2002–2003 Bombardier DS 650 / Baja ATV Factory Shop Manual (P/N 704100015)

This Bombardier factory shop manual covers the 2002–2003 DS 650, DS 650 Baja and their International versions, with repair procedures for the liquid-cooled DOHC engine, five-speed transmission and chassis.

Text search and diagram navigation: The main service text is searchable, with 14 PDF bookmarks linking the contents, introduction and all 12 major sections. Some illustration labels, including those in the Baja wiring diagram, are not searchable. Small wiring labels require zooming.

• Engine repair: Engine removal, cylinder leak testing, cylinder-head and piston inspection, valve-clearance adjustment, and crankshaft/balancer-shaft service.

• Clutch and transmission: Clutch-pack inspection, release-shaft service, gearshaft disassembly, shift-drum and fork checks, and transmission operation checks after assembly.

• Fuel system: Mikuni BSR42 carburetor disassembly, float-level and idle adjustments, fuel-system pressure testing, and air intake silencer service.

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

• Electrical diagnosis: Charging and starting tests, CDI diagnosis, Packard/Deutsch connector service, and separate DS 650 and Baja wiring diagrams.

• Drivetrain and suspension: Rear-axle bearing replacement and preload, eccentric chain adjustment, steering alignment, ball-joint replacement, and reservoir-shock service.

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

The procedures are suited to mechanics experienced in ATV engine repair and electrical testing, with access to the specified measuring equipment and service tools.

Engine, Clutch and Transmission Repair

Cylinder leak-test diagnosis connects leakage paths with intake or exhaust valves, head gaskets, piston rings and cylinder wear. This helps narrow down a compression problem before deciding which assemblies need to come apart.

Internal engine coverage includes camshaft timing, centrifugal-decompressor inspection, crankshaft bearing radial play, cylinder wear limits and crankshaft/balancer-shaft end-float adjustment. Valve-guide inspection also identifies a service limitation: worn guides require cylinder-head replacement.

The clutch section covers friction and steel plate inspection, basket and hub wear, pressure-plate bearings and release-shaft service. Transmission procedures extend to shaft bearings, engagement dogs, shift forks and the shift drum.

Special-tool references include the crankshaft locking bolt, P/N 529 035 617, and clutch basket holder, P/N 529 035 618.

Mikuni Carburetor and Cooling-System Service

Carburetor coverage includes diaphragm inspection, pilot-screw setup and throttle-cable adjustment. The float-adjustment notes explain how prying the float lever can damage the needle and valve seat.

Cooling diagnosis distinguishes radiator and pressure-cap leakage, water-pump seal problems, and temperature-switch or sensor faults. The lubrication section covers the separate pressure and return oil pumps, the oil-pressure regulator and strainers, supported by an oil viscosity chart.

CDI, Charging and Baja Electrical Equipment

Stator continuity, insulation and running-output tests accompany regulator/rectifier diagnosis and starting-system troubleshooting charts. The “Identification of Major Connector Pins” views show terminal arrangements for Packard and Deutsch connectors.

Baja-specific coverage includes the cooling-fan relay, auxiliary headlights and tachometer. The separate DS 650 and DS 650 Baja wiring diagrams help match electrical tests to the equipment fitted to the ATV.

Rear Axle, Suspension and Hydraulic Brakes

Rear-axle exploded views support the bearing-preload procedure and identify the crowfoot adjustment tool, P/N 529 035 729. Incorrect preload can damage bearings and seals; the section also covers the eccentric carrier, wear sleeves and brake-disc hub.

Front-suspension instructions include a template sheet for orienting upper and lower ball joints. Rear reservoir-shock coverage addresses spring service, inspection, nitrogen-pressure adjustment, preload, rebound and compression damping.

The brake chapters distinguish the independent front and rear circuits. Inspection criteria cover pad and disc wear, piston and seal condition, and replacement requirements for damaged master cylinders or calipers.

Brake and nitrogen-charged shock work requires the safety precautions and equipment specified in the manual.

Maintenance, Bodywork and Reference Tables

Maintenance charts cover break-in and recurring service, with separate storage and preseason preparation sections. Torque references include grade 8.8 hardware and assembly-specific fasteners; technical tables provide fluid capacities, clearances, wear limits and electrical test values.

Body and frame coverage includes panel removal, seat-cover replacement, frame inspection and welding precautions. The plastic-repair section identifies the HDPE and LDPE body parts as nonrepairable.

English PDF and Included Pages

One printable English PDF contains 206 pages: 10 pages of contents and introductory material plus 196 pages across the 12 technical sections. The one-page ball-joint template and three-page wiring section are already included. The cover and front-matter pages III–V (“Safety Notice” and “What’s New”) are absent.