BOMBARDIER DS 650 Manual

vmo2006 DS 650 X ang.FH8 Fri Mar 18 09:56:14 2005 Page 1
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This Operator’s Guide utilizes the following symbols to emphasize particular in-
formation:
The Safety Alert Symbol indicates a potential personal injury hazard.
WARNING Indicates a potential hazard that, if not avoided, could result in
serious injury or death.
CAUTION: Denotes an instruction which, if not followed, could severely
damage vehicle components.
WARNING
YOUR VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rollover
can occur quickly, even during routine maneuvers such as turning and driv-
ing on hills or over obstacles, if you fail to take proper precautions.
For your safety, understand and follow all the warnings contained in this Op-
erator's Guide and the labels on your vehicle. Failure to follow these warn-
ings can result in SEVERE INJURY OR DEATH!
Keep this Operator's Guide with the vehicle at all times.
WARNING
Disregarding any of the safety precautions and instructions contained in this
Operator’s Guide, Safety Videocassette and on-product labels could cause
injury including the possibility of death!
WARNING
This ATV may exceed the performance of other ATVs you have ridden in
the past. This category S (sport) is a high performance ATV for off road use
only. It is for sport type recreational and competitive use by operators with
advanced skills and substantial experience.
All safety documentation should remain with the vehicle at the time of sale.
All content of the Safety Information section should be interpreted by the reader
as a warning which, if not followed, may result in injury including the possibility
of death.
In Canada, products are distributed by Bombardier Recreational Products Inc.
(BRP). In USA, products are distributed by BRP US Inc.
The following trademarks are the property of Bombardier Recreational Products
Inc.:
DS650TM Rotax®XP-STM
Printed in Canada. (vmo2006-003 DR)
®™Trademarks of Bombardier Recreational Products Inc. or its affiliates.
©2005 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
* Trademark of Bombardier Inc. used under license.

FOREWORD
Congratulations on your purchase of
a new Bombardier*recreational vehi-
cle. It is backed by the BRP warran-
ty and a network of authorized Bom-
bardier ATV dealers ready to provide
the parts, service or accessories you
may require.
Your dealer is committed to your satis-
faction. He has taken training to per-
form the initial setup and inspection
of your vehicle as well as completed
the final adjustment before you took
possession. At delivery, your dealer
would have explained the operation,
maintenance and safety features of
the vehicle. We trust you have tak-
en full advantage of this! If you need
more complete servicing information,
please ask your dealer.
Atdelivery,youwerealsoinformedof
the warranty coverage and completed
the Warranty Registration Form which
is to be sent to us for processing. In
the near future you should be receiv-
ing a warranty card which will confirm
our receipt of the registration as well
as be used for warranty or recall pur-
poses.
You are invited to contact our cus-
tomer assistance center should you
experience problems which cannot be
resolved by an authorized Bombardier
ATV dealer.
It is understood that this Operator’s
Guide may be translated into another
language. In the event of any discrep-
ancy, the English version shall prevail.
Throughout this document the mascu-
line is used to denote the masculine or
feminine.
The information and components/sys-
tem descriptions contained in this doc-
ument are correct at the time of publi-
cation. BRP, however, maintains a pol-
icy of continuous improvement of its
products without imposing upon itself
any obligation to install them on prod-
ucts previously manufactured. Due to
late changes, some differences be-
tween the manufactured product and
the descriptions and/or specifications
in this guide may occur. BRP reserves
the right at any time to discontinue
or change specifications, designs, fea-
tures, models or equipment without
incurring any obligation upon itself.
The illustrations in this document
show the typical construction of the
different assemblies and may not re-
produce the full detail or exact shape
of the parts. However, they represent
parts that have the same or similar
function.
The use of RIGHT and LEFT indica-
tions in the text always refers to driv-
ing position (when sitting on vehicle).
Specifications are given in the SI met-
ric system with the SAE U.S. equiva-
lent in parenthesis. Where precise ac-
curacy is not required, some conver-
sions are rounded off for easier use.
We recommend genuine BRP prod-
ucts for replacement parts and acces-
sories. They’ve been especially de-
signed for your vehicle and manufac-
tured to meet BRP’s demanding stan-
dards.
AShop Manual can be obtained for
complete service and maintenance in-
formation and more repair information.
______________________ 1

TABLE OF CONTENTS
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious in-
jury or death.
NOTICE................................................................................. 7
INTRODUCTION ...................................................................... 8
SAFETY INFORMATION
SPECIAL SAFETY MESSAGES .................................................... 10
OPERATION WARNINGS........................................................... 13
SAFETY WARNING.................................................................. 39
Pre-Operation Check ............................................................ 40
Clothing........................................................................... 41
Carrying Loads ................................................................... 42
Recreational Riding.............................................................. 42
Environment...................................................................... 42
Design Limitation ................................................................ 43
Off-Highway Operation.......................................................... 43
General Operating and Safety Precautions.................................... 43
Uphill Driving ..................................................................... 44
Downhill Driving.................................................................. 44
Side Hilling........................................................................ 44
Drop-Offs......................................................................... 44
Riding Techniques ............................................................... 44
Routine Maintenance............................................................ 50
HANG TAG ........................................................................... 52
LOCATION OF THE IMPORTANT LABELS....................................... 53
VEHICLE INFORMATION
HOW TO IDENTIFY YOUR ATV.................................................... 58
NOISE EMISSION CONTROL SYSTEM REGULATION ........................ 59
EMISSION REQUIREMENTS ...................................................... 60
CONTROLS/COMPONENTS/INSTRUMENT.................................... 61
1) Throttle Lever ................................................................. 63
2) Front Brake Lever............................................................. 63
3) Clutch Lever................................................................... 64
4) Parking Lever Lock ........................................................... 64
5) Multi-Function Switch ........................................................ 65
2_______________________

6) Fuel Tank Cap ................................................................. 66
7) Ignition Switch ................................................................ 66
8) Indicator Lamps............................................................... 66
9) Front Brake Fluid Reservoir.................................................. 66
10) Fuel Valve .................................................................... 67
11) Gearshift Pedal .............................................................. 67
12) Tool Box ...................................................................... 68
13) Seat Latch.................................................................... 68
14) Footpeg....................................................................... 69
15) Foot Brake Pedal ............................................................ 69
16) Rear Brake Fluid Reservoir ................................................. 69
17) Engine/Transmission Oil Tank Cap......................................... 69
18) Tachometer .................................................................. 70
19) Auxiliary Headlamps......................................................... 70
20) Nerf Bar ...................................................................... 70
21) Radiator Cap ................................................................. 70
LIQUIDS............................................................................... 72
Fuel................................................................................ 72
Engine/Transmission Oil......................................................... 72
Engine Coolant................................................................... 74
Brake Fluid........................................................................ 75
Battery ............................................................................ 76
BREAK-IN PERIOD................................................................... 77
OPERATING INSTRUCTIONS...................................................... 78
General............................................................................ 78
Pre-Operation Check ............................................................ 78
Initial Cold Starting............................................................... 78
Warm Engine Starting........................................................... 79
Stopping the Engine............................................................. 79
Shifting the Transmission ....................................................... 79
SPECIAL PROCEDURES............................................................ 81
Flooded Engine................................................................... 81
Engine Overheat................................................................. 81
Turn Over ......................................................................... 81
ATV Immersion................................................................... 82
Post-Operation Care............................................................. 82
Storage and Preseason Preparation............................................ 82
______________________ 3

CARGO AND TRANSPORTATION................................................. 83
TROUBLESHOOTING............................................................... 84
SPECIFICATIONS .................................................................... 87
MAINTENANCE INFORMATION
MAINTENANCE CHART ............................................................ 92
GENERAL ............................................................................. 96
ENGINE/TRANSMISSION.......................................................... 97
Oil Change and Oil Filter Replacement........................................ 97
Coolant Replacement ........................................................... 98
Valves Adjustment............................................................... 98
Spark Arrester.................................................................... 99
Radiator......................................................................... 100
Gearshift Pedal Adjustment .................................................. 100
CARBURETOR ..................................................................... 101
AIR INTAKE SYSTEM ............................................................. 102
Air Filter Cleaning/Draining.................................................... 102
ELECTRICAL........................................................................ 104
Battery .......................................................................... 104
Fuses............................................................................ 104
Bulb Replacement............................................................. 105
Indicator Lamp Replacement................................................. 107
Beam Aiming Adjustment..................................................... 107
DRIVE TRAIN....................................................................... 108
Swing Arm and Wheel Hub................................................... 108
Drive Chain ..................................................................... 108
Drive Chain Slider.............................................................. 109
Sprocket and Pinion ........................................................... 109
Tires/Wheels.................................................................... 110
Front Wheel Bearing Condition............................................... 110
Rear Axle Inspection........................................................... 110
STEERING SYSTEM............................................................... 111
Throttle Cable Lubrication..................................................... 111
Throttle Lever Adjustment.................................................... 112
Clutch Cable Lubrication ...................................................... 113
SUSPENSION ...................................................................... 114
Lubrication...................................................................... 114
Inspection....................................................................... 114
Adjustment..................................................................... 114
BRAKES............................................................................. 117
BODY/FRAME...................................................................... 118
Engine Area .................................................................... 118
4_______________________

Skid Plate....................................................................... 118
Front Fenders .................................................................. 118
Fasteners....................................................................... 118
Seat Latch ...................................................................... 118
Frame ........................................................................... 118
Vehicle Cleaning and Protection.............................................. 118
WARRANTY
BRP LIMITED WARRANTY NORTH AMERICA: 2005 BOMBARDIER†ATV 120
BRP INTERNATIONAL LIMITED WARRANTY: 2005 BOMBARDIER†ATV 124
PRIVACY OBLIGATION/DISCLAIMER.......................................... 127
CHANGE OF ADDRESS/OWNERSHIP ......................................... 129
______________________ 5

6_______________________

NOTICE
This Operator's Guide has been pre-
pared to acquaint the owner/operator
of a new vehicle with the various ve-
hicle controls, maintenance and safe
operating instructions. It is indispens-
able for the proper use of the product.
This Operator's Guide uses the follow-
ing symbols.
WARNING
Indicates a potential hazard that, if
not avoided, could result in serious
injury or death.
CAUTION: Denotes an instruction
which, if not followed, could se-
verely damage vehicle compo-
nents.
NOTE: Indicates supplementary infor-
mation needed to fully complete an in-
struction.
Although the mere reading of such in-
formation does not eliminate the haz-
ard, the understanding and application
of the information will promote the
correct use of this vehicle.
To fully appreciate the pleasures, en-
joyment and excitement of using this
vehicle, there are some basic rules
that MUST be observed and followed
by any user.
______________________ 7

INTRODUCTION
Your dealer should have provided you
with some basic information on the
particular controls and features of
your new vehicle. Please take the
time to study this Operator's Guide
and all on-product warning labels as
well as the Safety Videocassette that
came with this vehicle. They more
completely describe what you should
know about this vehicle before riding
it.
Whether you are a new user or an ex-
perienced rider, it is important for your
personal safety as well as passenger
safety that you know the controls and
features of this vehicle. Equally impor-
tant is knowing how to properly ride.
Irrespective of your age, experience or
state regulations, it is always prudent
for you or any other person who may
ride your vehicle, to take an approved
safe riding course. Please check with
your dealer or local authorities for avail-
ability in your area. If you are a com-
pletely new rider, this should be done
before your first ride. Your instructor
should be able to provide advice on lo-
cal conditions and safe riding practices
particular to the area.
Riding conditions vary from place
to place. Each is subject to weather
conditions which may radically change
from time to time and from season to
season. Riding on sand is different
than riding on snow or through forests
or marshes. Each location may re-
quire a greater degree of awareness
and skill may not be suitable with a
passenger. Show good judgement.
Always proceed with caution. Please
do not take any unnecessary risks that
could leave you or your passenger
stranded or possibly injured.
The vehicle handling, stability and
braking distance may be affected
when riding with a passenger. Safe-
ly reduce speed when riding with a
passenger. Allow greater distance for
braking.
The contents of this Operator's Guide
provide riding information which has
been proven reliable by other users.
They are not intended as a definitive
means of avoiding accidents. How
you apply this information, coupled
with your mental and physical condi-
tion, the particular terrain hazard and
your risk acceptance level will have
an effect on your riding experience.
Have fun... and ride responsibly.
This Operator's Guide has been pre-
pared to acquaint the owner/operator
of a new vehicle with the various ve-
hicle controls, maintenance and safe
operating instructions. They are indis-
pensable for the proper use of the
product.
We would be pleased to receive any
comments on the content and format
of this Operator's Guide, the Safety
Videocassette or on-product warnings
labels.
8_______________________

SAFETY
INFORMATION
____________ SAFETY INFORMATION ____________ 9

SPECIAL SAFETY MESSAGES
THIS VEHICLE IS NOT A TOY AND
CAN BE HAZARDOUS TO OPERATE.
This vehicle handles differently from
other vehicles including motorcycles
and cars. A collision or rollover can
occur quickly, even during routine ma-
neuvers such as turning and driving on
hills or over obstacles, if you fail to take
proper precautions.
SEVERE INJURY OR DEATH can re-
sult if you do not follow these instruc-
tions:
Read this Operator's Guide and all
on-product warning labels careful-
ly and follow the operating proce-
dures described. Watch and pay at-
tention to the Safety Videocassette
before operation.
Never operate this vehicle without
proper instruction. Take a training
course. Beginners should receive
training from a certified instructor.
Contact an authorized Bombardier
ATV dealer to find out about avail-
able training course nearest you or
call the Specialty Vehicle Institute of
America (SVIA) at 1 800 877–2887
or in Canada, the Canada safety
Council (CSC) at 1 (613) 739–1535
ext. 227.
Always follow this age recommen-
dation: A person under 16 years old
should never operate this vehicle.
Never carry a passenger on this ve-
hicle.
Never operate this vehicle on any
paved surfaces, including side-
walks, driveways, parking lots and
streets.
Never operate this vehicle on any
public street, road or highway, even
a dirt or gravel one.
Never take place on this vehicle
without wearing an approved hel-
met that fits properly. You should
also wear eye protection (goggles
or face shield), gloves, boots, long
sleeved shirt or jacket, and long
pants.
Never consume alcohol or drugs be-
fore or while riding this vehicle.
Never operate at excessive speeds.
Always go at a speed that is prop-
er for the terrain, visibility, and op-
erating conditions, and your experi-
ence.
Never attempt wheelies, jumps, or
other stunts.
Always inspect your vehicle each
time you use it to make sure it is
in safe operating condition. Always
follow the inspection and mainte-
nance procedures and schedules
described in this Operator's Guide.
Always keep both hands on the
handlebars and both feet on the
footrests of the vehicle during op-
eration.
Always go slowly and be extra care-
ful when operating on unfamiliar
terrain. Always be alert to changing
terrain conditions when operating
this vehicle.
Never operate on excessively
rough, slippery or loose terrain un-
til you have learned and practiced
the skills necessary to control this
vehicle on such terrain. Always be
especially cautious on these kinds
of terrain.
Always follow proper procedures
for turning as described further in
this Operator's Guide. Practice
turning at low speeds before at-
tempting to turn at faster speeds.
Do not turn at excessive speed.
10 ___________ SAFETY INFORMATION ___________

Never operate this vehicle on hills
too steep for the vehicle or for your
abilities. Practice on smaller hills
before attempting larger hills.
Always follow proper procedures
for climbing hills as described
further in this Operator's Guide.
Check the terrain carefully before
you start up any hill. Never climb
hills with excessively slippery or
loose surfaces. Shift your weight
forward. Never open the throt-
tle suddenly or make sudden gear
changes. Never go over the top of
any hill at high speed.
Always follow proper procedures
for going down hills and for brak-
ing on hills as described further in
this Operator's Guide.Checkthe
terrain carefully before you start
down any hill. Shift your weight
backward. Never go down a hill at
high speed. Avoid going down a hill
at an angle that would cause the
vehicle to lean sharply to one side.
Go straight down the hill where
possible.
Always follow proper procedures
for crossing the side of a hill as
described further in this Operator's
Guide. Avoid hills with excessively
slippery or loose surfaces. Shift
your weight to the uphill side of
the vehicle. Never attempt to turn
the vehicle around on any hill un-
til you have mastered the turning
technique described in this Opera-
tor's Guide on level ground. Avoid
crossing the side of a steep hill if
possible.
Always use proper procedures if
you stall or roll backwards when
climbing a hill. To avoid stalling,
use proper gear and maintain a
steady speed when climbing a hill.
If you stall or roll backwards, follow
the special procedure for braking
described in this Operator's Guide.
Dismount on the uphill side or to a
side if pointed straight uphill. Turn
the vehicle around and remount,
following the procedure described
further in this Operator's Guide.
Always check for obstacles before
operating in a new area. Never at-
tempt to operate over large obsta-
cles, such as large rocks or fallen
trees. Always follow proper proce-
dures when operating over obsta-
cles as described further in this Op-
erator's Guide.
Always be careful when skidding
or sliding. Learn to safely control
skidding or sliding by practicing at
low speeds and on level smooth
terrain. On extremely slippery sur-
faces, such as ice, go slowly and be
very cautious in order to reduce the
chance of skidding out of control.
Never operate this vehicle in fast
flowing water or in water deeper
than that specified in this Opera-
tor's Guide. Remember that wet
brakes may have reduced stopping
ability. Test your brakes after leav-
ing water. If necessary, apply them
several times to let friction dry out
the pads.
Always use the size and type tires
specified further in this Operator's
Guide. Always maintain proper tire
pressure as described further in this
Operator's Guide.
Never modify this vehicle through
improper installation or use of ac-
cessories. Only use BRP's ap-
proved accessories.
____________ SAFETY INFORMATION ___________ 11

Never exceed the stated load lim-
its for this vehicle including opera-
tor, all other loads and added acces-
sories. Cargo should be properly
distributed and securely attached.
Reduce speed and follow instruc-
tions in this manual for carrying car-
go or pulling a trailer. Allow greater
distance for braking.
FOR MORE INFORMATION
ABOUT ATV SAFETY, call the Spe-
cialty Vehicle Institute of America
(SVIA) at 1 800 887–2887 or in
Canada, the Canada Safety Coun-
cil (CSC) at 1 (613) 739–1535 ext.
227 or contact an authorized Bom-
bardier ATV dealer to find out about
available training courses nearest
you.
12 ___________ SAFETY INFORMATION ___________

OPERATION WARNINGS
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious in-
jury or death.
The following warning and their format have been requested by the United States
Consumer Product Safety Commission and are required to be in the Operator's
Guide for all ATVs.
NOTE: The following illustrations are general representations only. Your model
may differ.
WARNING
V00A0AQ
POTENTIAL HAZARD
Operating this vehicle without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does not know
how to operate this vehicle properly in different situations and on different
types of terrain with or without passenger.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the training
course offered by BRP. They should then regularly practice the skills
learned in the course and the operating techniques described in this
Operator's Guide.
For more information about the training course, contact an authorized
Bombardier ATV dealer or call BRP at 1 (819) 566–3366.
____________ SAFETY INFORMATION ___________ 13

WARNING
V00A01Q
POTENTIAL HAZARD
Failure to follow the age recommendations for this vehicle.
WHAT CAN HAPPEN
A lack of respect for this age recommendation can lead to severe injury or
death of the child.
Even though a child may be within the age group for which this vehicle is
recommended, he may not have the skills, abilities, or judgment needed
to operate this vehicle safely and may be involved in a serious accident.
HOW TO AVOID THE HAZARD
No one under 16 should operate this vehicle.
14 ___________ SAFETY INFORMATION ___________

WARNING
V00A02Q
POTENTIAL HAZARD
Carrying a passenger on this vehicle.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and control this vehicle.
Could cause an accident, resulting in harm to you and/or your passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. Even with a long seat that provides unrestricted
operator movement, it is not designed nor intended to carry passenger(s).
____________ SAFETY INFORMATION ___________ 15

WARNING
V00A03Q
POTENTIAL HAZARD
Operating this vehicle on paved surfaces.
WHAT CAN HAPPEN
The ATV's tires are designed for off-road use only, not for use on pavement.
Paved surfaces may seriously affect handling and control of this vehicle,
and may cause the vehicle to go out of control.
HOW TO AVOID THE HAZARD
Never operate this vehicle on any paved surfaces, including sidewalks,
driveways, parking lots and streets.
16 ___________ SAFETY INFORMATION ___________

WARNING
V00A04Q
POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate this vehicle on any public street, road or highway, even a
dirt or gravel one. In many states or provinces it is illegal to operate ATVs
on public streets, roads or highways.
____________ SAFETY INFORMATION ___________ 17

WARNING
V00A06Q
POTENTIAL HAZARD
Riding this vehicle without wearing an approved helmet, eye protection
and protective clothing.
WHAT CAN HAPPEN
The following items concern all ATV's operator:
–riding without an approved helmet increases the chances of a severe head
injury or death in the event of an accident
–riding without eye protection can result in an accident and increases the
chances of a severe injury in the event of an accident
–riding without protective clothing increases the chances of severe injury
in the event of an accident.
HOW TO AVOID THE HAZARD
Always wear an approved helmet that fits properly. You should also wear:
–eye protection (goggles or face shield)
–gloves and boots,
–Iong sleeved shirt or jacket
–Iong pants.
18 ___________ SAFETY INFORMATION ___________