BOMBARDIER DS 650 Install guide

Shop Manual
2004
DS 650TM
DS 650TM BAJA
DS 650TM BAJA X

Legal deposit:
National Library of Quebec
2nd 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.
Valcourt (Québec) Canada
Printed in Canada
®Registered trademarks of Bombardier Inc. and its subsidiaries.
This document contains the trademarks of the following companies:
Kimtowels®is a trademark of Kimberly-Clark
Loctite®is a trademark of Loctite Corporation
Molykote®is a trademark of Dow Corning Corporation
Snap-on®is a trademark of Snap-on Tools Corporation

VMR2004_001_00_02A.FM I
SECTION SUBSECTION PAGE
SAFETY NOTICE ................................................................................................................................... III
INTRODUCTION .................................................................................................................................. IV
01 SERVICE TOOLS AND
SERVICE PRODUCTS
01 – Table of contents...................................................................... 01-01-1
02 – Service tools............................................................................. 01-02-1
03 – Service products....................................................................... 01-03-1
02 MAINTENANCE 01 – Table of contents...................................................................... 02-01-1
02 – Maintenance chart.................................................................... 02-02-1
03 – Maintenance/lubrication ........................................................... 02-03-1
04 – Storage/preseason preparation ................................................ 02-04-1
03 ENGINE 01 – Table of contents...................................................................... 03-01-1
02 – Troubleshooting........................................................................ 03-02-1
03 – Leak test................................................................................... 03-03-1
04 – Removal and installation........................................................... 03-04-1
05 – Cooling system......................................................................... 03-05-1
06 – Magneto system ...................................................................... 03-06-1
07 – Lubrication system................................................................... 03-07-1
08 – Cylinder and head..................................................................... 03-08-1
09 – Crankshaft/balancer shaft......................................................... 03-09-1
10 – Clutch ....................................................................................... 03-10-1
11 – Transmission ............................................................................ 03-11-1
04 FUEL SYSTEM 01 – Table of contents...................................................................... 04-01-1
02 – Fuel circuit................................................................................ 04-02-1
03 – Carburetor and air intake silencer............................................. 04-03-1
05 ELECTRICAL 01 – Table of contents...................................................................... 05-01-1
02 – Overview.................................................................................. 05-02-1
03 – Charging system ...................................................................... 05-03-1
04 – Starting system ........................................................................ 05-04-1
05 – Ignition system......................................................................... 05-05-1
06 – Accessories.............................................................................. 05-06-1
06 DRIVE TRAIN 01 – Table of contents...................................................................... 06-01-1
02 – Front drive ................................................................................ 06-02-1
03 – Rear axle .................................................................................. 06-03-1
07 STEERING SYSTEM 01 – Table of contents...................................................................... 07-01-1
02 – Steering system ....................................................................... 07-02-1
08 SUSPENSION 01 – Table of contents...................................................................... 08-01-1
02 – Front suspension...................................................................... 08-02-1
03 – Rear suspension....................................................................... 08-03-1
09 BRAKES 01 – Table of contents...................................................................... 09-01-1
02 – Hydraulic brakes....................................................................... 09-02-1
TABLE OF CONTENTS

II VMR2004_001_00_02A.FM
10 BODY/FRAME 01 –Table of contents ..................................................................... 10-01-1
02 –Body......................................................................................... 10-02-1
03 –Frame....................................................................................... 10-03-1
11 TECHNICAL DATA 01 –SI metric information guide...................................................... 11-01-1
02 –Engine and vehicle................................................................... 11-02-1
12 WIRING DIAGRAMS 01 –Wiring diagrams....................................................................... 12-01-1
SECTION SUBSECTION PAGE
TABLE OF CONTENTS