BOMBARDIER DS 650 2001 Shop Manual Download Page 3 | Manualshive

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BOMBARDIER DS 650 2001 Shop Manual Download Page 3

Legal deposit:

National Library of Quebec
3

rd

trimester 2000

National Library of Canada 2000

All rights reserved. No parts of this manual may be reproduced in any
form without the prior written permission of Bombardier Inc.

©

Bombardier Inc. 2000

Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada

Printed in Canada

®

*Registered trademarks of Bombardier Inc. and/or 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

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Summary of Contents for DS 650 2001

Page 1: ......

Page 2: ...Shop Manual 2001 DS 650 ...

Page 3: ...c Bombardier Inc 2000 Technical Publications Bombardier Inc Valcourt Quebec Canada Printed in Canada Registered trademarks of Bombardier Inc and or 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...

Page 4: ...stem 03 07 1 08 Clutch 03 08 1 09 Transmission 03 09 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...

Page 5: ...II VMR2001_001_00_02A FM 11 TECHNICAL DATA 01 SI metric information guide 11 01 1 02 Engine and vehicle 11 02 1 12 WIRING DIAGRAM 01 Wiring diagram 12 01 1 SECTION SUBSECTION PAGE TABLE OF CONTENTS ...

Page 6: ...bardier parts is most strongly recommended when considering replacement of any com ponent Dealer and or distributor assistance should be sought in case of doubt The engines and the corresponding components identified in this document should not be utilized on product s other than those mentioned in this document Torque wrench tightening specifications must be strictly adhered to Locking devices ex...

Page 7: ...er Added the following new products premix coolant Molykote 111 paste Molykote G n paste sealing compound Dreibond MAINTENANCE New clutch adjustment procedure Drive chain adjustment procedure is now in the MAINTENANCE section COOLING SYSTEM New refilling procedure CRANKSHAFT BALANCER SHAFT New procedure to recentre crankshaft and balancer shaft REAR SUSPENSION Rear suspension adjustment is added i...

Page 8: ...DUCTION 0 This Shop Manual covers the following Bombar dier made 2001 ATV Model 1 Model number VEHICLE AND ENGINE SERIAL NUMBER LOCATION 1 Vehicle 2 Engine DS 650 7449 Trademark of Bombardier Inc 1 V02A0PA 1 2 V02A0QA INTRODUCTION ...

Page 9: ...ECTION 4 3 2 1 SECTION 1 Class Make Manufacturer 8 7 6 5 4 SECTION 2 Factory use Engine type II Engine type I Product line Type of drive 9 SECTION 3 Check digit 10 11 12 13 14 15 16 17 SECTION 4 Number sequentially assigned by the manufacturer in the production process Plant of manufacture Model year V01A0PS INTRODUCTION ...

Page 10: ...bic centimeter DC direct current F degree Fahrenheit fl oz fluid ounce ft foot GRD ground hal halogen I D inside diameter IDI induction discharge ignition imp oz imperial ounce in inch in square inch in cubic inch k kilo thousand kg kilogram km h kilometer per hour kPa kilo pascal L liter lb pound lbf pound force lbf in pound per square inch LH left hand m meter MAG magneto Max maximum Min minimum...

Page 11: ...case nut must be torqued to 10 N m or 89 lbf in This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog Exploded view assists you in identifying parts and related positions TYPICAL PAGE V02A0TS Illustration number for publishing process Subsection title indicates beginning of the subsection Drop represents a liquid product to be applied to a surface ...

Page 12: ...h connector Removal Remove the upper support bracket no 10 com pletely Install engine lifting tool P N 529 035 610 then install a hoist Remove upper engine support bolt no 11 lower bolts no 12 retaining the engine support no 13 on either side then remove supports front lower mounting bolt no 14 rear lower mounting bolt no 15 rear upper mounting bolt no 16 Remove engine from vehicle Installation Fo...

Page 13: ...replaced by customary fasteners or vice versa Mismatched or incorrect fasteners could cause damage to the vehicle or possible per sonal injury As many of the procedures in this manual are in terrelated we suggest that before undertaking any task you read and thoroughly understand the entire section or subsection in which the proce dure is contained A number of procedures throughout the book re qui...

Page 14: ...s bolt and nut and allow to dry for 30 seconds 3 Choose proper strength Loctite threadlocker 4 Apply several drops along the threaded hole and at the bottom of the hole 5 Apply several drops on bolt threads 6 Tighten as required Stud in Blind Holes 1 On threads 2 On threads and in the hole 3 Onto nut threads 1 Clean threads stud and hole with solvent 2 Apply Loctite Primer N P N 293 800 041 on thr...

Page 15: ...Repair Stripped Threads 1 Release agent 2 Stripped threads 3 Form A Thread 4 Tape 5 Cleaned bolt 6 Plate 7 New threads 8 Threadlocker Standard Thread Repair 1 Follow instructions on Loctite FORM A THREAD P N 413 708 600 package 2 If a plate is used to align bolt a Apply release agent on mating surfaces b Put waxed paper or similar film on the surfaces 3 Twist bolt when inserting it to improve thre...

Page 16: ...ssemble as shown above Case In Components Metallic Gaskets 1 Proper strength Loctite 1 Clean inner housing diameter and outer gasket diameter 2 Spray housing and gasket with Loctite Primer N P N 293 800 041 3 Apply a strip of proper strength Loctite on lead ing edge of outer metallic gasket diameter NOTE Any Loctite product can be used here A low strength liquid is recommended as normal strength a...

Page 17: ... 9 2 M4 18 3 27 4 M5 35 5 44 6 53 7 62 8 71 9 80 10 M6 89 11 97 12 106 13 115 14 124 15 133 16 142 17 150 18 159 19 168 N M FASTENER SIZE 8 8 LBF FT 20 15 21 15 22 16 23 M8 17 24 18 25 18 26 19 27 20 28 21 29 21 30 22 31 23 32 24 33 24 34 25 35 26 36 27 37 27 38 28 39 29 40 30 41 30 42 31 43 32 44 32 45 33 46 34 47 35 48 M10 35 49 36 50 37 51 38 52 38 53 39 54 40 55 41 56 41 57 42 58 43 59 44 60 4...

Page 18: ...7 92 68 93 69 94 69 95 70 96 71 97 72 98 72 99 73 100 74 101 74 102 75 103 76 104 77 105 77 106 78 107 79 108 80 N M FASTENER SIZE 8 8 LBF FT 109 80 110 81 111 82 112 83 113 83 114 84 115 85 116 86 117 86 118 87 119 88 120 89 121 89 122 90 123 91 124 91 125 92 126 93 127 94 128 94 129 95 130 96 131 97 132 97 133 98 134 99 135 M14 100 136 100 137 101 138 102 139 103 140 103 141 104 142 105 143 105 ...

Page 19: ...______________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address _________________________________...

Page 20: ...tions After Sales Service 565 de la Montagne Street Valcourt Québec Canada J0E 2L0 Technical Publications After Sales Service 565 de la Montagne Street Valcourt Québec Canada J0E 2L0 Technical Publications After Sales Service 565 de la Montagne Street Valcourt Québec Canada J0E 2L0 ...

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