2001 Bombardier DS650 Service & Repair Manual

Shop Manual 2001 DS 650

VMR2001_001_00_02A.FM I SECTION SUBSECTION PAGE SAFETY NOTICE ................................................................................................................................... III WHAT’S NEW ....................................................................................................................................... IV INTRODUCTION .................................................................................................................................. V 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/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/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 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 – Final drive ................................................................................. 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 VMR2001_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

VMR2001_001_00_02A.FM III SAFETY NOTICE 0 This manual has been prepared as a guide to correctly service and repair 2001 ATV. 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 intent to 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. 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. This manual emphasizes particular information denoted by the wording and symbols: 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. 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 Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death. SAFETY NOTICE

IV VMR2001_001_00_02A.FM WHAT’S NEW 0 THIS SECTION INDICATES PROCEDURES THAT WERE MODIFIED OR NEWLY ADDED IN THIS MANUAL. INTRODUCTION • Self-locking fasteners procedure. • Loctite application procedure. SERVICE TOOLS AND PRODUCTS Added the following new tools: • ball joint guide • ball joint driver. Added the following new products: • premix coolant • Molykote 111 paste • Molykote G-n paste • sealing compound Dreibond. MAINTENANCE • New clutch adjustment procedure. • Drive chain adjustment procedure is now in the MAINTENANCE section. COOLING SYSTEM • New refilling procedure. CRANKSHAFT/BALANCER SHAFT • New procedure to recentre crankshaft and balancer shaft. REAR SUSPENSION • Rear suspension adjustment is added in the section. TECHNICAL DATA • New starter jet. • New torque for rear shock bolts. WHAT’S NEW

VMR2001_001_00_02A.FM V INTRODUCTION 0 This Shop Manual covers the following Bombar- dier made 2001 ATV: Model 1. Model number VEHICLE AND ENGINE SERIAL NUMBER LOCATION 1. Vehicle 2. Engine DS* 650 ..................................................... 7449 *Trademark of Bombardier Inc.      INTRODUCTION

VI VMR2001_001_00_02A.FM Serial Number Meaning                                                         INTRODUCTION

VMR2001_001_00_02A.FM VII 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

VIII VMR2001_001_00_02A.FM                                                                                            INTRODUCTION

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2001 Bombardier DS650 Service & Repair Manual

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