2002–2003 Bombardier DS 650 & DS 650 Baja ATV Shop Manual (P/N 704 100 015)

This Bombardier Shop Manual (P/N 704 100 015) covers the 2002–2003 DS 650 and DS 650 Baja ATVs, including International models. The Introduction identifies yellow, black, and red variants by factory model code and illustrates vehicle and engine serial-number locations. Dealer modifications after manufacture are outside its scope.

Text search and diagram navigation: Main chapter text is searchable, but the cover and many labels within illustrations and wiring diagrams are not. Embedded bookmarks provide section and subsection navigation. Small labels in both wiring diagrams are readable when enlarged.

• Engine repair: Cylinder leak testing, engine removal and installation, cylinder-head service, camshaft timing, and crankshaft/balancer-shaft inspection and recentering.

• Clutch and transmission: Multi-disc clutch disassembly, clutch-basket inspection, release-mechanism adjustment, and five-speed gearbox and shifting-mechanism repair.

• Fuel and cooling: Mikuni BSR42 carburetor adjustment, fuel-system pressure testing, thermostat testing, water-pump overhaul, and Baja-specific cooling-fan relay diagnosis.

• Electrical troubleshooting: CDI ignition, trigger-coil and charging-system tests, starter-circuit diagnosis, major connector-pin views, and separate standard and Baja wiring diagrams.

• Drive train and suspension: Rear-axle bearing replacement and preload adjustment, A-arm ball-joint installation, swing-arm service, and rear-shock preload and damping adjustment.

• Brakes and steering: Hydraulic brake bleeding, master-cylinder and caliper repair, steering-column bearing replacement, tie-rod inspection, and wheel-alignment adjustment.

Written for ATV mechanic technicians already familiar with Bombardier service procedures and equipped with the specified hand tools and special service tools.

Engine Repair and Maintenance Specifications

The engine troubleshooting charts cover overheating, low oil pressure, starting faults, and clutch problems. Cylinder leak-test diagnosis distinguishes leakage through valves, piston rings, and the head gasket, helping narrow down compression problems before engine disassembly.

Internal engine coverage extends to the centrifugal decompressor, camshaft carriers, crankshaft bushings, and shaft end-float shimming. Inspection limits cover valve guides, pistons, camshaft components, and crankshaft bearings. Worn valve guides require cylinder-head replacement under the manual's procedure.

The Clutch exploded view accompanies friction-plate, steel-plate, hub, and basket inspection. A specific caution explains that forcing the clutch cover or pulling the release lever backward can dislodge the pressure-plate bearing.

Carburetor, Cooling, and Lubrication

Carburetor service covers float-level measurement, diaphragm positioning, pilot-screw adjustment, and throttle-cable setup. Fuel-tank and line pressure tests support leak diagnosis.

The Water Pump exploded view accompanies shaft and seal service. Cooling coverage distinguishes the Baja fan-relay circuit and includes radiator-cap checks and temperature-switch and sensor tests.

Dry-sump lubrication procedures cover the pressure and return oil pumps, oil-pressure regulator, strainers, and oil-circuit bleeding. Factory tables provide fluid capacities, service intervals, torque specifications, and adjustment data; routine maintenance also covers spark-arrester cleaning.

Electrical Tests and Model-Specific Wiring

The Identification of Major Connector Pins view supports Packard and Deutsch connector service. Charging-system coverage separates stator continuity, insulation, and output tests from regulator/rectifier diagnosis.

Separate DS 650 and DS 650 Baja wiring diagrams show the different circuits, including Baja auxiliary lighting and its relay. Accessory coverage also addresses the Baja tachometer and lighting requirements.

Ignition diagnosis includes trigger-coil, ignition-coil, and electronic-module tests. Ignition timing cannot be checked with a timing lamp because the engine has no access window or timing mark.

Axle, Suspension, and Brake Repair

Rear-axle work includes the brake-disc hub, eccentric housing, seals, tapered roller bearings, and bearing-preload procedure. The axle section warns that a lubricated seal bore can let the seal move out of position and cause bearing failure.

Front suspension coverage includes a template page for orienting upper and lower A-arm ball joints. Rear suspension procedures address the reservoir shock, dual-rate spring assembly, and swing-arm bushings.

Brake coverage treats the front and rear hydraulic circuits separately, with master-cylinder and caliper disassembly and disc inspection. Body and frame sections cover panel removal, seat-latch adjustment, and frame work.

Follow the manual's workshop safety precautions for hot engine and cooling components, hydraulic brakes, and the nitrogen-charged rear shock.

Specified Service Tools

Tool references identify the magneto puller (P/N 529 035 748), oil-pressure gauge (P/N 529 035 709), its adapter (P/N 529 035 652), and rear-axle bearing-preload tool (P/N 529 035 729).

English PDF and Included Pages

One printable English PDF contains 211 pages: one illustrated cover, one title page, 13 preliminary pages, and 196 pages across 12 technical sections. The ball-joint template page and both wiring-diagram sheets are already included in that total.