Bombardier DS250 ATV 2006 -2015 Service Manual

SAFETY NOTICE
INTRODUCTION
GENERAL INFORMATION
VEHICLE SERIAL NUMBER LOCATION
ENGINE SERIAL NUMBER LOCATION
ARRANGEMENT OF THE MANUAL, ILLUSTRATIONS AND PROCEDURES
SELF-LOCKING FASTENERS PROCEDURE
LOCTITER APPLICATION PROCEDURE
TIGHTENING TORQUES
01 MAINTENANCE
01 ? MAINTENANCE CHART
NOISE EMISSION CONTROL SYSTEM REGULATION
MAINTENANCE CHART
02 ? PRESEASON PREPARATION
03 ? STORAGE PROCEDURES
FUEL SYSTEM
ENGINE
ELECTRICAL SYSTEM
COOLING SYSTEM
CVT TRANSMISSION
VEHICLE
04 ? SPECIAL PROCEDURES
ATV IMMERSION
02 TROUBLESHOOTING
01 ? TROUBLESHOOTING CHART
COOLING SYSTEM
ELECTRICAL SYSTEM
LUBRICATION SYSTEM
CYLINDER HEAD
CRANKSHAFT
GEARBOX
CVT
ENGINE GENERAL
STARTING SYSTEM
03 ENGINE
01 ? ENGINE REMOVAL AND INSTALLATION
GENERAL
REMOVAL
INSPECTION
INSTALLATION
02 ? ENGINE LEAK TEST
GENERAL
PROCEDURES
03 ? AIR INTAKE SYSTEM
GENERAL
PROCEDURES
AIR FILTER
AIR FILTER HOUSING
AIR INJECTION VALVE FILTER
04 ? EXHAUST SYSTEM
GENERAL
PROCEDURES
I
TABLE OF CONTENTS
MUFFLER
EXHAUST PIPE
SPARK ARRESTER
05 ? LUBRICATION SYSTEM
GENERAL
ENGINE OIL
ENGINE OIL PRESSURE
ENGINE OIL PRESSURE RELIEF VALVE
OIL PUMP
06 ? COOLING SYSTEM
GENERAL
COOLING SYSTEM INSPECTION
LEAK INDICATOR HOLE
COOLING SYSTEM LEAK TEST
PROCEDURES
ENGINE COOLANT
RADIATOR CAP
THERMOSTAT
THERMO-SWITCH
WATER PUMP
COOLING FAN MOTOR
RADIATOR
07 ? MAGNETO AND STARTER DRIVE
GENERAL
PROCEDURES
MAGNETO COVER
TRIGGER COIL
STATOR
CRANKSHAFT END BEARING
FLYWHEEL
STARTER REDUCTION GEAR
STARTING CLUTCH GEAR
08 ? CYLINDER HEAD
GENERAL
VALVE CLEARANCE ADJUSTMENT
CYLINDER HEAD REMOVAL
CYLINDER HEAD DISASSEMBLY
CLEANING
PARTS INSPECTION
CYLINDER HEAD ASSEMBLY
CYLINDER HEAD INSTALLATION
09 ? PISTON AND CYLINDER
GENERAL
DISASSEMBLY
INSPECTION
ASSEMBLY
10 ? CRANKSHAFT AND CRANKCASE
GENERAL
CRANKCASE DISASSEMBLY
INSPECTION
CRANKCASE ASSEMBLY
11 ? GEARBOX
GENERAL
GEARBOX OIL LEVEL
GEARBOX OIL CHANGE
GEARBOX SWITCH
II
TABLE OF CONTENTS
OIL SEAL REPLACEMENT
GEARBOX DISASSEMBLY
GEARBOX INSPECTION
GEARBOX ASSEMBLY
04 FUEL SYSTEM
01 ? CARBURETOR AND FUEL TANK
GENERAL
PROCEDURES
CARBURETOR
FUEL FILTER
FUEL VALVE
FUEL TANK
THROTTLE CABLE
CHOKE CABLE
05 ELECTRICAL SYSTEM
01 ? CHARGING SYSTEM
GENERAL
PROCEDURES
VOLTAGE REGULATOR/ RECTIFIER
STATOR
BATTERY
02 ? IGNITION SYSTEM
GENERAL
TROUBLESHOOTING
REPAIR PROCEDURES
FUSES
SPARK PLUG
BATTERY
IGNITION SWITCH
ENGINE STOP SWITCH
TRIGGER COIL
IGNITION COIL
IGNITION MODULE
SHIFT GEAR CONTROL MODULE
OVERRIDE SWITCH
ADJUSTMENT
IGNITION TIMING
03 ? STARTING SYSTEM
GENERAL
TESTING PROCEDURES
FUSES
BATTERY
IGNITION SWITCH
ENGINE STOP SWITCH
START SWITCH
STARTING SOLENOID
ELECTRICAL CABLES OR CONNECTIONS
ELECTRIC STARTER
SHIFT GEAR CONTROL MODULE
PART REPLACEMENT
ELECTRIC STARTER
04 ? LIGHTS AND ACCESSORIES
GENERAL
PROCEDURES
III
TABLE OF CONTENTS
FUSES
HEADLAMP
TURN SIGNAL LIGHTS
POSITION LIGHT
PILOT LAMPS
TAILLIGHT
HORN
12-VOLT POWER OUTLET
06 TRANSMISSION
01 ? CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
GENERAL
PROCEDURES
DRIVE BELT
CVT COVER
CVT COVER BEARING
DRIVE PULLEY
DRIVEN PULLEY
07 STEERING AND FRONT SUSPENSION
01 ? STEERING AND FRONT SUSPENSION
GENERAL
PROCEDURES
HANDLEBAR GRIP
MULTIFUNCTION SWITCH
AUXILIARY MULTIFUNCTION SWITCH
THROTTLE LEVER
MASTER CYLINDER
HANDLEBAR
TIE-ROD
STEERING COLUMN
STEERING COLUMN BEARING
FRONT WHEEL HUB
WHEEL BEARING
KNUCKLE
SHOCK ABSORBER AND SPRING
LOWER A-ARM
UPPER A-ARM
ADJUSTMENT
STEERING ALIGNMENT
08 REAR SUSPENSION AND AXLE
01 ? REAR SUSPENSION AND AXLE
GENERAL
PROCEDURES
REAR SHOCK
DRIVE CHAIN
ENGINE SPROCKET
AXLE SPROCKET
WHEEL HUB
BRAKE DISC HUB
REAR AXLE
SPROCKET HUB
CHAIN TENSIONER
SWING ARM
IV
TABLE OF CONTENTS
09 BRAKING SYSTEM
01 ? FRONT AND REAR BRAKES
ALL MODELS EXCEPT EUROPEAN MODELS
GENERAL
MAINTENANCE
BRAKE FLUID
PROCEDURES
CALIPERS
BRAKE PADS
MASTER CYLINDERS OF BRAKE LEVERS
REAR BRAKE PEDAL
MASTER CYLINDER OF REAR BRAKE PEDAL
PRESSURE CONTROL VALVE
BRAKE DISCS
BRAKE HOSES
BRAKE LIGHT SWITCHES
EUROPEAN MODELS
GENERAL
MAINTENANCE
BRAKE FLUID
PROCEDURES
PARKING BRAKE (CABLE AND LEVER)
CALIPERS
BRAKE PADS
MASTER-CYLINDERS OF BRAKE LEVERS
REAR BRAKE PEDAL
MASTER CYLINDER OF REAR BRAKE PEDAL
FRONT BRAKE PRESSURE CONTROL VALVE
REAR BRAKE PRESSURE CONTROL VALVE
BRAKE DISCS
BRAKE HOSES
BRAKE LIGHT SWITCHES
10 BODY/FRAME
01 ? BODY
PARTS REPLACEMENT
DECAL
SEAT
SEAT LATCH
FUEL TANK COVER
FRONT COVER
RADIATOR SHIELD
FRONT FENDER
REAR FENDER
FOOTREST
CLEANING
SEAT
PLASTIC
REPAIR
PLASTIC REPAIR
02 ? FRAME
GENERAL
PROCEDURES
FRONT BUMPER
FOOTPEG
FOOTREST SUPPORT
V
TABLE OF CONTENTS
REAR FRAME EXTENSION
FRONT FENDER SUPPORT
REAR FENDER SUPPORT
11 TECHNICAL SPECIFICATIONS
01 ? DS 250
12 WIRING DIAGRAMS
01 ? WIRING DIAGRAMS
WIRE COLORS
CONNECTORS