BOMBARDIER Quest 500 2002 Operator'S Manual Download

Page: 83 / 100

1. Taper side of nut

Steering/Control Systems

Throttle Cable Lubrication

The throttle cable must be lubricated
with Bombardier cable lubricant (P/N
293 600 041) or an equivalent with the
same characteristics.

Open the throttle lever.

1. Remove screws

Remove:

– the cable from the throttle lever

1. Throttle handle housing
2. Throttle cable

NOTE:

Slide cable in clip slot and re-

move the end of cable from clip.



WARNING

Using another lubricant without
same characteristics could cause
the throttle lever/cable sticking or
stiffness.

V01A08Y

V01I0ZY

V01I10Y

vmo2002_004a.book Page 81 Friday, August 3, 2001 10:27 AM

Summary of Contents for Quest 500 2002

Page 1: ......

Page 2: ...instruction which if not followed may cause injuries including the possibility of death WARNING YOUR ATV CAN BE HAZARDOUS TO OPERATE A collision or rollover can occur quickly even during routine mane...

Page 3: ...guide may be translated into another language In the event of any discrepancy the En glish version shall prevail The information and components system descriptions contained in this document are corr...

Page 4: ...Front Brake Lever 47 3 Rear Brake Lever 47 4 Brake Lever Lock 48 5 Transmission Lever 48 6 Headlight Switch 49 7 Engine Stop Switch 50 8 Start Button 50 9 Indicator Lights Cluster 50 10 Speedometer 51...

Page 5: ...Engine 67 Shifting the Transmission 67 SPECIAL PROCEDURES 68 Flooded Engine 68 Engine Overheat 68 Post Operation Care 68 Flipped Over 69 ATV Immersion 69 Limp Home Mode 69 Storage and Preseason Prepa...

Page 6: ...vehicle components 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 a...

Page 7: ...n approved helmet 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...

Page 8: ...ted straight uphill Turn the ATV around and remount following the proce dure described in the Operator s Guide and the Safety Handbook Always check for obstacles before operating in a new area Never a...

Page 9: ...L HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situation...

Page 10: ...their age can lead to severe injury or death of the child Even though a child may be within the age group for which an ATV is recommended he or she may not have the skills abilities or judgment neede...

Page 11: ...balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift pos...

Page 12: ...esigned for off road use only not for use on pave ment Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Never...

Page 13: ...ds or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is i...

Page 14: ...ent of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases...

Page 15: ...hol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Neve...

Page 16: ...ive speeds WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain visibili...

Page 17: ...ZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t t...

Page 18: ...accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always make sure that the rear cargo box is proper...

Page 19: ...bility to control the ATV or could cause you to lose your balance and fall off the ATV If you remove a foot from the footpegs your foot or leg may come into contact with the rear wheels which could in...

Page 20: ...APPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when...

Page 21: ...ause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have le...

Page 22: ...control causing a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Opera tor s Guide and the Safety Handbook Practice turning at low speeds...

Page 23: ...N HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your ab...

Page 24: ...s Guide and the Safety Handbook Always 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 t...

Page 25: ...as described in the Operator s Guide and the Safety Handbook NOTE A special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill S...

Page 26: ...ered the turning technique as described in the Operator s Guide and the Safety Handbook on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible Whe...

Page 27: ...ed Keep weight uphill Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill Never apply the rear brake while rolling backwards Apply the front bra...

Page 28: ...ion Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you g...

Page 29: ...action unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slipper...

Page 30: ...ich could lead to an accident HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in the Operator s Guide and the Safety Handbook Remember that...

Page 31: ...reverse WHAT CAN HAPPEN You could hit an obstacle or person behind you resulting in serious injury HOW TO AVOID THE HAZARD When you select reverse gear make sure there are no obstacles or people behi...

Page 32: ...his ATV or operation of this ATV with improper or uneven tire pressure may cause loss of control and increases the risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specif...

Page 33: ...situations could lead to an ac cident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accesso ries All parts and accessories added to this vehicle should be genu...

Page 34: ...an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer...

Page 35: ...porting inflammable or dangerous material can lead to explosions WHAT CAN HAPPEN This can cause serious injury or death HOW TO AVOID THE HAZARD Never transport inflammable or dangerous material WARNIN...

Page 36: ...performance of service under this warranty does not extend the life of this warranty beyond its original expiration date 3 CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only...

Page 37: ...zed servicing BOMBARDIER dealer Damage caused by abuse abnormal use neglect or operation of the product in a manner inconsistent with the recommended operation described in the Operator s Guide Damage...

Page 38: ...agreed to the transfer of ownership in addition to the coordinates of the new owner 9 CONSUMER ASSISTANCE a In the event of a controversy or a dispute in connection with this BOMBARDIER LIMITED WARRAN...

Page 39: ...pair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date 3 CONDITIONS TO HAVE WARRANTY COVERAGE This...

Page 40: ...ntenance mod ifications or use of parts not manufactured or approved by BOMBARDIER or resulting from repairs done by a person that is not an authorized servicing BOMBARDIER distributor dealer Damage c...

Page 41: ...ER is notified of such transfer of ownership in the following way a The former owner contacts BOMBARDIER or an authorized BOMBARDIER distributor dealer and gives the coordinates of the new owner or b...

Page 42: ...nce of my vehicle A In the Operator s Guide provided with the vehicle at the time of delivery Q Will the entire warranty be voided or cancelled if I do not operate or maintain my new vehicle exactly a...

Page 43: ...however that despite the best intentions of everyone concerned misunderstandings will sometimes occur Frequently complaints are the result of a breakdown in communications and can quick ly be resolve...

Page 44: ...ION OF THE IMPORTANT LABELS The following labels are on your ATV If missing or damaged they can be replaced free of charge See an authorized Bombardier ATV dealer V04M03L 5 1 2 11 5 9 3 4 6 9 10 5 7 8...

Page 45: ...43 Label 1 Label 2 Label 3 Label 4 Label 5 Label 6 Label 7 V01M01Z V01M02Z V01M03Z V01M04Z V01M050 V01M06Z V01M07Z...

Page 46: ...44 Label 8 Label 9 Label 10 Label 11 Label 12 V04M07Y V01M09Z V01M0BZ V04M08Y V04M0AL...

Page 47: ...rized Bombardier ATV dealer to complete war ranty claims properly No warranty will be allowed by Bombardier Inc if the engine identification number EIN or vehicle identification number VIN is removed...

Page 48: ...46 CONTROLS INSTRUMENTS EQUIPMENTS NOTE Some controls instruments equipments are optional 18 V04A04L 17 23 15 25 4 3 14 19 24 20 22 5 16 1 9 13 2 10 9 6 7 8 11 12 5 21 21 26...

Page 49: ...d to the type and condition of the terrain The front brake will have also an effect on rear wheels through the drive train See the note at Rear Brake Lever be low for additional information 1 Brake le...

Page 50: ...ition Always re lease brake lever lock before riding 5 Transmission Lever Located on the right side of vehicle A 5 position lever P R N H and L To change the transmission position completely stop vehi...

Page 51: ...owing H High gear This selects the high speed range of the transmission in the gear box It is the normal driving speed range It allows the vehicle to reach its maximum speed L Low gear This selects th...

Page 52: ...after engine is started 1 Start button To stop engine fully release throttle le ver then use the engine stop switch 9 Indicator Lights Cluster NOTE When first turning switch to ON either position the...

Page 53: ...nd km h The speedometer is backlit when the ignition switch is turned on either position 1 Speedometer 2 Odometer trip meter 3 Display selection button Odometer Trip Meter Combined LCD Liquid Crystal...

Page 54: ...be stopped by turning ignition key OFF we recom mend the engine be stopped by the engine stop switch 12 Choke Knob Lever Located at bottom of cluster This de vice features a variable lever to ease col...

Page 55: ...the ON position an emergen cy supply of fuel is available by turning the knob to RES The reserve contains approximately 30 of the fuel tank ca pacity Use only this position when the ON supply is empt...

Page 56: ...personal articles such as an a helmet spare spark plugs first aid kit etc Unlatch cover gently lift then remove cover The compartment is equipped with a drain plug under the tool box Remove plug to al...

Page 57: ...Insert this tab in hook 2 Hook 21 Front Rear Cargo Racks Located on top of chassis at front and rear Convenient racks to carry gear Refer to SPECIFICATIONS for carrying loads and cargo weight distrib...

Page 58: ...r It pro vides access to the radiator filling neck Pull the protector cap to give access to the radiator cap When finished prop erly reinstall radiator cap then protec tor cap 1 Protector cap 2 Radiat...

Page 59: ...block Winch if so equipped Located behind front skid plate 1 Winch 2 Front skid plate Winch Control Switch if so equipped Located on the LH side of the front fender To take out wire rope from winch tu...

Page 60: ...em and engine components CAUTION Never mix oil with fuel This ATV has a 4 stroke engine Oil must be added to engine base only Fuel Level Engine Transmission Oil Recommended Oil Use 4 stroke engine oil...

Page 61: ...me SAE 5W30 is recommended for winter time For other viscosity see applicative chart below V01A38L BOMBARDIER SYNTHETIC OIL 5W40 P N 293 600 039 SAE 10W30 SAE 10W40 SAE 15W40 SAE 20W50 C F 60 50 40 30...

Page 62: ...hould be near or equal to the upper mark 1 Full 2 Add 3 Operating range 4 Add oil up to upper mark if required 5 To add oil remove dipstick Place a funnel into the dipstick tube and fill with the reco...

Page 63: ...Refer to MAINTENANCE section Brake Fluid Recommended Fluid Always use brake fluid meeting the specification DOT 4 only CAUTION Never use other type of oil such as mineral based or syn thetic oil Flui...

Page 64: ...the holding straps Pull out vent tube from frame Remove battery from vehicle being careful not to tilt it so that electrolyte flows out of vent tube CAUTION Should any electrolyte spillage occur imme...

Page 65: ...tion Reinstall battery in vehicle Fasten bat tery and make sure to reinstall the vent tube NOTE Place the positive RED cable between holding straps and battery 1 Cable between battery and strap WARNIN...

Page 66: ...od Belt A new belt requires a break in peri od of 30 miles 50 km Avoid strong acceleration deceleration pulling a load or high speed cruising 10 Hour Inspection As with any precision piece of me chani...

Page 67: ...t is properly latched If you transport cargo respect load capacity Ensure cargo is properly secured to the racks If you are pulling a trailer or other equipment ensure it respects the tongue capacity...

Page 68: ...ull choke position Press start button and hold until en gine starts CAUTION Do not hold start button more than 30 seconds A rest period should be observed between the cranking cycles to let starter co...

Page 69: ...ever in PARK position Push the engine stop switch in OFF position Turn key in ignition switch to OFF Remove key from ignition switch Shifting the Transmission Let engine idle to warm up Apply brakes a...

Page 70: ...ean radiator fins See MAIN TENANCE section Reduce vehicle speed but try to keep vehicle moving to supply air to radiator If engine is still overheating after ap proximately one minute stop vehicle and...

Page 71: ...uced and not allowed to reach its maximum RPM as usual In this case letting the engine return to idle speed turning OFF the ignition key and restart ing engine may allow normal operation This performa...

Page 72: ...ucts and radiator fins I I CUSTOMER Drive belt I DEALER Cleaning condition of drive and driven pulleys C DEALER CVT air inlet duct condition cleanliness and sealing I I DEALER Rewind starter rope cond...

Page 73: ...EALER Wheel nuts studs I I CUSTOMER Wear Pressure of tires I I CUSTOMER Front wheel alignment I I DEALER SUSPENSION Swing arm I DEALER Shock absorber I DEALER A arm I CUSTOMER BRAKE Brake fluid front...

Page 74: ...ge should be done with a warm engine Ensure vehicle is on a level surface Clean the drain plug area Remove dipstick Place a drain pan under the engine drain plug area Unscrew drain plug 1 Oil drain pl...

Page 75: ...ded oil Refer to SPECIFICATIONS for ca pacity Start engine and let idle for a few min utes Ensure oil filter area and drain plug areas are not leaking Stop engine Wait a while to allow oil to flow dow...

Page 76: ...two or three times then add coolant if required Install radiator cap Inspect all connec tions for leaks and check coolant level in the reservoir Valve Adjustment Valve adjustment is not required on t...

Page 77: ...radia tor fins If available use a garden hose to rinse the radiator fins CAUTION Be careful not to damage the radiator fins when cleaning Do not use any object tool that could damage the fins The fins...

Page 78: ...lean the air filter Simple Green from Sunshine Makers Inc is available at hardware stores or at automotive parts retailer While filter soaks clean inside the air box Then let the filter dry completely...

Page 79: ...use out Check if filament is melted 1 Fuse 2 Check if melted Bulb Replacement Always check light operation after re placement Headlights CAUTION Never touch glass por tion of an halogen bulb with bare...

Page 80: ...ght Bulb Replacement Unscrew lens screws to expose bulb Push bulb in and hold while turning counterclockwise to release Install the new bulb by first pushing in while turning clockwise 1 Lens 2 Screws...

Page 81: ...ong nose pliers to pull bulb out or carefully pry out using a small screwdriver 1 Pull bulb out Reinstall new bulb using long nose pli ers Turn bulb socket clockwise to lock Drive Train Drive Shaft Bo...

Page 82: ...it is recommended to carry a tire pump and a repair kit Tire Wheel Condition Check tire for damage and wear Re place if necessary Do not rotate tires The front and rear tires have a different size The...

Page 83: ...t with the same characteristics Open the throttle lever 1 Remove screws Remove the cable from the throttle lever 1 Throttle handle housing 2 Throttle cable NOTE Slide cable in clip slot and re move th...

Page 84: ...back to expose throttle cable adjuster Loosen lock nut then turn the adjuster to obtain correct throttle lever free play NOTE Measure throttle free play at the tip of throttle lever Tighten lock nut...

Page 85: ...ese brakes are self adjusting and require no adjustment Rear Brake The rear brake employs two systems The first system used a cable an ad justment is necessary see an autho rized Bombardier ATV dealer...

Page 86: ...skid plate replaced if damaged Hitch Trailer Ball Condition Check tightness of fasteners and tightness condition of trailer ball Prop erly retighten as necessary and replace ball if worn Fasteners Ch...

Page 87: ...ks before operating the vehicle Safely reduce speed according to terrain conditions when carrying cargo or pulling a trailer Allow greater distance for breaking Always secure cargo as low as possible...

Page 88: ...rake Secure the vehicle to front by the front bumper and rear by the frame CAUTION Attaching vehicle at other locations may damage the vehicle Front Location TYPICAL Rear Location TYPICAL WARNING Neve...

Page 89: ...efer to SPECIAL PROCEDURES 4 No fuel to the engine spark plugs dry when removed Check fuel tank level turn fuel valve to ON also try on RES A failure of the fuel pump or carburetor may have occurred C...

Page 90: ...ystem leakage Contact an authorized Bombardier ATV dealer 2 Engine is running too hot See Engine lacks acceleration or power 3 Ignition timing is incorrect or there is an ignition system failure Conta...

Page 91: ...high Adjust the idle speed Refer to the specification 3 CVT dirty or wear Contact an authorized Bombardier ATV dealer SYMPTOM The RPM increases but the vehicle doesn t move POSSIBLE CAUSES WHAT TO DO...

Page 92: ...placeable oil filter lubrication of engine and transmission simultaneously Decompressor Automatic Exhaust system Spark arrester approved U S Forest Service USFD Air filter 2 stage foam filter TRANSMIS...

Page 93: ...0 W Taillight 5 27 W Pilot lamp cluster LEDS 0 7 V approx each FUSES Location no 1 empty N A Location no 2 empty N A Location no 3 accessories 15 A power outlet and auxiliary supply Location no 4 fan...

Page 94: ...es driver all other loads and added accessories GVWR Gross Vehicle Weight Rating 540 kg 1200 lb Towing capacity 500 kg 1100 lb Tongue capacity 14 kg 30 lb included with rear rack Front storage tray 10...

Page 95: ...l or synthetic blend oil other than Bombardier synthetic oil Refer to OIL VISCOSITY CHART for proper grade Coolant Ethylene glycol water mix 50 coolant 50 water Use coolant specifically designed for a...

Page 96: ...ton meter kilometer per hour SYMBOL m kg N L C kPa N m km h PREFIXES PREFIX kilo centi milli micro SYMBOL k c m MEANING one thousand one hundredth of one thousandth of one millionth of VALUE 1000 0 01...

Page 97: ...EET APT ______________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE ______________________________________________ COUNTRY NEW ADDRESS __________________________________________...

Page 98: ...ADDRESS N OTE This card is strictly for change of address only CHANGE OF ADDRESS AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUEBEC CANAD...

Page 99: ...rdier ATV MODEL No VEHICLE IDENTIFICATION NUMBER V I N ENGINE IDENTIFICATION NUMBER E I N Owner Purchase Date YEAR MONTH DAY Warranty Expiry Date YEAR MONTH DAY To be completed by the dealer at the ti...

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