This document is a shop manual for the Bombardier DS 250 ATV, covering models from 2006 to 2019. It provides comprehensive information for servicing and repairing these ATVs, targeting mechanical technicians familiar with BRP products.
Function Description:
The manual serves as a guide for the correct service and repair of the DS 250 ATV. It is divided into major sections covering various systems and components of the vehicle, including maintenance, troubleshooting, engine, fuel system, electrical system, transmission, steering and front suspension, rear suspension and axle, braking system, and body/frame. Each section is further broken down into subsections and divisions, detailing specific procedures and parts. The manual emphasizes the use of proper hand tools and special service tools for all procedures. It also highlights the importance of adhering to torque wrench specifications and replacing locking devices when necessary.
Important Technical Specifications:
The manual includes a dedicated section for technical specifications of the DS 250.
- Engine: 4-stroke, Single Over Head Camshaft (SOHC), liquid-cooled, electric starting, 1 cylinder, 4 valves with mechanical adjustment.
- Bore: 71 mm (2.8 in)
- Stroke: 63 mm (2.5 in)
- Displacement: 249.4 cm³ (15.22 in³)
- Compression ratio: 10.6:1
- Air filter type: Sponge wet type
- Engine RPM limiter: Forward 8450 ± 1500, Reverse 4000
- Valve clearance: Intake 0.08 - 0.12 mm (.0031 - .0047 in), Exhaust 0.13 - 0.17 mm (.0051 - .0067 in)
- Piston diameter (nominal): 70.430 - 70.480 mm (2.7728 - 2.7748 in)
- Piston/cylinder clearance (nominal): 0.010 - 0.040 mm (.0004 - .0016 in)
- Fuel System:
- Carburetor: KEHIN with manual choke (Model PTG-23)
- Idle engine speed: 1700 ± 100 RPM
- Fuel type: Regular unleaded gasoline (Octane no. 87 (Ron + Mon)/2 inside North America, 91 RON outside North America)
- Fuel tank capacity: 12 L (3.2 U.S. gal)
- Fuel tank reserve: 2.8 L (2.96 U.S. quarts)
- Lubrication System:
- Engine oil capacity: Replacement 1.2 L (1.27 U.S. quarts), Disassembly 1.4 L (1.48 U.S. quarts)
- Gearbox oil capacity: Replacement 800 mL (27 U.S. oz), Disassembly 900 mL (30.4 U.S. oz)
- Recommended engine oil: 4-stroke engine oil meeting API service classification SM, SL or SJ (SAE 5W30 for all seasons, XP-S 10W40 mineral oil for hottest days, XP-S 5W40 synthetic oil for improved overall performance and all season applications).
- Recommended gearbox oil: XP-S chaincase oil (P/N 413 801 900) or XP-S synthetic chaincase oil (P/N 413 803 300) or 85W-140.
- Cooling System:
- Coolant capacity: 1.2 L (1.27 U.S. quarts)
- Coolant type: BRP premixed coolant or ethyl glycol/water mix (50% coolant, 50% distilled water) specifically designed for aluminum engines.
- Engine thermostat opening temperature: 82°C to 95°C (180°F to 203°F)
- Radiator cap opening pressure: 90 kPa (13 PSI)
- Electrical System:
- Magneto/generator: 338 W @ 5000 RPM
- Ignition system type: CDI (Capacitor Discharge Ignition)
- Battery: Dry type, 12 volts, 10 A•h nominal rating
- Spark plug: NGK CR8E, Gap 0.8 mm (.03 in)
- Fuses: Fan 10 A, Headlamp 15 A, Other lights 15 A, Main fuse 30 A
- Transmission:
- Type: CVT (Continuously Variable Transmission) with HI range, neutral, and reverse.
- Drive belt width (nominal): 24.00 mm (.945 in), Service limit 22.50 mm (.886 in)
- Clutch drum inner diameter (nominal): 144.850 to 145.150 mm (5.7027 to 5.7146 in), Service limit 145.450 mm (5.7264 in)
- Centrifugal clutch lining thickness (nominal): 6.000 mm (.2362 in), Wear limit 3.000 mm (.1181 in)
- Drive Train:
- Rear axle: Chain driven/solid axle
- Rear axle ratio: 2.53:1
- Steering:
- Turning radius: 3.5 m (138 in) at low speed
- Total toe (vehicle on ground): 3 mm (.118 in) each side (showroom position)
- Camber angle: 0.7° (not adjustable)
- Brakes:
- Front brake: 2 discs, hydraulic
- Rear brake: 1 disc, hydraulic
- Parking brake: Brake lever lock on RH brake lever (North America), Separate RH lock lever on handlebar (European)
- Lining material: Organic
- Minimum pad thickness: 2.0 mm (.0787 in)
- Minimum brake disk thickness: 3.5 mm (.1378 in), Wear limit 2.0 mm (.0787 in)
- Maximum brake disk warpage: 0.1 mm (.0039 in)
- Tires and Wheels:
- Front tire size: 22 x 7 – 10
- Rear tire size: 20 x 11 – 9
- Front wheel size: 10 x 5.5
- Rear wheel size: 9 x 8
- Recommended tire pressure: 34 kPa (5 PSI) (Front and Rear)
- Minimum tire pressure: 26 kPa (3.8 PSI) (Front and Rear)
- Dimensions:
- Dry weight: 219 kg (483 lb)
- Overall length: 1.890 m (74.4 in)
- Overall width: 1.055 m (41.5 in)
- Overall height: 1.115 m (43.9 in)
- Seat height: 813 mm (32 in)
- Wheel base: 1.180 m (46.5 in)
- Wheel Track: Front 810 mm (32 in), Rear 805 mm (31.7 in)
- Ground clearance (center of vehicle): 150 mm (5.9 in)
- Rear rigid axle ground clearance: 220 mm (8.7 in)
- Capacities:
- Total vehicle load allowed: 150 kg (330 lb) (includes operator, all other loads and added accessories)
Usage Features:
The manual provides detailed instructions for various procedures, including:
- Engine Removal and Installation: Steps for safely removing and installing the engine, including disconnecting battery, draining fluids, and removing various components.
- Engine Leak Test: Procedures for performing a leak test to diagnose engine problems, including positioning the piston at TDC and using a leak down tester.
- Air Intake System: Instructions for air filter removal, cleaning, and installation, as well as air filter housing draining and air injection valve filter removal.
- Exhaust System: Procedures for muffler and exhaust pipe removal, inspection, and installation, including spark arrester cleaning.
- Lubrication System: Guidance on engine oil changes, oil level checks, oil pressure relief valve inspection, and oil pump removal and inspection.
- Cooling System: Procedures for checking coolant level, draining and filling the cooling system, thermostat and thermo-switch testing, and water pump disassembly and assembly.
- Magneto and Starter Drive: Instructions for trigger coil, stator, crankshaft end bearing, flywheel, starter reduction gear, and starting clutch gear removal, inspection, and installation.
- Cylinder Head: Procedures for valve clearance adjustment, cylinder head removal and disassembly, parts inspection (camshaft, rocker arm, valve spring, valve stem, valve guide), and cylinder head assembly.
- Piston and Cylinder: Instructions for piston and cylinder disassembly, inspection (cylinder, piston ring, piston, piston pin, connecting rod), and assembly.
- Gearbox: Procedures for gearbox oil level and change, gearbox switch testing, oil seal replacement, and gearbox disassembly and assembly.
- Fuel System: Detailed steps for carburetor and fuel tank removal, cleaning, inspection, and adjustment (float level, pilot screw, idle speed), as well as fuel filter and fuel valve procedures.
- Electrical System: Troubleshooting and repair procedures for the charging system (voltage regulator/rectifier, stator, battery), ignition system (spark plug, ignition coil, ignition module, shift gear control module, override switch, ignition timing), starting system (fuses, start switch, starting solenoid, electric starter), and lights and accessories (fuses, headlamp, turn signal lights, position light, pilot lamps, taillight, horn, 12-volt power outlet).
- Transmission (CVT): Procedures for drive belt removal and inspection, CVT cover and bearing removal, drive pulley disassembly and cleaning, and driven pulley disassembly and inspection.
- Steering and Front Suspension: Instructions for handlebar grip, multifunction switch, throttle lever, handlebar, tie-rod, steering column, front wheel hub, wheel bearing, knuckle, shock absorber and spring removal, inspection, and installation, as well as steering alignment.
- Rear Suspension and Axle: Procedures for rear shock, drive chain, engine sprocket, axle sprocket, wheel hub, brake disc hub, rear axle, sprocket hub, and chain tensioner removal, inspection, and installation, as well as swing arm lubrication.
- Braking System: Maintenance and procedures for front and rear brakes, including brake fluid checks, replacement, and bleeding, caliper removal and inspection, brake pad replacement, master cylinder procedures, pressure control valve, brake discs, brake hoses, and brake light switches.
- Body/Frame: Instructions for parts replacement (decal, seat, seat latch, fuel tank cover, front cover, radiator shield, front fender, rear fender, footrest), cleaning (seat, plastic), and repair (plastic repair, frame, front bumper, footpeg, footrest support, rear frame extension, front fender support, rear fender support).
Maintenance Features:
The manual includes a detailed maintenance chart that specifies inspection and replacement intervals for various components based on hours, kilometers, or years.
- Initial Inspection: 10 hours or 30 days or 200 km (125 mi).
- Regular Maintenance: Every 25 hours or 500 km (310 mi), every 50 hours or 1000 km (620 mi), every 100 hours or 2000 km (1250 mi) or 1 year, and every 200 hours or 4000 km (2485 mi) or 2 years.
- Preseason Preparation: Procedures for vehicles not used for an extended period, including cleaning pulleys, replacing engine oil and filter, draining and refilling fuel, and test driving.
- Storage Procedures: Detailed steps for preparing the ATV for storage, covering the fuel system (fuel stabilizer), engine (lubrication, spark plug), electrical system (battery removal), cooling system (coolant density check), CVT transmission (drive belt removal, pulley cleaning), and general vehicle cleaning and protection. It also includes procedures for ATVs submerged for short or long periods.
- Safety Notices: Emphasizes the importance of turning off and cooling the engine for maintenance, wearing safety glasses, and using proper tools and procedures to prevent injury or damage. It also warns against tampering with the noise control system.
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