Bombardier DS 650 & DS 650 Baja ATV - Comprehensive Service, Maintenance & Repair Manual (2002-2003)
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Models Covered & Key Technical Specifications
- Bombardier DS 650 (2002-2003)
- Bombardier DS 650 BAJA (2002-2003)
- Bombardier DS 650 (yellow) (2002)
- Bombardier DS 650 (black) (2002)
- Bombardier DS 650 Baja (2002)
- Bombardier DS 650 International (yellow) (2002)
- Bombardier DS 650 International (black) (2002)
- Bombardier DS 650 Baja International (2002)
- Bombardier DS 650 (red) (2003)
- Bombardier DS 650 Baja (2003)
- Bombardier DS 650 International (red) (2003)
- Bombardier DS 650 Baja International (2003)
Professional Workshop Service Manual & Technical Specifications
Bombardier DS 650 & Baja Series Service Manual - 2002/2003
This professional-grade workshop manual provides factory-sanctioned service protocols for the high-performance Bombardier DS 650 chassis. It features a critical synchronization sequence for the balancer shaft and crankshaft to eliminate parasitic engine vibration, ensuring maximum structural integrity and component longevity during high-load operations.
Technical Applicability & Model Identification
Chassis Series: 7463, 7527, 7483, 7528, 7484 (Model Year 2002)
- Bombardier DS 650 (Standard / Yellow / Black) (2002)
- Bombardier DS 650 Baja (2002)
- Bombardier DS 650 International (Yellow / Black) (2002)
- Bombardier DS 650 Baja International (2002)
Chassis Series: 7587, 7589, 7588, 7590 (Model Year 2003)
- Bombardier DS 650 (Standard / Red) (2003)
- Bombardier DS 650 Baja (2003)
- Bombardier DS 650 International (Red) (2003)
- Bombardier DS 650 Baja International (2003)
System Architecture & Operational ROI
- Engine Integrity: Detailed procedures for the 652cc Rotax engine ensure factory-spec compression and thermal management.
- Drive Train Precision: Exact bearing preload and axle alignment protocols prevent premature wear of the eccentric axle housing.
- Maintenance Uptime: Implementation of the mandatory 25-hour/1250km inspection intervals maintains vehicle compliance and resale value.
Document Metadata
- Documentation Type: Shop Manual
- Print Reference: VMR2002_072_00_02A.FM
- Total Pagination: 210 Pages
- Engine Type: 4-Stroke, DOHC, Liquid Cooled
Factory Benchmarks & Calibration Data
- Valve Clearance (Cold): Intake/Exhaust 0.10 to 0.15 mm (0.004 to 0.006 in).
- Lubrication Pressure: 50 kPa (7 PSI) minimum at idle; 300 kPa (44 PSI) at 6000 RPM.
- Thermostat Regulation: Unit begins opening at high engine operating temperatures to maintain a compression ratio of 9.7:1.
- Cylinder Limits: Maximum taper and out-of-round limit set at 0.10 mm (0.004 in).
Visual Navigation Aids & Schematic Overlays
- Engine Exploded Views: Component-level mapping for the cylinder head, crankshaft, and transmission assemblies.
- Electrical Routing: Full-color wiring diagrams for lighting, ignition (CDI), and charging systems.
- Suspension Geometry: Technical templates for proper ball joint orientation and A-arm installation.
Table of Contents
- Section 01: Service Tools and Service Products
- Section 02: Maintenance and Lubrication
- Section 03: Engine (Mechanical, Cooling, Magneto, Gearbox)
- Section 04: Fuel System (Carburetor, Fuel Circuit)
- Section 05: Electrical System (Starting, Ignition, Accessories)
- Section 06: Drive Train (Front Drive, Rear Axle, Drive Chain)
- Section 07: Steering/Control Systems
- Section 08: Suspension (Front and Rear)
- Section 09: Brakes (Hydraulic)
- Section 10: Body/Frame
- Section 11: Technical Data
- Section 12: Wiring Diagrams
Operational Limits & Specifications
- Fastener Torque (M10): 48 Nm (35 lbf-ft) for 8.8 grade bolts.
- Fastener Torque (M14): 135 Nm (100 lbf-ft) for 8.8 grade bolts.
- Fluid Capacities: Engine/Transmission Oil: 3 L (0.8 U.S. gal); Cooling System: 1.75 L (0.58 U.S. gal).
- Tire Pressure: Recommended 34 kPa (5 PSI) for both Front and Rear.
- Lubricant Grade: Bombardier Synthetic 5W40 (P/N 293 600 039) or Mineral SAE 10W40 (API SG, SH, or SJ).
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