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BOMBARDIER
Offroad Vehicle
DS 650 Baja X 2004
BOMBARDIER DS 650 Baja X 2004 User Manual
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Table of Contents
Table of Contents
39
Default Chapter
11
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
4
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BOMBARDIER DS 650 Baja X 2004 Specifications
General
Brand
BOMBARDIER
Model
DS 650 Baja X 2004
Category
Offroad Vehicle
Language
English
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