BOMBARDIER DS 650 Shop Manual
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BOMBARDIER DS 650 Shop Manual

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  • Page 2 Shop Manual 2004 DS 650 DS 650 BAJA DS 650 BAJA X...
  • Page 3 National Library of Quebec trimester 2003 National Library of Canada 2003 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 2003 Technical Publications Bombardier Inc.
  • Page 4 TABLE OF CONTENTS SECTION SUBSECTION PAGE SAFETY NOTICE ........................... INTRODUCTION ..........................SERVICE TOOLS AND 01 – Table of contents..............01-01-1 02 – Service tools................01-02-1 SERVICE PRODUCTS 03 – Service products............... 01-03-1 MAINTENANCE 01 – Table of contents..............02-01-1 02 – Maintenance chart..............02-02-1 03 –...
  • Page 5 TABLE OF CONTENTS SECTION SUBSECTION PAGE BODY/FRAME 01 – Table of contents ..............10-01-1 02 – Body..................10-02-1 03 – Frame..................10-03-1 TECHNICAL DATA 01 – SI metric information guide............11-01-1 02 – Engine and vehicle ..............11-02-1 WIRING DIAGRAMS 01 –...
  • Page 6 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.
  • Page 7 INTRODUCTION INTRODUCTION VEHICLE AND ENGINE SERIAL This Shop Manual covers the following Bombardier made 2004 ATVs: NUMBER LOCATION 2004 Models DS 650 ............. 7717 DS 650 Baja..........7718 DS 650 Baja X .......... 7995 DS 650 Intl ..........7719 DS 650 Baja Intl ........
  • Page 8 INTRODUCTION ARRANGEMENT OF THE inch MANUAL in² square inch The manual is divided into 12 major sections: in³ cubic inch kilo (thousand) 01 SERVICE TOOLS AND SERVICE PRODUCTS 02 MAINTENANCE kilogram 03 ENGINE km/h kilometer per hour 04 FUEL SYSTEM kilo pascal 05 ELECTRICAL liter...
  • Page 9 INTRODUCTION This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. Page heading indicates section and subsection detailed. Section 03 ENGINE CYLINDER AND HEAD Subsection title indicates beginning of the CYLINDER AND HEAD subsection.
  • Page 10 INTRODUCTION Section 03 ENGINE – footrest (refer to BODY) Remove: Bold face number – engine pinion (refer to sec- – upper engine support bolt tion) following part name – lower bolts retaining the engine support on either side, then, remove supports refers to exploded –...

  • Page 11: General Information

    Due to late changes, there may be some differences between the manufactured product and the descrip- tion 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.
  • Page 12 INTRODUCTION Threadlocker 1. Clean threads (bolt and hole) with solvent. 2. Apply Loctite Primer N (P/N 293 800 041) on Uncovered Holes (bolts and nuts) threads (bolt and nut) and allow to dry for 30 seconds. 3. Choose proper strength Loctite threadlocker. 4.
  • Page 13 INTRODUCTION Adjusting Screw 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.

  • Page 14: Tightening Torques

    INTRODUCTION 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. 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.
  • Page 15 Page______ ❏ ❏ Machine___________________ Report of error Suggestion ____________________________________________________________ We would be pleased if you could ____________________________________________________________ communicate to Bombardier any sug- gestions you may have concerning our publications. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ____________________________________________________ City and State/Prov. ________________________...
  • Page 16 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0...
  • Page 17 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS SERVICE TOOLS........................01-02-1 SERVICE PRODUCTS ......................01-03-1 01-01-1 VMR2004_033_01_01ATOC.FM...

  • Page 18: Service Tools

    Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) SERVICE TOOLS This is a list of tools to properly service ATV vehicles. If you need to replace or add to your tool inventory, these items can be ordered through the regular parts channel. Following mention points out new tool: 01-02-1 VMR2004_002_01_02A.FM...
  • Page 19 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Small Hose Pincher Valve Spring Compressor 295 000 076 529 035 724 All Models Insertion Jig Handle 420 877 650 Large Hose Pincher 529 032 500 All Models Fuel System Pressure Tester 529 033 100 Vacuum/Pressure Pump 529 021 800...
  • Page 20 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Terminal Remover Snap-On TT660-4 Shock Tool 529 035 636 Multimeter All Models 529 035 868 Handle Grip Insertion Tool 529 035 897 All Models Oil Pressure Adapter 529 035 652 Crimp Plier 529 035 730 Oil Pressure Gauge...
  • Page 21 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Caillau Pliers 295 000 054 Digital/Inductive Type Tachometer 529 014 500 DS 650/Baja/X Youth models CV Boot Clamp Installation and Outlander 330 Removal Tool Outlander 400 295 000 069...
  • Page 22 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) DS 650/Baja/X Outlander 330 Outlander 400 Quest 500/650 Traxter Exhaust Spring Installer/Remover Outlander 330 529 035 401 41 mm Socket PROTO 5541 Outlander 400 Quest 500/650 Traxter Outlander 330...
  • Page 23 Torque Angle Snap-On TA 36 Water Pump Ceramic Seal Installer 529 035 766 Outlander 330 Outlander 400 Quest 500/650 DS 650/Baja/X Outlander 330 Outlander 400 Engine Installation and Removal Tool Oil Seal Installer 529 035 619 (crankshaft oil seal on crankcase)
  • Page 24 Quest 500/650 Crankcase Support (CVT side) 529 035 754 64 mm (2-1/2 in) Crow-foot Rear Axle Nut 529 035 729 DS 650/Baja/X Output Shaft Oil Seal Installer 529 035 941 Rear Axle Key Valve Guide Installer 529 035 951 529 035 853...
  • Page 25 529 035 695 529 035 691 Clutch Shaft Seal Installer 529 035 693 Shock Charging Tool 529 035 570 DS 650/Baja/X DS 650/Baja/X Ball Joint Guide 529 035 705 Gas fill tool kit (needle type) 503 190 102 Ball Joint Drive...
  • Page 26 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Magneto Puller Crankshaft Bushing Installer (4-stroke engines) 529 035 689 529 035 798 DS 650/Baja/X Primary Crankshaft Gear Puller 529 035 624 Crankshaft Bearing Puller (4-stroke engines) 529 035 791 Crankshaft Bushing Remover...
  • Page 27 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Camshaft Locking Tool Crankshaft Puller 529 035 926 (2-stroke engines) 529 035 799 Youth models Valve Guide Remover 529 035 924 Bearing Puller Kit (2-stroke engines) 529 035 800 Piston Ring Compressor 529 035 919 Outlander 330...
  • Page 28 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Wear Ring Installer Balancer Shaft Oil Seal Installer (front drive shafts) 529 035 933 529 035 927 Outlander 330 Outlander 400 Starter drive needle bearing Wear Ring Installer installer (rear drive shafts) 529 035 934 529 035 915...
  • Page 29 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Crankcase Plain Bearing Remover/Installer (MAG side) 529 035 753 Quest 500/650 Lifting Ring 529 035 770 Crankcase Support (MAG side) 529 035 755 Oil Seal Installer (main shaft oil seal on crankcase) Quest 500/650 529 035 761 Clutch Holding Tool...
  • Page 30 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Clutch Holding Support Crankshaft Plain Bearing 529 035 864 Remover/Installer 529 035 855 Crankshaft Oil Seal Installer 529 035 847 Needle Bearing Installer 529 035 858 Rally 200 Water Pump Oil Seal Installer 529 035 849 Piston Circlip Installer 529 035 859...
  • Page 31 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Lifting Bar 529 035 610 Crimping Tool (for AMP connectors) 295 100 164 Jumper for Self Diagnosis 529 035 605 Traxter Traxter Crankshaft Locking Bolt Lifting Ring 529 035 645 529 035 644 UP to 2000 Front Suspension Spacer Bar...

  • Page 32: Service Products

    Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 03 (SERVICE PRODUCTS) SERVICE PRODUCTS This is a list of products to properly service ATV vehicles. If you need to replace or add to your tool inventory, these items can be ordered through the regular parts channel. Following mention points out new tool: 01-03-1 VMR2004_003_01_03A.FM...
  • Page 33 293 550 010 ® Loctite All Models Retaining Compound Loctite RC (10 mL) (green) All Models 413 703 100 Bombardier ATV Tire Sealant (946 mL) 715 000 130 ® Loctite Primer Primer N 128 g (5 oz) 293 800 041...
  • Page 34 (12 x 14 oz) (12 x 8 oz) 293 600 016 413 408 600 All Models All Models Bombardier Premixed Coolant 50/50 Bombardier Pulley Flange Cleaner - 37°C (- 35°F) (320 g) (16 x 1 L) 413 711 809 293 600 038...
  • Page 35 DS 650/Baja/X Quest 500/650 Traxter Loctite ® High Strength Threadlocker (10 mL) (red) 293 800 005 Bombardier Plastic & Vinyl Cleaner (6 x 1 L) 413 711 200 All Models ® Loctite High Strength Retaining Compound (10 mL) (red) 293 800 073...
  • Page 36 Rally 200 DS 650/Baja/X Gasket/Paint Remover Quest 500/650 510 g (18 oz) Rally 200 413 708 500 Traxter Bombardier Synthetic Chaincase Oil (12 x 355 mL) 413 803 300 Cable Lubricant (400 g) 293 600 041 DS 650/Baja/X DS 650/Baja/X...
  • Page 37 (must be used with tapered tip) (20 g) 293 800 095 DS 650/Baja/X Smoothflow Tapered Tips 16ga #511 rtt-b Kayaba shock absorber oil (not sold by Bombardier), 293 600 035 call EFD Inc, 1 800 556-3484 Loctite ® 5900 RTV Silicone Sealant...
  • Page 38 Loctite ® 5910 Flange Sealant Molykote G-n Paste (300 mL) (50 g) 293 800 081 711 297 433 Outlander 330 DS 650/Baja/X Outlander 400 Traxter Loctite ® Traxter Molykote PG 54 Paste Gasket (10 g) Gasket Eliminator 420 899 763...

  • Page 39: Table Of Contents

    Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS MAINTENANCE CHART ......................02-02-1 NOISE EMISSION CONTROL SYSTEM REGULATION ........... 02-02-1 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ........02-02-1 AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW ..................02-02-1 MAINTENANCE CHART ....................

  • Page 40: Maintenance Chart

    Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART) MAINTENANCE CHART NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED U.S. Federal law and Canadian provincial laws may prohibit the following acts or the causing there of: 1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2.
  • Page 41 Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART) MAINTENANCE CHART I: Inspect, verify, clean, adjust, lubricate, replace if necessary C: Clean L: Lubricate R: Replace ENGINE/TRANSMISSION Engine/transmission oil level EVERY INSPECTION N.A. Engine/transmission oil and filter Spark arrester Maintenance/ Lubrication Valve clearance Clutch lever Oil reservoir strainer Lubrication...

  • Page 42: Maintenance/Lubrication

    Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART) I: Inspect, verify, clean, adjust, lubricate, replace if necessary C: Clean L: Lubricate R: Replace STEERING/CONTROL SYSTEMS Throttle/housing/cable Handlebar fastener Steering/ Steering system Controls System Tie rod ends Front wheel alignment Carburetor and Air Choke Intake Silencer Tire wear and pressure...

  • Page 43: Adjust Valve Clearance

    Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) MAINTENANCE/LUBRICATION ADJUST VALVE CLEARANCE Unfasten socket head screw beside support for oil return and secure crankshaft with the crankshaft locking bolt (P/N 529 035 617). Removal NOTE: Check tightness with the allen key. Remove: To adjust valves, remove the camshaft bridges and –...

  • Page 44: Drive Chain

    Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) Adjust cable free play. Insert adjuster lock through rear hub and into ec- centric axle housing. A. 3.5 ± 0.5 mm (9/64 ± 1/64 in) DRIVE CHAIN Adjustment NOTE: Always adjust drive chain with the driver, 1.

  • Page 45: Air Filter Cleaning/Draining

    Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) Lubrication and Cleaning Air Filter Removal CAUTION: Never wash the chain with a high pres- CAUTION: Never remove or modify any compo- sure washer or gasoline. Damage to the O-ring nent in the air box. Always use genuine parts or will result, causing premature wear and drive suitable equivalent when replacing air filter and chain failure.

  • Page 46: Bolts, Fasteners And Nuts

    Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) Rinse air filter and foam with warm water. Drain all oil from oil tank by removing oil tank drain plug. Wipe out any oil spillage. Squeeze foam to remove excess water. Let dry air filter and foam thoroughly.

  • Page 47: Spark Arrester

    NOTE: The same oil lubricates both engine and transmission. Do not use synthetic oil, other than SPARK ARRESTER Bombardier brand name, any semi-synthetic oil or any special additives. They affect the clutching The muffler must be periodically purged of accumu- calibration.

  • Page 48: Tires And Wheels

    Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) Remove: Remove the old sealant joint and replace by a new one. Use ULTRA COOPER sealant (P/N 293 800 090). – the screws retaining the spark arrester to the muffler Be sure that insulating material is in place when inserting grill.

  • Page 49: Engine Area

    Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) NOTE: Tire pressure changes with temperature and altitude. Recheck pressure if one of these con- ditions has changed. TIRES PRESSURE FRONT REAR RECOMMENDED 35 kPa (5 PSI) 35 kPa (5 PSI) MINIMUM 21 kPa (3 PSI) 21 kPa (3 PSI) Tire/Wheel Condition Check tire for damage and wear.

  • Page 50: Storage/Preseason Preparation

    To clean the entire vehicle, including metallic parts, Inject storage oil until the engine stalls or until a use Bombardier Cleaner (P/N 293 110 001 (400 g) sufficient quantity of oil has entered the engine or 293 110 002 (4 L)) or an equivalent like Simple (approximately half a can).

  • Page 51: Coolant Density

    Section 02 MAINTENANCE Subsection 04 (STORAGE/PRESEASON PREPARATION) NOTE: Protect the vehicle with a cover to prevent dust accumulation during storage. CAUTION: The vehicle has to be stored in a cool and dry place and covered with an opaque tarpaulin. This will prevent sun rays and grime from affecting plastic components and vehicle finish.

  • Page 52: Preseason Preparation

    Section 02 MAINTENANCE Subsection 04 (STORAGE/PRESEASON PREPARATION) PRESEASON PREPARATION TO BE PERFORMED BY SYSTEM PRESEASON OPERATIONS REFER TO CUSTOMER DEALER Test Run Vehicle. Check Clutch and Transmission ✔ N.A. Operation Maintenance/ Engine Oil and Filter Oil Replacement ➀ ✔ Lubrication Coolant Replacement and Pressurization ✔...
  • Page 53 Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS TROUBLESHOOTING ......................03-02-1 COOLING SYSTEM ......................03-02-1 MAGNETO SYSTEM ......................03-02-2 LUBRICATION........................03-02-4 CYLINDER AND HEAD ...................... 03-02-5 CRANKSHAFT AND BALANCER SHAFT................03-02-6 GEARBOX .......................... 03-02-7 ENGINE GENERAL ......................03-02-8 LEAK TEST..........................
  • Page 54 Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) MAGNETO SYSTEM ......................03-06-1 GENERAL..........................03-06-2 STATOR ..........................03-06-2 ROTOR ..........................03-06-3 SPRAG CLUTCH ......................... 03-06-3 TRIGGER COIL........................03-06-4 ROTOR HUB ........................03-06-4 LUBRICATION SYSTEM......................03-07-1 ENGINE LUBRICATION...................... 03-07-1 OIL TANK ..........................03-07-2 GENERAL..........................
  • Page 55 Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) CRANKSHAFT/BALANCER SHAFT ..................03-09-1 PISTON PIN........................03-09-2 PISTON..........................03-09-2 PISTON RINGS ........................03-09-4 BALANCER SHAFT ......................03-09-4 BALANCER GEAR......................03-09-6 CRANKSHAFT........................03-09-6 COUNTER GEAR ....................... 03-09-7 CRANKSHAFT BUSHING ....................03-09-7 BALL BEARINGS IN HOUSING ..................03-09-7 RECENTER CRANKSHAFT ....................

  • Page 56: Troubleshooting

    Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) TROUBLESHOOTING The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. This section pertains to engine mechanical components only. Some related problems can come from other systems such as ignition system, fuel system etc.

  • Page 57: Magneto System

    Readjust gap (refer to TECHNICAL DATA). b. Spark plug tip light grey and therefore heat range is too high. Replace by Bombardier recommended spark plug (refer to TECHNICAL DATA). 2. Check ignition coils for damage and/or electrical failure. a. Ignition coils damaged.

  • Page 58: Lubrication

    1. Check oil level and search for leakage on crankcase and/or defective gaskets. a. Crankcase is leaking due to damage. Rebuild engine with new crankcase and gasket parts. Use Bombardier recommended oil (refer to TECHNICAL DATA). b. Crankcase is leaking due to loose screws. Retighten screws with recommended torque.
  • Page 59 Gears driving oil pump are broken or otherwise damaged. Replace gears. d. Incorrect oil being used. Use Bombardier recommended oil (refer to TECHNICAL DATA). 10. Check oil pressure regulator valve (spring) function. a. Valve spring damaged (valve always open).

  • Page 60: Cylinder And Head

    Retighten screws with recommended torque and/or replace oil. 4. Check oil for particles (may indicate possible damages inside the engine). a. Oil contamination due to metal or plastic particles. Replace possibly damaged parts. Use Bombardier recommended oil (refer to TECHNICAL DATA). CYLINDER AND HEAD SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATION IN IDLE SPEED.

  • Page 61: Crankshaft And Balancer Shaft

    Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM OIL CONTAMINATION ON CYLINDER AND/OR HEAD. CONDITION NORMAL USE. Test/Inspection 1. Check screws for torque. a. Loose screws. Retighten screws with recommended torque. b. Gaskets are brittle, hard, worn out or otherwise damaged. Replace damaged gaskets, O-rings or the V-ring on breather.

  • Page 62: Gearbox

    Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) GEARBOX SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATIONS CONDITION NORMAL USE. Test/Inspection 1. Check oil level in engine. a. Oil leakage from engine. Replace damaged gasket(s) and/or oil seal(s), torque screws and refill with oil up to specified level (refer to TECHNICAL DATA).

  • Page 63: Engine General

    Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM GEAR(S) IS (ARE) HARD TO SHIFT. CONDITION NORMAL USE. Test/Inspection 1. Check shift drum and/or shift forks for wear and/or damages. a. Shift drum has worn out and/or damaged tracks. Replace shift drum. b.
  • Page 64 Replace failed part(s) in electrical system (electronic module). c. Compression ratio is too high. Install genuine parts. d. Poor oil quality. Use BOMBARDIER recommended oil. e. Leaks at air intake manifold (engine gets too lean). Retighten screws or replace air intake manifold. 03-02-9...
  • Page 65 11. Check crankshaft movement. a. Oil pump failure due to leak of oil. Repair and replace defective parts and use Bombardier recommended oil. b. Oil contamination due to clogged oil filter/oil sieve. Oil passes through bypass valve Replace oil, replace defective part(s) (refer to MAINTENANCE CHART).
  • Page 66 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH SYMPTOM MAXIMUM OPERATING RPM. CONDITION NORMAL USE. Test/Inspection 1. Check items of ENGINE SUDDENLY TURNS OFF. 2. Check air intake system. a. Air filter is clogged due to contamination. Replace air filter.
  • Page 67 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM HIGH ENGINE OPERATING TEMPERATURE. CONDITION NORMAL USE. Test/Inspection 1. Check if cooling system shows any failure (see COOLING SYSTEM). a. System is leaking. Repair and/or replace damaged part(s). 2. Check function of lubrication system (see LUBRICATION). a.
  • Page 68 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM ENGINE DOES NOT START - NO SPARK AT SPARK PLUG (SEE MAGNETO SYSTEM). CONDITION AT ENGINE CRANKING. Test/Inspection 1. Verify spark plug condition. a. Defective, improperly set, worn out, fouled. Identify source of problem and correct. Replace spark plug. 2.
  • Page 69 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM THE CLUTCH DOES NOT “DISENGAGE”. CONDITION NORMAL USE. Test/Inspection 1. Verify engine oil. a. Engine oil is not to specifications. Drain engine oil and refill with the recommended oil. 2. Check clutch discs condition. a.

  • Page 70: Leak Test

    Section 03 ENGINE Subsection 03 (LEAK TEST) LEAK TEST VERIFICATION LEAK TEST PROCEDURE Before performing the cylinder leak test, verify the PREPARATION AND TEST following: NOTE: The following procedures should be done – clamp(s) tightness with a cold engine. – radiator and hoses condition Disconnect battery.
  • Page 71 Section 03 ENGINE Subsection 03 (LEAK TEST) On LH side, remove the larger socket screw then Torque the crankshaft locking bolt to lock crank- quickly install the crankshaft locking bolt (P/N 529 shaft. 035 617) to avoid oil leakage. Do not tighten. Remove radiator cap and dipstick.

  • Page 72: Diagnose

    Section 03 ENGINE Subsection 03 (LEAK TEST) DIAGNOSE Supply combustion chamber with air pressure. Listen for air leaks: – air escaping from spark plug means poor spark plug tightness or defective spark plug gasket – air escaping from intake means leaking intake valve –...

  • Page 73: Removal And Installation

    Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION 27 33 03-04-1 VMR2004_008_03_04A.FM...

  • Page 74: General

    Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) GENERAL Disconnect BLACK (-) cable from battery, then RED (+) cable. For installation, use the torque values and Loctite WARNING products from the exploded views. Clean threads before using Loctite when installing the screws. Always disconnect battery exactly in the spec- ified order, BLACK (-) cable first.
  • Page 75 Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) – starter cable – oil outlet hose no. 3 – gearshift pedal no. 4. RH SIDE OF ENGINE LH SIDE OF ENGINE 1. Exhaust pipes 1. Radiator outlet hose 2. Radiator inlet hose 2.

  • Page 76: Engine Installation

    Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) COUNTERSHAFT SPROCKET Install engine lifting tool (P/N 529 035 610) then, install a hoist. Removal Remove: – upper engine support bolt no. 12 Slack drive chain. – lower bolts no. 13 retaining the engine support Remove countershaft sprocket cover no.

  • Page 77: Exhaust System

    Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) EXHAUST SYSTEM Muffler Removal Remove exhaust pipes no. 6 and no. 7. WARNING Remove screw no. 25, washer no. 26 and spacer Never touch exhaust system components no. 27. immediately after the engine has been run Under rear fender, remove screw no.

  • Page 78: Cooling System

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) COOLING SYSTEM RADIATOR 03-05-1 VMR2004_009_03_05A.FM...

  • Page 79: Water Pump

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) WATER PUMP 03-05-2 VMR2004_009_03_05A.FM...

  • Page 80: Cooling System Leak Test

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) COOLING SYSTEM LEAK TEST WARNING To prevent burning yourself, do not remove the radiator cap or loosen the engine drain plug if the engine is hot. Remove radiator pressure cap no. 1. Install special plug (radiator cap) (P/N 529 021 400) and hose pincher (P/N 529 009 900) on overflow hose no.

  • Page 81: Cooling System Refilling

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) COOLING SYSTEM REFILLING Remove thrust washer no. 14, needle pin no. 15 and gear no. 16. Recommended Coolant Press out sealing rings no. 3 and no. 4. Use a blend of 50% antifreeze with 50% water. Inspection CAUTION: To prevent rust formation or freezing Check shaft no.

  • Page 82: Radiator Protector

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) – overflow hose no. 2 – headlight – ignition coils – radiator protector – radiator mounting bolts no. 19 on the top. Pull radiator no. 8 out of frame by the RH side. Inspection Check radiator air passage for clogging or damage.

  • Page 83: Fan And Heat Shield

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Installation – fan relay no. 28 (Baja model only, see procedure below) The installation is the reverse of the removal pro- cedure. FAN AND HEAT SHIELD Test Unplug temperature switch connectors. Install a jumper wire end between both connec- tors.

  • Page 84: Temperature Switch

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Fan Removal TEMPERATURE SWITCH Unscrew bolts no. 29, and pull fan in exhaust di- rection. NOTE: The exhaust can be remove to allow an easy access to the fan. 1. Temperature switch Removal Unplug temperature switch connectors.

  • Page 85: Temperature Sensor

    Section 03 ENGINE Subsection 05 (COOLING SYSTEM) TEMPERATURE SENSOR 1. Temperature sensor Removal Unplug temperature sensor connector. Unscrew temperature sensor no. 7. Test Using a multimeter, measure the resistance be- tween connector on the top of temperature sen- sor and threads. The multimeter should indicate an infinite resis- tance (O.L.), if not change the temperature sensor.
  • Page 86 Section 03 ENGINE Subsection 06 (MAGNETO SYSTEM) MAGNETO SYSTEM in in 03-06-1 VMR2004_010_03_06A.FM...

  • Page 87: General

    Remove gasket. Unfasten handle and install screw plug in ignition cover. NOTE: Clean all metal component in a non-ferrous metal cleaner. Use Bombardier gasket remover NOTE: Install a new gasket on ignition cover. (P/N 413 708 500) or suitable equivalent. 03-06-2...

  • Page 88: Rotor

    Section 03 ENGINE Subsection 06 (MAGNETO SYSTEM) ROTOR Removal Lock crankshaft with locking bolt (P/N 529 035 617). Refer to CRANKSHAFT/BALANCER SHAFT. Remove ignition cover no. 6. Unscrew nut no. 9 retaining rotor no. 2. Remove lock washer no. 10. Install magneto puller (P/N 420 976 235) and crankshaft protector (P/N 420 876 557) then re- move rotor.

  • Page 89: Trigger Coil

    Section 03 ENGINE Subsection 06 (MAGNETO SYSTEM) Installation For installation, reverse the removal procedure. NOTE: Apply engine oil on sprag clutch. Install sprag clutch. The arrow should be visible. 1. Guide piece TRIGGER COIL 2. Trigger coil 3. Feeler gauge Test GAP BETWEEN GUIDE PIECE 0.75 ±...
  • Page 90 Section 03 ENGINE Subsection 06 (MAGNETO SYSTEM) Installation Reinstall all parts. Before torque, check if the protrusion of rotor is aligned with the key way in the center of rotor hub. 1. Rotor protrusion 2. Rotor hub key way 03-06-5 VMR2004_010_03_06A.FM...

  • Page 91: Lubrication System

    Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) LUBRICATION SYSTEM ENGINE LUBRICATION 22 21 03-07-1 VMR2004_011_03_07A.FM...
  • Page 92 Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) OIL TANK 03-07-2 VMR2004_011_03_07A.FM...

  • Page 93: General

    Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) GENERAL NOTE: The maximum oil pressure is 600 kPa (87 PSI). Prior to changing the engine oil, ensure vehicle is If the engine pressure is out of specifications, on a level surface. check the points described in TROUBLESHOOT- Oil and oil filter no.
  • Page 94 Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) Drain all oil from oil tank no. 5 by removing oil tank NOTE: Check and change O-ring no. 9, if neces- drain plug no. 6. Wipe out any oil spillage. sary. TYPICAL — RH SIDE OF VEHICLE 1.

  • Page 95: Oil Tank Strainer

    Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) Bleeding Engine Oil Circuit Installation Remove oil filter no. 1. For installation, reverse the removal procedure. Unfasten bleeding screw no. 11. NOTE: Apply Loctite pipe sealant on oil tank strainer threads. ENGINE OIL PRESSURE REGULATOR The engine oil pressure regulator no.

  • Page 96: Return Oil Pump

    Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) RETURN OIL PUMP – oil pump cover no. 22 – oil pump shaft no. 23 The return oil pump no. 17 is located on the clutch – oil pump rotor no. 24 side of the crankcase housing. –...

  • Page 97: Pressure Oil Pump

    Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) PRESSURE OIL PUMP OIL PUMP ROTOR AND INNER ROTOR CLEARANCE The pressure oil pump no. 26 is located near the return oil pump. SERVICE LIMIT 0.25 mm (0.009 in) Measure oil pump rotor thickness and oil pump rotor bore depth.

  • Page 98: Oil Tank

    Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) OIL TANK The oil tank is located under front facia, near the headlight. Removal Drain oil tank. Remove the front facia. Unscrew headlight then disconnect and remove it. Remove nut no. 30. Unscrew bolts retaining fuel tank cover and oil tank to the frame.

  • Page 99: Cylinder And Head

    Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) CYLINDER AND HEAD CYLINDER AND HEAD 03-08-1 VMR2004_012_03-08A.FM...

  • Page 100: Valve

    Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) VALVE 03-08-2 VMR2004_012_03-08A.FM...

  • Page 101: General

    Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) GENERAL When disassembling parts that are duplicated in the engine, (eg: valves, springs, etc.), it is strongly NOTE: When diagnosing an engine problem, al- recommended to note their position (PTO, MAG ways perform the cylinder leak test. This will help side) and to keep the parts of the same assembly pin-point a problem.

  • Page 102: Adjust Valve Clearance

    Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) ADJUST VALVE CLEARANCE Installation NOTE: Before installation, check thickness of ad- Removal justing plates with micrometer. Remove: For installation, reverse the removal procedure. – fuel tank CAMSHAFT – valve cover – spark plugs. Removal Unfasten centre screw plug to right of engine Using the crankshaft locking bolt (P/N 529 035...
  • Page 103 Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Remove camshafts no. 7 and no. 8 with timing CAMSHAFT DIAMETER gears no. 9. MINIMUM 21.950 mm (.864 in) NOTE: Unfasten timing gears only if they need to be replaced. Secure timing chain no. 10 with a retaining wire. Remove front chain rail no.

  • Page 104: Centrifugal Decompressor

    Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Installation CAUTION: Install the timing gears so that the markings on the gears must be aligned and so that the dowel pin on each camshaft must be lo- cated on the top, as shown in the next illustration. A.

  • Page 105: Cylinder Head

    Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) CYLINDER HEAD Inspection Check valve spring for rust or corrosion and free Removal length. Remove: VALVE SPRING FREE LENGTH – engine from vehicle (refer to INSTALLATION AND REMOVAL) SERVICE LIMIT 44.5 mm (1-3/4 in) –...

  • Page 106: Valve Stem Seal

    Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Inspection Measure valve seat width, using a caliper. Inspection of valve stem seals is not needed as VALVE SEAT CONTACT WIDTH new seals should always be installed whenever a cylinder head is diassembled. SERVICE LIMIT Exhaust 1.8 mm (.07 in)

  • Page 107: Valve Guide Removal

    Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Valve Guide Removal Installation Remove: For installation, reverse the removal procedure. Pay attention to the following details. – cylinder head (see CYLINDER HEAD above) Clean the valve guide bore before reinstalling the –...
  • Page 108 Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Hand reamer (F1111 Hand Reamer 6H7) ordering and other information can be obtained from the following company: TITEX PRECISION CUTTING TOOLS TITEX USA 301 Industrial Avenue, Crystal Lake, IL 60012 Tel.: 1 (815) 4592040 Toll-free: 1 800 262-2436 Fax: 1 (413) 774-2110 e-mail: titex.usa@sandvik.com...

  • Page 109: Cylinder

    Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) CYLINDER Cylinder Out of Round Measure cylinder bore at distance of 60 mm (2-3/8 in) Removal from the upper edge with an internal micrometer at three points. Difference between measurements Remove: should not exceed 0.10 mm (.004 in). If so, replace –...

  • Page 110: Crankshaft/Balancer Shaft

    Section 03 ENGINE Subsection 09 (CRANKSHAFT/BALANCER SHAFT) CRANKSHAFT/BALANCER SHAFT 03-09-1 VMR2004_013_03-09A.FM...

  • Page 111: Piston Pin

    Section 03 ENGINE Subsection 09 (CRANKSHAFT/BALANCER SHAFT) PISTON PIN Installation For installation, reverse the removal procedure. Removal Pay attention to the following details. Remove engine. Refer to REMOVAL AND IN- Apply anti-seize lubricant on the piston pin. STALLATION. Insert piston pin into piston and connecting rod. Remove cylinder.
  • Page 112 Section 03 ENGINE Subsection 09 (CRANKSHAFT/BALANCER SHAFT) Using a micrometer, measure piston at 16 mm With the micrometer set to the dimension, adjust (5/8 in) perpendicularly (90°) to piston pin axis. a cylinder bore gauge to the micrometer dimen- sion and set the indicator to 0 (zero). TYPICAL 1.

  • Page 113: Piston Rings

    Section 03 ENGINE Subsection 09 (CRANKSHAFT/BALANCER SHAFT) Installation For installation, reverse the removal procedure. NOTE: Install piston with removal mark (on base of piston) in direction of exhaust end. PISTON RINGS Inspection Piston Ring/Piston Groove Clearance Using a feeler gauge measure each piston ring/piston groove clearance.
  • Page 114 Section 03 ENGINE Subsection 09 (CRANKSHAFT/BALANCER SHAFT) – oil filter – all bolts retaining housing. NOTE: Do not forget the bolts inside the oil filter housing. 1. Double drive gear 2. Timing chain 3. Oil pump intermediate gear 4. Oil pump gears Magneto Side 1.

  • Page 115: Balancer Gear

    Section 03 ENGINE Subsection 09 (CRANKSHAFT/BALANCER SHAFT) CRANKSHAFT First lift out crankshaft, then balancer shaft. NOTE: Take care of spacer discs on crankshaft. Removal Inspection Use the same removal procedure that balancer shaft. Check balancer shaft bearings nos. 11 and 12 in front and rear housing for excessive play and Inspection smooth operation.

  • Page 116: Counter Gear

    Section 03 ENGINE Subsection 09 (CRANKSHAFT/BALANCER SHAFT) Installation For installation, refer to balancer shaft installation. COUNTER GEAR Removal Clamp crankshaft in vise with protective jaws. Using extractor (P/N 529 035 624) extract counter gear. Installation Heat engine housing to 100°C (212°F). Coat bushing with Klueber grease (P/N 711 297 616) and drive home with punch (P/N 529 035 689), strik- ing from inside.

  • Page 117: Recenter Crankshaft

    Section 03 ENGINE Subsection 09 (CRANKSHAFT/BALANCER SHAFT) RECENTER BALANCER SHAFT NOTE: The sealed ends of the cage must point outwards. NOTE: Only fit shim on clutch end. RECENTER CRANKSHAFT Place balancer shaft into left engine housing (clutch side). Do not install shim on clutch side. NOTE: Only fit shim on clutch end.

  • Page 118: Clutch

    Section 03 ENGINE Subsection 10 (CLUTCH) CLUTCH 03-10-1 VMR2004_014_03-10A.FM...

  • Page 119: General

    Section 03 ENGINE Subsection 10 (CLUTCH) GENERAL Adjust cable free play. At installation, use torque values and Loctite prod- ucts from the exploded view. Clean threads before using Loctite products when installing screws. NOTE: For a better understanding, the following illustrations are taken with engine out of vehicle.

  • Page 120: Pressure Plate

    Section 03 ENGINE Subsection 10 (CLUTCH) Installation PRESSURE PLATE BEARING For installation, reverse the removal procedure. Inspection NOTE: Place the clutch actuator rack no. 11 in line Check the pressure plate bearing no. 2 for exces- with the clutch release lever. Do not force the sive play and smooth operation.

  • Page 121: Friction Drive Plate, Steel Driven Plate And Clutch Basket

    Section 03 ENGINE Subsection 10 (CLUTCH) Disassembly Remove the retaining ring no. 12 with retaining ring pliers. 1. Friction drive plate 2. Steel driven plate 3. Clutch basket Unlock the tab washer no. 13 then install spanner 1. Retaining ring tool for clutch basket (P/N 529 035 618).
  • Page 122 Section 03 ENGINE Subsection 10 (CLUTCH) Inspection The wear limit of the whole package is 11.5 mm (.453 in). Friction Drive Plate Measure the package of friction drive plate thick- ness. Clutch Basket Check slots of clutch basket for damage or wear caused by friction drive plates.

  • Page 123: Clutch Release Shaft

    Section 03 ENGINE Subsection 10 (CLUTCH) Clutch Hub Coat spline on countershaft with Loctite anti-seize. Check grooves of clutch hub for damage or wear First, install steel driven plate, then friction drive caused by steel driven plates. plate in alternate order. NOTE: Place the last friction drive plate in short slots of clutch basket.
  • Page 124 Section 03 ENGINE Subsection 10 (CLUTCH) With the extractor (P/N 529 035 690), remove both needle bearings nos. 20 and 21, and seal no. 22 together. 1. Clutch cover 2. Extractor NOTE: With a heat gun, heat the clutch cover near bearings area.

  • Page 125: Transmission

    Section 03 ENGINE Subsection 11 (TRANSMISSION) TRANSMISSION 11 12 03-11-1 VMR2004_015_03-11A.FM...

  • Page 126: Shifting Mechanism

    Section 03 ENGINE Subsection 11 (TRANSMISSION) SHIFTING MECHANISM Removal Remove engine from vehicle. Refer to REMOVAL AND INSTALLATION. Separate both crankcase housings. Refer to CRANKSHAFT/BALANCER SHAFT. Press shift pawl slightly outwards and withdraw shift shaft no. 1 with shift pawl. Remove index lever no.

  • Page 127: Transmission

    Section 03 ENGINE Subsection 11 (TRANSMISSION) Disassembly Install index lever no. 2 with index spring no. 3 in housing. Mainshaft Attach pawl spring no. 10 to pawl. Using special pliers slide circlip no. 17 slightly Insert shift shaft no. 1 in housing and secure index backwards to remove circlip no.

  • Page 128: Transmission Shaft Bearings

    Section 03 ENGINE Subsection 11 (TRANSMISSION) 1. Magneto end 2. Clutch side Check all bearings, bearing points, tooth flanks, taper grooves and annular grooves. Annular grooves must have sharp edges. Replace gears only together with the correspond- ing meshing gears. NOTE: Always replace circlips and install using special pliers.
  • Page 129 Section 04 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL CIRCUIT........................04-02-1 FUEL LINE .......................... 04-02-2 FUEL TANK ........................04-02-2 FUEL VALVE ........................04-02-2 FUEL SYSTEM PRESSURIZATION ................... 04-02-3 CARBURETOR AND AIR INTAKE SILENCER ............... 04-03-1 CARBURETOR ........................04-03-1 AIR INTAKE SILENCER .....................

  • Page 130: Fuel Circuit

    Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) FUEL CIRCUIT 04-02-1 VMR2004_016_04_02A.FM...

  • Page 131: Fuel Line

    FUEL LINE Removal Drain fuel tank. When replacing fuel line, be sure to use hoses as available from Bombardier parts department. This Remove following items from body. Refer to BODY will ensure continued proper and safe operation. for complete detailed procedure: –...

  • Page 132: Fuel System Pressurization

    Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) FUEL SYSTEM PRESSURIZATION Using air pump (P/N 529 021 800) inject air into fuel tank. See next photo. Fill up fuel tank no. 1. Remove seat. Install on fuel tank the special cap included in the fuel and oil system tester kit (P/N 529 033 100).

  • Page 133: Carburetor And Air Intake Silencer

    Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER) CARBURETOR AND AIR INTAKE SILENCER CARBURETOR 04-03-1 VMR2004_017_04_03A.FM...

  • Page 134: Air Intake Silencer

    Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER) AIR INTAKE SILENCER 04-03-2 VMR2004_017_04_03A.FM...

  • Page 135: General

    Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER) GENERAL Carburetor Float Level Adjustment Correct fuel level in float chamber is vital toward Before performing any job on fuel system, always maximum engine efficiency. To check for correct disconnect BLACK (-) cable from battery.
  • Page 136 Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER) Carburetor Adjustments TYPICAL — GAUGE ALIGNED WITH MAIN JET To adjust height, bend the contact tab of float arm until the specified height is reached. CAUTION: When adjusting lever, do not pry it. This will apply pressure on needle and damage valve seat/needle.
  • Page 137 Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER) Idle Speed Preliminary Adjustment Turn the pilot screw clockwise until you hear the engine misses or decreases air speed, then turn Adjust idle speed screw no. 6 to 1-1/2 turn or so counterclockwise until the engine again misses or that throttle valve no.

  • Page 138: Throttle Cable

    Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER) THROTTLE CABLE Separate cable end bushing from throttle cable end, as shown in the next photo. Keep bushing. NOTE: To ease reinstallation, take note cable rout- ing. Removal Remove carburetor side cover no. 11. REMOVE CABLE END BUSHING Loosen throttle cable nut.
  • Page 139 Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER) Throttle Cable Lubrication The throttle cable must be lubricated with cable lubricant (P/N 293 600 041) or an equivalent prod- uct. Open the throttle lever. Remove the carburetor side cover. Install the cable luber (P/N 529 035 738) on the cable.

  • Page 140: Air Intake Silencer

    Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR AND AIR INTAKE SILENCER) NOTE: Measure throttle free play at the tip of Installation throttle lever. For installation, reverse the removal procedure. Tighten lock nut and reinstall protector. Air Intake Tube Removal Remove air filter box. Separate air intake tube no.
  • Page 141 Section 05 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OVERVIEW..........................05-02-1 GENERAL OPERATION INFORMATION ................05-02-1 CHARGING SYSTEM......................05-02-1 STARTING SYSTEM ......................05-02-1 IGNITION SYSTEM......................05-02-2 ACCESSORIES ........................05-02-2 GENERAL TESTING/ TROUBLESHOOTING INFORMATION ......... 05-02-2 FUSES LOCATION......................05-02-3 SERVICING PACKARD CONNECTORS ................
  • Page 142 Section 05 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) IGNITION SYSTEM ........................ 05-05-1 IGNITION SYSTEM TESTING PROCEDURE..............05-05-1 GENERAL..........................05-05-1 IGNITION SYSTEM TEST ....................05-05-1 IGNITION TIMING ......................05-05-4 SPARK PLUG ........................05-05-5 DISASSEMBLY ........................05-05-5 FOULING..........................05-05-5 SPARK PLUG ANALYSIS ....................05-05-5 SPARK PLUG INSTALLATION ...................

  • Page 143: Overview

    Section 05 ELECTRICAL Subsection 02 (OVERVIEW) OVERVIEW GENERAL OPERATION Battery INFORMATION The battery supplies the entire vehicle. Therefore, DC current only is used in the entire electrical system. The electrical system consists of different sub- systems where some are inter-related: STARTING SYSTEM •...

  • Page 144: Ignition System

    Section 05 ELECTRICAL Subsection 02 (OVERVIEW) IGNITION SYSTEM ACCESSORIES An CDI (Capacitor Discharge Ignition) system is The battery supplies the DC current to all accessories. utilized. The ignition system is made up of the fol- GENERAL TESTING/ lowing components: TROUBLESHOOTING INFORMATION The following gives general electrical-related prob- lems.

  • Page 145: Fuses Location

    Section 05 ELECTRICAL Subsection 02 (OVERVIEW) Before replacing any electric or electronic part(s), Fuses are located under seat, between engine and always check electrical connections. Make sure air box. that they are very tight and they make good con- tact and that they are corrosion-free. The voltage and current might be too weak to go through dirty wire pins.
  • Page 146 Section 05 ELECTRICAL Subsection 02 (OVERVIEW) NOTE: Before extraction, push wire forward to re- lieve pressure on retaining tab. – Insert a 4.8 mm (.189 in) wide screwdriver blade inside the front of the contact cavity. – Pry back the retaining tab while gently pulling wire back until contact is removed.

  • Page 147: Identification Of Major Connector Pins

    Section 05 ELECTRICAL Subsection 02 (OVERVIEW) IDENTIFICATION OF MAJOR CONNECTOR PINS 05-02-5 VMR2004_018_05_02A.FM...

  • Page 148: Charging System

    Section 05 ELECTRICAL Subsection 03 (CHARGING SYSTEM) CHARGING SYSTEM TESTING PROCEDURE If multimeter reads over 15 volts, voltage regulator/ rectifier is defective. Replace it. NOTE: First, ensure that battery is in good condi- NOTE: Whatever the voltmeter type used (peak tion prior to performing the following test using a voltage or RMS), the voltage must not exceed current inductive ammeter such as Snap-on MT...
  • Page 149 Section 05 ELECTRICAL Subsection 03 (CHARGING SYSTEM) 2. Place either meter test probe into the remaining DYNAMIC TEST stator lead (AC-3) and note the resistance (same 1. Unplug magneto wiring harness connector. as step no. 1). If the readings are out of specifi- 2.

  • Page 150: Starting System

    Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) STARTING SYSTEM BATTERY Load Test This is the best test of battery condition under a TROUBLESHOOTING starting load. Use a load testing device that has an adjustable load. SYMPTOM: DISCHARGED OR WEAK BATTERY Apply a load of 3 times the ampere-hour rating of the battery.

  • Page 151: Inspection

    Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) INSPECTION ACTIVATION OF A NEW BATTERY Visually inspect battery casing for cracks or other WARNING possible damage. If casing is damaged, replace Never charge or boost battery while installed battery and thoroughly clean battery rack with wa- on vehicle.

  • Page 152: Starting System Troubleshooting

    Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY Starter does not turn. Ignition switch is in the OFF position. Turn switch in the ON position. Engine stop switch is in the OFF posi- Place the engine stop switch to run po- tion.

  • Page 153: Starting System Tests

    Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) STARTING SYSTEM TESTS Using a multimeter, measure the resistance be- tween the following wires. GENERAL POSITION WIRE RESISTANCE First ensure the problem is not related to engine 1 Ω max. Switch to OFF BLACK and mechanical components.

  • Page 154: Electric Starter

    Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) INSTALLATION Inspect connections and clean as necessary. Sole- noid condition can be checked with an ohmmeter. Installation is essentially the reverse of removal Install test probes on large connectors of solenoid. procedure. However, pay particular attention to Measure resistance when current is applied to small the following.
  • Page 155 Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) Install the appropriate terminal on the wire accord- ing to the requirement. Refer to appropriate parts catalog. INSTALLATION OF TERMINAL Follow the instructions provided with the crimp plier (P/N 529 035 730) to select the proper position of the tool.

  • Page 156: Ignition System

    Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) IGNITION SYSTEM IGNITION SYSTEM TESTING IGNITION SYSTEM TEST PROCEDURE Safety Precautions GENERAL WARNING Ignition Problems To prevent powerful electric shocks while cranking engine, neither touch any electronic When dealing with ignition problems, the follow- ignition components (ignition coil, high ten- ing items should be checked in this order.
  • Page 157 Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) TROUBLESHOOTING Check that the transmission is in NEUTRAL position and the engine stop switch is in “RUN” position. Check that main fuse is not burned and if battery is fully-charged before diagnosing. Check ignition system connector for poor connections.
  • Page 158 Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) Battery Condition 3. Press START button, note result. The obtained value should be between 0.4 and 0.7 Vac. Re- A battery must be present in the vehicle to allow peat operation 3 times. the ignition system to work.

  • Page 159: Ignition Timing

    Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) Electronic Module NEGATIVE (-) TESTER LINE ∞ 2.18 MΩ 2.18 MΩ UP to- 2.18 MΩ 2.18 MΩ 2590 Ω 2590 Ω ∞ O.L. UP to- 5.58 KΩ 2590 Ω 0.02 Ω 2965 Ω ∞...

  • Page 160: Spark Plug

    Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) SPARK PLUG SPARK PLUG INSTALLATION CAUTION: Always use the recommended DISASSEMBLY spark plug. Prior to installation make sure that contact surfaces Unplug the spark plug cable of the cylinder head and spark plug are free of Unscrew the spark plug one turn.

  • Page 161: Ngk Spark Plug Symbol Explanation

    Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) NGK SPARK PLUG SYMBOL EXPLANATION 05-05-6 VMR2004_021_05_05A.FM...

  • Page 162: Accessories

    Section 05 ELECTRICAL Subsection 06 (ACCESSORIES) ACCESSORIES REMOVAL AND Detach bulb and replace. INSTALLATION CAUTION: It is recommended to always dis- connect the battery when replacing any electric or electronic parts. HEADLAMP Bulb Replacement Remove front facia. Remove rubber boot. Properly reinstall removed parts in the reverse or- der of their removal.

  • Page 163: Taillight

    Section 05 ELECTRICAL Subsection 06 (ACCESSORIES) Beam Aiming Adjustment AUXILIARY HEADLAMP Adjust beam aiming as follows: Baja and Baja X Models Remove the front facia. Bulb Replacement Using a long screwdriver, turn the adjusting screw Disconnect the auxiliary headlamp then remove it clockwise to lift the inside of headlamp and coun- from support.

  • Page 164: Tachometer

    Section 05 ELECTRICAL Subsection 06 (ACCESSORIES) TACHOMETER Remove the screw retaining the BLACK wire. Baja and Baja X Models Bulb Replacement The bulb in the tachometer is not replaceable. If the tachometer bulb is burnt, replace the tachometer. Removal Remove dashboard. Unplug wires under tachometer.

  • Page 165: Tests

    Section 05 ELECTRICAL Subsection 06 (ACCESSORIES) Press both tabs then push indicator lamp out of hole. Using a multimeter, measure the resistance be- tween the following wires. POSITION WIRE RESISTANCE RED/VIOLET Switch OFF Infinite (0.L) and GREEN RED/VIOLET Switch OFF Infinite (0.L) and BLUE RED/VIOLET...
  • Page 166 Section 06 DRIVE TRAIN Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FRONT DRIVE ........................06-02-1 GENERAL ........................... 06-02-2 WHEEL HUB........................06-02-2 WHEEL HUB BEARING ..................... 06-02-2 KNUCKLE ........................... 06-02-3 REAR AXLE ..........................06-03-1 GENERAL ........................... 06-03-2 DRIVE CHAIN ........................06-03-2 SLIDER-SHOE ........................

  • Page 167: Front Drive

    Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE) FRONT DRIVE 06-02-1 VMR2004_023_06_02A.FM...

  • Page 168: General

    Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE) GENERAL Install a new cotter pin. Both ends of cotter pin must be folded. For installation, use the torque values and Loctite CAUTION: Make sure each end of cotter pin products from the exploded views. Clean threads does not protrude too far and rubs against the before using Loctite when installing the screws.

  • Page 169: Knuckle

    Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE) Installation Use a ball joint remover and detach upper and low- er A-arm from knuckle. Drive in a new bearing squarely until it is fully seat- CAUTION: Never hit the knuckle with a hammer. Install inside bushing and drive the outer new Inspection bearing squarely until it is fully seated.

  • Page 170: Rear Axle

    Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) REAR AXLE 06-03-1 VMR2004_024_06-03A.FM...

  • Page 171: General

    Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) GENERAL Insert adjuster lock (from the vehicle’s tool kit) through rear hub and into eccentric axle housing. For installation, use the torque values and Loctite Turn the axle forward to increase or backward to products from the exploded views.

  • Page 172: Slider-Shoe

    Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) Inspection SLIDER-SHOE With the drive chain no. 1 installed on vehicle and Removal the free play adjusted correctly, measure the dis- tance between a span of 13 links from pin center Remove swing arm. Refer to REAR SUSPENSION. to pin center.

  • Page 173: Rear Sprocket

    Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) Installation Install sprocket with the flat side on hub side. For installation, reverse the removal procedure. Pay attention to the following details. Apply synthetic grease (P/N 293 550 019) on splines. IMPORTANT: Do not apply grease on axle threads.
  • Page 174 Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) CAUTION: Do not try to “open” the ends to re- lease the locking tab. It would impair its effi- ciency. To remove it, slide it out. Release rear brake. Remove caliper and place it on the swing arm. Re- Place transmission on first gear and/or apply rear fer to HYDRAULIC BRAKES.
  • Page 175 Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) Install the nut. Pay attention to position the flanged side of nut against the hub. 1. Flanged side against brake hub 1. Wear ring Temporarily tighten nut by hand. 2. Tool (P/N 529 035 694) 3.

  • Page 176: Rear Axle

    Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) REAR AXLE NOTE: If slots of nut are not properly aligned with slots of disc hub, continue tightening nut until slots align without exceeding 35 N•m (26 lbf•ft). Removal Lift rear of vehicle and install jack stands under the frame to support the rear of vehicle out off the ground.

  • Page 177: Rear Sprocket Hub

    Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) Inspection REAR SPROCKET HUB Check axle for bending, torsion or other damage. Removal Change if necessary. CAUTION: Removing rear sprocket hub from Check axle for spots of rust. A spot of rust indicates rear axle will permanently damage the hub a possible damage to axle.

  • Page 178: Eccentric Axle Housing

    Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) Turn rear axle upside down. Apply some synthetic grease (P/N 293 550 019) on splines. Press the hub out of rear axle. IMPORTANT: Do not apply grease on axle threads. Using the same steel tube as for removal, press hub until the C-clip groove allows C-clip insertion.
  • Page 179 Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) CAUTION: Be carful not to damage the seal be- ECCENTRIC AXLE LH O.D. tween surfaces. SERVICE LIMIT 75 mm (2.95 in) Use a soft tool to hammer out the eccentric axle housing if required. Seal leakage will occur after assembly if its bore is dented.

  • Page 180: Eccentric Axle Bearings

    Clean all grease, outside and inside, from ec- centric housing before putting in oven. 1. Eccentric axle housing Using a bearing packer, pack the bearing with 2. Position thin side here Bombardier Sea-Doo ® bearing grease (P/N 293 Install caliper bracket in place. 550 010).

  • Page 181: Protectors

    Section 06 DRIVE TRAIN Subsection 03 (REAR AXLE) PROTECTORS Apply grease to the race in the eccentric axle housing. Removal CAUTION: If the seal is pressed into a slippery bore, it will misalign or pop out when the vehi- LH Protector cle will be running, which will lead to bearing Remove brake disc hub with brake disc.
  • Page 182 Section 07 STEERING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ......................07-02-1 GENERAL ........................... 07-02-2 HANDLEBAR GUARD......................07-02-2 HANDLEBAR GRIP ......................07-02-2 HANDLEBAR ........................07-02-3 STEERING COLUMN ......................07-02-3 TIE-ROD..........................07-02-3 STEERING COLUMN BEARING..................07-02-4 MULTI-FUNCTION SWITCH ..................... 07-02-4 THROTTLE HANDLE......................

  • Page 183: Steering System

    Section 07 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) STEERING SYSTEM DS 650 Baja/Baja X DS 650 DS 650 Baja/Baja X 07-02-1 VMR2004_025_07_02A.FM...

  • Page 184: General

    The installation is the reverse of removal procedure. NOTE: Install a new handlebar grip screw. HANDLEBAR GRIP Removal DS 650 Models Remove: CAUTION: Installing handlebar grip without the – throttle lever and/or multi-function switch from special tool is likely to damage it.

  • Page 185: Handlebar

    Section 07 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) HANDLEBAR Inspection Inspect steering column for cracks, bending or oth- Removal er damages. Replace if any problem is detected. Remove: Check if the O-rings no. 23 are brittle, hard or oth- – steering cover no. 8 erwise damaged.

  • Page 186: Steering Column Bearing

    Section 07 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) STEERING COLUMN BEARING The maximum length for tie-rod groove to ball joint end must be the value A in the following chart: Removal Place vehicle on jack stands and remove front wheels. Remove steering column.

  • Page 187: Throttle Handle

    Section 07 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Separate multi-function switch from handlebar. Unscrew the locking nut of the cable adjuster then screw the adjuster to release the cable tension. Remove front facia. Refer to BODY. Remove throttle cable no. 36 from housing. Unplug multi-function switch connector.
  • Page 188 Section 08 SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FRONT SUSPENSION ......................08-02-1 GENERAL ........................... 08-02-2 SHOCKS ABSORBER ASS’Y..................... 08-02-2 SHOCK ABSORBER REBUILDING ..................08-02-3 UPPER A-ARM ........................08-02-7 LOWER A-ARM ........................08-02-9 BALL JOINT ........................08-02-10 REAR SUSPENSION......................08-03-1 GENERAL ...........................

  • Page 189: Front Suspension

    Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) FRONT SUSPENSION Baja/Baja X Baja X 08-02-1 VMR2004_026_08_02A.FM...

  • Page 190: General

    Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) GENERAL CAUTION: The Baja and Baja X models are equipped with shocks absorber protectors. Open or remove them if the vehicle is used intensively or if the ambient temperature is high. Otherwise, shock absorber performance degradation or damage can occur.

  • Page 191: Shock Absorber Rebuilding

    Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) Replace shock if any of these conditions are found. On both ends, check the bushings for excessive wear or other damages. Replace bushings in pair. Assembly and Installation For assembly and installation, reverse the disas- sembly and removal procedures.
  • Page 192 Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) NOTE: If an oil mist occurs, it is an indication of a Hold a rag over shock absorber end to catch float- faulty sealing of the floating piston either caused ing piston. Allow room for parts to leave shock ab- by wear of shock absorber or floating piston seal- sorber.
  • Page 193 Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) Compression stack: Ø28 x t0.38 Ø32 x t0.30 Ø33 x t0.25 Ø18 x t0.30 Ø33 x t0.3 Piston: 1 - Ø2.4 Assembly Tightly secure the shock absorber base in a vise with soft jaws. Apply shock absorber oil on floating piston seal.
  • Page 194 Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) Slowly push piston into shock absorber to prevent displacement of the floating piston. Apply a short stroke of slight up and down movement to allow air to pass through piston stack assembly. Gently tap with a clean soft hammer on the shock eye to dislodge air trapped in the submerged piston.

  • Page 195: Upper A-Arm

    Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) Carefully inspect shock absorber for gas or oil leaks. Any leak must be corrected before continuing. Stroke the piston rod to ensure full travel and smooth compression and rebound action. If the shaft moves in or out erratically or if you hear a gurgling sound, this could indicate air is trapped inside.
  • Page 196 Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) Inspection Remove cotter pin no. 10 (discard), castellated nut no. 11 and hardened washer no. 12 from upper Check upper A-arm for cracks, pitting, distortion or ball joint no. 13. other damages. Replace as required. Inspect pivot bushings for wear or damages.

  • Page 197: Lower A-Arm

    Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) LOWER A-ARM Inspection Check lower A-arm for cracks, distortion or other Removal damages. Replace as required. Remove cotter pin no. 10 (discard), castellated nut Inspect pivot bushings for wear or damages. no. 11 and hardened washer no. 12 retaining low- Replace pivot bushings if necessary.

  • Page 198: Ball Joint

    Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) BALL JOINT Inspection Upper Ball Joint Take the top of tire and check upper ball joint lateral play, by push and pull. The maximum lateral play should be 1.5 mm (.060 in). If the lateral play is out of specification, change the ball joints no.
  • Page 199 Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) Removal Remove upper or lower A-arm. Remove the circlip no. 17. Extract the ball joint. Installation CAUTION: The ball joints have an oblong shape and therefore must be properly installed in their oblong openings in the A-arms. Use the appro- priate template, supplied at the end of this sec- tion to ensure proper orientation of the ball joint relative to the A-arm.
  • Page 200 Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) Right/Left Upper Ball Joints Bend the template down, at the mark indicated. Insert the ball joint into the template with the cor- rect orientation. Flat grooves of ball joint must be in contact with the flat sides of the template. Place the ball joint and the template on the A-Arm and orient it in the way that the bent section of the template is between the two tubes of the A-arm.
  • Page 201 Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION) 08-02-13 VMR2004_026_08_02A.FM...

  • Page 202: Rear Suspension

    Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) REAR SUSPENSION Baja Baja X 08-03-1 VMR2004_027_08_03A.FM...

  • Page 203: General

    Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) GENERAL CAUTION: The Baja and Baja X models are equipped with shocks absorber protectors. Open or remove them if the vehicle is used in- tensively or if the ambient temperature is high. Otherwise, shock absorber performance deg- radation or damage can occur.
  • Page 204 Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) Disassembly Pay attention to the following conditions that will denote a defective shock absorber: WARNING – a skip or a hang back when reversing stroke at mid travel The shock absorber contains high pressure ni- trogen gas.
  • Page 205 Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) Before adjusting the spring preload, first measure Preload Adjustment: the ATV’s height, without rider, from the rear bumper To reduce: nut to the ground. • Turn the shock spring adjuster counterclock- NOTE: Lift the vehicle by the rear bumper. The wise for a light load and smooth condition.

  • Page 206: Shock Absorber Rebuilding

    Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) Unscrew valve cap from reservoir. WARNING Whenever working with high pressure gas, use eye wear protection. Never direct gas pressure toward anybody. Release gas pres- sure before removing components. Place a rag over valve to protect against possible mist and to prevent gas being directed towards someone.
  • Page 207 Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) CAUTION: Be careful not to scratch inside wall Shock Absorber of reservoir or C-clip. Also be careful not to dis- Tightly secure the shock absorber bottom eyelet tort the C-clip. in a vise with soft jaws. Empty oil from reservoir.
  • Page 208 Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) Inspection Using a suitable punch, gently punch seal carrier ass’y down alternating each side. Push down just Check the following: enough to free the C-clip. Using a small tool, re- – Compression bumpers for chipping, cracking move the C-clip.
  • Page 209 Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) Air will escape in shock absorber. Repeat the pumping twice. Hold reservoir lower than shock absorber. Temporarily install bladder upside down on shock absorber. Push down enough to have a tight seal. Squeeze bladder to pump oil towards reservoir. Ensure enough oil remain in shock absorber.
  • Page 210 Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) Reinstall valve pin in reservoir valve. Shock Absorber Wrap shock absorber in a rag to collect oil over- flow while installing piston rod. Apply shock absorber oil on piston seal ring. Pour oil in shock absorber so that it is filled to 3/4. Carefully insert piston rod in shock absorber.

  • Page 211: Swing Arm

    Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) 3. Open nitrogen tank valve and gradually set reg- Reinstall valve cap. ulator pressure to 980 kPa (142 PSI), this gas Reinstall spring and adjuster, then perform adjust- pressure will restore the correct pressure into ments.
  • Page 212 Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) Measure shaft diameter on bearing contact sur- face. If it is lower than 19.7 mm (.776 in), replace shaft. Installation Installation is essentially the reverse of removal procedure. However, pay attention to the follow- ing details.
  • Page 213 Section 09 BRAKES Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS HYDRAULIC BRAKES......................09-02-1 FRONT BRAKES ........................ 09-02-1 REAR BRAKE ........................09-02-2 GENERAL ........................... 09-02-3 HYDRAULIC BRAKES SYSTEM ..................09-02-3 MASTER CYLINDER ......................09-02-4 CALIPER ..........................09-02-6 BRAKE PADS ........................09-02-7 BRAKE DISC........................

  • Page 214: Hydraulic Brakes

    Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) HYDRAULIC BRAKES FRONT BRAKES 09-02-1 VMR2004_028_09_02A.FM...

  • Page 215: Rear Brake

    Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) REAR BRAKE 09-02-2 VMR2004_028_09_02A.FM...

  • Page 216: General

    Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) GENERAL For installation, use the torque values and Loctite products from the exploded views. Clean threads before using Loctite when installing the screws. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be in- stalled or replaced with new ones where...

  • Page 217: Master Cylinder

    Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) MASTER CYLINDER NOTE: Check fluid level often to prevent air from being pumped into the system. Removal Repeat the procedures until air bubbles don’t ap- pear in bleed hose. Front Brakes NOTE: For the front brake system, switch to LH Drain brake fluid from master cylinder no.
  • Page 218 Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Discard sealing washers. – master cylinders and pistons for scoring, scratch- es or other damage. Unhook push rod no. 19 from brake pedal no. 5. Change part(s) if necessary. Remove bolts no. 20 retaining master cylinder to frame.

  • Page 219: Caliper

    Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Front Brakes Remove wheels. Place the master cylinder no. 8 on the handlebar. Position cylinder holding bracket with the UP mark upward. Install bolts and tighten loosely. With the handlebar in straight ahead position, po- sition cylinder reservoir parallel to the ground.

  • Page 220: Brake Pads

    Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Disassembly Installation Remove brake pads, see the following section. For the installation, reverse the removal proce- dure, pay attention to the following details. Remove: Use new sealing washers when installing Banjo – caliper bracket no. 32 bolt retaining brake hose to caliper.

  • Page 221: Brake Disc

    Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Unscrew pad pins and remove pads no. 37. Discard pad pins. Inspection CAUTION: Do not clean brake pads in petro- leum based solvent. Use brake system cleaner. Soiled brake pads must be replaced by new ones.

  • Page 222: Brake Lever

    Remove circlip no. 41, washer no. 42 and O-ring no. 43 then remove pedal no. 5 from pivot. Remove the O-ring no. 44 on the pivot. NOTE: Clean O-ring and pivot pin with BOMBARDIER LUBE (P/N 293 600 016). Installation For installation, reverse the removal procedure.

  • Page 223: Brake Light Switch

    Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) BRAKE LIGHT SWITCH Installation For installation, reverse the removal procedure. Removal NOTE: Apply pipe sealant on threads. Front Brake Light Switch Bleed the brake system. The front brakes switch no. 45 is located on the master cylinder and cannot be adjusted.
  • Page 224 Section 10 BODY/FRAME Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS BODY............................10-02-1 BODY PARTS ........................10-02-1 SEAT........................... 10-02-3 SEAT........................... 10-02-4 DASHBOARD ........................10-02-4 FRONT SKID PLATE/FRONT BUMPER................10-02-4 MUDGUARD/FRONT FENDER/SUPPORT................ 10-02-4 FRONT FACIA ........................10-02-5 FRONT FACIA BRACKET....................10-02-5 AUXILIARY HEADLAMP SUPPORT..................

  • Page 225: Body

    Section 10 BODY/FRAME Subsection 02 (BODY) BODY BODY PARTS DS 650 Models 10-02-1 VMR2004_029_10_02A.FM...
  • Page 226 Section 10 BODY/FRAME Subsection 02 (BODY) DS 650 Baja and Baja X Models X models only in 22 X models only 10-02-2 VMR2004_029_10_02A.FM...

  • Page 227: Seat

    Section 10 BODY/FRAME Subsection 02 (BODY) SEAT 10-02-3 VMR2004_029_10_02A.FM...

  • Page 228: Dashboard

    Remove screws no. 6. Front Bumper WARNING Remove front skid plate no. 7 (DS 650 models). Make sure both front tabs are properly hooked on frame before riding. Remove bolts no. 8 then the front bumper no. 9. Installation Installation is the reverse order of removal.

  • Page 229: Front Facia

    Section 10 BODY/FRAME Subsection 02 (BODY) Installation Remove bolts no. 15 retaining the support no. 16 to the knuckle. Installation is the reverse order of removal. Installation FRONT FACIA BRACKET For the installation, reverse the removal procedure. WARNING FRONT FACIA Never perform this operation immediately af- ter the engine has been run because the oil Removal...

  • Page 230: Foot Protector/Foot Protector Support

    Section 10 BODY/FRAME Subsection 02 (BODY) Installation On the front side, unscrew the bolts no. 23 retain- ing the fuel tank cover and oil tank. Installation is the reverse order of removal. On the rear side, unscrew the bolts no. 24 and remove spacers no.

  • Page 231: A-Arm Protector Plate

    Section 10 BODY/FRAME Subsection 02 (BODY) Baja X Models only On wheel side, secure with a bolt no. 52 and a nut no. 51. Installation is the reverse of the removal but pay attention to the following: Fully turn the handlebar into both directions and check for interference.

  • Page 232: Latch Base/Latch Lever/Spring

    Section 10 BODY/FRAME Subsection 02 (BODY) Inspection Check nerf bar for cracks or bents and net strap for wear. Change or repair as required. Installation Installation is essentially the reverse of removal procedure but pay attention to the following: After installing the net strap on the frame, make sure to tight it properly.

  • Page 233: Seat Cleaning

    Section 10 BODY/FRAME Subsection 02 (BODY) Installation There are 2 types of decals used on ATV’s. One has a protective film on back side and the other has a protective film on both sides. They are used on 2 types of materials; plastic and metal. Decals Having a Protective Film on Back Side Only These decals usually contain written information...

  • Page 234: Repair

    Section 10 BODY/FRAME Subsection 02 (BODY) CAUTION: The following products must not be used to clean or wax any of the plastic compo- nents used on the vehicles: – gasoline – brake fluid – kerosene – diesel fuel – lighter fluid –...

  • Page 235: Frame

    Section 10 BODY/FRAME Subsection 03 (FRAME) FRAME DS 650 Baja/Baja X DS 650 10-03-1 VMR2004_030_10_03A.FM...

  • Page 236: Footpeg

    Section 10 BODY/FRAME Subsection 03 (FRAME) FOOTPEG Inspection Check for cracks or bent tube. Change or repair if Removal necessary. Baja X Models Installation Remove short plates no. 10,bolt no. 11 and nut no. 12. For installation, reverse the removal procedure. REAR FRAME EXTENSION Removal Remove:...
  • Page 237 Section 10 BODY/FRAME Subsection 03 (FRAME) Cleaning Clean frame no. 4 and rear extension frame no. 3 with appropriate cleaners and rinse with high pres- sure hose. Touch up all metal spots where paint has been scratched off. Spray all bare metal parts of vehicle with metal protector.

  • Page 238: Technical Data

    Section 11 TECHNICAL DATA Subsection 01 (SI METRIC INFORMATION GUIDE) TECHNICAL DATA SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length ..............meter ............. mass ..............kilogram ..........force ..............newton ........... liquid ..............liter ............temperature ............Celsius ........... °C pressure ..............
  • Page 239 (gap from sealing face to piston of chain tensioner) Lubrication Dry Sump Lubrication by Oil Pump Replaceable Oil Filter Oil Filter Main-Flow Type Air Filter Type Cleanable Synthetic Panelette/Foam Type Bombardier, Stainless Header Pipe Painted Steel Muffler Exhaust System Spark Arrester USFS Approved 11-02-1 VMR2004_031_11_02A.FM...
  • Page 240 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) VEHICLE MODEL DS 650 DS 650 BAJA DS 650 BAJA X Magneto/Generator 290 W @ 6000 RPM Ignition System Type CDI (Capacitor Discharge Ignition) Make and Type NGK DR8EA Spark Plug mm (in) 0.65 (.026)
  • Page 241 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) VEHICLE MODEL DS 650 DS 650 BAJA DS 650 BAJA X Transmission Type Integrated 5-Speed Constant Mesh Transmission Clutch 1 Multi-Disc Clutch Drum I.D. mm (in) 145 (5.71) Friction Plate Warpage (fall through a slot) mm (in) 3.75 (.1476)
  • Page 242 SAE 10W40, 4 Stroke Mineral Based Oil SG, SH or SJ or Bombardier synthetic oil 5W40 (P/N 293 600 039). Engine/Transmission Oil Recommended Do Not Use Synthetic Oil, other than Bombardier brand name or any Synthetic Blend Oil. Refer to OIL VISCOSITY CHART for proper grade. Capacity 250 mL (8.5 U.S.
  • Page 243 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) VEHICLE MODEL DS 650 DS 650 BAJA DS 650 BAJA X Material Steel Frame Color Grey Material Steel Aluminum Front/Rear Bumper Color Grey Aluminum Material High Density Polyethylene Front/Rear Fender Color...
  • Page 244 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) VEHICLE MODEL DS 650 DS 650 BAJA DS 650 BAJA X ENGINE 26 N•m (19 lbf•ft) Engine Support 64 N•m (47 lbf•ft) 135 N•m (100 lbf•ft) Spark Plug 20 N•m (15 lbf•ft) Magneto Nut 180 N•m (133 lbf•ft)
  • Page 245 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) VEHICLE MODEL DS 650 DS 650 BAJA DS 650 BAJA X SUSPENSION Front 48 N•m (35 lbf•ft) Shock Absorber Bolt Rear 85 N•m (63 lbf•ft) Rear Swing Arm LH First Nut 100 N•m (74 lbf•ft), Unscrew Nut a Quarter Turn...

  • Page 246: Wiring Diagrams

    Section 12 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS WARNING Ensure all terminals are properly crimped on the wires and all connector housings are properly fastened. WIRE COLORS It identifies the color of a wire. When a 2-color scheme is used, the first color is the main color while the second color is the tracer color.
  • Page 247 Section 12 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) DS 650 12-01-2 VMR2004_032_12_01A.FM...
  • Page 248 Section 12 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) DS 650 Baja/Baja X 12-01-3 VMR2004_032_12_01A.FM...

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