................................................................... 244 FOOTREST.......................................................................................................... 245 CLEANING.................................................................................................... 246 SEAT................................................................................................................. 246 PLASTIC............................................................................................................. 246 REPAIR ........................................................................................................ 246 PLASTIC REPAIR ................................................................................................... 246 02 – FRAME ........................................................................................................ 247 GENERAL ..................................................................................................... 249 PROCEDURES ............................................................................................... 249 FRONT BUMPER................................................................................................... 249 FOOTPEG ........................................................................................................... 249 FOOTREST SUPPORT ............................................................................................. 250 V

TABLE OF CONTENTS REAR FRAME EXTENSION........................................................................................ 250 FRONT FENDER SUPPORT ....................................................................................... 251 REAR FENDER SUPPORT ......................................................................................... 251 11 TECHNICAL SPECIFICATIONS 01 – DS 250 ........................................................................................................ 253 12 WIRING DIAGRAMS 01 – WIRING DIAGRAMS ........................................................................................ 261 WIRE COLORS ..................................................................................................... 261 CONNECTORS ..................................................................................................... 261 VI

SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair the 2006 DS 250™ ATVs as describe in the model list in the INTRODUCTION. This edition was primarily published to be used by mechanical technicians who are already familiar with all service procedures relating to BRP products. Mechanical technicians should attend training courses given by BRP Training Dept. Please note that the instructions will apply only if proper hand tools and special service tools are used. This Vehicle Shop Manual uses technical terms which may be slightly different from the ones used in the PARTS CATALOG. It is understood that this manual may be translated into another language. In the event of any discrepan- cy, the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser- vice 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 BRP, 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 BRP parts is most strongly recommended when considering replacement of any component. 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 for which it was designed.  WARNING Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair procedures. This manual emphasizes particular information denoted by the wording and symbols:  WARNING Identifies an instruction which, if not followed, could cause serious personal injury including pos- sibility of death. CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle 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. This information relates to the preparation and use of Bombardier † ATV and has been utilized safely and effectively by BRP. However, BRP 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. vmr2006-060 VII

2006-2015 Can-Am DS 250 OEM Service & Repair Manual

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