Bombardier 2002–2003 Quest & Traxter ATV Shop Manual Set (P/N 704 100 017)

The 12-section Quest manual supplies the base service procedures. The supplement has separate contents tables for the Quest and Traxter series so you can see which publication covers a job and when you need both.

Traxter coverage is supplemental. The set includes Traxter updates, specifications, and wiring diagrams. Base engine, clutch, transmission, and electric-shift repairs require the separate 2002 Traxter Shop Manual (P/N 704 100 013).

Searchable Shop Text and Wiring Drawings

Both PDFs have searchable text and section bookmarks. Zoom in to read small connector, pin, and wire-color labels in the wiring drawings. Those labels are outside the text search.

The ZIP contains two printable PDFs with 453 pages in total, including title and copyright pages, publication feedback forms, blank pages, and the supplement’s wiring dividers. Both files include the same outer cover and Quest wiring diagram.

Engine, Drivetrain, and Electrical Work

This selection of shop procedures gives an overview of the set. The Quest base manual also includes a fuel-tank pressure test.

• Quest engine repair covers cylinder leak-down testing, engine removal, cylinder-head and crankcase disassembly, camshaft timing, and crankshaft and balancer-shaft service.

• CVT and gearbox service covers step-by-step procedures for drive-belt and pulley work, plus one-way clutch inspection, shift-component service, and bevel-gear shimming.

• Axle and differential work includes differential teardown, ring-gear carrier recentering, axle bearings, CV boots, and propeller-shaft U-joints.

• Electrical diagnosis covers stator output, trigger and ignition coils, starting circuits, and regulator/rectifier testing.

• Hydraulic brake service includes master-cylinder and caliper repair, brake bleeding, and brake-control adjustment.

• Suspension and steering service covers A-arm bushings, swing-arm pivot bearings, and front-wheel alignment.

Bombardier wrote both publications primarily for ATV technicians already familiar with its service procedures and equipped with the appropriate hand tools and special service tools.

Quest Top-End, Cooling, and Lubrication

The Quest base manual covers the liquid-cooled, four-valve OHC engine with hydraulic lifters. It shows how to remove the cylinder head, cylinder, and piston with the engine still in the frame.

Cooling coverage includes leak testing, thermostat and temperature-sender checks, coolant bleeding, and water-pump seal replacement. The supplement adds Quest oil-pump rotor and clearance checks to the base lubrication and oil-pressure diagnosis procedures.

Driving in the water-pump seal can damage the ceramic component. Incorrect crankcase plain-bearing orientation can block an oil passage. The tool listings identify the ceramic seal installer 529 035 766 and piston circlip installer 529 035 765.

Output-Shaft and Differential Updates

The supplement revises the Quest output-shaft axial-clearance procedure and specifies bearing alignment tool 529 035 806. Its output-shaft shim chart links measured clearance to shim thickness, and separate MAG- and PTO-side tables support bevel-gear setup. The base manual’s Output Shaft and Transmission exploded view identifies the related components.

The supplement updates front and rear differential backlash procedures for both series where those assemblies are fitted. Check the condition of shop equipment and follow standard lifting and support practices when handling heavy ATV drivetrain components.

Carburetor and Circuit Diagnosis

Quest Mikuni BSR42 carburetor service covers float-level checks, pilot-screw adjustment, and diaphragm inspection. The fuel-pump section includes pressure and vacuum tests. Engine, gearbox, and CVT troubleshooting charts group symptoms by likely cause.

Quest electrical diagnosis extends to the electronic module, speedometer circuit, and XT winch controls. The Identification of Major Connector Pins drawing and the connector-location and wire-color keys support circuit tracing. Wiring diagrams cover the Quest series and the Traxter Autoshift, XL, and XT.

Model Identification and Service Data

The introductions identify domestic and international model codes and show where to find vehicle and engine identification labels. The specifications distinguish Quest CDI ignition from Traxter IDI ignition. Traxter tables identify the two-valve OHV engine and Mikuni BSR33 carburetor and list XL-specific suspension and cargo-box data.

The service tables provide fluid capacities, component torque specifications, inspection limits, and electrical test values such as trigger-coil resistance. Separate charts cover periodic maintenance, storage, and preseason preparation.

Selected Piston Clearance and Differential Backlash Specs

For the Quest 650 and 650 XT, the base manual lists a new piston-to-cylinder clearance of 0.031 to 0.059 mm and a wear limit of 0.090 mm.

For the Quest and Traxter differentials covered by the supplement’s front and rear axle procedures, the acceptable backlash is 0.102 to 0.356 mm at the specified one-inch measuring radius.