BOMBARDIER DS 650 Baja X 2004 Manuals

Manuals and User Guides for BOMBARDIER DS 650 Baja X 2004. We have 1 BOMBARDIER DS 650 Baja X 2004 manual available for free PDF download: Shop Manual

BOMBARDIER DS 650 Baja X 2004 Shop Manual

BOMBARDIER DS 650 Baja X 2004 Shop Manual (248 pages)

Brand: BOMBARDIER | Category: Offroad Vehicle | Size: 15 MB

Table of Contents

Table of Contents

39
- General Information
  11
- Tightening Torques
  14
- Service Tools
  18
- Service Products
  32
- Maintenance Chart
  40
- Noise Emission Control System Regulation
  40
- Maintenance/Lubrication
  
  42
- Maintenance Chart
  
  43
  - Adjust Valve Clearance
    43
  - Clutch Adjustment
    43
  - Drive Chain
    44
  - Air Filter Cleaning/Draining
    45
  - Bolts, Fasteners and Nuts
    46
  - Engine Oil and Filter
    46
  - Bolts/Fasteners/Nuts
    46
  - Spark Arrester
    47
  - Tires and Wheels
    48
  - Engine Area
    49
- Storage/Preseason Preparation
  
  50
- Storage
  
  50
  - Fuel Stabilizer
    50
  - Engine Lubrication
    50
  - Rags in Air Intake and Exhaust System
    50
  - Vehicle Cleaning and Protection
    50
  - Coolant Density
    51
- Preseason Preparation
  
  52
Table of Contents

53
- Troubleshooting
  
  56
- Cooling System
  
  56
- Magneto System
  
  57
- Lubrication
  
  58
- Cylinder and Head
  
  60
- Crankshaft and Balancer Shaft
  
  61
- Gearbox
  
  62
- Engine General
  
  63
- Leak Test
  
  70
  - Verification
    70
- Leak Test Procedure
  
  70
  - Preparation and Test
    70
  - Diagnose
    72
- Removal and Installation
  
  73
  - General
    74
  - Engine Removal
    74
  - Engine Installation
    76
  - Countershaft Sprocket
    76
  - Exhaust System
    77
  - Oil Tank
    77
- Cooling System
  
  78
- Radiator
  
  78
- Water Pump
  
  79
  - Cooling System Leak Test
    80
  - Inspection
    80
  - Draining the System
    80
  - Cooling System Refilling
    81
  - Pressure Cap
    81
  - Water Pump
    81
  - Radiator
    81
  - Radiator Protector
    82
  - Thermostat
    82
  - Coolant Tank
    82
  - Fan and Heat Shield
    83
  - Temperature Switch
    84
  - Temperature Sensor
    85
  - General
    87
  - Stator
    87
  - Rotor
    88
  - Sprag Clutch
    88
  - Trigger Coil
    89
  - Rotor Hub
    89
- Engine Lubrication
  
  91
  - General
    93
  - Engine Pressure Test
    93
  - Oil Change and Oil Filter Replacement
    93
  - Oil Tank Strainer
    95
  - Engine Oil Pressure Regulator
    95
  - Return Oil Pump
    96
  - Pressure Oil Pump
    97
  - Engine Oil Strainer
    97
  - Oil Tank
    98
- Lubrication System
  
  91
- Cylinder and Head
  
  99
- Valve
  
  100
  - General
    101
  - Cylinder Head Cover
    101
  - Adjust Valve Clearance
    102
  - Camshaft
    102
  - Centrifugal Decompressor
    104
  - Cylinder Head
    105
  - Valve Spring
    105
  - Valve
    105
  - Valve Stem Seal
    106
  - Valve Guide
    106
  - Valve Guide Removal
    107
  - Cylinder
    109
- Crankshaft/Balancer Shaft
  
  110
  - Piston Pin
    111
  - Piston
    111
  - Piston Rings
    113
  - Balancer Shaft
    113
  - Balancer Gear
    115
  - Crankshaft
    115
  - Counter Gear
    116
  - Crankshaft Bushing
    116
  - Ball Bearings in Housing
    116
  - Recenter Crankshaft
    117
  - Recenter Balancer Shaft
    117
- Clutch
  
  118
  - General
    119
  - Clutch Adjustment
    119
  - Clutch Cover
    119
  - Pressure Plate
    120
  - Pressure Plate Bearing
    120
  - Friction Drive Plate, Steel Driven Plate and Clutch Basket
    121
  - Clutch Release Shaft
    123
- Transmission
  
  125
  - Shifting Mechanism
    126
  - Transmission
    127
  - Transmission Shaft Bearings
    128
Table of Contents

129
- Fuel Circuit
  
  130
  - Fuel Line
    131
  - Fuel Tank
    131
  - Fuel Valve
    131
  - Fuel System Pressurization
    132
- Carburetor and Air Intake Silencer
  
  133
- Carburetor
  
  133
- Air Intake Silencer
  
  134
  - General
    135
  - Carburetor
    135
  - Throttle Cable
    138
  - Air Intake Silencer
    140
Table of Contents

141
- Overview
  
  143
- General Operation Information
  
  143
  - Charging System
    143
  - Starting System
    143
  - Ignition System
    144
  - Accessories
    144
- General Testing/ Troubleshooting Information
  
  144
  - Fuses Location
    145
  - Servicing Packard Connectors
    145
  - Servicing Deutsch Connectors
    145
  - Identification of Major Connector Pins
    147
- Charging System
  
  148
  - Testing Procedure
    148
- Battery
  
  150
  - Troubleshooting
    150
  - Battery Testing
    150
  - Removal
    150
  - Cleaning
    150
  - Inspection
    151
  - Battery Storage
    151
  - Activation of a New Battery
    151
  - Installation
    151
- Starting System
  
  150
- Starting System Troubleshooting
  
  152
- Starting System Tests
  
  153
  - General
    153
- Electric Starter
  
  154
  - Removal
    154
  - Installation
    154
  - Cable Terminal Installation
    154
- Ignition System
  
  156
- Ignition System Testing Procedure
  
  156
  - General
    156
  - Ignition System Test
    156
  - Ignition Timing
    159
- Spark Plug
  
  160
  - Disassembly
    160
  - Fouling
    160
  - Spark Plug Analysis
    160
  - Spark Plug Installation
    160
- Ngk Spark Plug Symbol Explanation
  
  161
- Removal and Installation
  
  162
  - Headlamp
    162
  - Taillight
    163
  - Auxiliary Headlamp
    163
  - Tachometer
    164
  - Ignition Switch
    164
  - Indicator Lights
    164
- Accessories
  
  162
- Tests
  
  165
  - Cooling Fan Operation Test
    165
  - Headlamp
    165
  - Multi-Function Switch
    165
  - Indicator Lights
    165
Table of Contents

166
- Front Drive
  
  167
  - General
    168
  - Wheel Hub
    168
  - Wheel Hub Bearing
    168
  - Knuckle
    169
- Rear Axle
  
  170
  - General
    171
  - Drive Chain
    171
  - Slider-Shoe
    172
  - Chain Roller
    172
  - Rear Wheel Hub
    172
  - Rear Sprocket
    173
  - Brake Disc Hub
    173
  - Rear Axle
    176
  - Rear Sprocket Hub
    177
  - Eccentric Axle Housing
    178
  - Eccentric Axle Bearings
    180
  - Protectors
    181
Table of Contents

182
- Steering System
  183
- General
  184
- Handlebar Grip
  184
- Handlebar Guard
  184
- Handlebar
  185
- Steering Column
  185
- Tie-Rod
  185
- Multi-Function Switch
  186
- Steering Column Bearing
  186
- Throttle Handle
  187
Front Suspension/Rear Suspension

188
- Front Suspension
  
  189
  - General
    190
  - Shocks Absorber Ass'y
    190
  - Shock Absorber Rebuilding
    191
  - Upper A-Arm
    195
  - Lower A-Arm
    197
  - Ball Joint
    198
- Rear Suspension
  
  202
  - General
    203
  - Shock Absorber Ass'y
    203
  - Shock Absorber Rebuilding
    206
  - Swing Arm
    211
Table of Contents

213
- Hydraulic Brakes
  
  214
- Front Brakes
  
  214
- Rear Brake
  
  215
  - General
    216
  - Hydraulic Brakes System
    216
  - Master Cylinder
    217
  - Caliper
    219
  - Brake Pads
    220
  - Brake Disc
    221
  - Brake Lever
    222
  - Brake Pedal
    222
  - Brake Light Switch
    223
  - Rear Caliper Bracket
    223
Table of Contents

224
- Body
  
  225
- Body Parts
  
  225
- Seat
  
  227
  - Dashboard
    228
  - Front Skid Plate/Front Bumper
    228
  - Mudguard/Front Fender/Support
    228
  - Front Facia
    229
  - Front Facia Bracket
    229
  - Auxiliary Headlamp Support
    229
  - Fuel Tank Cover
    229
  - Foot Protector/Foot Protector Support
    230
  - Rear Fender
    230
  - Rear Bumper
    230
  - Engine Skid Plate
    230
  - A-Arm Protector Plate
    231
  - Nerf Bar
    231
  - Latch Base/Latch Lever/Spring
    232
  - Seat Adjustment
    232
  - Seat Cover Replacement
    232
  - Seat Cleaning
    233
  - Decals Replacement
    233
- Plastic Maintenance/Repair
  
  233
  - Maintenance
    233
  - Repair
    234
- Frame
  
  235
  - Footpeg
    236
  - Dashboard Support
    236
  - Rear Frame Extension
    236
  - Frame
    236
    
    Technical Data
    238
    
    Wiring Diagrams
    246

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