2003 Bombardier Traxter 500 / Quest 500/650 XT ATV Shop Manual (P/N 704 100 017)

• Combines the 2002 Quest base manual with 2003 Quest/Traxter updates; Traxter coverage is supplemental, not a complete standalone repair manual.
• Quest engine procedures cover leak-down testing, engine removal, cylinder-head and crankcase disassembly, camshaft timing, and crankshaft/balancer-shaft service.
• CVT work includes drive and driven pulley inspection, belt service, and one-way clutch repair. Gearbox chapters cover shift components and bevel-gear shimming.
• Front-drive and rear-axle sections address differential teardown, gear-carrier recentering, axle bearings, CV boots, and propeller-shaft U-joints.
• Electrical diagnostics cover stator output, trigger and ignition coils, starting circuits, and regulator/rectifier testing, supported by connector views and wiring diagrams.
• Hydraulic-brake service includes master-cylinder and caliper repair, bleeding, and brake-control adjustment. Chassis procedures cover A-arm bushings, swing-arm bearings, and steering alignment.

Technical Documentation and Model Coverage

This 453-page PDF set contains the 2002 Quest Shop Manual, P/N 704 100 017 (342 pages), and the 2003 Traxter/Quest Shop Manual Supplement (111 pages).

The 12-section base manual covers the 2002 Quest 650 and Quest 650 XT. The supplement addresses the 2003 Quest 500 2 x 4 and 4 x 4, Quest 650/650 XT, and Traxter 500, XL, and XT models. Factory model-number lists distinguish domestic and international versions, with vehicle and engine identification locations.

Traxter owners need the separate 2002 Traxter Shop Manual, P/N 704 100 013, for the base engine, clutch, transmission, and electric-shift repair instructions. That manual is not included. The supplement’s contents tables identify which work uses the base manual, the supplement, or both.

Quest Engine Repair and 2003 Updates

The engine chapters address the liquid-cooled, four-valve OHC engine with hydraulic lifters, including top-end service with the engine still in the frame. Cooling system leak testing, thermostat checks, coolant bleeding, and water pump seal replacement accompany oil-pressure diagnosis and oil-pump inspection.

The 2003 supplement revises the Quest output-shaft axial-clearance procedure, specifies bearing alignment tool 529 035 806, and supplies MAG- and PTO-side shim-selection tables. It also updates front and rear differential backlash procedures for both model families.

The water-pump instructions warn that impact installation can damage the ceramic seal. Incorrect crankcase plain-bearing orientation can also block oil flow and damage the engine.

Fuel Systems, Electrical Diagnostics, and Drawings

Mikuni BSR42 carburetor service covers float-level checks, pilot adjustment, and diaphragm inspection, with pressure/vacuum testing for the fuel pump. Electrical troubleshooting extends to the electronic module, speedometer circuits, and XT winch controls.

Engine, gearbox, and CVT troubleshooting charts organize faults by symptom and probable cause. Reference drawings include the Output Shaft and Transmission exploded view and Identification of Major Connector Pins. Separate Quest, Traxter Autoshift, Traxter XL, and Traxter XT wiring diagrams include wire-color and connector-location coding.

Engine and Maintenance Specifications

The documentation provides fluid capacities, component-specific torque tables, inspection limits, and electrical test specifications, including temperature-sender and trigger-coil resistance checks. Periodic maintenance and storage/pre-season charts cover service scheduling beyond engine repair.

The model-specific data keep the Quest CVT and CDI ignition separate from the Traxter five-speed, electronically controlled hydraulic-shift transmission and IDI ignition. Traxter tables identify its two-valve OHV engine and BSR33 carburetor, along with XL-specific suspension and cargo-box data.

The manual cross-references factory service tools by part number. Examples include piston circlip installer 529 035 765 and water pump ceramic seal installer 529 035 766, linking these specialized jobs to the required tooling.

Always verify equipment conditions and adhere strictly to standard workshop safety protocols before beginning any service work. Working with heavy ATV drivetrain components carries inherent physical risks.