2005-2007 Bombardier DS650 / DS650 X / DS650 Intl Service Manual
Complete shop manual with troubleshooting, parts diagrams, and technical data for maintenance, repair, and service procedures. Covers all systems and components for reliable ATV operation.
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Sample pages from the 2005-2007 Bombardier DS650 / DS650 X / DS650 Intl Service Manual manual
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Models Covered & Key Technical Specifications
Bombardier DS650, DS650 X, DS650 Intl — 2005–2007 Service & Maintenance Technical Reference | DS650 Series ATV Collection.
- Designated Alignment Specs: 35 kPa (5 PSI) is configured at the front tire pressure requirement Sequences.
- Primary Wattage Specs: For optimal engine operation, 649 cc limits the cylinder displacement capacity Baseline.
- Advanced Operating Temps: The cooling system is set to maintain 75–100°C (167–212°F) thermostat opening range Requirements.
- Defined Angular Speed: Maximum engine speed produces 3200 rpm as the rated limit Threshold.
- Key Optical Resolution: The fuel tank represents 17 L (4.5 US gallons) storage volume Mapping.
- Certified Play Limits: Oil capacity is measured at 1.7 L (1.8 US quarts) engine lubrication Configuration.
Professional Workshop Service Manual & Technical Specifications
In-Depth undefined Operator's Manual: ATV Factory Service & Maintenance: Bombardier DS650, DS650 X, DS650 Intl (2005-2007) Reference-Archive
Product-Line: DS650™ (2005-2007), DS650™ X (2005-2007), DS650™ Intl (2005-2007) // Product-Line: Engine and transmission systems, cooling and magneto circuits // Product-Line: Comprehensive 247-page technical reference covering 11 major system categories with specification tables and wiring documentation.
| Category | Coverage | Documentation Details |
|---|---|---|
| Engine Systems | Troubleshooting, cooling, magneto, lubrication, cylinder/head, crankshaft, clutch, transmission | Complete reference data provided |
| Fuel & Ignition | Fuel circuit, carburetor, air intake, electrical overview, charging, starting, ignition | Specification tables included |
| Chassis & Components | Drive train, steering, suspension, brakes, body, frame | Technical specifications documented |
The service manual covers fundamental engine maintenance beginning with valve clearance documentation, followed by clutch release mechanism reference data, drive chain adjustment guidance, and spark arrester cleaning parameters. Fuel system sections reference fuel line compatibility, fuel valve inspection procedures, and carburetor float level adjustment parameters. The document includes engine and transmission oil change intervals, coolant density reference, and radiator condition assessment procedures.
Core Parameters
Engine cooling system documentation addresses thermostat opening specifications, water pump assembly procedures, and radiator protection methodologies. The magneto system section presents stator testing resistance values, trigger coil gap measurement guidance, and rotor inspection protocols. Lubrication system reference material encompasses engine pressure test values, oil pump configuration details, and oil strainer maintenance guidance. Cylinder and head sections document valve clearance reference ranges, valve spring free length specifications, and cylinder bore measurement procedures.
Precise Methodology
Crankshaft and balancer shaft sections include crankshaft locking procedures, bearing radial play reference data, and piston ring end gap specifications. The clutch assembly covers friction drive plate thickness documentation, clutch spring minimum length reference, and pressure plate bearing inspection protocols. Transmission sections reference shift fork claw thickness specifications, mainshaft wear limits, and clutch shaft measurement data.
Modular Protocol
Front suspension documentation covers shock absorber disassembly procedures, upper and lower A-arm inspection protocols, and ball joint lateral play reference values. Rear suspension sections address swing arm bearing specifications, shock absorber nitrogen charge parameters, and spring preload adjustment reference ranges. The manual documents torque specifications for the rear sprocket hub nut to ensure proper fastening, addresses brake disc hub bearing preload procedures, and covers eccentric axle housing inspection methodologies.
Structured Protocol
Hydraulic brake system documentation includes master cylinder seal installation procedures, caliper piston removal techniques, and brake pad lining minimum thickness specifications. The electrical section references battery charge state testing, starter motor troubleshooting procedures, and ignition system CDI operation principles. Charging system material documents voltage regulator specifications, stator continuity resistance values, and magneto output testing methodologies.
Modular Interface
Drive train sections document front wheel hub bearing replacement procedures, knuckle assembly specifications, and rear axle wear ring inspection protocols. Steering system reference material covers handlebar grip installation guidance, tie-rod ball joint alignment procedures, and steering column bearing installation protocols. Brake system documentation references hydraulic hose fitting specifications, brake fluid DOT 4 compatibility requirements, and brake caliper bracket installation procedures.
The manual documents torque specifications for engine mounting bolts to ensure proper installation and structural integrity across the powertrain assembly. Additional sections provide wiring diagram reference materials, connector identification guides, fuse location documentation, and technical data tables addressing engine displacement, fuel capacity, and transmission gear specifications for all three model variants covered (standard DS650, high-performance DS650 X, and international DS650 Intl configurations).
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