2005–2007 Bombardier DS650 / DS650 X / DS650 Intl ATV Service Manual

This Bombardier DS650 shop manual covers the standard, X, and Intl configurations, including DS650 X Intl. Its eleven sections address maintenance, engine repair, electrical diagnosis, drivetrain service, and chassis work.

• Engine repair: Engine removal and installation, cylinder-head and camshaft service, centrifugal decompressor inspection, piston and ring checks, and crankshaft/balancer-shaft work.

• Clutch and transmission: Clutch-pack inspection, release-mechanism adjustment, internal gearbox disassembly, shift-fork inspection, and transmission-shaft bearing replacement.

• Fuel and cooling: Mikuni BSR42 carburetor service, float-level adjustment, fuel-system leak testing, thermostat testing, radiator removal, and water-pump repair.

• Electrical diagnosis: Charging and starting-system tests, CDI electronic-module checks, sprag-clutch service, ignition troubleshooting charts, and connector pin-identification views.

• Suspension and steering: DS650 X front-shock rebuilding, rear-shock overhaul and valving, swing-arm service, ball-joint installation templates, and steering alignment.

• Axles and brakes: Eccentric axle housing and bearing service, drive-chain adjustment, steering-knuckle replacement, master-cylinder and caliper inspection, and hydraulic brake bleeding.

This manual suits technicians and experienced owners familiar with engine measurement and electrical testing; internal repairs and nitrogen-shock rebuilding require the specified workshop equipment.

Engine Repair and Fault Diagnosis

The leak-down section connects leakage at the intake, exhaust, radiator, and crankcase with the corresponding valve, gasket, and piston/ring checks. That helps narrow a mechanical fault before committing to engine teardown.

Cylinder-head coverage includes valve-clearance adjustment plates, camshaft timing marks, valve-seat inspection, and valve-stem seal replacement. Crankshaft and balancer-shaft procedures cover bearing inspection, alignment, and end-float shimming.

The clutch chapter distinguishes friction-plate wear, steel-plate distortion, basket damage, and release-shaft service. Gearbox instructions address the shift drum, engagement dogs, shaft bearings, and operational checks after assembly.

Carburetor, Cooling, and Lubrication Service

Carburetor exploded views and float-gauge illustrations support diaphragm inspection, float-level adjustment, pilot-screw settings, and throttle-cable adjustment. The carburetor notes explain how improper float-arm handling can damage the needle and valve seat.

Cooling coverage includes pressure testing, water-pump seal diagnosis, thermostat testing, and fan-switch checks. A separate fan-relay test applies to X models.

Dry-sump lubrication coverage includes pressure and return pumps, oil strainers, and illustrated pressure-gauge connections. Separate oil-circuit bleeding procedures address engine installation and a red indicator that remains lit after an oil change.

Electrical Tests and Wiring References

Ignition troubleshooting charts and Identification of Major Connector Pins views support checks of the trigger coil, ignition coils, electronic module, and starting interlocks. Packard and Deutsch connector service is covered alongside charging-system tests.

The appended black-and-white wiring sheets are labeled DS 650 and DS 650 Baja/Baja X and carry 2004 source codes. The Baja designation applies to the appended wiring sheet.

Suspension, Axles, and Hydraulic Brakes

Front-shock rebuilding applies specifically to DS650 X models. Rear-shock coverage includes reservoir-bladder inspection, compression and rebound valving, oil bleeding, and nitrogen charging; the manual identifies shock charging tool P/N 529 035 570.

The rear-axle section explains bearing preload and eccentric housing installation. Incorrect preload can damage axle seals and bearings. Steering coverage adds tie-rod inspection, knuckle service, and toe adjustment, while suspension maintenance includes swing-arm lubrication.

Front and Rear Brake exploded views accompany master-cylinder and caliper service, pad and disc inspection, and bleeding methods with or without a vacuum pump. Torque references include a grade-based M4–M14 fastener chart and component-specific values in the assembly views.

Follow the manual's precautions for pressurized nitrogen shocks, fuel vapors, and brake-system work.

A Sample of Oil-Pressure and Valve-Clearance Data

These values are a small selection of the lubrication-test and engine-adjustment specifications in the manual.

With a warm engine, the recommended oil, and the correct oil level, the pressure test specifies a minimum of 50 kPa (7 PSI) at idle and 300 kPa (44 PSI) at 6,000 rpm.

Cold intake and exhaust valve clearance is listed as 0.10–0.15 mm (.004–.006 in), with engine temperature no higher than 35°C (95°F).

PDF Search, Bookmarks, and Wiring Detail

Text search and diagram access: Main service text is searchable, and embedded bookmarks navigate the main sections. Some diagram labels and illustrated reference pages are not reliably searchable. Small wiring labels are clear when enlarged; the sideways diagrams also benefit from page rotation.

Supplied as one English-language, printable 243-page PDF: 241 pages of shop-manual material plus two appended wiring-diagram pages. Both additional wiring pages are already included in the total.