Bombardier DS 650 ATV Service Manual, 2001 (P/N 704 100 011)

This Bombardier Technical Publications shop manual, P/N 704 100 011, covers the 2001 DS 650, model 7449, with a 2000 copyright.

PDF Search, Bookmarks, and Diagram Detail

Text search and navigation: Body text is searchable, but cover text and some illustration labels, including those in the vehicle wiring diagram, are not. Chapter-level bookmarks work; most nested bookmarks point to separate files and do not work within this combined PDF. Small wiring codes and connector-pin numbers require zooming.

One printable English PDF contains 181 pages, including the original front and back covers and two service-publication feedback pages.

Engine, Drivetrain, and Electrical Service

The following selected topics show the repair coverage rather than reproduce the complete contents. Other included subjects range from headlight beam aiming to seat-cover replacement.

• Engine repair: Engine removal and installation, cylinder-head and valve-train work, camshafts, centrifugal decompressor, piston and rings, crankshaft, balancer shaft, and magneto service.

• Clutch and drivetrain: Clutch overhaul and adjustment, shifting-mechanism and transmission-shaft service, plus chain, sprocket, hub, solid rear-axle, and eccentric-bearing work.

• Fuel system: Fuel-system pressurization, carburetor removal and cleaning, float-level and idle adjustment, throttle-cable adjustment, and air-intake silencer service.

• Cooling and lubrication: Cooling-system leak testing and refilling, water-pump service, thermostat testing, oil-pressure diagnosis, oil-pump inspection, and oil-circuit bleeding.

• Electrical diagnosis: Charging, starting, and CDI ignition tests; Packard and Deutsch connector service; major connector-pin identification; battery troubleshooting; accessory tests; and the vehicle wiring diagram.

• Steering and suspension: Toe adjustment, steering-column and tie-rod service, A-arms, ball joints, front shocks, rear shock with reservoir, and swing-arm work.

• Hydraulic brakes: Front and rear master-cylinder and caliper disassembly, inspection and reassembly, pad and disc checks, fluid replacement, and bleeding.

This edition is intended for ATV mechanics familiar with Bombardier service procedures and equipped with the specified hand tools, measuring equipment, and special service tools.

Maintenance and Internal Engine Work

The maintenance material covers valve-clearance inspection and adjustment, air-filter service, oil and filter changes, spark-arrester service, storage, and pre-season preparation.

The edition’s “What’s New” page identifies revised procedures for clutch and drive-chain adjustment, cooling-system refilling, crankshaft and balancer-shaft recentering, and rear-suspension adjustment.

Internal engine coverage includes camshaft and valve inspection, cylinder and piston measurement, ring and bearing limits, crankcase work, and shaft end-float setup. Step-by-step procedures extend through internal transmission disassembly and reassembly, with gear-selection checks after assembly.

The clutch section warns that pulling the release lever backward while the engine is hot can dislodge the pressure-plate bearing.

Fuel, Cooling, and Oil-System Diagnosis

Fuel-system repair covers the tank, valve, lines, leak testing, and Mikuni BSR42 carburetor, including pilot adjustment and intake-adaptor inspection.

Cooling procedures address the radiator, water-pump shaft and seals, thermostat, fan, and temperature switches. Lubrication troubleshooting distinguishes low oil level, low or absent pressure, and oil contamination, linking these symptoms to checks of the strainers, pumps, seals, and pressure regulator.

The engine and transmission use mineral-based SAE 10W-40 four-stroke oil. Synthetic or synthetic-blend oil is excluded because it affects clutch calibration.

Starting and Ignition Fault Tracing

The starting-system symptom tables and component tests help distinguish neutral/clutch interlock faults from solenoid or starter faults before components are replaced.

Ignition diagnosis includes trigger-coil checks, ignition-coil tests, and an electronic-module test matrix. Ignition timing cannot be checked with a timing light because the engine has no access window or timing mark.

Chassis Repair and Assembly Cautions

Front-hub, bearing, and knuckle procedures are accompanied by rear-axle and eccentric-housing service, including tapered-bearing preload adjustment. Body coverage includes panel removal, seat-latch adjustment, frame inspection, and welding precautions.

The oblong front ball joint requires the correct tab lock and orientation; incorrect installation can restrict stud travel and lead to stud damage or failure.

Rear-shock coverage includes spring removal, preload and damping adjustment, and nitrogen charging. The pressurized damper unit itself must not be disassembled.

Exploded Views, Specifications, and Special Tools

Visual references include the Engine Removal and Installation, Crankshaft/Balancer Shaft, Clutch, Final Drive, and Hydraulic Brakes exploded views, plus the Wiring Diagram. Component callouts identify tightening torques, lubricants, sealants, and locking compounds. Technical tables supply capacities, approved fluids, electrical test values, adjustment data, clearances, and wear limits.

Tool references include the crankshaft locking bolt P/N 529 035 617, clutch basket holder P/N 529 035 618, oil-pressure gauge P/N 529 035 652, float-level gauge P/N 529 035 520, and ball-joint guide and driver P/Ns 529 035 705 and 529 035 706.

Coverage concerns the factory-built model; post-production dealer modifications are outside the manual, and later Service or Warranty Bulletins may update its procedures. Secure frame support on jack stands is required for raised-vehicle work; engine removal calls for a lifting tool and hoist.

Selected Shaft End-Float and Carburetor Settings

Shaft setup: The crankshaft and balancer-shaft recentering sections each specify 0.1 to 0.3 mm (.004 to .012 in) end float, with shim-selection measurements for replacement housings or shafts.

Carburetor adjustment: The Mikuni BSR42 float-level specification is 10 ± 0.5 mm (.39 ± .02 in), measured with the carburetor inverted. Photographs identify the gauge position and float-arm measurement.