2002 Bombardier DS90 2-Stroke ATV Service & Repair Manual

2002 Shop Manual DS50 DS90 DS90 (4-STROKE)

SECTION SUBSECTION PAGE TABLE OF CONTENTS .......................................................................................................... I SAFETY NOTICE .................................................................................................................... III 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 ENGINE 01 – Table of contents .................................................................... 03-01-1 02 – Removal and installation ....................................................... 03-02-1 03 – Generator, starter motor ........................................................ 03-03-1 04 – Cylinder and head .................................................................. 03-04-1 05 – Crankcase/crankshaft ............................................................. 03-05-1 06 – Lubrication system ................................................................. 03-06-1 07 – Transmission/kick start .......................................................... 03-07-1 08 – Clutch....................................................................................... 03-08-1 09 – Exhaust system....................................................................... 03-09-1 04 FUEL SYSTEM 01 – Table of contents .................................................................... 04-01-1 02 – Fuel circuit ............................................................................... 04-02-1 03 – Carburetor and air cleaner ..................................................... 04-03-1 05 ELECTRICAL 01 – Table of contents .................................................................... 05-01-1 02 – Charging system..................................................................... 05-02-1 03 – Starting system....................................................................... 05-03-1 04 – Ignition system ....................................................................... 05-04-1 06 DRIVE TRAIN 01 – Table of contents .................................................................... 06-01-1 02 – Chain drive system................................................................. 06-02-1 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 – Brakes ...................................................................................... 09-02-1 10 TECHNICAL DATA 01 – SI metric information guide................................................... 10-01-1 02 – Engine and vehicle ................................................................. 10-02-1 11 WIRING DIAGRAMS 01 – Wiring diagrams ..................................................................... 11-01-1 TABLE OF CONTENTS

VMR2002_105_00_02AB.FM III SAFETY NOTICE 0 This manual has been prepared as a guide to correctly service and repair 2002 ATVs. This edition was primarily published to be used by ATV mechanical technicians who are already familiar with all service procedures relating to Bombardier made vehicles. Mechanical 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 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, could severely damage vehicle compo- nents. 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 Bombardier Inc. However, Bombardier Inc. 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

INTRODUCTION VMR2002_105_00_02AC.FM V INTRODUCTION 0 This Shop Manual covers the following Bombardier made 2002 ATV: Models VEHICLE IDENTIFICATION NUMBER LOCATION 1. V.I.N. ENGINE IDENTIFICATION NUMBER LOCATION 2-stroke engine On 2-stroke engines, the engine identification number is located on the top side of engine. 4-stroke engine On 4-stroke engines, the engine identification number is located on the clutch cover near trans- mission shifter. ARRANGEMENT OF THE MANUAL The manual is divided into 11 major sections: 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 TECHNICAL DATA 11 WIRING DIAGRAMS Each section is divided in various subsections, and again, each subsection has one or more division. DS50 TM ..................................................... 7557 DS90 TM ..................................................... 7558 DS90 4-stroke .......................................... 7559  

VI VMR2002_105_00_02AC.FM LIST OF ABBREVIATIONS USED IN THIS MANUAL 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 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 k kilo (thousand) kg kilogram km/h kilometer per hour kPa kilo pascal L liter LH left hand lb pound lbf pound (force) 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 0.L overload (open circuit) O.D. outside diameter OHC Over head camshaft OPT optional oz ounce P/N part number PSI pound per square inch PTO power take off RH Right hand RPM revolution per minute TDC top dead center U.S. oz ounce (United States) USFD U.S. Forest Service V volt Vac volt (alternative current) INTRODUCTION

VMR2002_105_00_02AC.FM VII 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, it may have some differences between the manufactured product and the de- scription and/or specifications in this document. Bombardier Inc. reserves the right at any time to discontinue 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 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 proce- dure 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). 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 act during 30 minutes and wipe off. The solvent utilization is to ensure 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. INTRODUCTION

VIII VMR2002_105_00_02AC.FM 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 sec- onds. 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        INTRODUCTION

VMR2002_105_00_02AC.FM IX Preassembled Parts 1. Apply here 2. Do not apply 1. Clean bolts and nuts with solvent. 2. Assemble components. 3. Tighten nuts. 4. Apply drops of proper strength Loctite on bolt/nut contact surfaces. 5. Avoid touching metal with tip of flask. NOTE: For preventive maintenance on existing equipment, retighten nuts and apply proper strength Loctite on bolt/nut contact surfaces. 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. A00A3OA 1 2    A00A3UA 1 2 3 INTRODUCTION

X VMR2002_105_00_02AC.FM 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. TIGHTENING TORQUES Tighten fasteners to torque mentioned in explod- ed views and text. When they are not specified refer to following table.The table also gives 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. NOTE: When possible, always apply the torque on nut. 3. Torque at the recommended torque value. NOTE: Always torque screws, bolts and/or nuts in a criss-cross sequence. * TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS A00A3VA 1  WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, 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. BOLT OR NUT SIZE TIGHTENING TORQUE* N•m lbf•in M4 2 18 M5 4 35 M6 10 89 BOLT OR NUT SIZE TIGHTENING TORQUE* N•m lbf•ft M8 23 17 M10 48 35 M12 80 59 M14 135 100 INTRODUCTION