ds650
ds650
ds650
WARNING Indicates a potential hazard that, if not avoided, could result in seri-
ous injury or death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle com-
ponents.
WARNING
YOUR VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rollover can occur
quickly, even during routine maneuvers such as turning and driving on hills or over obstacles,
if you fail to take proper precautions.
For your safety, understand and follow all the warnings contained in this Operator’s Guide and
the labels on your vehicle. Failure to follow these warnings can result in SEVERE INJURY
OR DEATH.
Keep this Operator’s Guide with the vehicle at all times.
WARNING
Disregarding any of the safety precautions and instructions contained in this Operator’s
Guide, Safety Videocassette and on-product labels could cause injury including the possibility
of death!
WARNING
This ATV may exceed the performance of other ATVs you have ridden in the past. This
category S (sport) is a high performance ATV for off road use only. It is for sport type recre-
ational and competitive use by operators with advanced skills and substantial experience.
All safety documentation should remain with the vehicle at the time of sale.
All content of the Safety Information section should be interpreted by the reader as a warning
which, if not followed, may result in injury including the possibility of death.
In Canada, products are distributed by Bombardier Recreational Products Inc. (BRP). In USA,
products are distributed by BRP US Inc.
The following trademarks are the property of Bombardier Recreational Products Inc.:
DS 650 TM
ROTAX ®
XP-STM
1
TABLE OF CONTENTS
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.
NOTICE ............................................................................................................... 7
INTRODUCTION ................................................................................................. 8
SAFETY INFORMATION
SPECIAL SAFETY MESSAGES......................................................................... 10
OPERATION WARNINGS................................................................................... 12
SAFETY WARNING ............................................................................................ 38
Pre-Operation Check............................................................................... 39
Clothing ................................................................................................... 40
Carrying Loads ........................................................................................ 41
Recreational Riding ................................................................................. 41
Environment ............................................................................................ 42
Design Limitation ..................................................................................... 42
Off-Highway Operation ............................................................................ 43
General Operating and Safety Precautions............................................. 43
Uphill Driving ........................................................................................... 43
Downhill Driving....................................................................................... 44
Side hilling ............................................................................................... 44
Drop-Offs ................................................................................................. 44
Riding Techniques................................................................................... 44
Routine Maintenance............................................................................... 50
HANG TAG.......................................................................................................... 51
LOCATION OF THE IMPORTANT LABELS ...................................................... 52
VEHICLE INFORMATION
HOW TO IDENTIFY YOUR ATV ......................................................................... 56
Engine and Vehicle Identification Number Location ................................ 56
Compliance Label.................................................................................... 56
NOISE EMISSION CONTROL SYSTEM REGULATION.................................... 57
EMISSION REQUIREMENTS ............................................................................. 58
CONTROLS/COMPONENTS/INSTRUMENTS................................................... 59
1) Throttle Lever .................................................................................... 61
2) Front Brake Lever ............................................................................. 61
3) Clutch Lever ...................................................................................... 62
4) Parking Lever Lock ........................................................................... 62
5) Multi-Function Switch ........................................................................ 63
6) Fuel Tank Cap .................................................................................. 64
2
7) Ignition Switch .................................................................................. 64
8) Indicator Lamps................................................................................ 64
9) Front Brake Fluid Reservoir ............................................................. 64
10) Fuel Valve ........................................................................................ 65
11) Gearshift Pedal ................................................................................ 65
12) Tool Box ........................................................................................... 66
13) Seat Latch ........................................................................................ 66
14) Footpeg ............................................................................................ 67
15) Foot Brake Pedal ............................................................................. 67
16) Rear Brake Fluid Reservoir .............................................................. 67
17) Engine/Transmission Oil Tank Cap ................................................. 68
18) Tachometer ...................................................................................... 68
19) Auxiliary Headlamps ........................................................................ 68
20) Nerf Bar ............................................................................................ 68
21) Radiator Cap .................................................................................... 69
LIQUIDS............................................................................................................... 70
Fuel......................................................................................................... 70
Engine/Transmission Oil ........................................................................ 70
Engine Coolant ....................................................................................... 72
Brake Fluid.............................................................................................. 73
Battery .................................................................................................... 74
BREAK-IN PERIOD ............................................................................................. 75
Engine..................................................................................................... 75
10-Hour Inspection ................................................................................. 75
OPERATING INSTRUCTIONS ............................................................................ 76
General ................................................................................................... 76
Pre-Operation Check .............................................................................. 76
Initial Cold Starting.................................................................................. 76
Warm Engine Starting............................................................................. 77
Stopping the Engine ............................................................................... 77
Shifting the Transmission ....................................................................... 77
SPECIAL PROCEDURES ................................................................................... 79
Flooded Engine....................................................................................... 79
Engine Overheat..................................................................................... 79
Turn Over................................................................................................ 79
ATV Immersion ....................................................................................... 80
Post-Operation Care............................................................................... 80
Storage and Preseason Preparation ...................................................... 80
CARGO AND TRANSPORTATION ..................................................................... 81
Cargo ...................................................................................................... 81
Transportation......................................................................................... 81
TROUBLESHOOTING......................................................................................... 82
SPECIFICATIONS ............................................................................................... 85
3
MAINTENANCE INFORMATION
MAINTENANCE CHART..................................................................................... 90
GENERAL ........................................................................................................... 93
ENGINE/TRANSMISSION .................................................................................. 94
Oil Change and Oil Filter Replacement ................................................... 94
Coolant Replacement .............................................................................. 95
Valves Adjustment................................................................................... 96
Spark Arrester ......................................................................................... 96
Radiator ................................................................................................... 97
Gearshift Pedal Adjustment..................................................................... 97
CARBURETOR ................................................................................................... 98
AIR INTAKE SYSTEM......................................................................................... 99
Air Filter Cleaning/Draining...................................................................... 99
ELECTRICAL ...................................................................................................... 101
Battery ..................................................................................................... 101
Fuses....................................................................................................... 101
Bulb Replacement ................................................................................... 102
Indicator Lamp Replacement................................................................... 104
Beam Aiming Adjustment ........................................................................ 104
DRIVE TRAIN...................................................................................................... 105
Swing Arm and Wheel Hub ..................................................................... 105
Drive Chain.............................................................................................. 105
Drive Chain Slider.................................................................................... 106
Sprocket and Pinion ................................................................................ 106
Tires/Wheels ........................................................................................... 107
Front Wheel Bearing Condition ............................................................... 107
Rear Axle Inspection ............................................................................... 107
STEERING SYSTEM .......................................................................................... 108
Throttle Cable Lubrication ....................................................................... 108
Throttle Lever Adjustment ....................................................................... 109
Clutch Cable Lubrication ......................................................................... 110
SUSPENSION ..................................................................................................... 111
Lubrication ............................................................................................... 111
Inspection ................................................................................................ 111
Adjustment............................................................................................... 111
BRAKES ............................................................................................................. 114
Front and Rear Brakes ............................................................................ 114
BODY/FRAME .................................................................................................... 115
Engine Area............................................................................................. 115
Skid Plate ................................................................................................ 115
Front Fenders .......................................................................................... 115
Fasteners................................................................................................. 115
Seat Latch ............................................................................................... 115
4
Frame ..................................................................................................... 115
Vehicle Cleaning and Protection............................................................. 115
WARRANTY
BRP INTERNATIONAL LIMITED WARRANTY: 2006 BOMBARDIER*
ATV PRODUCTS ................................................................................................. 118
PRIVACY OBLIGATION/DISCLAIMER ............................................................... 121
CHANGE OF ADDRESS/OWNERSHIP .............................................................. 123
5
6
NOTICE
This Operator’s Guide has been prepared to
acquaint the owner/operator of a new vehicle
with the various vehicle controls, mainte-
nance and safe operating instructions. It is in-
dispensable for the proper use of the product.
This Operator’s Guide uses the following
symbols.
WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.
7
INTRODUCTION
Your dealer should have provided you with The vehicle handling, stability and braking
some basic information on the particular con- distance may be affected when riding with a
trols and features of your new vehicle. Please passenger. Safely reduce speed when riding
take the time to study this Operator’s Guide with a passenger. Allow greater distance for
and all on-product warning labels as well as braking.
the Safety Videocassette that came with this The contents of this Operator's Guide provide
ATV. They more completely describe what riding information which has been proven re-
you should know about this vehicle before liable by other users. They are not intended
riding it. as a definitive means of avoiding accidents.
Whether you are a new user or an experi- How you apply this information, coupled with
enced rider, it is important for your personal your mental and physical condition, the par-
safety as well as passenger safety that you ticular terrain hazard and your risk accep-
know the controls and features of this vehicle. tance level will have an effect on your riding
Equally important is knowing how to properly experience. Have fun... and ride responsibly.
ride. This Operator's Guide has been prepared to
Irrespective of your age, experience or state acquaint the owner/operator of a new vehicle
regulations, it is always prudent for you or any with the various vehicle controls, mainte-
other person who may ride your vehicle, to nance and safe operating instructions. They
take an approved safe riding course. Please are indispensable for the proper use of the
check with your dealer or local authorities for product.
availability in your area. If you are a complete- We would be pleased to receive any com-
ly new rider, this should be done before your ments on the content and format of this Oper-
first ride. Your instructor should be able to pro- ator's Guide, the Safety Videocassette or on-
vide advice on local conditions and safe riding product warning labels.
practices particular to the area.
Riding conditions vary from place to place.
Each is subject to weather conditions which
may radically change from time to time and
from season to season. Riding on sand is dif-
ferent than riding on snow or through forests
or marshes. Each location may require a
greater degree of awareness and skill may
not be suitable with a passenger. Show good
judgement. Always proceed with caution.
Please do not take any unnecessary risks that
could leave you or your passenger stranded
or possibly injured.
8
SAFETY
INFORMATION
9
SPECIAL SAFETY MESSAGES
THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
This vehicle handles differently from other vehicles including motorcycles and cars. A collision
or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills
or over obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this Operator’s Guide and all on-product warning labels carefully and follow the oper-
ating procedures described. Watch and pay attention to the Safety Videocassette before
operation.
Never operate this vehicle without proper instruction. Take a training course.
Always follow this age recommendation: A person under 16 years old should never operate
this vehicle.
Never carry a passenger on this vehicle.
Never operate this vehicle on any paved surfaces, including sidewalks, driveways, parking
lots and streets.
Never operate this vehicle on any public street, road or highway, even a dirt or gravel one.
Never take place on this vehicle without wearing an approved helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, long sleeved shirt or
jacket, and long pants.
Never consume alcohol or drugs before or while riding this vehicle.
Never operate at excessive speeds. Always go at a speed that is proper for the terrain,
visibility, and operating conditions, and your experience.
Never attempt wheelies, jumps, or other stunts.
Always inspect your vehicle each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in this
Operator’s Guide.
Always keep both hands on the handlebars and both feet on the footrests of the vehicle during
operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert
to changing terrain conditions when operating this vehicle.
Never operate on excessively rough, slippery or loose terrain until you have learned and
practiced the skills necessary to control the vehicle on such terrain. Always be especially
cautious on these kinds of terrain.
Always follow proper procedures for turning as described further in this Operator’s Guide.
Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at
excessive speed.
Never operate the vehicle on hills too steep for the vehicle or for your abilities. Practice on
smaller hills before attempting larger hills.
Always follow proper procedures for climbing hills as described further in this Operator’s
Guide. Check the terrain carefully before you start up any hill. Never climb hills with exces-
sively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly
or make sudden gear changes. Never go over the top of any hill at high speed.
Always follow proper procedures for going down hills and for braking on hills as described
further in this Operator’s Guide. Check the terrain carefully before you start down any hill.
Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at
an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill
where possible.
Always follow proper procedures for crossing the side of a hill as described further in this
Operator’s Guide. Avoid hills with excessively slippery or loose surfaces. Shift your weight to
the uphill side of the vehicle. Never attempt to turn the vehicle around on any hill until you
have mastered the turning technique described in this Operator’s Guide on level ground.
Avoid crossing the side of a steep hill if possible.
10
Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid
stalling, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll
backwards, follow the special procedure for braking described further in this Operator’s
Guide. Dismount on the uphill side or to a side if pointed straight uphill. Turn the vehicle
around and remount, following the procedure described further in this Operator’s Guide.
Always check for obstacles before operating in a new area. Never attempt to operate over
large obstacles, such as large rocks or fallen trees. Always follow proper procedures when
riding over obstacles as described further in this Operator’s Guide.
Always be careful when skidding or sliding. Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such
as ice, go slowly and be very cautious in order to reduce the chance of skidding out of control.
Never operate this vehicle in fast flowing water or in water deeper than that specified further
in this Operator’s Guide. Remember that wet brakes may have reduced stopping ability. Test
your brakes after leaving water. If necessary, apply them several times to let friction dry out
the pads.
Always be sure there are no obstacles or people behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly.
Always use the size and type tires specified further in this Operator’s Guide. Always maintain
proper tire pressure as described further in this Operator’s Guide.
Never modify this vehicle through improper installation or use of accessories. Only use BRP's
approved accessories.
Never exceed the stated load limits for this vehicle including operator, all other loads and
added accessories. Cargo should be properly distributed and securely attached. Reduce
speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater
distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, contact an authorized Bombardier ATV
dealer to find out about the training courses nearest you.
11
OPERATION WARNINGS
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.
The following warnings and their format have been requested by the United States Consumer
Product Safety Commission and are required to be in this Operator’s Guide for all ATVs.
NOTE: The following illustrations are general representations only. Your model may differ.
WARNING
V00A0AQ
POTENTIAL HAZARD
Operating this vehicle without proper instruction.
12
WARNING
V00A01Q
POTENTIAL HAZARD
Failure to follow the age recommendations for this vehicle.
13
WARNING
V00A02Q
POTENTIAL HAZARD
Carrying a passenger on this vehicle.
14
WARNING
V00A03Q
POTENTIAL HAZARD
Operating this ATV on paved surfaces.
15
WARNING
V00A04Q
POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways.
16
WARNING
V00A06Q
POTENTIAL HAZARD
Riding this vehicle without wearing an approved helmet, eye protection and protective cloth-
ing.
17
WARNING
V00A07Q
POTENTIAL HAZARD
Riding this vehicle after consuming alcohol or drugs.
18
WARNING
V00A08Q
POTENTIAL HAZARD
Operating this ATV at excessive speeds.
19
WARNING
V00A09Q
POTENTIAL HAZARD
Attempting wheelies, jumps and other stunts.
20
WARNING
POTENTIAL HAZARD
Failure to inspect the vehicle before operating.
Failure to properly maintain the vehicle.
WARNING
POTENTIAL HAZARD
Riding on frozen waterways.
21
WARNING
V00A0BQ
POTENTIAL HAZARD
Removing hands from handlebar or feet from the footrests during operation.
22
WARNING
V00A0CQ
POTENTIAL HAZARD
Failure to use extra care when operating this vehicle on unfamiliar terrain.
23
WARNING
V00A0DQ
POTENTIAL HAZARD
Failure to use extra care when operating on excessively rough, slippery or loose terrain.
24
WARNING
V00A0EQ
POTENTIAL HAZARD
Turning improperly.
25
WARNING
V00A0QQ
POTENTIAL HAZARD
Operating on excessively steep hills.
26
WARNING
V00A0FQ
POTENTIAL HAZARD
Climbing hills improperly.
27
WARNING
V00A0GQ
POTENTIAL HAZARD
Going down a hill improperly.
28
WARNING
V00A0HQ
POTENTIAL HAZARD
Improperly crossing hills or turning on hills.
29
WARNING
V00A0IQ
POTENTIAL HAZARD
Stalling, rolling backwards or improperly dismounting while climbing a hill.
30
WARNING
V00A0JQ
POTENTIAL HAZARD
Improperly operating over obstacles.
31
WARNING
V00A0KQ
POTENTIAL HAZARD
Skidding or sliding improperly.
32
WARNING
V00A0LQ
POTENTIAL HAZARD
Operating this vehicle through deep or fast flowing water.
33
WARNING
V00A0OQ
POTENTIAL HAZARD
Operating this vehicle with improper tires, or with improper or uneven tire pressure.
34
WARNING
V00A0NQ
POTENTIAL HAZARD
Operating this vehicle with improper modifications.
35
WARNING
V02A02Q
POTENTIAL HAZARD
Overloading this vehicle or carrying or towing cargo improperly.
36
WARNING
V03M01Q
POTENTIAL HAZARD
Transporting inflammable or dangerous material can lead to explosions.
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.
37
SAFETY WARNING
To fully appreciate the pleasures and excitement of riding this vehicle, there are some basic rules
and tips that you should follow. Some may be new to you while others may be common sense
or obvious. Irrespective, we ask that you take a few minutes to read this Operator’s Guide
completely before you operate the vehicle.
Information in this Operator’s Guide is limited. It is strongly recommended that you obtain further
information and training from your local authorities, ATV clubs or a recognized ATV training
organization.
ATV manufacturers do not recommend anyone under the age of 16 to ride an ATV having an
engine higher than 90 cc. For the child’s safety, we strongly recommend you also follow and
enforce this recommendation. You are the sole judge of a rider’s capability to understand the
risks and operate a vehicle safely.
Persons with cognitive or physical impairments or who are high risk takers have an increased
exposure to overturns or collisions which may result in injury including death.
Become completely familiar with the operational controls and the general operation of the vehicle
before venturing into off road conditions. Practice driving in a suitable area free of hazards and
feel the response of each control. Drive at low speeds. Higher speeds require greater
experience, knowledge and suitable riding conditions.
Not all vehicles are the same. Each has its own unique performance characteristics, controls
and features. Each will ride and handle differently.
Never assume that the vehicle will go everywhere safely. Sudden changes in terrain caused by
holes, depressions, banks, softer or harder “ground” or other irregularities, may cause the vehicle
to topple or become unstable. To avoid this, slow down and always observe the terrain ahead.
If the vehicle does begin to topple or tipover, it is usually the best advice to immediately get off…
AWAY from the direction of the tipover!
38
Pre-Operation Check • Ensure fuel valve is in fully open position
(ON).
WARNING • Clean headlamp and taillight.
• Ensure seat is properly latched.
• If you transport cargo, respect load capac-
The pre-operation check is very important ity. Ensure cargo is properly secured to the
prior to operating the vehicle. Always vehicle.
check the proper operation of critical con-
trols, safety features and mechanical com- • Look and feel for loose parts while engine
ponents before starting. If not done, se- is off. Check fasteners.
vere injury or death might occur. • Ensure the path of travel is free of persons
and obstacles.
• Check operation of ignition switch, start
Before using this vehicle, the operator should button, engine stop switch and headlamp
always: switch.
• Apply parking brake and check if it oper- • Start engine, remove parking brake and
ates properly. drive forward slowly a few feet then apply
• Check tire pressure and condition. all brakes individually to test them.
• Check wheels and bearings for wear and
damage. Correct any problem you may have found be-
fore riding. See an authorized Bombardier
• Check location of controls and ensure they ATV dealer as necessary.
work properly.
• Verify if steering operates freely.
• Activate throttle control lever several times
to ensure it operates freely. It must return
to idle position when released.
• Activate the brake lever and brake pedal
to make sure the brakes fully apply. They
must fully return when released.
• Check all brake line fittings for tightness
and against leaks.
• With parking brake correctly applied, acti-
vate the clutch lever. It must fully return
when released.
• Check drive chain for adjustment and lu-
brication.
• Check sprockets for wear and damages.
• Check tightening of rear axle fasteners.
• Check swing arm, if any lateral play is de-
tected DO NOT USE THE VEHICLE.
• Check fuel, oil and coolant levels.
• Check for oil leaks on the engine, oil tank
and transmission.
39
Clothing
Actual weather conditions should help you decide how to dress. However, it is important that the
operator always wears the appropriate protective clothing and apparel, including an approved
helmet, eye protection, boots, gloves, long sleeved shirt and pants. This type of clothing will
provide you protection from some of the minor hazards you may encounter en route. Operator
must never wear loose clothing such as a scarf that may get entangled in the vehicle or on tree
branches and shrubs. Depending on conditions, antifogging goggles or sun glasses may be
required. Different colored lenses available for goggles or sun glasses help you distinguish ter-
rain variations. Sun glasses should only be worn during the daytime.
Approved
Helmet
Eye protection
Rigid
Chin
guard
Chest protector
Long
sleeves
Gloves
Long, sturdy
pants
Boots
40
Carrying Loads
Any load carried on the vehicle will affect the stability and control of the vehicle. For this reason,
do not exceed the load limits of the vehicle manufacturer. Always make sure the load is secured
and cannot interfere with your proper control. Always be aware that the “load” may slide or fall
off and create an accident. Avoid loads that may protrude sideways and get snagged or caught
in brush or other obstacles. Avoid covering and obstructing the headlamp or taillight with the
cargo.
This vehicle is designed specifically to carry an operator only. Even with a long seat that provides
unrestricted operator movements, it is not designed nor intended to carry passenger(s). Carrying
passenger(s) may affect the stability and your control of the ATV.
Recreational Riding
Respect the rights and limitations of others. Stay away from areas designated for other types of
off road use. This includes snowmobile trails, equestrian trails, cross country ski trails, mountain
bike trails etc. Never assume there are no other users on the trail. Always stay to the complete
right of the trail and do not zig zag to one side of the trail then the other. Be prepared to stop or
pull off to the side if another trail user appears in front of you.
Join a local ATV club. They will provide you with a map and advice or inform you where you can
ride. If a club does not exist in your area, help start one. Group riding and club activities provide
a pleasurable, social experience.
Always keep a safe distance from other riders. Your judgment of speed, terrain conditions,
weather, mechanical condition of your vehicle and the “trust in judgment” you have in others
around you will help you make a better choice of appropriate safe distance. This vehicle, like
any other motorized vehicle, cannot stop “on a dime”.
Before you ride, tell someone where you are planning to travel and your expected time of return.
Never consume alcohol or drugs before or while riding!
Depending on the length of your ride, carry additional tools or emergency equipment. Find out
where you can get additional gasoline and oil. Be prepared for the possible conditions you may
encounter. An emergency first aid kit should always be a consideration.
41
Environment
One of the benefits of this vehicle is that it can take you off the beaten path away from most
communities. However, you should always respect nature and the rights of others to enjoy it. Do
not ride in environmentally sensitive areas. Do not drive over forest crops or shrubs… nor cut
down trees or take down fencing… nor spin your wheels and destroy the terrain. “Tread Lightly”.
Chasing wildlife is in many areas illegal. Wildlife can die of exhaustion after being chased by a
motorized vehicle. If you encounter animals on the trail, stop and observe quietly and with cau-
tion. It will be one of the better memories of your life.
Observe the rule…”what you take in, carry out”. Do not litter. Do not start campfires unless you
have permission to do so… and then only… away from dry areas. The hazards you may create
on the trail may cause injury to others or yourself, even at a later date.
Respect farm lands. Always obtain the permission of the landowner before riding on private land.
Respect crops, farm animals and property lines. If you come to a closed gate, close it again after
yourself.
Finally, do not pollute streams, lakes or rivers and do not modify the engine or muffling system,
or remove any of its components.
Design Limitation
Although the vehicle is exceptionally rugged for its class, it is still a light vehicle by definition and
its operation must be restricted to its proper purpose.
The addition of weight to any part of the vehicle changes its gravitational stability and modifies
its performance.
42
Off-Highway Operation
The very nature of off-highway operation is dangerous. Any terrain, which has not been specially
prepared to carry vehicles, presents an inherent danger where angularity, terrain substance and
exact steepness are unpredictable. The terrain itself presents a continual element of danger,
which must be knowingly accepted by anyone venturing over it.
An operator who takes a vehicle off-road should always exercise the utmost care in selecting
the safest path and keeping close watch on the terrain ahead of him. On no account should the
vehicle be operated by anyone who is not completely familiar with the driving instructions appli-
cable to the vehicle, nor should it be operated on steep or treacherous terrain.
Uphill Driving
Due to configuration, this vehicle has excellent climbing ability, so much that tipover is possible
before traction is lost. For example, its common to encounter terrain situations where the top of
the hill has eroded to a point that the hill peak rises very sharply. The vehicle can readily negotiate
such a condition, however, in doing so, when the front of the vehicle is driven to a point that the
vehicle’s balance changes rearward tipover can occur.
The same situation may apply if an embedded object causes the front of the vehicle to climb
more than desired. If such a situation occurs take an alternate route. Be aware of side hilling
dangers when doing so.
It is also wise to know the terrain condition on the other side of the hill or bank. All too often there
exists a sharp drop-off that is impossible to negotiate or descend.
43
Downhill Driving
This vehicle can climb slopes that are steeper than it can safely descend. Therefore, it is essen-
tial to assure that a safe route exists to descend a slope before you climb it.
Decelerating while negotiating a slippery downhill slope could “toboggan” the vehicle. Maintain
steady speed and/or accelerate slightly to regain control.
Side hilling
Whenever possible, such operation should be avoided. If necessary, do so with extreme caution.
Side hilling on steep inclines could result in rollover. In addition, slippery or unfirm surfaces could
result in uncontrollable side sliding. Do not attempt to turn the vehicle downhill with the slide.
Avoid all objects or depressions that will intensify the raising of one side of the vehicle higher
than the other, thus causing rollover.
Drop-Offs
This vehicle will “bottom-out” and usually stop if either the front or rear wheels are driven over
a drop-off. If the drop is sharp or deep, the vehicle will nose dive and tipover.
WARNING
Avoid negotiating drop-offs. Reverse and select an alternate route.
Riding Techniques
Riding your vehicle too fast for the conditions may result in injury. Apply only enough throttle to
proceed safely. Statistics show that high speed turns usually result in mishaps and injury. Always
remember that this vehicle is heavy! Its pure weight alone may entrap you should it fall and pin
you down.
This vehicle is not designed for jumping nor can it, or you, absorb the energy of high impacts
such as jumping. Performing “wheelies” can cause the vehicle to flip over onto you. Both prac-
tices have a high risk for you and should be avoided at all times.
To maintain proper control it is strongly advised that you keep your hands on the handlebar and
within easy reach of all controls. The same holds true for your feet. To minimize the possibility
of any leg or foot injury, keep your feet on the footrests at all times. Do not direct your toes
outwards nor place your foot out to assist turning as they can be hit or snagged by passing
obstacles or may contact the wheels.
44
V00A0UL
Even though there is an adequate suspensions system on this vehicle there are “washboard” or
rough terrain conditions that will make you feel uncomfortable and even cause back injury. “Post-
ing” or riding in a crouched position will often be required. Slow down and allow your flexed legs
to absorb impact.
This vehicle is not designed for riding on roads or highways. In most places it is an illegal practice.
Riding your vehicle on roads or highways could cause a collision to occur with another vehicle.
ATV tires are not suited for paved road use. Pavement may seriously affect the handling and
control of the vehicle. Riding on roads or soft shoulders may confuse other road users, especially
if your lights are on. If you have to cross a road, the lead driver should get off his vehicle then
observe and give directions to the other riders. The last person after crossing then assists the
lead driver to cross. Do not travel sidewalks. They are designated for pedestrian use.
45
Water can be a unique hazard. If it is too deep the vehicle may “float” and topple. Check the
water depth and current before you attempt to cross any water. Water should not go above the
footrest. Be wary of slippery surfaces such as rocks, grass, logs, etc., both in the water and on
its banks. A loss of traction may occur. Do not attempt to enter the water at high speed. The
water will act as a brake and could throw you.
V00A0VL
Water will affect the braking ability of your vehicle. Make sure you dry the brakes by applying
them several times after the vehicle leaves the water.
Mud or marsh lands may be encountered near water. Be prepared for sudden “holes” or changes
in depth. Similarly so, be watchful of hazards such as rocks, logs, etc., partially covered by
vegetation.
If your trip crosses frozen waterways, make sure that the ice is thick enough and sound enough
to support the total weight of yourself, the vehicle and its load. Be ever watchful of open water…
it is a sure indication that the ice thickness will vary. If in doubt, do not attempt to cross.
Ice will also affect the control of the vehicle. Slow down and do not “gun” the throttle. This will
only result in spinning of the tires and possible tipover of the vehicle. Avoid rapid braking. This
again will possibly result in an uncontrolled slide and tipover of the vehicle. Slush should be
avoided at all times since it could block the operation or controls of the vehicle.
Sand and riding on sand dunes or on snow is another unique experience but there are some
basic precautions that should be observed. Wet, deep or fine sand/snow may create a loss of
traction and cause the vehicle to slide, drop off or become “bogged” down. If this occurs look for
a firmer base. Again, the best advice is to slow down and be watchful of the conditions.
When riding in sand dunes it is advisable to equip the ATV with an antenna type safety flag. This
will help make your location more visible to others over the next sand dune. Proceed carefully
should you see another safety flag ahead. Since the antenna type safety flag can snag and
rebound on your body if caught, do not use it in areas where there are low hanging branches or
obstacles.
46
Riding on loose stones or gravel is very similar to riding on ice. They will affect the steering of
the vehicle... possibly causing it to slide and tipover especially at high speeds. In addition, brak-
ing distance may be effected. Remember that “gunning” the throttle or sliding may cause loose
stones to be ejected rearwards into the path of another rider's way. Never do it deliberately.
V00A0WL
If you do get into a slide or skid, it may help to turn the handlebar into the direction of the skid
until you regain control. Never jam the brakes and lock the wheels.
Respect and follow all posted trail signs. They are there to help you and others.
Obstacles in the “trail “should be traversed with caution. This includes loose rocks, fallen trees,
slippery surfaces, fences, posts, and embankments and depressions. You should avoid them
whenever possible. Remember that some obstacles are too large or dangerous to cross and
should be avoided. Small rocks or fallen trees may be safely crossed… approach at a 90° angle.
Stand on the footrests while keeping your knees flexed. Adjust speed without losing momentum
and do not “gun” the throttle. Hold handgrips firmly. Place your body weight rearwards and
proceed. Do not try to lift the ATV front wheels off the ground. Be aware that the object may be
slippery or may move while crossing.
When driving on hills or slopes two things are highly important… be prepared for slippery sur-
faces or terrain variations and obstacles and… use proper body positioning.
47
Uphill
Keep your body weight forward towards the top of the hill. Keep your feet on the footpegs and
shift into low gear then accelerate and when necessary, change gear quickly as you climb. Do
not over-speed since this may cause the front of the vehicle to lift from the ground and fall back
on you. If the hill is too steep and you cannot proceed or the vehicle begins to roll backwards,
apply the brake, being careful not to slide. Dismount then use the “U” turn or “K” turn (while
walking back, next to the vehicle on the up hill side and with a hand on the brake lever, slowly
back the rear of the vehicle toward the top of the hill then drive downhill). Always walk or dismount
on the upside of the slope while keeping clear of the vehicle and its rotating wheels. Do not try
to hold on to the vehicle if it begins to topple. Stay clear. Do not ride over the crest of the hill at
high speed. Obstacles, including sharp drop-offs, may exist.
V00A0XL
48
Downhill
Keep your body weight rearwards. Apply the brake gradually to prevent skidding. Do not “coast”
down the slope using solely engine compression or in neutral gear.
V00A0YL
Side hilling
This is one of the most risky types of riding since it may drastically change the balance of the
vehicle. It should be avoided wherever possible. If it is necessary to do so however, it is important
that you ALWAYS keep your body weight on the upside of the slope… and be prepared to
dismount on that side should the vehicle begin to topple. Do not try to stop or save the vehicle
from damage.
49
V00A0ZL
Routine Maintenance
Once your ride is completed it is wise to remove any build up of snow, ice, mud and grime. Not
only will this help you keep the vehicle longer and in good condition for resale but will eliminate
potential hazards the next time you use the vehicle. Wash your vehicle in warm soapy water
then allow it to dry. (A towel may help). Do not wash your vehicle outside during freezing weather.
Apply appropriate lubrication as described in the MAINTENANCE section.
Part of your responsibility towards safety is to respect the contents of this Operator’s Guide. It
provides valuable advice on how to properly take care of your ATV. If further assistance is re-
quired, your authorized Bombardier ATV dealer is always willing to help.
Modification of the vehicle to increase speed and performance may violate the terms and con-
ditions of your vehicle limited warranty. In addition, certain modifications including the removal
of engine or exhaust components are illegal under most laws.
Changing the wheel and/or tire size may affect the stability of the ATV. Incorrect tire pressure
may lead to blow outs or cause a tire to move around on its rim and become lost or damaged.
Wheels or tires which are damaged should always be replaced.
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.
50
HANG TAG
This vehicle comes with a hang tag and labels containing important safety information.
Any person who rides this vehicle should read and understand this information before riding.
S WARNING
SPORT MODEL
THIS ATV IS FOR Improper ATV use can result in SEVERE injury or DEATH.
RECREATIONAL USE
BY EXPERIENCED OPERATORS ONLY
51
LOCATION OF THE IMPORTANT LABELS
The following labels are on your vehicle and they should be considered permanent parts of the
vehicle. If missing or damaged, they can be replaced free of charge. See an authorized
Bombardier ATV dealer.
NOTE: The following illustrations used in this Operator's Guide are a general representation
only. Your model may differ.
6
5
V02L02M
4
52
LABEL 1 LABEL 4
DRIVE CHAIN 22 mm (7/8")
WARNING DRIVE CHAIN MUST BE WELL ADJUSTED
AND LUBRICATED. FREE PLAY IS 22 mm
(7/8") WITH DRIVER ON VEHICLE. SEE
Improper ATV use can result in SEVERE INJURY or DEATH. OWNERS MANUAL FOR COMPLETE
INSTRUCTIONS.
ALWAYS USE
AN APPROVED
NEVER USE
ON PUBLIC
NEVER CARRY NEVER USE
PASSENGERS. WITH DRUGS
LABEL 5
HELMET AND ROADS. OR ALCOHOL.
PROTECTIVE
GEAR.
NEVER operate:
• without proper training or instructions.
WARNING
• at speeds too fast for your skills or the conditions.
• on public roads - a collision can occur with NEVER ride as a
another vehicle.
• with a passenger - passengers affect balance and passenger.
steering and increase risk of loosing control.
Passengers can
ALWAYS: cause a loss of
• use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns. control, resulting in
• avoid paved surfaces - pavement may seriously
affect handling and control. SEVERE INJURY or
DEATH.
LOCATE AND READ OPERATOR’S GUIDE.
FOLLOW ALL INSTRUCTIONS & WARNINGS.
LABEL 6
LABEL 2
WARNING WARNING
Improper tire pressure LOAD COLD TIRE PRESSURE
or overloading can
cause loss of control UP TO FRONT
UNDER resulting in SEVERE 100 kg MAX: 34.5 kPa (5 psi)
16 INJURY or DEATH.
ALWAYS maintain
(220 lb) MIN: 21.0 kPa (3 psi)
REAR
MAX: 34.5 kPa (5 psi)
proper tire pressure MIN: 21.0 kPa (3 psi)
as shown.
Operating this ATV if you are under the NEVER set tire pressure below minimum. It could cause
age of 16 increases your chance of the tire to dislodge from the rim.
SEVERE INJURY or DEATH. NEVER exceed the vehicle load capacity of 100 kg (220 lb)
NEVER operate this ATV if you are including weight of operator, cargo, accessories and
under age 16. trailer tongue weight.
LABEL 3
WARNING
This ATV may exceed the performance of other ATV’s you
may have ridden in the past.
This category S (sport) is a high performance ATV for off
road use only. It is for sport type recreational and
competitive use by operators with advanced skill and
substantial experience.
53
LABEL 7
ENGINE FAMILY 6BCXX.6522GC ENGINE FAMILY
FEL 13.4 g/kW-hr HC + NOx FEL
ENGINE DISPLACEMENT 651.88 cm3 ENGINE DISPLACEMENT
EXHAUST EMISSION CONTROL SYSTEM CARB EXHAUST EMISSION CONTROL SYSTEM
EMISSION CONTROL INFORMATION FUEL Unleaded 87 octane (ron+mon)/2 FUEL EMISSION CONTROL INFORMATION
THIS VEHICLE MEETS U.S. ENVIRONMENTAL SAE 10W40 THIS VEHICLE MEETS U.S. ENVIRONMENTAL
ENGINE OIL ENGINE OIL
PROTECTION AGENCY AND C.A.R.B. PROTECTION AGENCY AND C.A.R.B.
IDLE SPEED 1300 RPM ± 100 RPM IDLE SPEED
REGULATIONS FOR MODEL YEAR 2006 REGULATIONS FOR MODEL YEAR 2006
SPARK PLUG TYPE NGK DR8E SPARK PLUG TYPE
SPARK PLUG GAP 0.6-0.8 mm / 0.024-0.028 in SPARK PLUG GAP
SEE OPERATOR’S GUIDE FOR MAINTENANCE SPECIFICATIONS SEE OPERATOR’S GUIDE FOR MAINTENANCE SPECIFICATIONS
BOMBARDIER RECREATIONAL PRODUCTS INC.
LABEL 8
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.
54
VEHICLE
INFORMATION
55
HOW TO IDENTIFY YOUR ATV
The main components of your vehicle (engine Compliance Label
and frame) are identified by different serial
numbers. It may sometimes become neces- This label indicates vehicle's conformity in
sary to locate these numbers for warranty many countries.
purposes or to trace your vehicle in the event The label is located on the right side of
of loss. These numbers are required by the vehicle, on the upper bar of frame.
authorized Bombardier ATV dealer to com-
plete warranty claims properly. No warranty
will be allowed by BRP if the engine identifi-
cation number (EIN) or vehicle identification
number (VIN) is removed or mutilated in any
way. We strongly recommend that you take
note of all the serial numbers on your vehicle V00M02Y
and supply them to your insurance company.
USA AND CANADA
Engine and Vehicle
Identification Number Location
3
1
V00M03Y
2
V02A1PY
56
NOISE EMISSION CONTROL SYSTEM REGULATION
Tampering with Noise Control System Is Prohibited!
U.S. Federal law and Canadian provincial laws may prohibit the following acts or the causing
there of:
1. The removal or rendering inoperative by any person other than for purposes of maintenance,
repair or replacement of any device or element of design incorporated into any new vehicle
for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while
it is in use or,
2. The use of the vehicle after such device or element of design has been removed or rendered
inoperative by any person.
Among those Acts Presumed to Constitute Tampering Are the Acts Listed
Below:
1. Removal or alteration or the puncturing of the muffler or any engine component which con-
ducts removal of engine exhaust gases.
2. Removal or alteration or the puncturing of any part of the intake system.
3. Replacing any moving parts of the vehicle or parts of the exhaust or intake system, with parts
other than those specified by the manufacturer.
4. Lack of proper maintenance.
57
EMISSION REQUIREMENTS
The California Air Resources Board (CARB) requires that your ATV complies with applicable
exhaust emissions standards during its useful life, when operated and maintained according to
the instructions supplied.
A non-compliance Red Label (as well as a Green Label) is obtained annually during California
Vehicle registration. The appropriate label is denoted by the vehicle identification number (in the
8th character detailed herein).
58
CONTROLS/COMPONENTS/INSTRUMENTS
NOTE: Some controls/instruments/equipment are optional.
13 6 5 21
19
16 14 15
3 5 17 18 8 7 9 4 2
V02A19L 6 1
59
6
13
10
17
19
20 11 14
12
21
19
16
14 20
V02A1CL
60
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.
WARNING WARNING
This ATV may exceed the performance of Always release the throttle when shifting
other ATVs you may have ridden in the gears. Shifting gears without releasing the
past. throttle, could cause loss of control includ-
This category S (sport) is a high perfor- ing the ATV to overturn and mechanical
mance ATV for off road use only. It is for damages.
sport type recreational and competitive
use by operators with advanced skills and
substantial experience. 2) Front Brake Lever
Located on the right side of handlebar. When
NOTE: This section gives basic functions of compressed, the brake is applied. When re-
the various controls of your ATV. For more de- leased, it should automatically return to its
tails of how to operate one control in conjunc- original position. Braking effect is proportional
tion with some others, refer to OPERATING to the force applied on the lever and to the
INSTRUCTIONS further in this section. type and condition of the terrain.
1) Throttle Lever 1
Located on the right side of handlebar. When
pushed, it increases the engine speed that al-
lows the engagement of the transmission on 2
the selected gear.
When released, the engine speed should re-
turn automatically to idle and the vehicle will
gradually slow down.
V02I02Z
2 1. Brake lever
2. To apply brake
V02I02Y 1
1. Throttle lever
2. To accelerate
3. To decelerate
61
3) Clutch Lever
Located on the left side of handlebar. When
WARNING
compressed, the clutch is disengaged. When
released, the clutch is engaged. Make sure brake lever lock is fully disen-
gaged before operating the ATV.
1 When you ride the vehicle, brakes that are
caused to drag by a continuous pressure
on the lever may cause damage to the
3 brake system and cause loss of braking
capacity and/or fire.
1
2
V02D02Y
1. Clutch lever
2. To disengage
3. To engage
WARNING
Always release the throttle when shifting
gears. Shifting gears without releasing the
throttle, could cause loss of control includ-
ing the ATV to overturn and mechanical V02I02O
damages.
1. Parking lever lock
2. Press to apply parking break
4) Parking Lever Lock
Located on right side of handlebar on the front To release mechanism: Squeeze front
brake lever. When applied, it temporarily pre- brake lever. Lever lock should automatically
vents the vehicle from moving. Useful when return to its original position. Front brake lever
the brake needs to be locked for example should return to rest position.
such as doing a K-turn, during transportation
or when the vehicle is not in operation.
WARNING
Always use the brake lever lock when the
vehicle is not in operation.
62
5) Multi-Function Switch NOTE: While engine can be stopped by turn-
ing ignition key OFF, we recommend the en-
The multi-function switch is located on the left gine be stopped by the engine stop switch.
side of handlebar.
V02I0WY 1
1. Multi-functions switch
Headlamp Switch
V02I03Z 1
Located on the top of multi-function switch.
Place switch to LO for the low beam and tail- 1. Engine stop switch
light. Place switch to HI for the high beam and
taillight. To close headlamp, move the head- Start Button
lamp switch to OFF position.
Located under engine stop switch. To start en-
1 gine:
– Place the engine stop switch to RUN.
– Select transmission to the NEUTRAL po-
sition or squeeze the clutch lever.
– Turn ignition key to ON.
– Press and hold the start button.
Release immediately after engine is started.
V02I03Y
1. Headlamp switch
63
6) Fuel Tank Cap Engine Indicator Lamp (red)
Unscrew counterclockwise and remove cap When the engine oil pressure is too low or the
to allow fuel tank filling then fully tighten clock- engine temperature is too high, the engine in-
wise. dicator lamp comes ON.
WARNING 2 1
Always stop engine before refueling.
Open cap slowly. If a differential pressure
condition is noticed (whistling sound heard
when loosening fuel tank cap) have vehi-
cle inspected and/or repaired before fur-
ther operation. Fuel is flammable and ex-
plosive under certain conditions. Never
use an open flame to check fuel level. Nev-
er smoke or allow flame or spark in vicinity.
Always work in a well-ventilated area.
Never top up the fuel tank before placing V02I01Y
the vehicle in a warm area. As tempera-
ture increases, fuel expands and may 1. Neutral indicator lamp (green)
overflow. Always wipe off any fuel spillage 2. Engine indicator lamp (red)
from the vehicle.
In the event that the vehicle is flipped over or
stays tilted on the side, be sure to check RED
7) Ignition Switch engine indicator lamp after restarting engine.
Located on the right side of the control panel. If lamp stays ON, stop engine and refer to
Key-operated, 2 position switch: OFF, and SPECIAL PROCEDURES section.
ON without lights. CAUTION: Failure to stop the engine imme-
Insert key in switch and turn to the desired diately after RED engine indicator lamp
position. To remove key, turn key to OFF then comes ON will adversely affect the service life
of the engine.
pull it out.
NOTE: While engine can be stopped by turn- 9) Front Brake Fluid Reservoir
ing ignition key OFF, we recommend the en-
gine be stopped by pushing the engine stop Located above front brake lever.
switch.
1
8) Indicator Lamps
The indicator lamps are located above igni-
tion switch.
64
10) Fuel Valve CAUTION: Improper opening of fuel valve
will restrict the flow of fuel. Make sure
Located on right side under fuel tank. It is a 3- valve is fully open while running.
position rotary valve: OFF, ON, RES. Rotate
the knob to align its pointer with ON, OFF or
RES. 11) Gearshift Pedal
OFF Located in front of left footpeg.
Stops fuel supply to carburetor.
CAUTION: Turn valve to OFF position when
ATV is not being operated or when transport-
ing.
ON
Allows fuel to flow to carburetor. This is the
normal position for operation of the vehicle.
RES (reserve)
When fuel is exhausted in the fuel tank when
in the ON position, an emergency supply of
fuel is available by turning the knob to RES.
The reserve contains approximately 20% of
the fuel tank capacity. Use only this position
when the ON supply is empty.
When down to the reserve, refuel as soon as
possible. Ensure to turn the valve back to the
ON position after refuelling.
1
V02A0LY
1. Gearshift pedal
V02A0KY
65
12) Tool Box 13) Seat Latch
The tool box is located in the service compart- Located underneath rear end of seat. It allows
ment, near the air box. the removal of seat to give access to air box
and storage compartment.
1
2
V02A0MY
1. Storage compartment
2. Air box
V02A0NY
The tool box contains tools for basic mainte-
nance and this Operator’s Guide. 1. Seat
The tools included in the tool box are: 2. Seat latch
– pliers (1)
– screwdriver (1) Seat Removal
– open wrench 10/13 mm (1) Pull latch upward while gently lifting rear of
– open wrench 15/17 mm (1) seat. Continue lifting movement until you can
– socket wrench 10/13 mm (1) release the front retaining devices then com-
– socket wrench 16/18 mm (1) pletely remove seat.
– tire pressure gauge (1)
– Allen key 3 mm (1)
– Allen key 5 mm (1)
– offset screwdriver for rear shock
absorber (1)
– drive chain adjuster lock (1)
– fuse 25 A (1)
– fuse 15 A (1).
66
Seat Installation 15) Foot Brake Pedal
Insert seat front tab into body hook. Pull latch Located in front of right footpeg. When
lever to insert it over the rear lock pin. Release pressed down, the rear brake is applied.
latch lever then firmly push on rear of the seat When released, it should return to its original
to relatch. position.
2 1
V02L07Y V02K01Y 1
1. Seat tab 1. Foot brake pedal
2. Body hook
NOTE: Braking effect is proportional to the
WARNING force applied on the lever and to the type and
condition of the terrain.
Periodically verify the seat lock pin and 16) Rear Brake Fluid Reservoir
tighten if needed. Make sure seat is se- Located near the right rear fender.
curely latched before riding.
14) Footpeg
Located on both sides of the vehicle.
V02K02Z
V02L0NY 1
1. Footpeg
67
17) Engine/Transmission Oil Tank 19) Auxiliary Headlamps
Cap Located on each side of front of vehicle, under
Located on LH of control panel. front fascia.
V02I01Z
WARNING
The oil tank can be hot. Do not touch with V02G0RY 1
your hands.
1. Auxiliary headlamps
V02L0NZ 1
V02I0TY
1. Nerf bar
The tachometer indicates the revolution per
minute (RPM) of the engine. Multiply by 1000
to obtain an approximation of the actual RPM.
68
21) Radiator Cap
The radiator cap is located under front fascia,
on the top of radiator.
WARNING
In order to avoid potential burns, do not
remove the radiator cap if the engine is
hot.
V02C4VY
69
LIQUIDS
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.
70
Oil Viscosity
SAE 10W40 is recommended for summer
time and SAE 5W30 for winter time.
Other viscosity should be used if the average
temperature is outside the range of the rec-
ommended oil. See chart below.
°C °F
60 140
50
120
40
BOMBARDIER SYNTHETIC OIL 5W40 (P/N 293 600 039)
SAE 20W50
100
30
80
SAE 15W40
20
60
SAE 10W40
10
SAE 10W30
40
0
SAE 5W30
20
-10
0
-20
-30 -20
V02A1OY
71
Oil Level To add oil, remove the dipstick. Place a funnel
into the dipstick tube to avoid spillage. Add a
CAUTION: Check level frequently and refill if small amount of oil and recheck oil level.
necessary. Do not overfill. Operating the en- Repeat the operation until oil level reaches
gine/transmission with an improper level may the dipstick’s upper mark. Do not overfill.
severely damage engine/transmission. Wipe Properly tighten dipstick.
off any spillage.
Engine Coolant
Recommended Coolant
Always use ethylene-glycol antifreeze con-
taining corrosion inhibitors specifically for in-
ternal combustion aluminum engines.
Cooling system must be filled with
Bombardier premixed coolant (P/N 219 700
362) or with distilled water and antifreeze so-
lution (50% water, 50% antifreeze).
1
3
2 V02A08Y 2 1 3
1. Coolant reservoir
2. Radiator
3. RH front shock
V02C3NY
1. Full
2. Add
3. Operating range
72
With vehicle on a level surface, liquid should Fluid Level
be between MIN. and MAX. level marks of
coolant reservoir. With vehicle on a level surface, check brake
NOTE: When checking level at temperature fluid in reservoirs for proper level. It should be
lower than 20°C (68°F), it may be slightly low- above MIN. mark.
er than MIN. mark. Clean and remove the filler cap then add fluid
Remove filler cap then add coolant up to as required. Do not overfill.
MAX. mark if required. Use a funnel to avoid CAUTION: Use only DOT 4 brake fluid from
spillage. Do not overfill. a sealed container. Do not use brake fluid tak-
Properly reinstall and tighten filler cap. en from old or already opened containers.
If coolant is added in the coolant reservoir, NOTE: A low level may indicate leaks or worn
check the level in the radiator too. Add coolant brake pads. See an authorized Bombardier
if necessary. ATV dealer.
Front Brake Fluid Reservoir
WARNING Turn steering in the straight-ahead position to
ensure reservoir is level.
In order to avoid potential burns, do not Check brake fluid level, the reservoir is full
remove the radiator cap if the engine is when fluid reaches of the top of window.
hot. Visually inspect lever boot condition. Check
for cracks, tears etc. Replace if damaged.
NOTE: A cooling system that frequently re-
quires coolant is the indication of leaks or en-
gine problems. See an authorized
Bombardier ATV dealer.
Coolant Replacement
Refer to MAINTENANCE section.
Brake Fluid
Recommended Fluid
Always use brake fluid meeting the specifica-
tion DOT 4 only. V02K03Y
73
Rear Brake Fluid Reservoir
With vehicle on a level surface, check brake
fluid in reservoir for proper level. It should be
above MIN. mark.
V02K02Y
RH SIDE OF VEHICLE
Battery
This vehicle is equipped with a dry type bat-
tery that requires no maintenance.
Refer to MAINTENANCE section to remove
or install the battery.
74
BREAK-IN PERIOD
Engine 10-Hour Inspection
A break-in period of 10 operating hours is re- NOTE: The 10-hour inspection is at the ex-
quired before running the vehicle at sustained pense of the vehicle owner.
full throttle. As with any precision piece of mechanical
CAUTION: Never mix oil with fuel. This vehi- equipment, we suggest that after the first
cle has a 4-stroke engine. Oil must be added 10 hours or 30 days or 400 km (250 m.) after
to oil tank only. the purchase, whichever comes first, your ve-
During this period, maximum throttle should h i c le b e i n s p e ct e d b y a n a u t h o r i ze d
not exceed 3/4. However, brief full accelera- Bombardier ATV dealer. This inspection will
tion and speed variations contribute to a good give you the opportunity to discuss the unan-
break-in. Continued wide open throttle accel- swered questions you may have encountered
erations, prolonged cruising speeds and en- during the first hours of operation.
gine overheating are detrimental during the
break-in period.
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.
75
OPERATING INSTRUCTIONS
General • If you transport cargo, respect load capac-
ity. Ensure cargo is properly secured to the
This vehicle has five-forward gears. vehicle.
To allow engine starting, the transmission • Look and feel for loose parts while engine
must be on NEUTRAL or squeeze the clutch is off. Check fasteners.
lever to start in any gear. • Ensure the path of travel is free of persons
and obstacles.
Pre-Operation Check • Check operation of ignition switch, start
button, engine stop switch and head-
WARNING lamps.
• Start engine, remove parking brake and
The pre-operation check is very important drive forward slowly a few feet then apply
prior to operating the vehicle. Always all brakes individually to test them.
check the proper operation of critical con- Correct any problem you may have found
trols, safety features and mechanical com- before riding. See an authorized Bombar-
ponents before starting. If not done as dier ATV dealer if necessary.
specified here, severe injury or death
might occur. Initial Cold Starting
Insert key in ignition switch and turn to ON.
Before using this vehicle, the operator should Place the engine stop switch to run position.
always: In severe cold weather, colder than -20°C
• Apply parking break and check if it oper- (-4°F), move the choke lever to full position.
ates properly. Press start button and hold until engine starts.
• Check tire pressure and condition. Release start button immediately when en-
• Check wheels and bearings for wear and gine has started.
damage.
• Check location of controls and ensure they
work properly. WARNING
• Verify if steering operates freely.
• Activate throttle control lever several times Do not apply throttle while starting.
to ensure it operates freely. It must return
to idle position when released. After a few seconds, move the lever to half
• Activate the brake levers and brake pedal position.
to make sure the brakes fully apply. Levers NOTE: Overusing choke may flood engine
and pedal must fully return when released. and make it hard to start. Refer to SPECIAL
• Check all brake line fittings for tightness PROCEDURES if it occurs.
and against leaks.
• With parking break correctly applied, acti-
vate the clutch lever. It must fully return
when released.
• Check drive chain for adjustment and lu-
brication.
• Check sprockets for wear and damages.
• Check tightening of rear axle fasteners.
• Check swing arm, if any lateral play is de-
tected DO NOT USE THE VEHICLE.
• Check fuel, oil and coolant levels.
• Check for oil leaks on the engine, oil tank
and transmission.
• Ensure fuel valve is in fully open position
(ON).
• Clean headlamp and taillight.
• Ensure seat is properly latched.
76
When the engine is warm, move the choke Warm Engine Starting
lever to OFF and release brakes.
Start the engine as explained above but with-
out any choke. If the engine will not start after
two 4-second attempts with the electric start-
er, move choke lever to half position. Start the
engine without activating the throttle lever. Af-
ter a few times, move the choke lever to OFF.
WARNING
Avoid parking vehicle on slope.
77
One full stroke of the pedal shifts the trans-
mission to the next higher or lower gear in the
shifting sequence. The pedal should automat-
ically return to its original position.
To upshift to a higher gear, put the end of your
boot under gearshift lever and lift up the pedal
one full stroke. To downshift, lean the tip of the
gearshift pedal and depress pedal one full
stroke.
V02D05Y
WARNING
Always release the throttle when shifting
gears. Shifting gears without releasing the
throttle could cause loss of control or
cause the ATV to overturn.
78
SPECIAL PROCEDURES
Flooded Engine Ensure radiator is not obstructed.
Check and clean radiator fins. See MAINTE-
When the engine does not start after several NANCE section.
attempts, the engine may be fuel flooded.
Proceed as follows.
Turn ignition switch to ON and ensure choke WARNING
is not applied.
Ensure the transmission is in NEUTRAL or The radiator can be very hot, wear gloves
squeeze the clutch lever. to touch the radiator.
Fully press throttle lever and hold while start-
ing the engine. Try several times. Reduce vehicle speed but try to keep it mov-
As soon as the engine starts, release throttle ing to supply air to radiator. If engine is still
lever. Do not race engine. overheating after approximately one minute,
If it does not work: stop vehicle and set transmission to NEU-
Disconnect spark plug cables. TRAL. Apply parking brake and stop engine.
Clean the spark plug area then remove spark Place the ignition switch to ON position (do
plugs (tools are supplied in tool box). not restart engine yet). The radiator fan will
cool the radiator.
WARNING Let engine cool down before checking coolant
level and refill if possible.
Always wear eye protector and gloves
when the spark plug hole is cleaned. WARNING
Never refill cooling system when engine is
Crank engine several times. Install clean dry hot. Let engine cool down.
spark plugs or news spark plugs if possible.
Start engine as explained above. If engine
continues to flood, see an authorized See an authorized Bombardier ATV dealer as
Bombardier ATV dealer. soon as possible.
79
On the LH side, remove the oil inlet hose on Post-Operation Care
the engine.
When vehicle is used in salt-water environ-
ment (beach area, launching/loading boats,
etc.), rinsing the vehicle with fresh water is
necessary to preserve vehicle and its compo-
nents. Metallic parts lubrication is highly rec-
ommended. Use BOMBARDIER LUBE
(P/N 293 600 016) or an equivalent. This
must be performed at the end of each operat-
ing day.
When vehicle is operated in muddy condi-
tions, rinsing the vehicle is recommended to
preserve vehicle and its components and to
keep lights clean.
NOTE: Never use a high pressure washer to
V02C4DY 1 clean the vehicle. USE LOW PRESSURE
ONLY (like a garden hose). The high pressure
1. Oil inlet hose can cause electrical or mechanical damages.
80
CARGO AND TRANSPORTATION
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.
Transportation
When transporting a vehicle, secure vehicle
to trailer with suitable tie-downs. Using ordi-
nary ropes is not recommended.
WARNING
V00A174
81
TROUBLESHOOTING
Engine does not turn
82
4. Engine is overheating.
– Check ENGINE OVERHEATING in SPECIAL PROCEDURES.
– If overheating persists, contact an authorized Bombardier ATV dealer.
5. Air filter/box plugged or dirty.
– Check air filter and clean if necessary.
– Check liquid/deposits in air box drain tube.
– Check the position of the air intake tube.
Engine backfire
Engine misfire
1. Valve adjustment.
– Contact an authorized Bombardier ATV dealer.
2. Chain tensioner plugged.
– Contact an authorized Bombardier ATV dealer.
3. Timing chain wear.
– Contact an authorized Bombardier ATV dealer.
83
Vehicle cannot reach full speed
1. Engine.
– See ENGINE LACKS ACCELERATION OR POWER.
2. Parking brake.
– Ensure brake lever lock is completely removed.
3. Air filter/box plugged or dirty.
– Check air filter and clean if necessary.
– Check liquid/deposits in air box drain tube.
– Check the position of the air intake tube.
84
SPECIFICATIONS
VEHICLE MODEL DS650™ X
ENGINE
BRP - ROTAX, 4 stroke.
Type Double overhead camshaft engine, bush chain
drive
Number of cylinder Single cylinder
Number of valve 4 bucket tappet-operated valves
Displacement 653 cc (39.8 cu. in)
Bore Standard 100 mm (3.9 in)
Stroke 83 mm (3.3 in)
Compression ratio 9.7:1
Dry sump lubrication by oil pump with replaceable
Lubrication oil filter (lubrication of engine and transmission
simultaneously)
Decompressor Automatic
Exhaust system BRP, stainless header pipe painted steel muffler
Air filter 2 stage foam filter
TRANSMISSION
Clutch 1 multi-disc
Transmission Integrated 5 speeds constant mesh transmission
COOLING
Type Liquid cooled with integrated water pump
Radiator Front mounted with thermostatic fan
CARBURETION
Make Mikuni
Carburetor
Type BSR 42 constant depression type
Choke Manual choke
Idle speed ± 100 1300 RPM
85
VEHICLE MODEL DS650™ X
ELECTRICAL
Magneto Make Denso
generator Type 290 W @ 6000 RPM
Breakerless high voltage condenser ignition
Ignition type system with electronic spark advance
Ignition timing Not adjustable
Engine RPM limiter 7900 RPM (any gear in forward)
Make NGK
Spark plug Type DR 8 EA
Gap 0.6 to 0.7 mm (.024 to .027 in)
Number of spark plug 2
Type Dry type battery
Battery
Volt 12 Volts, 13 Ah
Instrument Tachometer
Electric start. Start in any gear
Starting system (with clutch applied or on NEUTRAL)
Headlamp bulb 2 x 30 W
Taillight and brake light bulb 8/27 W, 1157
Auxiliary headlight 2 x 35 W, H3
Fan 15 A
Fuses Auxiliary headlight 15 A
Charging system 25 A
DRIVE TRAIN
Rear axle Chain driven/solid axle
Turning radius 3.16 m (10 ft)
SUSPENSION
Independent suspension — double A-arm
Type
Front 2 shock absorbers (oil/gas)
Travel 305 mm (12 in)
Rigid swing-arm
Type
Rear 1 shock absorber (oil/gas)
Travel 279 mm (11 in)
86
VEHICLE MODEL DS650™ X
TIRES
Front 35 kPa (5 PSI) recommended
Pressure
Rear 35 kPa (5 PSI) recommended
Front 22 x 7 – 10
Size
Rear 20 x 10 – 9
WHEELS
Front 10 x 5.5 with reinforced ring
Size
Rear 9 x 8.5 with reinforced ring
Wheel nut torque 53 N·m (39 lbf·ft)
BRAKES
Front Nissin hydraulic, 2 discs (Stainless)
Rear Nissin hydraulic, 1 disc (Stainless)
Parking device RH brake lever includes a lock on front wheels
STEERING
Toe-out (vehicle on ground and measure
0.5 mm ± 0.5 mm (.0197 in ± .0197 in) each side
on the rim)
LOADING CAPACITY
Total vehicle load allowed 125 kg (220 lb) includes operator, all other loads
and added accessories
GVWR (Gross Vehicle Weight Rating) 333 kg (733 lb)
Weight distribution (front/rear) 50/50%
DIMENSIONS
Dry mass 225 kg (495 lb)
Overall length 1.97 m (77.5 in)
Overall width 1.23 m (48 in)
Overall height 1.21 m (47 in)
Wheel base 1.24 m (49 in)
Front 1.05 m (41 in)
Wheel track
Rear 978 mm (38.5 in)
Ground clearance 297 mm (11.7 in)
87
VEHICLE MODEL DS650™ X
LIQUIDS
SAE 10W40, 4-stroke mineral-based. API
classification SG, SH or SJ or XP-S 5W40
Oil type (engine and transmission) synthetic 4-stroke oil. Do not use other synthetic
oil, synthetic blend oil or special additive. Refer
to OIL VISCOSITY CHART for proper grade
Ethylene-glycol/water mix (50% coolant, 50%
Coolant distilled water). Use Bombardier premixed coolant
or a coolant specially designed for aluminum
engines
Type Super unleaded gasoline
Fuel Octane Inside North America: 91 (R + M)/2
Outside North America: 95 RON
Hydraulic brake Brake fluid, DOT 4
CAPACITIES
Approximately 3 hours depending on many factors
Vehicle range
such as temperature and operating conditions
Fuel tank 12 L (3.2 U.S. gal) including approximately
2.4 L (0.6 U.S. gal) reserve
Engine/transmission oil 3.1 L (3.3 U.S. quarts)
Coolant 1.75 L (1.9 U.S. quarts)
A = ampere
Ah = ampere hour
cc = cubic centimeters
cu. in = cubic inches
hp = horsepower
kW = kilowatt
RPM = revolution per minute
V = volt
W = Watt
Because of our ongoing commitment to product quality and innovation, BRP reserves the right,
at any time, to make changes in design and specifications and/or to make additions to, or im-
provements in its products without imposing any obligation upon itself to install them on its
products previously manufactured.
88
MAINTENANCE
INFORMATION
89
MAINTENANCE CHART
The maintenance is very important; if you are not familiar with safe service practices and adjust-
ment procedures, see your authorized Bombardier ATV dealer.
PERIODIC MAINTENANCE CHART
INITIAL INSPECTION 10 H OR 30 DAYS OR 400 KM (250 mi)
(To be performed by an authorized Bombardier BRP ATV dealer. The
initial maintenance is very important and must not be neglected.)
A: ADJUST
25 H OR 1250 KM (800 mi)
C: CLEAN
I: INSPECT 50 H OR 2500 KM (1600 mi)
L: LUBRICATE
R: REPLACE 100 H OR 1 YEAR OR 5000 KM (3100 mi)
T: PROCEED WITH TASK 200 H OR 2 YEARS OR 10000 KM
(6200 mi)
TO BE PERFORMED
BY
PART/TASK LEGEND
ENGINE/TRANSMISSION
Engine/transmission oil level ! EVERY RIDE CUSTOMER
Engine/transmission oil and R R CUSTOMER
filter
Oil reservoir strainer C CUSTOMER
Valve clearance T T DEALER
Engine mounting fasteners ! I I DEALER
(2) Every 50 hours, check
Exhaust system I I DEALER coolant strength.
(3) Pre-ride inspection item.
Spark arrester C CUSTOMER (4) More often under severe
use such as dusty area,
Coolant " T T R CUSTOMER sand, snow, wet or
Radiator cap/cooling system muddy conditions.
I I DEALER
pressure test
Radiator condition/cleanliness I I CUSTOMER
(radiator fins) #
Clutch and transmission I DEALER
operation !
Clutch lever ! I I DEALER
FUEL
Air filter # C R CUSTOMER (4) More often under severe
use such dusty area,
Fuel lines and connections I I DEALER sand, snow, wet or
Fuel tank strainers R DEALER muddy conditions.
Carburetor A A DEALER
90
PERIODIC MAINTENANCE CHART
INITIAL INSPECTION 10 H OR 30 DAYS OR 400 KM (250 mi)
(To be performed by an authorized Bombardier BRP ATV dealer. The
initial maintenance is very important and must not be neglected.)
A: ADJUST
25 H OR 1250 KM (800 mi)
C: CLEAN
I: INSPECT 50 H OR 2500 KM (1600 mi)
L: LUBRICATE
R: REPLACE 100 H OR 1 YEAR OR 5000 KM (3100 mi)
T: PROCEED WITH TASK 200 H OR 2 YEARS OR 10000 KM
(6200 mi)
TO BE PERFORMED
BY
PART/TASK LEGEND
ELECTRICAL
Spark plug $ T R DEALER
Battery connections I I DEALER
Wiring harnesses, cables and I I DEALER
lines (3) Pre-ride inspection item.
(5) Make sure the spark plug
Condition of ignition switch, start I I CUSTOMER is correctly gapped.
button and engine stop switch !
Condition of lighting system
(HI/LO intensity, brake lamp, I I CUSTOMER
headlamp aiming, etc.) !
DRIVE TRAIN
Drive chain lubrication ! EVERY RIDE CUSTOMER
Drive chain adjustment ! EVERY RIDE CUSTOMER
Drive chain slider and roller EVERY RIDE CUSTOMER
condition ! (3) Pre-ride inspection item.
Sprockets # I I CUSTOMER (4) More often under severe
use such as dusty area,
Wheel bearing condition ! I I L CUSTOMER sand, snow, wet or
muddy conditions.
Rear wheel hub L CUSTOMER
Rear axle tightness (eccentric
axle housing bolts and I I CUSTOMER
adjustment nut)
STEERING
Handlebar fasteners ! I I DEALER
Throttle/housing/cable ! I I CUSTOMER
Choke I I DEALER
Steering system ! I I# DEALER (3) Pre-ride inspection item.
(4) More often under severe
Tie rod ends I I CUSTOMER use such dusty area,
sand, snow, wet or
Wheel nuts/studs ! I I CUSTOMER muddy conditions.
Tire pressure and wear ! EVERY RIDE CUSTOMER
Front wheel hub EVERY RIDE CUSTOMER
Front wheel alignment I I DEALER
91
PERIODIC MAINTENANCE CHART
INITIAL INSPECTION 10 H OR 30 DAYS OR 400 KM (250 mi)
(To be performed by an authorized Bombardier BRP ATV dealer. The
initial maintenance is very important and must not be neglected.)
A: ADJUST
25 H OR 1250 KM (800 mi)
C: CLEAN
I: INSPECT 50 H OR 2500 KM (1600 mi)
L: LUBRICATE
R: REPLACE 100 H OR 1 YEAR OR 5000 KM (3100 mi)
T: PROCEED WITH TASK 200 H OR 2 YEARS OR 10000 KM
(6200 mi)
TO BE PERFORMED
BY
PART/TASK LEGEND
SUSPENSION
Swing arm inspection I I CUSTOMER (4) More often under severe
use such dusty area,
Swing arm lubrication EVERY RIDE CUSTOMER sand, snow, wet or
A-arms I I, L CUSTOMER muddy conditions.
BRAKE
Brake fluid (front and rear) ! I I R% CUSTOMER (3) Pre-ride inspection item.
(6) Brake fluid replacement
Brake pads % I CUSTOMER or any brake system
Brake system (discs, hoses repairs must be
I CUSTOMER performed by an
etc.) !
authorized BRP ATV
Brake line fittings ! I EVERY RIDE CUSTOMER dealer.
BODY/FRAME
Engine area C C CUSTOMER
Skid plates and A-arm EVERY RIDE CUSTOMER
protectors (3) Pre-ride inspection item.
(4) More often under severe
Frame I DEALER use such as dusty area,
Chassis fasteners ! I CUSTOMER sand, snow, wet or
muddy conditions.
Seat latch EVERY RIDE CUSTOMER
Vehicle cleaning and protection C# CUSTOMER
92
GENERAL
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.
WARNING
Unless otherwise specified, engine should not be running for all maintenance procedures.
Before performing any service or inspection operation on the vehicle, wait until the engine
and exhaust have cooled down to avoid potential burns.
WARNING
Should removal of a locking device (e.g. lock tabs, self-locking fasteners, etc.) be required,
when undergoing disassembly/assembly, always replace with a new one.
NOTE: The following covers the maintenance items that can be performed by the customer if
desired. Other items found in MAINTENANCE CHART must be performed by an authorized
Bombardier ATV dealer.
93
ENGINE/TRANSMISSION
Among other things, this section gives the Allow enough time for oil to flow out of oil filter.
procedures to replace the liquids. Refer to Unscrew oil filter cover.
LIQUIDS for procedures to check levels and Remove the oil filter and replace by a new fil-
refill. ter.
NOTE: Check and change the O-ring, if nec-
Oil Change and Oil Filter essary.
Replacement
Oil and filter are to be replaced at the same 1 3
time. Oil change should be done with a warm
engine.
.
WARNING
The engine oil can be very hot. Wait until
engine oil is warm.
94
Check if the RED indicator lamp stays ON, if
so, stop engine and bleed system by remov-
ing oil filter and bleeding screw.
V02C10Y 1
1. Cooling plug
Drain the system completely and reinstall the
drain plug.
V02C05Y 1 Remove the temperature sensor on the top of
BEHIND OIL FILTER thermostat housing.
1. Bleeding screw Fill radiator until coolant comes out by the
temperature sensor hole.
Reinstall all removed parts then start the en- Install the temperature sensor and continue
gine. Check if the RED indicator lamp stays the cooling system filling by the radiator.
ON. If so, repeat the bleeding procedure. If Complete the radiator filling.
the RED indicator lamp stays continually ON, Check the level in the coolant reservoir and
stop the engine and see an authorized refill if necessary.
Bombardier ATV dealer. Run engine at idle with the radiator cap off.
Ensure oil filter area, hose and drain plug ar- Slowly add additional coolant if necessary.
eas are not leaking. At this point, wait until engine reaches normal
Stop engine and check oil level. Refill as nec- operating temperature. Depress the throttle
essary. lever two or three times; then add coolant if
Dispose oil as per your local environmental required.
regulations. Install radiator cap. Inspect all connections for
leaks and check coolant level in the reservoir.
Coolant Replacement
WARNING
In order to avoid potential burns, do not
remove the radiator cap or loosen the en-
gine drain plug if the engine is hot.
95
Valves Adjustment – spark arrester and sealant joint
See an authorized Bombardier ATV dealer for
valves adjustment. 2
Insufficient clearance will cause loss of power
and possibly damage the valves. Excessive
clearance will cause noise.
Spark Arrester
The muffler must be periodically purged of ac-
cumulated carbon. See the MAINTENANCE
CHART.
Removal
WARNING
Never run engine in an enclosed area. V02C07Y 1 3
Never perform this operation immediately 1. Spark arrester
after the engine has been run because ex- 2. Sealant joint
haust system is very hot. Make sure that 3. Muffler
there are no combustible materials in the
area. Wear eye protection and gloves. – inner grill with wool.
Never stand behind the vehicle while purg-
ing exhaust system. Respect all applicable Remove all carbon deposit in the muffler.
laws and regulations. Remove carbon deposits from the spark ar-
rester using a brush.
NOTE: Use a soft brush and be careful to
Remove: avoid damaging spark arrester.
– the screws retaining the spark arrester to
the muffler Installation
For installation, reverse the removal proce-
dure, pay attention to the following details:
Check:
1 1 – insulated wool and change if it is deterio-
rated
– the spark arrester condition, it must be free
of breaks and holes. Replace if necessary.
2
V02C06Y
1. Screws
2. Spark arrester
96
Remove the old sealant joint and replace by Gearshift Pedal Adjustment
a new one. Use ULTRA COOPER sealant
(P/N 293 800 090) or an equivalent product. Unfasten socket screw near selector shaft
end then remove gearshift pedal.
V02C08Y
WARNING
Never clean radiator with your hands
when it is hot. Let the radiator cool down
before cleaning.
97
CARBURETOR
See an authorized Bombardier ATV dealer
each year or after using the vehicle 100 hours
or after 5000 km (3100 m.) to verify and clean
the fuel system.
98
AIR INTAKE SYSTEM
Air Filter Cleaning/Draining
1
Periodically inspect air filter box drain tube for
liquid or deposits.
V02A0DY 2
1. Latches
2. Air filter box cover
99
Pour cleaning solution (P/N 219 700 341) or
an equivalent into a bucket. Put the filter in to
soak.
While filter soaks, clean inside of air box.
Rinse air filter and foam with warm water.
Squeeze foam to remove excess water. Let
dry air filter and foam thoroughly.
NOTE: Slight dust may be cleaned using a
low-pressure airgun. Blow compressed air
backward of operating air flow.
If air filter element or foam is dirty, replace with
a new one.
When the filter is dried, re-oil with air filter oil
(P/N 219 700 340) or an equivalent.
Air Filter Installation
Properly reinstall removed parts in the re-
verse order of their removal.
100
ELECTRICAL
Fuses
WARNING If a fuse is damaged, replace it by one of the
same rating.
Unless otherwise indicated, always turn CAUTION: Do not use a higher rated fuse as
ignition switch to the OFF position before this can cause severe damage.
performing any maintenance or repair on Fuses are located under seat, between en-
electrical system. gine and air box.
Battery
Cleaning
Clean battery post with a wire brush. Apply
dielectric grease (P/N 293 550 004) or an
equivalent on post to protect against oxida-
tion.
Removal
Disconnect BLACK (-) cable first, then RED
(+) cable.
WARNING 1
2
Always respect this order for disassembly;
disconnect BLACK (-) cable first. V02A0OY
1. Fan (15 A)
Remove bolts retaining battery holder and 2. Charging system (25 A)
rack.
V02G0SY 2 1
1. Battery holder
2. Rack
Installation
Reinstall battery in vehicle. Fasten battery
holder.
WARNING
Connect RED (+) cable first, then BLACK
(-) cable. Always connect RED (+) cable
first.
101
To remove fuse from holder, pull fuse out. – Push and turn counterclockwise bulb
Check if filament is melted. socket ring then remove the bulb.
V02G1NY
Bulb Replacement
Always check light operation after replace-
ment.
Headlamp
If the headlamp bulb is burnt:
– Remove front fascia.
– Remove rubber boot.
V02G1OY
V02G1MY
V02G1PY
102
Taillight Remove the back cover of auxiliary headlight.
Unscrew lens screws to expose bulb.
1
V02A06Y 2 1 2
1. Lens
2. Screws
V02G0OY 1
Push bulb in and hold while turning counter-
clockwise to release. 1. Remove these screws
Install the new bulb by first pushing in while
turning clockwise. Remove screw retaining the BLACK wire.
Auxiliary Headlight
Disconnect the auxiliary headlight then re-
move it from support.
V02G0PY
V02G0NY 2
1. Auxiliary headlight
2. Support
V02G0QY
103
NOTE: ALWAYS USE A 35 WATTS BULB. If Beam Aiming Adjustment
a 55 watts bulb is used, the regulator might
not be able to recharge the battery properly. Remove the front fascia.
Properly reinstall removed parts in the re- Using a long screwdriver, turn the adjusting
verse order of their removal. screw clockwise to lift the inside of headlamp
CAUTION: Never touch glass portion of a and counterclockwise to go down it.
halogen bulb with bare fingers, it shortens its
operating life. If glass is touched, clean it with 1
isopropyl alcohol which will not leave a film on
the bulb.
Tachometer
The bulb in the tachometer is not replaceable.
If the tachometer bulb is burnt, replace the ta-
chometer. See an authorized Bombardier
ATV dealer.
V02A0FY
1. Tabs
Installation
For installation, reverse the removal proce-
dure.
104
DRIVE TRAIN
Swing Arm and Wheel Hub Adjustment
NOTE: Always adjust drive chain with the
Inspection driver, or equivalent weight, seated on the ve-
Check these parts for damages (cracks, ex- hicle.
cessive play or corrosion pin-holes) at each Select a level surface and set transmission to
25 hours or at each 1250 km (800 m.). If one NEUTRAL.
of these damages is detected DO NOT USE Loosen rear axle lock bolts.
THE VEHICLE AND SEE AN AUTHORIZED
BOMBARDIER ATV DEALER.
WARNING
Never ride a vehicle with a defective swing
arm or a defective wheel hub.
Lubrication
Lubricate the swing arm with Bombardier sus-
pension synthetic grease (P/N 293 550 033)
or an equivalent.
Drive Chain
Adjust the drive chain before every ride. V02H15Y 1
Inspection
This ATV is equipped with O-ring sealed per-
manently greased pins and rollers. Before op-
erating the vehicle, always inspect the drive
chain.
Check for damage or missing O-ring, rollers
and correct slack adjustment.
Lubrication and Cleaning
CAUTION: Never wash the chain with a high
pressure washer or gasoline. Damage to the
O-ring will result, causing premature wear
and drive chain failure.
Clean the side surfaces of the chain with a dry
V02H16Y 2
cloth. 1. Drive chain
NOTE: Do not brush chain. 2. Adjuster lock
Lubricate only with an approved O-ring chain 3. Sprocket hub
lubricant. Other commercial chain lubricants 4. Eccentric axle housing
may contain solvent which could damage the
O-rings.
105
Turn the axle forward to increase or back- Drive Chain Slider
wards to decrease chain free play.
NOTE: Correct chain free play adjustment is Check the drive chain slider frequently, see
19 to 25.4 mm (3/4 to 1 in) at midway be- the MAINTENANCE CHART.
tween sprockets. Replace the drive chain slider when it is worn.
Tighten the rear axle lock bolts to 23 N·m See an authorized Bombardier ATV dealer for
(17 lbf·ft). replacement.
Use the following sequence to tighten the rear
axle lock bolts correctly. Sprocket and Pinion
Check the sprocket axle and pinion for distor-
tion.
V02H15Z 26 4 3 15 V02H02Y
V02H01Y
106
Tires/Wheels Tire/Wheel Condition
Check tire for damage and wear. Replace if
WARNING necessary. Do not make a tire rotation. The
front and rear tires have a different size. The
tires are directional and their rotation must be
When the tires are replaced, never install kept in a specific direction for proper opera-
a bias tire with a radial tire. This combined tion.
application may create handling and/or
stability problems. Wheel Removal
Do not mix tires of different size and/or de- Occasionally, wheel nuts should be removed
sign on the same axle. to apply an anti-seize lubricant on studs to
Front tire pairs or rear tire pairs must be ease future removal. This is particularly im-
the identical model and manufacturer. portant when vehicle is used in salt-water en-
For unidirectional tread pattern, ensure vironment or in mud. Remove one nut at a
that the tires are installed in the correct di- time, lubricate then retorque.
rection of rotation. Loosen nuts then lift vehicle. Place a support
The radial tires must be installed as a com- under vehicle. Remove nuts then remove
plete set. wheel. At installation, it is recommended to
apply an anti-seize lubricant on threads. Gen-
Severe injury or death can result if you do tly tighten nuts in a criss-cross sequence then
not follow these instructions. apply a final torque of 53 N·m (39 lbf·ft).
CAUTION: Always use the recommended
Tire Pressure wheel nuts (P/N 732 610 084). Using a differ-
ent nut could cause damages to the rim.
WARNING Front Wheel Bearing Condition
Tire pressure greatly affects vehicle han- Push and pull the wheels from the upper edge
dling and stability. Underpressure may t o f e e l t h e p l a y. S e e a n a u t h o r i z e d
cause tire to deflate and rotate on wheel. Bombardier ATV dealer if there is any play.
Overpressure may burst the tire. Always
follow recommended pressure. Since tires Rear Axle Inspection
are low-pressure types, a manual pump
should be used. Lift rear of vehicle high enough to have
wheels off the ground. Push and pull rear axle
t o f e e l t h e p l a y. S e e a n a u t h o r i z e d
Check pressure when tires are COLD before Bombardier ATV dealer if there is any play.
using the vehicle. Tire pressure changes with
temperature and altitude. Recheck pressure
if one of these conditions has changed.
For your convenience, a pressure gauge is
supplied in tool box.
TIRE PRESSURE
FRONT REAR
RECOMMENDED
35 kPa 35 kPa
(5 PSI) (5 PSI)
107
STEERING SYSTEM
Throttle Cable Lubrication Remove:
– the cable from the throttle lever
The throttle cable must be lubricated with
Bombardier cable lubricant (P/N 293 600 041)
or an equivalent. 2 1
WARNING
Always use a silicone-based lubricant. Us-
ing another lubricant (like water-based lu-
bricant) could cause the throttle lever/ca-
ble sticking or stiffness.
V01I10Y
V01I0ZY
1. Remove screws
V00I02Y
108
Install the cable luber (P/N 529 035 738) or an Throttle Lever Adjustment
equivalent on the cable.
Slide rubber protector back to expose throttle
cable adjuster.
Loosen lock nut then turn the adjuster to ob-
tain correct throttle lever free play.
NOTE: Measure throttle free play at the tip of
throttle lever.
Tighten lock nut and reinstall protector.
V02I04Y 2 3 4 1
V00I03Y 1. Throttle lever
2. Protector
Insert the needle of spray can in the cable lu- 3. Cable adjuster
ber hole. 4. Lock nut
A. 3 to 8 mm (1/8 to 5/16 in)
WARNING Clutch Adjustment
Loosen cable tension by closing the cable ad-
Always wear eye protection and gloves juster on the clutch lever.
when you lubricate a cable. Adjust clutch release mechanism as follows.
The release lever must locate on the spline in
NOTE: Place a rag around the cable luber to such a way that dimension A is obtained. See
prevent the lubricant from splashing. the following illustration.
Put the lubricant until it passes through the
cable.
Reinstall the cable.
Spray a little quantity of lubricant on the throt-
tle lever mechanism then close the housing.
Adjust the throttle lever.
109
NOTE: If necessary, unscrew the Allen sock- Clutch Cable Lubrication
et screw and withdraw release lever. Replace
the lever at the appropriate position then tight- Remove the cable from the engine.
en socket screw to 8 N·m (71 lbf·in). Remove the cable from the hand lever.
Put the cable luber (P/N 529 035 738) or an
equivalent on the cable.
Insert the needle of the spray can in the hole.
Spray silicone lubricant (P/N 293 600 041) or
an equivalent until it exits the other end of the
cable.
A
WARNING
Always use a silicone-based lubricant. Us-
ing another lubricant (like water-based lu-
bricant) could cause the clutch lever/cable
sticking or stiffness.
V02D03Y
A
V02D04Y
110
SUSPENSION
Adjustment
CAUTION: The DS 650 X are equipped with Front Shocks
shock protectors. Open or remove them when
the ambient temperature is high or when the
vehicle is used intensively. Otherwise, perfor- WARNING
mance degradation or damage can be
caused to the shock absorbers. Adjust both springs to the same load. Un-
NOTE: Do not remove the shock protectors if even adjustment can cause poor handling
the vehicle is used on a gravel surface. and loss of stability, and/or control, and in-
crease the risk of an accident.
Lubrication
Front A-Arm Preload Adjustment
Lubricate front A-arms with a grease gun. Use Shorten the spring for a firmer ride and rough
Bombardier suspension synthetic grease road condition.
(P/N 293 550 033) or an equivalent. Lengthen the spring for a light load and a
smooth road condition.
WARNING
The front shocks contain high pressure ni-
trogen gas. Do not attempt to disassem-
ble the shock absorber. Do not dispose
of it. See an authorized Bombardier ATV
dealer.
V02J01Y 1 A A
1. Grease fittings
Inspection
A-Arms
Check these parts for damages (cracks, ex-
cessive play or corrosion pin-holes) at each
25 hours or at each 1250 km (800 m.). If one V02J02Y
of these damages is detected DO NOT USE
THE VEHICLE AND SEE AN AUTHORIZED A. Same length
BOMBARDIER ATV DEALER.
WARNING
Never ride a vehicle with a defective A-
arm.
Shock Absorbers
Inspect shock absorber for oil leaks and fas-
teners for tightness. See an authorized
Bombardier ATV dealer if necessary.
111
Rear Shock Next, sit the rider, with gear, on the ATV and
measure the distance between the same two
WARNING points.
CAUTION: Add all other loads and accesso-
ries before measuring the height of the vehi-
The rear shock includes a damper unit that cle with the rider on. Do not exceed the total
contains high pressure nitrogen gas. Do vehicle load allowed.
not attempt to disassemble the damp-
er. Do not dispose of it. See an authorized Calculate the difference between the two
Bombardier ATV dealer. lengths. If the vehicle’s height decreases
more than 127 mm (5 in), increase the pre-
load by 3 mm (1/8 in) increments. If the vehi-
Spring Preload cle’s height decreases of less than 102 mm
Spring preload may vary from rider to rider de- (4 in), decrease the preload by 3 mm (1/8 in)
pending upon their weight. Preload can be increments. The optimum adjustment range
changed by setting the two lock nuts up or is between 102 mm (4 in) and 127 mm (5 in)
down to compress the spring to different but, for heavier or more aggressive riders, it
lengths. Shortening or lengthening the spring could be between 76 mm (3 in) and 102 mm
length will increase or decrease the preload. (4 in).
Before adjusting the spring preload, first mea-
sure the ATV’s height, without rider, from the
rear bumper nut to the ground.
NOTE: Lift the vehicle by the rear bumper.
The shock should be fully extended.
V02A0WY
112
Preload Adjustment: Compression Damping:
– To reduce: – To reduce:
• Turn the shock spring adjuster counter- • Turn the damper adjuster counter-
clockwise for a light load and smooth clockwise for a light load and smooth
condition. condition.
– To increase: – To increase:
• Turn the shock spring adjuster clock- • Turn the damper adjuster clockwise for
wise for a firmer ride and rough condi- a firmer ride and rough condition.
tion.
Rebound Damping:
– To reduce:
• Turn the shock adjuster counterclock-
wise for a light load and smooth condi-
tion.
– To increase:
• Turn the shock adjuster clockwise for a
firmer ride and rough condition.
V02J04Y 1
1. Adjuster
V02J0PY 1
1. Adjuster
NOTE: The adjuster tool is included in the tool
kit.
113
BRAKES
Front and Rear Brakes
The front and rear brakes are hydraulic disc
types. These brakes are self-adjusting and re-
quire no adjustment.
Check brake line fittings tightness before ev-
ery ride.
114
BODY/FRAME
Engine Area Fasteners
Check engine area for any damage and Check fastener condition and tightness on the
leaks. Ensure all hose clamps are properly vehicle. Retighten if required.
secured and no hose is cracked, kinked or
damaged otherwise. Inspect muffler, battery Seat Latch
and reservoir fastening devices. Check elec-
trical connections for corrosion and tightness. Remove seat and check latch mechanism
Replace or have damaged parts repaired. a n d p in fo r w e a r. S e e a n a u th o ri z ed
Bombardier ATV dealer for parts replacement
if damaged.
Skid Plate
Check tightness of fasteners and condition of Frame
plate for cracks or other damage. Properly re-
tighten fasteners as necessary and have skid Check frame for cracks or other damage. See
plate replaced if damaged. an authorized Bombardier ATV dealer for re-
place or repair.
Front Fenders
Vehicle Cleaning and Protection
Check tightness of fasteners and condition of
front fender for cracks or other damage. Prop- Painted parts which are damaged should be
erly retighten fasteners if necessary and have properly repainted to prevent rust.
front fender replaced if damaged. When required, wash the body with hot water
and soap (only use mild detergent). Apply
WARNING non-abrasive wax.
CAUTION: Never clean plastic parts with
strong detergent, degreasing agent, paint
Never remove the front fenders. The im- thinner, acetone, etc.
portant labels are applied on the front NOTE: Never use a high pressure washer to
fenders. Operating without front fender, in- clean the vehicle USE LOW PRESSURE
creases your chances of severe injury in ONLY (like a garden hose). The high pressure
the event of an accident. can cause electrical or mechanical damages.
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.
115
116
WARRANTY
117
BRP INTERNATIONAL LIMITED WARRANTY:
2006 BOMBARDIER* ATV PRODUCTS
1. SCOPE OF THE LIMITED WARRANTY
Bombardier Recreational Products Inc. (hereinafter “BRP”), warrants its 2006 Bombardier ATV
products from defects in material or workmanship for the period described below.
All genuine Bombardier parts and accessories, installed by an authorized Bombardier distribu-
tor/dealer (as hereinafter defined) at the time of delivery of the 2006 Bombardier ATV product,
carry the same warranty as that of the ATV.
Use of the product for racing or any other competitive activity, at any point, even by a previous
owner, will render this warranty null and void.
1.The warranty is TWENTY FOUR (24) consecutive months if the product was sold in any of the member states of the
European Union (EC directive 1999/44/EC).
The warranty period, however, is SIX (6) consecutive months if the product is used for commercial purposes.
118
5. WHAT BRP WILL DO
BRP's obligations under this warranty are limited to, at its sole discretion, repairing parts found
defective under normal use, maintenance and service, or replacing such parts with new genuine
Bombardier parts without charge for parts and labor, at any authorized Bombardier distribu-
tor/dealer.
BRP reserves the right to improve or modify products from time to time without assuming any
obligation to modify products previously manufactured.
7. LIMITATIONS OF LIABILITY
THIS WARRANTY IS EXPRESSLY GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTH-
ER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TO THE
EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED
IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSE-
QUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY.
SOME STATES/PROVINCES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND
EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS
WARRANTY GIVES YOU SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH MAY VARY FROM COUNTRY TO COUNTRY.
Neither the distributor, any Bombardier ATV dealer nor any other person has been authorized
to make any affirmation, representation or warranty regarding the product, other than those
contained in this limited warranty, and if made, shall not be enforceable against BRP.
BRP reserves the right to modify this warranty at any time, being understood that such modifi-
cation will not alter the warranty conditions applicable to the products sold while this warranty is
in effect.
119
8. TRANSFER
If the ownership of a product is transferred during the warranty coverage period, this warranty
shall also be transferred and be valid for the remaining coverage period provided that BRP is
notified of such transfer of ownership in the following way:
BRP or an authorized Bombardier ATV distributor/dealer receives a proof that the former owner
agreed to the transfer of ownership, in addition to the coordinates of the new owner. The distrib-
utor will then forward this information directly to BRP.
9. CONSUMER ASSISTANCE
a) In the event of a controversy or a dispute in connection with this BRP LIMITED WAR-
RANTY, BRP suggests that you try to resolve the issue at the dealership level. We
recommend discussing the issue with the authorized dealer's service manager or owner.
b) If further assistance is required, the distributor's service department should be contacted
in order to resolve the matter.
c) If the matter still remains unresolved then contact BRP by writing to us at the address
listed below.
120
PRIVACY OBLIGATION/DISCLAIMER
We wish to inform you that your coordinates will be used for safety and warranty purposes.
Sometimes, we also use the coordinates of our clients to inform them about our products and
to present them offers. Should you prefer not to receive information on our product, services and
offers, please let us know by writing to the address below.
Also note that, from time to time, carefully selected and trustworthy organizations may be per-
mitted to use the coordinates of our clients to promote quality products and services. If you prefer
not to have your name and address released, please let us know by writing to the address below:
121
122
CHANGE OF ADDRESS/OWNERSHIP
If your address has changed or if you are the new owner of the ATV, be sure to notify BRP by
either:
– mailing the card below;
– notifying an authorized Bombardier ATV dealer.
In case of change of ownership, please join a proof that the former owner agreed to the transfer.
Notifying BRP, even after the expiration of the limited warranty, is very important as it enables
BRP to reach the ATV owner if necessary, like when safety recalls are initiated. It is the owner’s
responsibility to notify BRP.
STOLEN UNITS: If your personal ATV is stolen, you should notify BRP or an authorized
Bombardier ATV dealer. We will ask you to provide your name, address, phone number, the
vehicle identification number and the date it was stolen.
___________________________________________
NO. STREET APT
___________________________________________
CITY STATE/PROVINCE ZIP/POSTAL CODE
___________________________________________
COUNTRY
___________________________________________
NO. STREET APT
___________________________________________
CITY STATE/PROVINCE ZIP/POSTAL CODE
___________________________________________
COUNTRY
123
'
AFFIX
PROPER
POSTAGE
124
CHANGE OF ADDRESS/OWNERSHIP
If your address has changed or if you are the new owner of the ATV, be sure to notify BRP by
either:
– mailing the card below;
– notifying an authorized Bombardier ATV dealer.
In case of change of ownership, please join a proof that the former owner agreed to the transfer.
Notifying BRP, even after the expiration of the limited warranty, is very important as it enables
BRP to reach the ATV owner if necessary, like when safety recalls are initiated. It is the owner’s
responsibility to notify BRP.
STOLEN UNITS: If your personal ATV is stolen, you should notify BRP or an authorized
Bombardier ATV dealer. We will ask you to provide your name, address, phone number, the
vehicle identification number and the date it was stolen.
___________________________________________
NO. STREET APT
___________________________________________
CITY STATE/PROVINCE ZIP/POSTAL CODE
___________________________________________
COUNTRY
___________________________________________
NO. STREET APT
___________________________________________
CITY STATE/PROVINCE ZIP/POSTAL CODE
___________________________________________
COUNTRY
125
'
AFFIX
PROPER
POSTAGE
126
ATV MODEL No.
VEHICLE
IDENTIFICATION NUMBER (V.I.N.)
ENGINE
IDENTIFICATION NUMBER (E.I.N.)
Owner:
________________________________________________________
NAME
________________________________________________________
NO. STREET APT
________________________________________________________
CITY STATE/PROVINCE ZIP/POSTAL CODE
Purchase Date
YEAR MONTH DAY
Please verify with your dealer to ensure your vehicle has been registered with BRP.
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.