In the event of any discrepancy, the english version shall prevail. Service and Warranty Bulletins may be published to update the content of this manual.
Make sure to read and understand these. It does not include dealer modifications, whether authorized or not by Bombardier, after manufacturing the product. In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts.
They are not to be interpreted as technical drawings or exact replicas of the parts. The use of Bombardier parts is most strongly recommended when considering replacement of any com- ponent. The engines and the corresponding components identified in this document should not be utilized on product s other than those mentioned in this document. Torque wrench tightening specifications must be strictly adhered to. Locking devices ex.
If the efficiency of a locking device is impaired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols: CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo- nents. NOTE: Indicates supplementary information needed to fully complete an instruction. I printed pages from this pdf easily.
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Rated 5 out of 5 based on 94 customer ratings. Add to wishlist. Guaranteed Safe Checkout. Description Reviews 94 Bombardier Ds Service Manual Repair Ds PS This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task.
This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle.
Using this repair manual is an inexpensive way to keep your car working properly. Instant download of the factory repair manual for the Bombardier DS atv. Covers complete tear down and rebuild, pictures and part diagrams, torque specs, maintenance, troubleshooting, etc. What customer say about us! Incorrect oil being used. Check oil pressure regulator valve spring function. Valve spring damaged valve always open.
Check oil for particles may indicate possible damages inside the engine. Oil contamination due to metal or plastic particles. Replace possibly damaged parts. Check screws for torque. Loose screws. Gaskets are brittle, hard, worn out or otherwise damaged. Replace damaged gaskets, O-rings or the V-ring on breather. Check oil level in engine. Oil leakage from engine. Replace shift drum. Page 64 Replace failed part s in electrical system electronic module.
Compression ratio is too high. Install genuine parts. Poor oil quality. Leaks at air intake manifold engine gets too lean. Retighten screws or replace air intake manifold. Page 65 Check crankshaft movement.
Oil pump failure due to leak of oil. Repair and replace defective parts and use Bombardier recommended oil. Check air intake system. Air filter is clogged due to contamination. Replace air filter. System is leaking. Verify spark plug condition.
Defective, improperly set, worn out, fouled. Identify source of problem and correct. Replace spark plug. Verify engine oil. Engine oil is not to specifications. Drain engine oil and refill with the recommended oil. Check clutch discs condition.
Do not tighten. Remove radiator cap and dipstick. Listen for air leaks: — air escaping from spark plug means poor spark plug tightness or defective spark plug gasket — air escaping from intake means leaking intake valve — Clean threads before using Loctite when installing the screws.
Exhaust pipes 1. Radiator outlet hose 2. Radiator inlet hose 2. Removal Remove: — upper engine support bolt no. Remove radiator pressure cap no. Recommended Coolant Press out sealing rings no. Pull radiator no. Inspection Check radiator air passage for clogging or damage. Install a jumper wire end between both connec- tors.
NOTE: The exhaust can be remove to allow an easy access to the fan. Temperature switch Removal Unplug temperature switch connectors. Temperature sensor Removal Unplug temperature sensor connector. Unscrew temperature sensor no. Test Using a multimeter, measure the resistance be- tween connector on the top of temperature sen- sor and threads. The multimeter should indicate an infinite resis- tance O.
Page General Remove gasket. Unfasten handle and install screw plug in ignition cover. NOTE: Clean all metal component in a non-ferrous metal cleaner. Remove ignition cover no. Unscrew nut no. Remove lock washer no. NOTE: Apply engine oil on sprag clutch. Install sprag clutch. The arrow should be visible.
Trigger coil 3. Before torque, check if the protrusion of rotor is aligned with the key way in the center of rotor hub. Rotor protrusion 2. Prior to changing the engine oil, ensure vehicle is If the engine pressure is out of specifications, on a level surface. For installation, reverse the removal procedure. Unfasten bleeding screw no. Removal Drain oil tank.
Remove the front facia. Unscrew headlight then disconnect and remove it. Remove nut no. Unscrew bolts retaining fuel tank cover and oil tank to the frame. This will help side and to keep the parts of the same assembly pin-point a problem. Remove: For installation, reverse the removal procedure. Secure timing chain no. Remove front chain rail no. Pay attention to the following details.
Difference between measurements Remove: should not exceed 0. If so, replace — Removal Pay attention to the following details. Remove engine. Insert piston pin into piston and connecting rod. Remove cylinder. NOTE: Install piston with removal mark on base of piston in direction of exhaust end.
NOTE: Do not forget the bolts inside the oil filter housing. Double drive gear 2. Timing chain 3. Oil pump intermediate gear 4. Oil pump gears Magneto Side 1. NOTE: Take care of spacer discs on crankshaft. Removal Inspection Use the same removal procedure that balancer shaft.
Check balancer shaft bearings nos. NOTE: Only fit shim on clutch end. Do not install shim on clutch side. At installation, use torque values and Loctite prod- ucts from the exploded view. Clean threads before using Loctite products when installing screws. NOTE: For a better understanding, the following illustrations are taken with engine out of vehicle. Do not force the sive play and smooth operation.
Friction drive plate 2. Steel driven plate 3. Clutch basket Unlock the tab washer no. Friction Drive Plate Measure the package of friction drive plate thick- ness. Clutch Basket Check slots of clutch basket for damage or wear caused by friction drive plates. Check grooves of clutch hub for damage or wear First, install steel driven plate, then friction drive caused by steel driven plates.
NOTE: Place the last friction drive plate in short slots of clutch basket. Clutch cover 2.
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