2000 Bombardier DS650 Service & Repair Manual

Shop Manual 2000 DS 650

VMR2000_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 and lubrication .................................................... 02-03-1 04 – Storage and pre-season preparation......................................... 02-04-1 03 ENGINE 01 – Table of contents...................................................................... 03-01-1 02 – Removal and installation........................................................... 03-02-1 03 – Cooling system......................................................................... 03-03-1 04 – Magneto system ...................................................................... 03-04-1 05 – Cylinder and head ..................................................................... 03-05-1 06 – Crankshaft and balancer shaft .................................................. 03-06-1 07 – Lubrication system ................................................................... 03-07-1 08 – Clutch ....................................................................................... 03-08-1 09 – Transmission ............................................................................ 03-09-1 04 FUEL SYSTEM 01 – Table of contents...................................................................... 04-01-1 02 – Fuel circuit ................................................................................ 04-02-1 03 – Carburetor and fuel pump ........................................................ 04-03-1 04 – Air intake silencer ..................................................................... 04-04-1 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 – Drive chain................................................................................ 06-02-1 03 – Rear axle................................................................................... 06-03-1 07 STEERING/CONTROL SYSTEMS 01 – Table of contents...................................................................... 07-01-1 02 – Steering/control systems ......................................................... 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 10 BODY/FRAME 01 – Table of contents...................................................................... 10-01-1 02 – Body ......................................................................................... 10-02-1 03 – Frame ....................................................................................... 10-03-1 TABLE OF CONTENTS

II VMR2000_001_00_02A.FM 11 TECHNICAL DATA 01 – SI metric information guide...................................................... 11-01-1 02 – Engine and vehicle ................................................................... 11-02-1 12 WIRING DIAGRAM 01 – Wiring diagram......................................................................... 12-01-1 SECTION SUBSECTION PAGE TABLE OF CONTENTS

IV VMR2000_001_00_02A.FM INTRODUCTION This Shop Manual covers the following Bombar- dier made 2000 ATV: Model 1. Model number VEHICLE AND ENGINE SERIAL NUMBER LOCATION 1. Vehicle 2. Engine DS* 650......................................................7404 *Trademark of Bombardier Inc. 1 V02A0PA 1 2 V02A0QA INTRODUCTION

VMR2000_001_00_02A.FM V Serial Number Meaning 10 11 12 13 14 15 16 17 9 8 7 6 5 4 3 2 1 SECTION 1 SECTION 2 SECTION 3 SECTION 4 3 2 1 SECTION 1 Class Make Manufacturer 8 7 6 5 4 SECTION 2 Factory use Engine type II Engine type I Product line Type of drive 9 SECTION 3 Check digit 10 11 12 13 14 15 16 17 SECTION 4 Number sequentially assigned by the manufacturer in the production process Plant of manufacture Model year V01A0PS INTRODUCTION

VI VMR2000_001_00_02A.FM 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 division. 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/CONTROL SYSTEMS 08 SUSPENSION 09 BRAKES 10 BODY/FRAME 11 TECHNICAL DATA 12 WIRING DIAGRAM A ampere amp ampere A•h 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) lbf/in² pound per square inch LH left hand m meter MAG magneto Max. maximum Min. minimum mL milliliter mm millimeter MPEM multi-purpose electronic module MPH mile per hour N newton N.A. not applicable no. number 00.0 continuity 0.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

VMR2000_001_00_02A.FM VII 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 specifications. Some of these are in lbfft instead of lbf in. Use appropriate torque wrench. Document number for publishing process. INTRODUCTION

VIII VMR2000_001_00_02A.FM 2 V02C18A 5 4 1 3 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 10-02)  engine pinion no. 2 (refer to Engine Pinion section) 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 04-03)  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 vehicle runs correctly 2 V02C18A 5 4 1 3 V02C19A 1 V02C05A Call-out 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. V02A0US INTRODUCTION

VMR2000_001_00_02A.FM IX GENERAL INFORMATION The information and component/system descrip- tions contained in this manual are correct at 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, it may have some differences between the manufactured product and the descrip- tion and/or specifications in this document. Bombardier reserves the right at any time to dis- continue or change specifications, designs, fea- tures, 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 which have the same or a similar function. CAUTION: Most components of those 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 per- sonal 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 in which the procedure is contained. A number of procedures throughout the book re- quire the use of special tools. Before commencing any procedure, be sure that you have on hand all the tools required, or approved equivalents. The use of RIGHT and LEFT indications in the text, always refers to driving position (when sitting on vehicle). 1. Left 2. Right V02L02A 2 1 INTRODUCTION

2000 Bombardier DS650 Service & Repair Manual

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