BOMBARDIER DS 7404 Operator's Manual

Particularly important information in this Operator’s Guide is designated by the
following:



The Safety Alert Symbol means ATTENTION!

Identifies an instruction which if not followed, may cause

WARNING



injuries including the possibility of death.

CAUTION: Denotes an instruction which if not followed, may damage the
ATV and/or components.

WARNING



YOUR ATV 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 the

Operator’s Guide

, the

Safety Handbook

and the labels on your vehicle.

Failure to follow these warnings can result in SEVERE INJURY OR DEATH.

Keep this

Operator’s Guide

and the

Safety Handbook

with the vehicle at

all times.

WARNING



This ATV may exceed the performance of other ATV’s you may have rider
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 skills and substantial experience.

AFTER SALES SERVICE
BOMBARDIER
RECREATIONAL PRODUCTS
VALCOURT, QUEBEC
CANADA J0E 2L0

Printed in Canada (vmo2000_001a.fm AP)

®

*Trademarks of Bombardier Inc.

©

9/8/99 Bombardier Inc. All rights reserved.

FOREWORD

Congratulations on your purchase of a
new Bombardier all-terrain vehicle
(ATV). It is backed by the Bombardier
warranty and a network of authorized
Bombardier ATV dealers ready to pro­vide the parts, service or accessories
you may require.

Your dealer is committed to your satis­faction. He has taken training to per­form the initial set-up and inspection of
your vehicle as well as completed the
final adjustment before you took pos­session. At delivery, your dealer would
have explained the vehicle for the oper­ation, maintenance and safety features.
We trust you have taken full advantage
of this! If you need more complete ser­vicing information, please ask your
dealer about the proper model-year ATV

Shop Manual

At delivery, you were also informed of
the warranty coverage and completed
the Warranty Registration Form which
is to be sent to us for processing. In
the near future you should be receiv­ing a warranty card which will confirm
our receipt of the registration as well
as be used for warranty or recall pur­poses.

You are invited to contact our custom­er assistance center should you expe­rience problems which cannot be re­solved by an authorized Bombardier
ATV dealer.

It is understood that this guide may be
translated into another language. In
the event of any discrepancy, the En­glish version shall prevail.

.

The information and components/
system descriptions contained in this
document are correct at the time of
publication. Bombardier however, main­tains a policy of continuous improve­ment of its products without imposing
upon itself any obligation to install them
on products previously manufactured.
Due to late changes, it may have some
differences between the manufactured
product and the descriptions and/or
specifications in this guide. Bombardier
reserves the right at any time to discon­tinue or change specifications, designs,
features, models or equipment without
incurring any obligation upon itself.

The illustrations in this document show
the typical construction of the different
assemblies and may not reproduce the
full detail or exact shape of the parts.
However, they represent parts that have
the same or similar function.

Specifications are given in the SI metric
system with the SAE U.S. equivalent in
parenthesis. Where precise accuracy
is not required, some conversions are
rounded off for easier use.

We recommend genuine Bombardier
products for replacement parts and ac­cessories. They’ve been specialy de­signed for your vehicle and manufac­tured to meet of Bombardier demanding
standards.

A

Shop Manual

complete service, maintenance and
more repair information.

can be obtained for

1

TABLE OF CONTENTS

WARNING



Indicates a potenial hazard that could result in serious injury or death.

NOTICE....................................................................................... 4

SPECIAL SAFETY MESSAGES.................................................... 5

OPERATION WARNINGS ............................................................ 7

BOMBARDIER LIMITED WARRANTY 2000 BOMBARDIER

ATV ALL-TERRAIN VEHICLE ....................................................... 32

FREQUENTLY ASKED QUESTIONS ............................................. 34

EMISSION REQUIREMENTS........................................................ 36

HANG TAG ................................................................................. 36

LOCATION OF THE IMPORTANT LABELS ................................... 37

HOW TO IDENTIFY YOUR ATV ................................................... 39

Engine and Vehicle Identification Number Location................................ 39

CONTROLS/INSTRUMENTS/EQUIPMENTS.................................. 40

1) Throttle Lever.................................................................................... 42

2) Front Brake Lever ............................................................................. 42

3) Clutch Lever...................................................................................... 43

4) Parking Lever Lock............................................................................ 43

5) Headlight Switch............................................................................... 44

6) Engine Stop Switch........................................................................... 44

7) Start Button....................................................................................... 44

8) Fuel Tank Cap ................................................................................... 44

9) Ignition Switch .................................................................................. 45

10) Indicator Lamp .................................................................................. 45

11) Front Brake Fluid Reservoir............................................................... 45

12) Fuel Valve.......................................................................................... 45

13) Gearshift Pedal.................................................................................. 46

14) Storage Compartment ...................................................................... 46

15) Seat Latch ......................................................................................... 47

16) Footpeg............................................................................................. 47

17) Foot Brake Pedal............................................................................... 47

18) Rear Brake Fluid Reservoir................................................................ 48

19) Engine/Transmission Oil Tank Cap ................................................... 48

2

LIQUIDS...................................................................................... 49

Fuel.......................................................................................................... 49

Engine/Transmission Oil.......................................................................... 49

Engine Coolant ........................................................................................ 51

Brake Fluid............................................................................................... 51

Battery..................................................................................................... 52

BREAK-IN PERIOD ...................................................................... 53

Engine ..................................................................................................... 53

10-Hour Inspection.................................................................................. 53

PRE-OPERATION CHECK ............................................................ 54

OPERATING INSTRUCTIONS ...................................................... 55

General.................................................................................................... 55

Initial Cold Starting .................................................................................. 55

Warm Engine Starting ............................................................................. 56

Stopping the Engine................................................................................ 56

Shifting the Transmission........................................................................ 56

SPECIAL PROCEDURES.............................................................. 57

Flooded Engine........................................................................................ 57

Engine Overheat...................................................................................... 57

Post-Operation Care................................................................................ 57

Storage and Preseason Preparation ........................................................ 57

MAINTENANCE CHART .............................................................. 58

Noise Emission Control System Regulation............................................ 58

Emission Requirements .......................................................................... 58

MAINTENANCE .......................................................................... 61

Lubrication............................................................................................... 61

Maintenance............................................................................................ 63

Fuel System ............................................................................................ 65

Electrical.................................................................................................. 66

Drive Train ............................................................................................... 69

Suspension.............................................................................................. 70

Tires/Wheels ........................................................................................... 71

Brake ....................................................................................................... 72

Body/Frame............................................................................................. 72

CARGO AND TRANSPORTATION................................................ 73

Cargo....................................................................................................... 73

Transportation ......................................................................................... 73

TROUBLESHOOTING................................................................... 74

SPECIFICATIONS ........................................................................ 76

SI METRIC INFORMATION GUIDE............................................... 79

CHANGE OF ADDRESS............................................................... 81

3

NOTICE

The

Operator’s Guide

have been prepared to acquaint the
owner/operator of a new vehicle with
the various vehicle controls, mainte­nance and safe operating instructions.
They are indispensable for the proper
use of the product.

This guide uses the following symbols.

WARNING



Identifies an instruction which, if
not followed, could cause serious
personal injuries including the
possibility of death.

CAUTION: Denotes an instruction
which, if not followed, could severe­ly damage vehicle components.

and

Safety book

NOTE: Indicates supplementary infor­mation needed to fully complete an in­struction.

Although the mere reading of such in­formation does not eliminate the haz­ard, the understanding and application
of the information will promote its cor­rect use.

To fully appreciate the pleasures, en­joyment and excitement of using an
all-terrain vehicle (ATV), there are
some basic rules that MUST be ob­served and followed by any four­wheeler.

4

SPECIAL SAFETY MESSAGES

AN ATV IS NOT A TOY AND CAN BE
HAZARDOUS TO OPERATE.

An ATV 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 the

ty Handbook

and follow the operating procedures
described.

• Never operate an ATV without proper
instruction. Take a training course.
Beginners should receive training
from a certified instructor. Contact an
authorized ATV dealer to find out
about the training courses nearest
you or call the Specialty Vehicle Insti­tute of America (SVIA) at 1-800-887­2887 or in Canada, the Canada Safety
Council (CSC) at 1-613-739-1535 ext.

227.

• Always follow this age recommen­dation: A child under 16 years old
should never operate this ATV.

• Never carry a passenger on an ATV.

• Never operate an ATV on any paved
surfaces, including sidewalks, drive­ways, parking lots and streets.

• Never operate an ATV on any public
street, road or highway, even a dirt
or gravel one.

• Never operate an ATV 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.

Operator’s Guide

and all labels carefully

, the

Safe-

• Never consume alcohol or drugs be­fore or while operating this ATV.

• 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 ATV 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 the
the

Safety Handbook

• Always keep both hands on the han­dlebars and both feet on the foot­pegs of the ATV during operation.

• Always go slowly and be extra care­ful when operating on unfamiliar
terrain. Always be alert to changing
terrain conditions when operating
the ATV.

• Never operate on excessively rough,
slippery or loose terrain until you
have learned and practiced the skills
necessary to control the ATV on
such terrain. Always be especially
cautious on these kinds of terrain.

• Always follow proper procedures
for turning as described in the

erator’s Guide
book

before attempting to turn at faster
speeds. Do not turn at excessive
speed.

• Never operate the ATV on hills too
steep for the ATV or for your abili­ties. Practice on smaller hills before
attempting larger hills.

. Practice turning at low speeds

Operator’s Guide

.

and the

Safety Hand-

and

Op-

5

• Always follow proper procedures
for climbing hills as described in the

Operator’s Guide
Handbook

fully before you start up any hill.
Never climb hills with excessively
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 in the

tor’s Guide
book

fore 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 in the
the
with excessively slippery or loose
surfaces. Shift your weight to the
uphill side of the ATV. Never at­tempt to turn the ATV around on any
hill until you have mastered the
turning technique described in the

. Check the terrain carefully be-

Safety Handbook

. Check the terrain care-

and the

Operator’s Guide

Operator’s Guide
Handbook

crossing the side of a steep hill if
possible.

• 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 in the
the

Safety Handbook

the uphill side or to a side if pointed
straight uphill. Turn the ATV around
and remount, following the proce­dure described in the

Guide

6

on level ground. Avoid

Operator’s Guide

and the

and the

and the

. Dismount on

Safety Handbook

Safety

Opera-

Safety Hand-

and

. Avoid hills

Safety

and

Operator’s

.

• 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 operating over obsta­cles as described in the

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 an ATV in fast flow­ing water or in water deeper than
that specified in the

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 in the
Always maintain proper tire pres­sure as described in this guide.

• Never modify an ATV through im­proper installation or use of acces­sories.

• Never exceed the stated load limits
for an ATV. Cargo should be properly
distributed and securely attached.
Reduce speed and follow instruc­tions in the
the
cargo or pulling a trailer. Allow great­er distance for braking.

• FOR MORE INFORMATION ABOUT
ATV SAFETY, call the Specialty Ve­hicle Institute of America (SVIA) at
1-800-887-2887 or in Canada, the
Canada Safety Council (CSC) at 1­613-739-1535 ext. 227.

and the

and the

Safety Handbook

Safety Handbook

Operator’s Guide

Operator’s Guide

Safety Handbook

Operator’s

.

Operator’s

and

for carrying

.

.

OPERATION WARNINGS

While reading this guide, remember that:

WARNING



Indicates a potential hazard that 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 the

erator's Guide

NOTE: The following illustrations are a general representation only. Your model
may differ.

and

Safety Handbook

WARNING



for all ATV's.

Op-

V00A0AR

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator does not know
how to operate the ATV properly in different situations and on different
types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should complete the certified
training course offered by Bombardier. They should then regularly prac­tice the skills learned in the course and the operating techniques described
in the

For more information about the training course, contact an authorized
ATV dealer or call Bombardier at 1-450-532-5000.

Operator’s Guide

and the

Safety Handbook

.

7

WARNING



V00A01Q

POTENTIAL HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN HAPPEN

Use by children of ATVs that are not recommended for their age can lead
to severe injury or death of the child.

Even though a child may be within the age group for which an ATV is
recommended, he or she may not have the skills, abilities, or judgment
needed to operate the ATV safely and may be involved in a serious acci­dent.

HOW TO AVOID THE HAZARD

No one under 16 should operate a Bombardier ATV.

8

WARNING



V00A02Q

POTENTIAL HAZARD

Carrying a passenger on this ATV.

WHAT CAN HAPPEN

Greatly reduces your ability to balance and control this ATV.
Could cause an accident, resulting in harm to you and/or your passenger.

HOW TO AVOID THE HAZARD

Never carry a passenger. The long seat is to allow the operator to shift
position as needed during operation. It is not for carrying passengers.

9

WARNING



V00A03Q

POTENTIAL HAZARD

Operating this ATV on paved surfaces.

WHAT CAN HAPPEN

The ATV's tires are designed for off-road use only, not for use on pave­ment. Paved surfaces may seriously affect handling and control of the
ATV, and may cause the vehicle to go out of control.

HOW TO AVOID THE HAZARD

Never operate the ATV on any paved surfaces, including sidewalks, drive­ways, parking lots and streets.

10

WARNING



V00A04Q

POTENTIAL HAZARD

Operating this ATV on public streets, roads or highways.

WHAT CAN HAPPEN

You can collide with another vehicle.

HOW TO AVOID THE HAZARD

Never operate this ATV on any public street, road or highway, even a dirt
or gravel one. In many states it is illegal to operate ATV’s on public streets,
roads and highways.

11

WARNING



V00A06Q

POTENTIAL HAZARD

Operating this ATV without wearing an approved motorcycle helmet, eye
protection and protective clothing.

WHAT CAN HAPPEN

Operating without an approved motorcycle helmet increases your chanc­es of a severe head injury or death in the event of an accident.

Operating without eye protection can result in an accident and increases
your chances of a severe injury in the event of an accident.

Operating without protective clothing increases your chances of severe
injury in the event of an accident.

HOW TO AVOID THE HAZARD

Always wear an approved motorcycle helmet that fits properly. You
should also wear:

– eye protection (goggles or face shield)
– gloves
– boots
– Iong sleeved shirt or jacket
– Iong pants

12

WARNING



V00A07Q

POTENTIAL HAZARD

Operating this ATV after consuming alcohol or drugs.

WHAT CAN HAPPEN

Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while driving this ATV.

13

WARNING



V00A08Q

POTENTIAL HAZARD

Operating this ATV at excessive speeds.

WHAT CAN HAPPEN

Increases your chances of losing control of the ATV, which can result in
an accident.

HOW TO AVOID THE HAZARD

Always travel at a speed which is proper for the terrain, visibility and op­erating conditions, and your experience.

14

WARNING



V00A09Q

POTENTIAL HAZARD

Attempting wheelies, jumps and other stunts.

WHAT CAN HAPPEN

Increases the chance of an accident, including an overturn.

HOW TO AVOID THE HAZARD

Never attempt stunts, such as wheelies or jumps. Don't try to show off.

WARNING



POTENTIAL HAZARD

Failure to inspect the ATV before operating. Failure to properly maintain
the ATV.

WHAT CAN HAPPEN

Increases the possibility of an accident or equipment damage.

HOW TO AVOID THE HAZARD

Always inspect your ATV each time you use it to make sure the ATV is in
safe operating condition.

Always follow the inspection and maintenance procedures and schedules
described in the

Operator’s Guide

and the

Safety Handbook

.

15

WARNING



V00A0BQ

POTENTIAL HAZARD

Removing hands from handlebars or feet from footpegs during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce your ability to control the
ATV or could cause you to lose your balance and fall off the ATV. If you
remove a foot from the footpegs, your foot or leg may come into contact
with the rear wheels, which could injure you or cause an accident.

HOW TO AVOID THE HAZARD

Always keep both hands on the handlebars and both feet on the footpegs
of your ATV during operation.

16

WARNING



V00A0CQ

POTENTIAL HAZARD

Failure to use extra care when operating this ATV on unfamiliar terrain.

WHAT CAN HAPPEN

You can come upon hidden rocks, bumps, or holes, without enough time
to react.

Could result in the ATV overturning or going out of control.

HOW TO AVOID THE HAZARD

Go slowly and be extra careful when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating the ATV.

17

V00A0DQ

POTENTIAL HAZARD

WARNING



Failure to use extra care when operating on excessively rough, slippery
or loose terrain.

WHAT CAN HAPPEN

Could cause loss of traction or vehicle control, which could result in an
accident, including an overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose terrain until you
have learned and practiced the skills necessary to control the ATV on such
terrain.

Always be especially cautious on these kinds of terrain.

18

WARNING



V00A0EQ

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

ATV could go out of control, causing a collision or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in the

tor’s Guide

fore attempting to turn at faster speeds.
Do not turn at excessive speed.

and the

Safety Handbook

. Practice turning at low speeds be-

Opera-

19

WARNING



V00A0QQ

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle can overturn more easily on extremely steep hills than on
level surfaces or small hills.

HOW TO AVOID THE HAZARD

Never operate the ATV on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.

20

WARNING



V00A0FQ

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause ATV to overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills as described in the

Operator's Guide

Always check the terrain carefully before you start up any hill.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly or make sudden gear changes. The ATV

could flip over backwards.
Never go over the top of any hill at high speed. An obstacle, a sharp drop,

or another vehicle or person could be on the other side of the hill.

and the

Safety Handbook

.

21

WARNING



V00A0GQ

POTENTIAL HAZARD

Going down a hill improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause ATV to overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for going down hills as described in the

Operator's Guide

NOTE: A special technique is required when braking as you go down a hill.
Always 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 which would cause the vehicle to lean

sharply to one side. Go straight down the hill where possible.

and the

Safety Handbook

.

22

WARNING



V00A0HQ

POTENTIAL HAZARD

Improperly crossing hills or turning on hills.

WHAT CAN HAPPEN

Could cause loss of control or cause ATV to overturn.

HOW TO AVOID THE HAZARD

Never attempt to turn the ATV around on any hill until you have mastered
the turning technique as described in the

Handbook

Avoid crossing the side of a steep hill if possible.

When crossing the side of a hill:

Always follow proper procedures as described in the
and the

Avoid hills with excessively slippery or loose surfaces.
Shift your weight to the uphill side of the ATV.

on level ground. Be very careful when turning on any hill.

Safety Handbook

.

Operator's Guide

Operator's Guide

and the

Safety

23

V00A0IQ

POTENTIAL HAZARD

WARNING



Stalling, rolling backwards or improperly dismounting while climbing a
hill.

WHAT CAN HAPPEN

Could result in ATV overturning.

HOW TO AVOID THE HAZARD

Use proper gear and maintain steady speed when climbing a hill.

If you lose all forward speed:

Keep weight uphill.
Apply the brakes.
Lock parking device after you are stopped.

If you begin rolling backwards:

Keep weight uphill.
Never apply the rear brake while rolling backwards.
Apply the front brake gradually.
When fully stopped, apply rear brake as well, and then lock parking device.
Dismount on uphill side, or to a side if pointed straight uphill.
Turn the ATV around and remount, following the procedure described in

the

Operator's Guide

24

and the

Safety Handbook

.

WARNING



V00A0JQ

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Could cause loss of control or a collision. Could cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles.
Never attempt to ride over large obstacles, such as large rocks or fallen

trees.
When you go over obstacles, always follow proper procedures as de-

scribed in the

Operator's Guide

and the

Safety Handbook

.

25

WARNING



V00A0KQ

POTENTIAL HAZARD

Skidding or sliding improperly.

WHAT CAN HAPPEN

You may lose control of this ATV.
You may also regain traction unexpectedly, which may cause the ATV to

overturn.

HOW TO AVOID THE HAZARD

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 or sliding out of control.

26

WARNING



V00A0LQ

POTENTIAL HAZARD

Operating this ATV through deep or fast flowing water.

WHAT CAN HAPPEN

Tires may float, causing loss of traction and loss of control, which could
lead to an accident.

HOW TO AVOID THE HAZARD

Never operate this ATV in fast flowing water or in water deeper than that
specified in the

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.

Operator's Guide

and the

Safety Handbook

.

27

WARNING



V00A0MQ

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

You could hit an obstacle or person behind you, resulting in serious injury.

HOW TO AVOID THE HAZARD

When you select reverse gear, make sure there are no obstacles or people
behind you. When it is safe to proceed, go slowly.

28

WARNING



V00A0OQ

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or uneven tire
pressure.

WHAT CAN HAPPEN

Use of improper tires on this ATV, or operation of this ATV with improper
or uneven tire pressure, may cause loss of control, and increases the risk
of an accident.

HOW TO AVOID THE HAZARD

Always use the size and type, tires specified in the
this vehicle.

Always maintain proper tire pressure as described in the
and the

Safety Handbook

.

Operator’s Guide

Operator’s Guide

for

29

WARNING



V02A01Q

POTENTIAL HAZARD

Operating this ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of this vehicle may
cause changes in handling which in some situations could lead to an ac­cident.

HOW TO AVOID THE HAZARD

Never modify this ATV through improper installation or use of accesso­ries. All parts and accessories added to this vehicle should be genuine
Bombardier or equivalent components designed for use on this ATV and
should be installed and used according to instructions. If you have ques­tions, consult an authorized Bombardier ATV dealer.

30

WARNING



V02A02Q

POTENTIAL HAZARD

Overloading this ATV or carrying or towing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in vehicle handling which could lead to an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow greater dis-

tance for braking.
Always follow the instructions in the

Handbook

While reading this guide, remember that:

for carrying cargo or pulling a trailer.

WARNING



Operator’s Guide

and the

Safety

Indicates a potential hazard that could result in serious injury or death.

31

BOMBARDIER LIMITED WARRANTY 2000
BOMBARDIER ATV ALL-TERRAIN VEHICLE

1. WARRANTY COVERAGE PERIOD

In Canada, BOMBARDIER INC. or in the USA, BOMBARDIER MOTOR CORPORATION OF AMERICA
(“Bombardier”), warrants FROM THE DATE OF DELIVERY TO THE FIRST CONSUMER that each
2000 BOMBARDIER ATV sold, as NEW and UNUSED and PREDELIVERED by an authorized North
American BOMBARDIER ATV dealer, will be free from any defects in material and/or workmanship
for a period of:

SIX (6) CONSECUTIVE MONTHS, for private use owners, or
THREE (3) CONSECUTIVE MONTHS, for commercial use owners.
Tires supplied as original equipment on your ATV are warranted separately by the individual tire man-

ufacturers as identified below. If an original tire on your Bombardier ATV has a defect in material or
workmanship, please contact the corresponding tire manufacturer or ask your authorized Bombardier
ATV dealer for assistance.

Carlisle Tire & Wheel Company
23 Windham Boulevard
Aiken, SC 29805
Warranty Information: 1-800-260-7959
Kenda U.S.A.
7095 Americana Parkway
Reynoldsburg, OH 43068
Warranty Information: [phone], Ext. 210

All genuine Bombardier accessories, installed by an authorized BOMBARDIER ATV dealer at the time
of delivery of the new and unused BOMBARDIER ATV, carry the same Warranty Coverage Period as
for the BOMBARDIER ATV.

2. WHAT BOMBARDIER WILL DO

BOMBARDIER will repair or replace, at its option, all genuine BOMBARDIER part found defective in
material and/or workmanship, under normal use, maintenance and service, with a genuine BOMBAR­DIER part without charge for parts and labor, at any authorized BOMBARDIER ATV dealer during the
Warranty Coverage Period.

3. CONDITION TO HAVE WARRANTY WORK VALIDATED

The customer must notify an authorized BOMBARDIER ATV dealer within two (2) days of the appear­ance of a defect in material and/or workmanship and present to the servicing authorized BOMBAR­DIER ATV dealer the BOMBARDIER ATV Warranty Registration Card or a proof of purchase of the
NEW and UNUSED 2000 BOMBARDIER ATV and must sign the repair/work order prior to the start
of the repair in order to validate a warranty repair. All parts replaced under this limited warranty become
the property of BOMBARDIER.

4. EXCLUSIONS - ARE NOT WARRANTED

• Normal wear and tear items;

• Labor, parts and lubricant costs of all maintenance services;

• Damage caused by failure to provide proper maintenance and/or storage, as described in the

BOMBARDIER ATV Operator's Guide”

• Damage resulting from improper repairs, modifications or use of non-approved parts or, repairs
done by a non-authorized BOMBARDIER ATV dealer;

• Damage resulting from abuse, misuse, neglect or racing.

• Damage resulting from accident, fire, theft, vandalism or any act of God;

• Incidental or consequential damages, or damages of any kind as but not limited to towing charges,
telephone calls or taxi; and

• Damages resulting from improper service or maintenance.

;

“2000

32

5. LIMITATIONS OF LIABILITY

This warranty gives you specific rights, and you may also have other legal rights which may vary from
state to state, or province to province. WHERE APPLICABLE, THIS WARRANTY IS EXPRESSLY

GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESSED OR IM­PLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FIT­NESS FOR ANY PARTICULAR PURPOSE.

Neither the distributor, any authorized BOMBARDIER ATV dealer nor any other person has been
authorized to make any affirmation, representation or warranty other than those contained in this
warranty, and if made, such affirmation, representation or warranty shall not be enforceable against
BOMBARDIER or any other person.

In no event shall BOMBARDIER be liable for special, consequential or incidental damages, including
but not limited to loss of use and transportation costs. Some states or provinces do not allow the
exclusion or limitation of incidental or consequential damages, or limitations on how long an implied
warranty lasts, so the above limitation or exclusion may not apply.

BOMBARDIER reserves the right to modify this warranty at any time, being understood that such
modification will not alter the warranty conditions applicable to the BOMBARDIER ATV sold while this
warranty is in effect.

6. TRANSFER

If the customer sells the ATV guaranteed under the present, he shall assign and transfer this warranty,
which shall be valid for the rest of the relevant PERIOD as defined in section 1 hereinabove, to the
new customer.

7. CONSUMER ASSISTANCE

a) In the event of a controversy or a dispute arising in connection with this BOMBARDIER LIMITED

WARRANTY, BOMBARDIER 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 issue has still not been resolved, please submit in writing your complaint to:

IN CANADA:

BOMBARDIER INC.

RECREATIONAL PRODUCTS
ATV
CUSTOMER ASSISTANCE CENTER
VALCOURT QC J0E 2L0

Tel: [phone]

IN USA:

BOMBARDIER MOTOR
CORPORATION OF AMERICA

RECREATIONAL PRODUCTS
ATV
CUSTOMER ASSISTANCE CENTER
P.O. BOX 8035
7575 BOMBARDIER COURT
WAUSAU WI 54402-8035

Tel: [phone]

BOMBARDIER
RECREATIONAL PRODUCTS

JUNE 1999

® Registered trademark of Bombardier Inc. and/or subsidiaries.

33

FREQUENTLY ASKED QUESTIONS

Q: Why must my vehicle be registered with the factory? After all, I do have my

original invoice as proof of when I purchased my vehicle.

A: Registration is very important and an authorized Bombardier ATV dealer

must register your vehicle with Bombardier. Make sure the card has been
sent. All of this will allow you to:

a) Have warranty work performed at any authorized Bombardier ATV dealer

in North America. Your registration card will provide the dealer with all
the necessary data to complete warranty claim forms.

b)Be advised by Bombardier should there be a safety recall or a particular

warranty campaign.

c) Be contacted much faster by the police, in the event that they find your

vehicle subsequent to a theft.

Q: Why must my vehicle be registered with the governing body having jurisdic-

tion over vehicle use?

A: Vehicle registration has two purposes: In many provinces or States, it is

mandatory to register a vehicle in the same way as for a car. It allows the
State or province to maintain records of existing vehicles. In some juridic­tions, governmental agencies use part of the registration fees for establish­ing and maintaining trails.

Q: Where can I find information on the lubrication and maintenance of my vehicle?

A: In the

Q: Will the entire warranty be voided or cancelled, if I do not operate or maintain

my new vehicle exactly as specified in the

Operator’s Guide

provided with the vehicle at the time of delivery.

Operator’s Guide

?

A: The warranty of the new vehicle cannot be VOIDED or CANCELLED if pre-

delivered by an authorized Bombardier ATV dealer. However, if a particular
failure is caused by operation or maintenance other than is shown in the

Operator’s Guide

, THAT failure may not be covered under warranty. This
includes service work performed by the customer, oil and filter change and
especially the critical adjustments such as the carburetor.

Q: Would you give some examples of abnormal use or strain, neglect or abuse

which may affect the limited warranty coverage?

A: These terms are general and overlap each other in some cases. Some spe-

cific examples may include: running the engine out of oil, operating the
vehicle with a broken or damaged part which causes another part to fail,
and so on. If you have any specific questions on operation or maintenance,
please contact an authorized Bombardier ATV dealer for advice.

Q: What costs are my responsibility during the warranty period?

A: The customer’s responsibility includes all costs of normal maintenance ser-

vices, non-warranty repairs, accidents and collision damage, as well as oils,
and spark plugs, and incidental or consequential damages costs as ex­plained in the warranty.

34

Q: Are “Genuine” Bombardier replacement parts used in warranty repairs also

covered by the limited warranty coverage?

A: Yes. When installed by an authorized Bombardier ATV dealer, any “Genu-

ine” Bombardier part used in warranty repairs assumes the remaining war­ranty that exists on the vehicle.

Q: If I sell my vehicle within the warranty period, will the new owner qualify for

the balance of the limited warranty coverage?

A: Yes, provided the re-sale has been registered with the manufacturer.

Q: How can I receive the best owner assistance?

A: The satisfaction and goodwill of the owners of Bombardier products are of

primary concern to your ATV dealer and Bombardier. Normally, any prob­lems that arise in connection with the sales transaction or the operation of
your vehicle will be handled by your Dealer’s Sales or Service Departments.
It is recognized, however, that despite the best intentions of everyone con­cerned, misunderstandings will sometimes occur. Frequently, complaints
are the result of a breakdown in communications and can quickly be re­solved by a member of the dealership management. If the problem already
has been reviewed with the Sales Manager or Service Manager, contact
the Dealer Principal himself or the General Manager.

We are always pleased to receive your comments on the Bombardier ATV.

35

EMISSION REQUIREMENTS

The California Air Resources Board (CARB) requires that your ATV observe 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 8

VEHICLE CATEGORY VIN 8TH CHARACTER

Non-complying Red Label Must denote a C or 3

Complying Green Label Any alphanumeric designation other than a C or 3

th

character detailed herein).

HANG TAG

This ATV comes with a hang tag and labels containing important safety informa­tion.

The labels should be considered as permanent parts of the vehicle. If a label
comes off or becomes hard to read, please contact an authorized Bombardier ATV
dealer for replacements.

Any person who rides this vehicle should read and understand this information
before riding.

V02M01L

36

LOCATION OF THE IMPORTANT LABELS

The following labels are on your ATV. If missing or damaged, they can be replaced
free of charge. See an authorized Bombardier ATV dealer.

1

3

7

2

6

5

V02L02L

4

37

LABEL 1

LABEL 4

V02M06Y

LABEL 5

V01M01Z

V01M02Z

LABEL 2

LABEL 3

V01M07Z

LABEL 6

V02M03Y

V02M05Y

38

LABEL 7

V02M07Y

HOW TO IDENTIFY YOUR ATV

The main components of your vehicle
(engine and frame) are identified by
different serial numbers. It may some­times become necessary to locate
these numbers for warranty purposes
or to trace your vehicle in the event of
loss. These numbers are required by
the authorized Bombardier ATV dealer
to complete warranty claims properly.
No warranty will be honored by Bom­bardier if the engine identification
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 and supply them
to your insurance company.

Engine and Vehicle
Identification Number
Location

1

V02A03Y

1. EIN (Engine Identification Number)

2. VIN (Vehicle Identification Number)

2

39

CONTROLS/INSTRUMENTS/EQUIPMENTS

19

10

9

19

5,6,7

16

11

4

3

2
1

8

17

16

14

15

V02L08L

40

14

18

16

12

17

19

V02L09L

13

15

14

16

41

While reading this guide, remember that:

WARNING



Indicates a potential hazard that could result in serious injury or death.

WARNING



This ATV may exceed the performance of other ATV’s you may have rider
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 skills and substantial experience.

NOTE: This section gives basic func-

tions of the various controls of your
ATV. For more details of how to oper­ate one control in conjunction with
some others, refer to OPERATING IN­STRUCTIONS in this
and

Safety Handbook

Operator's Guide

.

1) Throttle Lever

Located on the right side of handlebar.
When pushed, it increases the engine
speed that allows the engagement of
the transmission on the selected gear.

When released, the engine speed
should return automatically to idle and
the vehicle will gradually slow down.

WARNING



Always release the throttle when
shifting gears. Shifting gears with­out releasing the throttle, could
cause loss of control including the
ATV to overturn and mechanical
damages.

2) Front Brake Lever

Located on the right side of handlebar.
When compressed, the brake is ap­plied. When released, it should auto­matically return to its original position.
Braking effect is proportional to the
force applied on the lever and to the
type and condition of the terrain.

1

2

V02I02Y

1. Throttle lever

2. To accelerate

3. To decelerate

42

1

2

3

V02I02Z

1. Brake lever

2. To apply brake

3) Clutch Lever

Located on the left side of handlebar.
When compressed, the clutch is dis­engaged. When released, the clutch is
engaged.

1

3

2

WARNING



Make sure parking device is fully
disengaged before operating the
ATV.

When you ride the vehicle, the
prolonged use of brakes may
cause damage to the brake sys­tem and cause loss of efficiency
which could lead to a loss of con­trol.

To engage mechanism: Squeeze front

brake lever and maintain while moving
lever lock with a finger. Front brake lever
is now compressed and applying front
brake.

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 including the
ATV to overturn and mechanical
damages.

4) Parking Lever Lock

Located on right side of handlebar on
brake lever. When applied, it tempo­rarily prevents the vehicle from mov­ing. Useful when the brake needs to
be locked for example such as doing a
K-turn.

1

2

V02I02O

1. Parking lever lock

2. To apply parking device

To release mechanism: Squeeze front
brake lever. Lever lock should automat­ically return to its original position. Front
brake lever should return to rest posi­tion.

43

5) Headlight Switch

7) Start Button

Located on left side of handlebar.
Place switch to LO for the low beam
and taillight. Place switch to HI for the
high beam and taillight. Place switch to
OFF position for closed the headlight.

1

V02I03Y

1. Headlight switch

Located on left side of handlebar. To
start engine:

– Place the engine stop switch to

RUN.

– Select transmission to the NEU-

TRAL position or squeeze the clutch

lever.
– Turn ignition key to ON.
– Press and hold the start button.

CAUTION: Do not hold start button
more than 4 seconds. A rest period
should be observed between the
cranking cycles to let starter cool
down. Pay attention not to discharge
battery.

Release immediately after engine is
started.

6) Engine Stop Switch

Located on left side of handlebar. The
engine will not run or start if the engine
stop switch is turned to OFF position.

This switch is used to stop engine and
as an emergency control.

NOTE: While engine can be stopped
by turning ignition key OFF, we recom­mend the engine be stopped by the
engine stop button.

V02I03O

1. Start button

1

8) Fuel Tank Cap

Unscrew counterclockwise and re­move cap to allow fuel tank filling then
fully tighten clockwise.

WARNING



V02I03Z

1. Engine stop switch

1

44

Never use an open flame to check
fuel level.

9) Ignition Switch

Located on the right side of the control
panel.

Key-operated, 2 position switch: OFF,
and ON without lights.

In the event that the vehicle is flipped
over or stays tilted on the side, be sure
to check RED engine indicator lamp af­ter restarting engine. If lamp stays ON,
stop engine and see an authorized
Bombardier ATV dealer.

Insert key in switch and turn to the de­sired position. To remove key, turn key
to OFF then pull it out.

NOTE: While engine can be stopped
by turning ignition key OFF, we recom­mend the engine be stopped by push­ing the engine stop switch.

10) Indicator Lamp

The indicator lamps are located above
ignition switch.

Neutral Indicator Lamp (green)

When the transmission is in neutral,
the neutral indicator lamp light comes
ON.

Engine Indicator Lamp (red)

When the engine oil pressure is too
low or the engine temperature is too
high, the engine indicator lamp comes
ON.

21

CAUTION: Failure to stop the engine
immediately after RED engine indi­cator lamp comes ON will adversely
affect the service life of the engine.

11) Front Brake Fluid
Reservoir

Located above front brake lever.

12) Fuel Valve

Located on right side under fuel tank.
3-position rotary valve: OFF, ON, RES.
Rotate the knob to align its pointer
with ON, OFF or RES.

OFF

Stops fuel supply to carburetor.

CAUTION: Turn valve to OFF posi­tion when ATV is not being operated
or when transporting.

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 30% of the fuel tank ca­pacity. Use only this position when the
ON supply is empty.

V02I01Y

1. Neutral indicator lamp (green)

2. Engine indicator lamp (red)

When down to the reserve, refuel as
soon as possible. Ensure to turn the
valve back to the ON position after re­fuelling.

45

14) Storage Compartment

Located on back of air box, under seat.

V02A0KY

CAUTION: Improper opening of fuel
valve will restrict the flow of fuel.
Make sure valve is fully opened while
running.

13) Gearshift Pedal

Located in front of left footpeg.

1

2

V02A0MY

1. Storage compartment

2. Air box

Tool Box

Located in storage compartment. The
tool box contains tools for basic main­tenance, the

Safety Handbook

Operator’s Guide

.

and the

1

V02A0LY

1. Gearshift pedal

46

15) Seat Latch

Located underneath rear end of seat.
It allows the removal of seat to give
access to air box and storage compart­ment.

2

V02L07Y

1. Seat tab

2. Body hook



1

WARNING

Periodically verify the seat lock
pin and tighten if needed. Make
sure seat is securely latched be­fore riding.

2

V02A0NY

1. Seat

2. Seat latch

1

Seat Removal

Pull latch upward while gently lifting
rear of seat. Continue lifting movement
until you can release the front retaining
devices then completely remove seat.

Seat Installation

Insert seat front tab into body hook.
Pull latch lever to insert it over the rear
lock pin. Release latch lever then firmly
push on rear of the seat to relatch.

16) Footpeg

Located on both side of the vehicle.

17) Foot Brake Pedal

Located in front of right footpeg.
When pressed down, the rear brake is
applied. When released, it should re­turn to its original position.

V02K01Y

1. Foot brake pedal

1

47

NOTE: Braking effect is proportional

to the force applied on the lever and to
the type and condition of the terrain.

18) Rear Brake Fluid
Reservoir

Located near the right rear fender.

1

V02K02Z

1. Rear brake fluid reservoir

19) Engine/Transmission
Oil Tank Cap

Located on LH of control panel.

1

V02I01Z

1. Engine/transmission oil tank cap

WARNING



The oil tank can be hot. Do not
touch with your hands.

48

LIQUIDS

While reading this guide, remember that:

WARNING



Indicates a potential hazard that could result in serious injury or death.

This section specifies the recom­mended liquids and procedures to
check their levels. Refer to MAINTE­NANCE for procedures to replace the
liquids.

Fuel

Recommended Fuel

Use super unleaded gasoline or gaso­hol containing less than 10% of etha­nol or methanol, available from most
service stations. Use The gasoline
used must have an octane number of
91 ((R + M)/2) or higher.

NOTE: In most service station, pump
octane number corresponds to
(R + M)/2 octane number. Usually a
sticker can be found on the pump.

CAUTION: Never experiment with
other fuels. The use of unrecom­mended fuel can result in vehicle
performance deterioration and dam­age to critical parts in the fuel sys­tem and engine components.

CAUTION: Never mix oil with fuel.
This ATV has a 4-stroke engine. Oil
must be added to oil tank only.

Fuel Level

WARNING



Never top up the fuel tank before
placing the vehicle in a warm area.
As temperature increases, fuel ex­pands and may overflow. Fuel is
flammable and explosive under
certain conditions. Always wipe
off any fuel or oil spillage from the
vehicle.

Engine/Transmission Oil

Recommended Oil

Always use 4-stroke mineral-based
engine oil that meets or exceeds the
requirements for API service classifi­cation SH or SJ. Always check the API
service label on the oil container to be
sure it includes the letters SH or SJ.
Only use high-quality high-detergent
oil.

CAUTION: The same oil lubricates
both engine and transmission. Do
not use synthetic, synthetic blend oil
or special oil additive. They affect
the clutching calibration.

49

Oil Viscosity

SAE 10W40 is recommended for general use.
Other viscosity should be used if the average temperature is outside the range

of the recommended oil. See chart below.

°C

60

50

40

30

SAE 20W50

20

SAE 15W50

°F

140

120

100

80

60

SAE 10W40

SAE 10W30

SAE 5W30

SAE 15W40

10

-10

-20

-30

40

0

20

0

-20

V01A0VL

50

Oil Level

CAUTION: Check level frequently
and refill if necessary. Do not overfill.
Operating the engine/transmission
with an improper level may severely
damage engine/transmission. Wipe
off any spillage.

V02A07Y

LH SIDE OF DASH

1. Dipstick

1

With vehicle on a level surface and en­gine not running, check oil level as fol­lows:

1. Unscrew dipstick out and wipe clean.

2. Screw dipstick until it bottoms.

3. Remove dipstick and check oil level.
It should be between lower and up­per marks.

4. Add oil up to upper mark if required.

5. To add oil, use a funnel to avoid spill­age. Do not overfill.

6. Properly tighten dipstick.

Engine Coolant

V02A08Y

1. Coolant reservoir

2. Radiator

3. RH front shock

2

1 3

With vehicle on a level surface, liquid
should be between MIN. and MAX.
level marks of coolant reservoir.

NOTE: When checking level at tem­perature lower than 20°C (69°F), it may
be slightly lower than MIN. mark.

Remove filler cap then add coolant up
to MAX. mark if required. Use a funnel
to avoid spillage. Do not overfill.

Properly reinstall and tighten filler cap.
NOTE: A cooling system that fre-

quently requires coolant is the indica­tion of leaks or engine problems. See
an authorized Bombardier ATV dealer.

Recommended Coolant

Always use ethylene-glycol antifreeze
containing corrosion inhibitors specifi­cally for internal combustion aluminum
engines.

Cooling system must be filled with wa­ter and antifreeze solution (40% water,
60% antifreeze).

Coolant Level

WARNING



Check coolant level with engine
cold. Never add coolant in cool­ing system when engine is hot.

Brake Fluid

Recommended Fluid

Always use brake fluid meeting the
specification DOT 4 only.

CAUTION: Never use other type of oil
such as mineral-based or synthetic
oil.

Fluid Level

With vehicle on a level surface, check
brake fluid in reservoir for proper level.
It should be above MIN. mark.

Add fluid as required. Do not overfill.
Clean filler cap before removing.

51

CAUTION: Use only DOT 4 brake flu­id from a sealed container.

NOTE: A low level may indicate leaks

or worn brake pads. See an authorized
Bombardier ATV dealer.

Front Brake Fluid Reservoir

Turn steering in the straight-ahead po­sition to ensure reservoir is level.

Visually inspect lever boot condition.
Check for cracks, tears etc. Replace if
damaged.

Cleaning

Clean battery post with a wire brush.
Apply dielectric grease on post to pro­tect against oxidation.

Removal

Disconnect negative BLACK cable first
then positive cable.

WARNING



Always respect this order for dis­assembly; disconnect BLACK
negative cable first. Oil or fuel va­pors can be present in engine
compartment and a spark may ig­nite them and possibly cause per­sonal injuries.

Remove bolts retaining battery holder
from rack.

V02K03Y

Rear Brake Fluid Reservoir

V02K02Y

RH SIDE OF VEHICLE

Battery

This vehicle is equipped with a dry bat­tery that requires no maintenance.

V02F01Y

1. Battery holder

2. Rack

2

1

Installation

Reinstall battery in vehicle. Fasten bat­tery holder.

WARNING



Connect positive RED cable first
then negative cable. Always con­nect RED positive cable first.

52

BREAK-IN PERIOD

Engine

A break-in period of 10 operating hours
is required before running the vehicle
at sustained full throttle.

CAUTION: Never mix oil with fuel.
This vehicle has a 4-stroke engine.
Oil must be added to engine base
only.

During this period, maximum throttle
should not exceed 3/4. However, brief

full acceleration and speed varia­tions contribute to a good break-in.

Continued wide open throttle acceler­ations, prolonged cruising speeds and
engine overheating are detrimental
during the break-in period.

10-Hour Inspection

As with any precision piece of me­chanical equipment, we suggest that
after the first 10 hours or 30 days after
the purchase, whichever comes first,
your vehicle be inspected by an autho­rized Bombardier ATV dealer. This in­spection will give you the opportunity
to discuss the unanswered questions
you may have encountered during the
first hours of operation.

The 10-hour inspection is at the expense
of the vehicle owner.

53

PRE-OPERATION CHECK

WARNING



The pre-operation check is very
important prior to operating the
vehicle. Always check the proper
operation of critical controls,
safety features and mechanical
components before starting. If not
done as specified here, severe in­jury or death might occur.

• Check the parking device. Apply
parking device and check if it oper­ates properly.

• Check tire pressure and condition.

• Check wheels and bearings for
wear and damage.

• Check location of controls and en­sure they work properly.

• Verify steering operates freely.

• Activate throttle control lever sever­al times to ensure it operates freely.
It must return to idle position when
released.

• Check operation of ignition switch,
start button, headlight switch (HI­LO), taillight, brake light, indicator
lights and engine stop switch.

• Check drive chain for lubrication and
adjustment.

• Check sprockets for wear and dam­ages.

• Check fuel, oil and coolant levels.

• Check for oil leaks on the engine/
transmission and oil tank.

• Ensure fuel valve is in fully open po­sition (ON).

• Clean headlight and taillight.

• Ensure seat is properly latched.

• If you transport cargo, respect load
capacity. Ensure cargo is properly
secured to the vehicle.

• If you are pulling a trailer or other
equipment, ensure it respects the
tongue capacity and towing capaci­ty. Ensure trailer is properly secured
to hitch.

• Activate the brake lever and foot
pedal to make sure the brakes fully
apply. Lever and pedal must fully re­turn when released.

• Check all brake line fitting for tight­ness and against leaks.

• With the parking device correctly
applied. Activate the clutch lever.
Lever must fully return when re­leased.

• Look and feel for loose parts while
engine is off. Check fasteners.

• Ensure the path of travel is free of
persons and obstacles.

• Drive forward slowly a few feet and
apply all brakes individually to test
them.

Correct any problem you may have
found. See an authorized Bombar­dier ATV dealer as necessary.

54

OPERATING INSTRUCTIONS

General

This vehicle has five-forward gears.
Engine can be started in any gear (from
1 to 5).

Transmission must be on NEUTRAL or
pull in the clutch lever to allow engine
starting.

Initial Cold Starting

Insert key in ignition switch and turn to
ON.

Place the engine stop switch to run po­sition.

In severe cold weather, colder than

- 20°C (- 4°F), move the choke lever to
full position.

1

Press star button and hold until engine
starts.

CAUTION: Do not hold start button
more than 4 seconds. A rest period
should be observed between the
cranking cycles to let starter cool
down. Pay attention not to discharge
battery.

Release start button immediately
when engine has started.

WARNING



Do not apply throttle while start­ing.

After a few minutes, move the lever to
half position.

NOTE: Overusing choke may flood en­gine and make it hard to start. Refer to
SPECIAL PROCEDURES if it occurs.

When the engine is warm, move the
choke lever to OFF and release brakes.

V02A19Y

UNDER SEAT, ON THE LH SIDE

1. Off position

2. Half position

3. Full position

2

3

55

Warm Engine Starting

Start the engine as explained above
but without any choke. If the engine
will not start after two 4-second at­tempts with the electric starter, move
choke lever to position 1. Start the en­gine without activating the throttle le­ver. After few times, move the choke
lever to OFF.

Stopping the Engine

Release throttle and completely stop
the vehicle.

Apply the parking device.
Press the clutch lever and shift to 1

gear.
Push the engine stop switch.
Turn key in ignition switch to OFF.

One full stroke of the pedal shifts the
transmission to the next higher or low­er gear in the shifting sequence. The
pedal should automatically 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, step on the gearshift pedal
and depress pedal one full stroke.

st

Remove key from ignition switch.

Shifting the Transmission

Gearshift Control

To shift the transmission, pull in the
clutch lever, then operate gearshift
pedal as follow.

WARNING



Always use the clutch lever to up­shift or downshift

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.

CAUTION: Make sure parking de­vice is fully disengaged before oper­ating the ATV.

56

SPECIAL PROCEDURES

Flooded Engine

When the engine does not start after
several attempts, the engine may be
fuel flooded. Proceed as follows.

Turn ignition switch to ON and ensure
choke is not applied.

Ensure the transmission is in NEU­TRAL or pull in the clutch lever.

Fully press throttle lever and hold
while starting the engine. Try several
times.

As soon as the engine starts, release
throttle lever. Do not race engine.

If it does not work:

Disconnect spark plug cables.
Clean the spark plug area then remove

spark plugs (tools are supplied in tool
box).

Crank engine several times. Install
clean dry spark plugs if possible.

Start engine as explained above. If en­gine continues to flood, see an autho­rized Bombardier ATV dealer.

Inspect radiator area and clean as nec­essary. Check coolant level and refill if
possible.

WARNING



Never refill cooling system when
engine is hot. Let engine cool
down.

See an authorized Bombardier ATV
dealer as soon as possible.

Post-Operation Care

When vehicle is used in salt-water en­vironment (beach area, launching/
loading boats etc.), rinsing the vehicle
with fresh water is necessary to pre­serve vehicle and its components. Me­tallic parts lubrication is highly recom­mended. Use BOMBARDIER LUBE.
This must be performed at the end of
each operating day.

When vehicle is operated in muddy
conditions, rinsing the vehicle is rec­ommended to preserve vehicle and its
components and to keep lights clean.

Engine Overheat

If engine overheats and engine indica­tor lamp (red) comes ON, try the fol­lowing:

Check oil level in oil tank and refill if
necessary.

Ensure radiator is not obstructed.
Check radiator fins. See MAINTE-

NANCE section.
Reduce vehicle speed but try to keep

vehicle moving to supply air to radiator.
If engine is still overheating after ap­proximately one minute, stop vehicle
and set transmission to NEUTRAL. Ap­ply parking device and stop engine.

Storage and Preseason
Preparation

When a vehicle is not in use for more
than one month, proper storage is a
necessity.

See an authorized Bombardier ATV
dealer for proper procedures.

When using your ATV after storage, a
preparation is required. See an autho­rized Bombardier ATV dealer for proper
procedures.

57

MAINTENANCE CHART

Noise Emission Control System Regulation

Tampering with Noise Control System Prohibited!

U.S Federal law and Canadian provincial laws may prohibit the following acts or
the causing thereof:

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 conducts 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.

Emission Requirements

The California Air Resources Board (CARB) requires that your ATV observe 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 8

VEHICLE CATEGORY VIN 8TH CHARACTER

Non-complying red label Must denote a C or 3

th

character detailed herein).

Complying green label Any alphanumeric designation other than a C or 3

58

Refer to MAINTENANCE section of Shop Manual for more details.

LUBRICATION AND MAINTENANCE CHART

INITIAL 10-HOUR

INSPECTION EVERY

25 HOURS

EVERY

50 HOURS

EVERY 100 HOURS

OR ONCE A YEAR

Engine/transmission oil level EVERY RIDE CUSTOMER

ENGINE/
TRANSMISSION

FUEL SYSTEM

ELECTRICAL

DRIVE TRAIN

Engine/transmission oil and filter replacement

Valve clearance

Engine mount fasteners

Exhaust system/spark arrester

Condition of seals

Coolant level EVERY RIDE CUSTOMER

Coolant replacement

Cooling system condition

Radiator cap pressure test

Radiator condition/cleanliness (radiator fins)

Clutch and transmission operation

Clutch lever adjustment

Air filter cleaning/draining

Air filter and foam replacement

Fuel lines and connections

Fuel tank strainer replacement

Carburetor adjustment

Spark plugs inspection/replacement

Battery connections

Wiring harnesses, cables and lines

Condition of ignition switch and start button EVERY RIDE CUSTOMER

Condition of lighting system
(HI/LO intensity, brake light, etc.)

Headlight beam aiming

Drive chain lubrication EVERY RIDE CUSTOMER

Drive chain adjustment EVERY RIDE CUSTOMER

Drive chain slider condition

Sprockets inspection

Wheel bearing condition

Rear hub wheel lubrication

Axle adjustment nut lubrication

 
























EVERY RIDE CUSTOMER









EVERY 200 HOURS

OR 2 YEARS

CUSTOMER



CUSTOMER

CUSTOMER

CUSTOMER



CUSTOMER

CUSTOMER

CUSTOMER




TO BE

PERFORMED BY

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

DEALER

59

LUBRICATION AND MAINTENANCE CHART



EVERY

EVERY

25 HOURS

50 HOURS

INSPECTION

INITIAL 10-HOUR

EVERY 100 HOURS

OR 2 YEARS

OR ONCE A YEAR

EVERY 200 HOURS

TO BE

PERFORMED BY

STEERING/
CONTROL
SYSTEMS

SUSPENSION

BRAKE

BODY/FRAME

Handlebar fastener tightness

Throttle condition EVERY RIDE CUSTOMER

Choke condition EVERY RIDE CUSTOMER

Steering system mechanism

Tie rod ends

Tire pressure EVERY RIDE CUSTOMER

Wheel mount tightness and stud lubrication

Wear and condition of tires EVERY RIDE CUSTOMER

Front wheel alignment and steering adjustment

Swing arm condition

Swing arm lubrication

A-arm lubrication

A-arm condition

Ball joint boot inspection

Ball joint condition

Shock absorber condition

Brake fluid level front/rear EVERY RIDE CUSTOMER

Brake fluid replacement front/rear

Brake pad condition

Brake system condition (discs, hoses etc.)

Brake line fittings EVERY RIDE CUSTOMER

Engine area cleaning

Skid plate condition

Frame condition EVERY RIDE CUSTOMER

Fastener condition/tightness

Seat latch

Vehicle cleaning and protection








































DEALER

DEALER

DEALER

CUSTOMER

DEALER

DEALER

CUSTOMER

CUSTOMER

DEALER

CUSTOMER

DEALER

DEALER

DEALER

DEALER

DEALER

CUSTOMER

CUSTOMER

CUSTOMER

CUSTOMER

CUSTOMER



To be performed by an authorized Bombardier ATV dealer.



Before installing new spark plugs at pre-season preparation, it is suggested to
burn excess storage oil by starting the engine with the old spark plugs. Only
perform this operation in a well ventilated area.

NOTE: Some riding conditions may result in requiring more frequent mainte­nance. See a Bombardier ATV dealer. Some items are part of the pre-operation
checks and must always be performed prior to operating the vehicle.

60

MAINTENANCE

While reading this guide, remember that:

WARNING



Indicates a potential hazard that could result in serious injury or death.

WARNING



Unless otherwise specified, engine should not be running for all mainte­nance procedures.

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.

The following covers the maintenance
items that can be made by the custom­er if desired. Other items found in
maintenance chart must be performed
by an authorized Bombardier ATV dealer.

Lubrication

Among other things, this section gives
the procedures to replace the liquids.
Refer to LIQUIDS for procedures to
check levels and refill.

Oil Change and Oil Filter
Replacement

Oil and filter are to be replaced at the
same time. Oil change should be done
with a warm engine.

WARNING



The engine oil can be very hot.
Wait until engine oil is warm.

Ensure vehicle is on a level surface.
Remove dipstick.
Clean the drain plug area.
Drain all oil from oil tank by removing

the rubber hose on the engine. Wipe
out any oil spillage on engine.

V02C02Y

LEFT SIDE OF VEHICLE

1. Remove this hose to drain oil tank

1

61

Place a drain pan under the engine
drain plug area.

Unscrew drain plug.

Wipe out any oil spillage on engine.
Change gasket on drain plug. Clean

gasket area on engine and drain plug
then reinstall plug. Refill oil tank at the
proper level with the recommended
oil. Refer to SPECIFICATIONS for ca­pacity.

Start engine and let idle for a few min­utes.

Check if the RED indicator lamp stay
ON, if yes, stop engine and bleed sys­tem by removing oil filter and bleeding
screw.

V02C03Y

UNDER VEHICLE

1. Oil drain plug

1

Wait a while to allow oil to flow out of
oil filter.

Reinstall the rubber hose on engine.
Unscrew oil filter cover.
Remove the oil filter and replace by a

new.
NOTE: Check and change the O-ring,

if necessary.

1

3

V02C05Y

BEHIND OIL FILTER

1. Bleeding screw

1

Ensure oil filter area, hose and drain
plug areas are not leaking.

Stop engine and check oil level. Refill
as necessary.

V02C04Y

RH SIDE OF ENGINE

1. Oil filter cover

2. Oil filter

3. O-ring

2

62

Dispose oil as per your local environ­mental regulations.

Other Components

CAUTION: Do not lubricate throttle
and clutch cables.

Suspension

Front A-arm

Lubricate front A-arms with a grease
gun. Use synthetic grease (P/N 293
550 010).

Loosen lock nut then turn the adjuster
to obtain correct throttle lever free play.

NOTE: Measure throttle free play at
the tip of throttle lever.

Tighten lock nut and reinstall protector.

A

V02J01Y

1. Grease fittings

1

Swing Arm

Lubricate swing arm with a grease
gun. Use synthetic grease (P/N 293
550 010).

Occasionally, wheel nuts should be re­moved to apply anti-seize lubricant on
studs to ease further removal. This is
particularly important when vehicle is
used in salt-water environment or in
mud. Remove one nut at a time, lubri­cate then retorque.

Maintenance

Periodically check the engine and the
radiator area for cleanliness.

Valves Adjustment

V02I04Y

1. Throttle lever

2. Protector

3. Cable adjuster

4. Lock nut
A. 3 to 8 mm (1/8 to 5/16 in)

2

3 41

Gearshift Pedal Adjustment

Unfasten socket screw near selector
shaft end then remove gearshift pedal.

Install gearshift pedal at your conve­nience then torque socket screw.

Clutch Adjustment

Loosen cable tension.
Adjust clutch release mechanism.

See an authorized Bombardier ATV
dealer for valves adjustment.

Insufficient clearance will cause loss
of power and possibly damage the
valves. Excessive clearance will cause
noise.

Throttle Lever Adjustment

Slide rubber protector back to expose
throttle cable adjuster.

A

V02D03Y

A. 68 to 75 mm (2-11/16 to 2-31/32 in)

63

Adjust cable free play.

V02D04Y

A

Removal

WARNING



Never perform this operation im­mediately after the engine has
been run because exhaust sys­tem is very hot. Wear eye protec­tion and gloves. Respect all appli­cable laws and regulations.

Remove:

A. 2 ± 0.5 mm (5/64 ± 1/64 in)

Radiator

Inspect radiator fins. They must be
clean, free of mud, dirt, leaves and any
other deposit that would prevent the
radiator to cool properly.

Remove the deposits as much as you
can with your hands. If water is avail­able in proximity, try rinsing the radia­tor fins.

If available, use a garden hose to rinse
the radiator fins.

WARNING



Never clean radiator with your
hands when it is hot. Let the radi­ator cool down before cleaning.

CAUTION: Be careful not to damage
the radiator fins when cleaning. Do
not use any object/tool that could
damage the fins. The fins are pur­posely thin parts to allow efficient
cooling. When hosing, use low pres­sure only.

– the screws retaining the spark ar-

rester to the muffler

1

1

2

V02C06Y

1. Screws

2. Spark arrester

– spark arrester and sealant joint

Spark Arrester

The muffler must be periodically purged
of accumulated carbon. See the mainte­nance chart.

64

V02C07Y

1. Spark arrester

2. Sealant joint

3. Muffler

1

3

– inner grill with wool
Remove all carbon deposit in the muf-

fler.
Remove carbon deposits from the

spark arrester using a brush.
NOTE: Use a soft brush and be careful

to avoid damaging spark arrester.

Installation

For installation, reverse the removal
procedure, paying attention to the fol­lowing details:

Check:
– wool and change if it deteriorate
– the spark arrester condition, it must

be free of breaks and holes. Replace
if necessary

Remove the old sealant joint and re­place by a new one. Use ULTRA COO­PER sealant (P/N 413 710 300).

V02C08Y

Be sure that wool is in place when in­serting grill.

Align grill properly in bottom of muffler
shell.

Fuel System

Air Filter Cleaning/Draining

Periodically inspect air filter box drain
plug for water or deposits.

V02A0CY

1. Air filter box

2. Drain plug

3. Clamp

132

NOTE: If vehicle is used in dusty area,
inspect more frequently than specified
in maintenance chart.

If water/deposits are found, squeeze
and remove the clamps. Pull drain
tubes out.

CAUTION: Do not start engine when
water is found in the drain tubes.

When water/deposits are found, the air
filter must be inspected/dried/replaced
depending on its condition.

Remove air filter as explained below.

Air Filter Removal
CAUTION: Never remove or modify

any component in the air box. Always
use genuine parts or suitable equiva­lent when replacing air filter and
foam. The engine carburetion is cali­brated to operate specifically with
these components. Otherwise, en­gine performance degradation or
damage can occur.

Remove seat.

65

Release latches and remove air filter
box cover.

1

Clean inside of air box.
Wash air filter and foam with warm

water and mild detergent as neces­sary.

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.

V02A0DY

1. Latches

2. Air filter box cover

2

Remove screw driver cap, push inside
of air box.

Loosen screw on clamp and remove
filter.

Remove foam.

31 2

V02A0EY

Air Filter Installation

Properly reinstall removed parts in the
reverse order of their removal.

Electrical

Battery

Cleaning

Clean battery post with a wire brush.
Apply dielectric grease on post to pro­tect against oxidation.

Removal

Disconnect negative BLACK cable first
then positive cable.

WARNING



Always respect this order for dis­assembly; disconnect BLACK
negative cable first. Oil or fuel va­pors can be present in engine
compartment and a spark may ig­nite them and possibly cause per­sonal injuries.

1. Clamp

2. Air filter and foam

3. Screw driver cap

66

Remove bolts retaining battery holder
and rack.

1

2

V02F01Y

1. Battery holder

2. Rack

2

1

Installation

Reinstall battery in vehicle. Fasten bat­tery holder.

WARNING



Connect positive RED cable first
then negative cable. Always con­nect RED positive cable first.

Fuses

If a fuse is damaged, replace it by one
of the same rating.

CAUTION: Do not use a higher rated
fuse as this can cause severe damage.

V02A0OY

1. Fan (15 A)

2. Charging system (25 A)

Bulb Replacement

Always check light operation after re­placement.

Headlight

If the headlight bulb is burnt:
– Remove front facia and control panel.
– Remove rubber boot and turn coun-

terclockwise bulb retaining ring.

Fuses are located under seat, between
engine and air box.

V02I05Y

1. Retaining ring

1

67

– Detach bulb and replace.
Properly reinstall removed parts in the

reverse order of their removal.

CAUTION: On applicable models,
never touch glass portion of an halo­gen bulb with bare fingers, it short­ens its operating life. If glass is
touched, clean it with isopropyl al­cohol which will not leave a film on
the bulb.

Adjust beam aiming as follows:
Turn knobs to adjust beam height ori-

entation to your convenience.

V02I06Y

1. Headlight

2. Beam height adjustment

21

V02A06Y

1. Lens

2. Screws

221

Indicator Lamp Replacement

Removal

Remove the control panel.
Unplug wires on indicator lamp.
Press both taps then push indicator

lamp out of hole.

1

1

Taillight

Unscrew lens screws to expose bulb.
Push bulb in and hold while turning

counterclockwise to release.
Install the new bulb by first pushing in

while turning clockwise.

68

V02A0FY

1. Tabs

Installation

For installation, reverse the removal
procedure.

Drive Train

Drive Chain

Adjust the drive chain frequently, see
the maintenance chart.

WARNING



Place ignition switch to OFF be­fore check, adjust or lubricate
drive chain.

Inspection

This ATV is equipped with O-ring
sealed permanently greased pins and
rollers. Before operating 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 cloth.

NOTE: Do not brush chain.
Lubricate only with the approved O-ring

chain lubricant. Other commercial chain
lubricants may contain solvent which
could damage the O-rings.

V02H03Y

1. Rear axle lock bolts

1

Insert adjuster lock through sprocket
hub and into eccentric axle housing.

Turn the axle ahead to increase or back
to decrease chain slack.

4

V02H04Y

2

31

Adjustment
NOTE: Always adjust drive chain with

the driver seated on the vehicle.
Select a level surface and set transmis-

sion to NEUTRAL.
Loosen rear axle lock bolts.

1. Drive chain

2. Adjuster lock

3. Sprocket hub

4. Eccentric axle housing

NOTE: Correct chain slack adjustment
is 19 to 25.4 mm (3/4 to 1 in) at the
midway between sprockets.

Tighten the rear axle lock bolts to 28
N•m (21 lbf•ft).

Lift rear of vehicle (without driver) and
recheck the chain slack. The chain slack
should be 44.5 to 51 mm (1-3/4 to 2 in).
If not, start again the drive chain adjust­ment.

69

Replacement

Suspension

With the chain installed on vehicle,
measure the distance between a span
of 13 links from pin center to pin cen­ter. Change drive chain if the distance
exceeds the service limits, see an au-
thorized Bombardier ATV dealer.

A

V02H01Y

A. 403 mm (15-7/8 in)

Drive Chain Slider

Check the drive chain slider frequently,
see the maintenance chart.

Replace the drive chain slider when it
is worn.

See an authorized Bombardier ATV deal­er for replacement.

Sprocket and Pinion

Inspection

Inspect shock absorber for oil leaks
and fasteners for tightness. See an au­thorized Bombardier ATV dealer as
necessary.

Adjustment

Front Shocks

WARNING



Adjust the both springs at the
same load. Ensure even adjust­ment. Uneven adjustment can
cause poor handling and loss of
stability, and/or control, and in­crease the risk of an accident.

Preload Adjustment

Turn the spring clockwise for a firmer
ride and rought road condition.

Turn the spring counterclockwise for a
light load and a smooth road condition.

Check the sprocket axle and pinion for
distortion.

1

2

V02H02Y

1. Good

2. Replace

CAUTION: Replace chain, sprocket
axle and pinion together to prevent
rapid chain and sprocket wear. In­stall a new retaining ring each time
the pinion is removed.

AA

V02J02Y

A. Same length

Rear Shock

WARNING



The rear shock includes a damper
unit that contains high pressure
nitrogen gas. Do not attempt to

diassemble or dispose of the
damper, see an authorized Bom-

bardier ATV dealer.

70

Preload Adjustment:

–To reduce:

• Turn the shock spring adjuster
counterclockwise for a light load
and smooth road condition.

– To increase:

• Turn the shock spring adjuster
clockwise for a firmer ride and
rought road condition.

Rebound Damping:
–To reduce:

• Turn the shock adjuster counter­clockwise for a light load and
smooth road condition.

– To increase:

• Turn the shock adjuster clock­wise for a firmer ride and rought
road condition.

V02J03Y

1. Adjuster

1

NOTE: The adjuster tool is included in
the tool kit.

Compression Damping:
–To reduce:

• Turn the damper adjuster coun­terclockwise for a light load and
smooth road condition.

– To increase:

• Turn the damper adjuster clock­wise for a firmer ride and rought
road condition.

V02J04Y

1. Adjuster

1

Tires/Wheels

Tire Pressure

WARNING



Tire pressure greatly affects vehi­cle handling and stability. Under­pressure may cause tire to deflate
and rotate on wheel. Overpressure
may burst the tire. Always follow
recommended pressure. Since tires
are low-pressure types, a manual
pump should be used.

Check pressure when tires are COLD
before 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

MINIMUM

Although the tires are specifically de­signed for off-road use, a flat may still
occur. Therefore, it is recommended
to carry a tire pump and a repair kit.

35 kPa
(5 PSI)

21 kPa
(3 PSI)

35 kPa
(5 PSI)

21 kPa
(3 PSI)

71

Tire/Wheel Condition

Front Fender

Check tire for damage and wear. Re­place if 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 kept in a
specific direction for proper operation.

Wheel Removal

Loosen nuts then lift vehicle. Place a sup­port under vehicle, as shown. Remove
nuts then remove wheel. At installation,
it is recommended to apply anti-seize lu­bricant on threads. Gently tighten nuts in
a criss-cross sequence then apply a final
torque of 52.5 N•m (39 lbf•ft).

Wheel Bearing Condition

Push and pull the wheels from the up­per edge to feel the play. See an autho­rized Bombardier ATV dealer if there is
any play.

Check tightness of fasteners and con­dition of front fender for cracks or oth­er damage. Properly retighten fasten­ers as necessary and have front fender
replaced if damaged.

WARNING



Never remove the front fenders.
The important labels are applied
on the front fenders. Operating
without front fender, increases
your chances of severe injury in
the event of an accident.

Fasteners

Check fastener condition and tight­ness on the vehicle. Retighten as re­quired.

Seat Latch

Brake

Front and Rear Brakes

The front and rear brakes are hydraulic
disc types. These brakes are self- ad­justing and require no adjustment.
Check brake line fittings tightness be­fore every ride.

Body/Frame

Engine Area

Check engine area for any damage and
leaks. Ensure all hose clamps are prop­erly secured and no hose is cracked,
kinked or otherwise damaged. Inspect
muffler, battery and reservoir fastening
devices. Check electrical connections
for corrosion and tightness. Replace or
have damaged parts repaired.

Skid Plate

Remove seat and check latch mecha­nism and pin for wear. See an autho­rized Bombardier ATV dealer for parts
replacement if damaged.

Frame

Check frame for cracks or other dam­age. See an authorized Bombardier
ATV dealer for replace or repair.

Vehicle Cleaning and Protection

Painted parts which are damaged
should be properly repainted to pre­vent rust.

When required, wash the body with
hot water and soap (only use mild de­tergent). Apply non-abrasive wax.

CAUTION: Never clean plastic parts
with strong detergent, degreasing
agent, paint thinner, acetone, etc.

Check tightness of fasteners and con­dition of plate for cracks or other dam­age. Properly retighten fasteners as
necessary and have skid plate re­placed if damaged.

72

CARGO AND TRANSPORTATION

While reading this guide, remember that:

WARNING



Indicates a potential hazard that could result in serious injury or death.

Cargo

WARNING



This vehicle is not designed or
manufactured to carry cargo or
tow a trailer. If you decide to add
accessories to allow you to carry
cargo or tow a trailer, use com­mon sense.

When cargoing vehicle, respect these
maximum loads.

Transportation

When transporting a vehicle, secure
vehicle to trailer with suitable tie­downs. Using ordinary ropes is not
recommended.

WARNING



CAUTION: Attaching vehicle at oth­er locations may damage the vehi­cle.

Never tip this vehicle on end for
transporting. We recommend
that you carry the vehicle in its
normal operating position (on all
four wheels).

Follow these procedure:
– Place the fuel valve to OFF position.
– Select the parking device and place

st

the transmission in 1

– Secure the vehicle, using the appro-

priate areas. See the following illus­tration.

gear.

V02A0IY

WARNING



Do not tow this vehicle behind a
car or other vehicle.

73

TROUBLESHOOTING

SYMPTOM:

Engine does not turn

Possible causes What to do

1. Ignition switch is in the OFF

Place switch in the ON position.

position.

2. Transmission is not set on the
NEUTRAL.

3. Weak battery or loose
connections.

Set transmission either in NEUTRAL or squeeze
the clutch lever.

Check connections and terminals condition. Have
the battery checked. Contact an authorized
Bombardier ATV dealer.

4. Engine stop switch is in OFF

Place switch in the ON position.

position.

SYMPTOM:

Engine turns over but fails to start

Possible causes What to do

1. Mixture not rich enough to
start cold engine.

2. Flooded engine (spark plugs

Check fuel tank level and check starting procedure,
particularly use of the choke.

Refer to SPECIAL PROCEDURES.

wet when removed).

3. No fuel to the engine (spark
plugs dry when removed).

Check fuel tank level; turn fuel valve to ON (also try
on RES). A failure of the fuel pump or carburetor
may have occurred. Contact an authorized
Bombardier ATV dealer.

4. Spark plug/ignition (no spark). Check ignition fuse condition. Remove spark plugs

then reconnect to spark plug caps. Check that
ignition switch is at the ON position. Start engine
with spark plugs grounded to engine away from
spark plug holes. If no spark appears, replace spark
plugs. If trouble persists, contact an authorized
Bombardier ATV dealer.

5. Engine compression. If no pulsating resistance is felt, it suggests a major

loss of compression. Contact an authorized
Bombardier ATV dealer.

SYMPTOM:

Engine lacks acceleration or power

Possible causes What to do

1. Fouled or damaged spark plug. Check item Engine turns over but fails to start.

2. Lack of fuel to engine. Check item Engine turns over but fails to start.

3. Carburetor adjustments. Contact an authorized Bombardier ATV dealer.

4. Engine is overheating. Check Engine Overheat in SPECIAL

74

PROCEDURES. If overheating persists, contact an
authorized Bombardier ATV dealer.

SYMPTOM:

Engine backfire

Possible causes What to do

1. Faulty spark plugs

See Engine turns over but fails to start.

(carbon accumulation).

2. Engine is running too hot. See Engine lacks acceleration or power.

3. Ignition timing is incorrect or

Contact an authorized Bombardier ATV dealer.
there is an ignition system
failure.

4. Improper carburetor setting. Contact an authorized Bombardier ATV dealer.

SYMPTOM:

Engine misfire

Possible causes What to do

1. Fouled/damaged/worn spark
plugs.

Clean/verify spark plugs and heat range. Replace
as required.

2. Water in fuel. Drain fuel system and refill with fresh fuel.

SYMPTOM:

Vehicle cannot reach full speed

Possible causes What to do

1. Engine. See Engine lacks acceleration or power.

2. Parking device. Ensure parking lever lock is completely removed.

SYMPTOM:

Transmission does not shift smoothly

Possible causes What to do

1. Engine/transmission oil level is
low.

Refill oil tank with recommended oil at the proper
level.

2. Transmission shifting system. Try depressing the throttle lever more while

shifting.

3. Improper oil type. Drain oil in engine and use recommended oil only.

4. Transmission. See an authorized Bombardier ATV dealer.

75

SPECIFICATIONS

BOMBARDIER DS

VEHICLE MODEL NUMBER 7404

ENGINE

Type

Number of cylinder Single cylinder
Number of valve 4 bucket tappet-operated valves
Displacement 652 cc (39.7 cu. in)
Compression ratio 9.7:1

Dry sump lubrication by oil pump with replaceable

Lubrication

Decompressor Automatic

Exhaust system

TRANSMISSION

Clutch 1 multi-disc
Transmission Integrated 5 speeds constant mesh transmission.

COOLING

Type Liquid cooled with integrated water pump

654 BOMBARDIER-ROTAX, 4 stroke,

double overhead camshaft, bush chain drive

oil filter (lubrication of engine and transmission

simultaneously)

Bombardier, stainless header pipe painted steel

muffler

Radiator Front mounted with thermostatic fan

CARBURETION

Carburetor make and type

Idle speed ± 100 1300 RPM

ELECTRICAL

Magneto generator make and type Denso, 290 W

Ignition type

Ignition timing Not adjustable
Engine RPM limiter 7700 RPM (any gear in forward)
Spark plug make and type NGK DR8EA
Number of spark plug 2
Spark plug gap 0.6 to 0.7 mm (0.024 to 0.027 in)
Battery 12 V, 13 Ah. Dry type battery.

Starting system

Constant depression type with manual choke

Breakerless high voltage condenser ignition

system with electronic spark advance

Electric start. Start in any gear

(with clutch applied or on NEUTRAL)

Mikuni BSR42.

Headlight 60/55 W, H4V
Taillight and brake light 8/27 W, 1157

76

FUSES

Fan 15 A

Charging system 25 A

DRIVE TRAIN

Rear axle Chain driven/solid axle

SUSPENSION

Front

Type Independent suspension — double A-arm

Travel 305 mm (12 in)

Type Rigid swing-arm

Rear

Travel 292 mm (11.5 in)

TIRES

Front 34 kPa (5 PSI) recommended

Pressure

Rear 34kPa (5 PSI) recommended

Front 533 OD x 178 W x 254 ID mm (21 x 7 x10 in)

Size

Rear 508 OD x 279 W x229 ID mm (20 x 11 x 9 in)

Front 290 kg (638 lb) maximum

Load

Rear 340 kg (748 lb) maximum

WHEELS

Wheel nut torque 52.5 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

DIMENSIONS

Dry mass 209 kg (460 lbs)

Overall length 1956 mm (77 in)

Front 1219.2 mm (48 in)

Overall width

Rear 1270 mm (50 in)

Overall height 1181 mm (46.5 in)

Wheel base 1321 mm (52 in)

Front 1048 mm (41 in)

Wheel track

Rear 994 mm (34 in)

Turning radius 2.4 m (8 ft)

Total toe-out (vehicle on ground) 2.6 mm ± 0.5 mm (0.102 in ± 0.0197 in)

Ground clearance

Front and

under engine

121 mm (4-3/4 in)

Rear axle 105 mm (4-1/8 in)

77

LIQUIDS

Oil type (engine and transmission)

Coolant

SAE 10W40, 4-stroke mineral-based engine oil.

API classification SH or SJ. Do not use synthetic

or synthetic blend oil

Ethyl glycol/water mix (60% coolant, 40% water).

Use coolant specifically designed for aluminum

engines

Fuel

Hydraulic brake Brake fluid, DOT 4

CAPACITIES

Vehicle range

Fuel tank

Engine/transmission oil 3.1L (3.3 U.S. quarts)
Coolant 1.75L (1.9 U.S. quarts)

OD = outside diameter
ID = inside diameter

Type Super unleaded gasoline

Octane 91 (R + M)/2 or higher

Approximately 3 hours depending on many

factors such as temperature and operating

conditions

12.2 L (3.5 U.S. gal) including approximately 2.4 L
(0.8 U.S. gal) reserve

W = width

LEDS = light-emitting diodes
dia. = diameter
Because of our ongoing commitment to product quality and innovation, Bombar-

dier reserves the right, at any time, to make changes in design and specifications
and/or to make additions to, or improvements in its products without imposing
any obligation upon itself to install them on its products previously manufactured.

78

SI* METRIC INFORMATION GUIDE

BASE UNITS

DESCRIPTION

length .................................................

mass...................................................

force ...................................................

liquid ...................................................

temperature........................................

pressure..............................................

torque .................................................

land velocity........................................

PREFIX

kilo ......................

centi....................

milli .....................

micro...................

TO CONVERT

in.........................................................

in.........................................................

in² .......................................................

in³ .......................................................

ft .........................................................

oz........................................................

lb.........................................................

lbf .......................................................

lbf•in ..................................................

lbf•ft ...................................................

lbf•ft ...................................................

PSI ......................................................

imp. oz................................................

imp. oz................................................

imp. gal...............................................

imp. gal...............................................

U.S. oz ................................................

U.S. gal ...............................................

MPH ...................................................

Fahrenheit...........................................

Celsius................................................

hp .......................................................

SYMBOL

k........................

c........................

m.......................

µ........................

CONVERSION FACTORS

UNIT

meter.................................

kilogram.............................

newton ..............................

liter.....................................

Celsius...............................

kilo pascal ..........................

newton-meter....................

kilometer per hour .............

PREFIXES

MEANING

one thousand.....................

one hundredth of...............

one thousandth of .............

one millionth of..................

TO



mm ....................................

cm......................................

cm² ....................................

cm³ ....................................

m .......................................

g.........................................

kg.......................................

N ........................................

N•m ...................................

N•m ...................................

lbf•in .................................

kPa.....................................

U.S. oz ...............................

mL .....................................

U.S. gal ..............................

L.........................................

mL .....................................

L.........................................

km/h...................................

Celsius...............................

Fahrenheit..........................

kW .....................................

SYMBOL

m
kg
N
L
°C
kPa
N•m
km/h

VALUE

1000

0.01

0.001

0.000001

MULTIPLY BY

25.4

2.54

6.45

16.39

0.3

28.35

0.45

4.4

0.11

1.36
12

6.89

0.96

28.41

1.2

4.55

29.57

3.79

1.61
(°F - 32) ÷ 1.8
(°C x 1.8) + 32
.75

* The international system of units abbreviates SI in all languages.



To obtain the reverse sequence, divide by the given factor. To convert milli­meters to inches, divide by 25.4.

NOTE: Conversion factors are rounded off to 2 decimals for easier use.

79

ATV MODEL No. ________________________________________________
VEHICLE

IDENTIFICATION NUMBER (V.I.N.) ________________________________

ENGINE

IDENTIFICATION NUMBER (E.I.N.) ________________________________

IDENTIFICATION NUMBER (E.I.N.) ________________________________

Purchase Date

year month day

Warranty Expiry Date

year month day

To be completed by the dealer at the time of the sale

DEALER IMPRINT AREA

Please verify with your selling dealer to ensure your ATV has been regis­tered with Bombardier.

80

CHANGE OF ADDRESS

CHANGE OF ADDRESS

If your address has changed, be sure to fill out and mail the card provided on this
page.

Such notification is likewise necessary for your own safety even after expiration
of the original warranty, since Bombardier will be in a position to contact you if
correction to your ATV becomes necessary.

NOTE: This card is strictly for change of address only.



CHANGE OF ADDRESS

VEHICLE IDENTIFICATION NUMBER

Model Number Vehicle Identification Number (V.I.N.)

OLD ADDRESS: ______________________________________________

NEW ADDRESS: ______________________________________________



NAME

______________________________________________

NO. STREET APT

______________________________________________

CITY STATE/PROVINCE ZIP/POSTAL CODE

______________________________________________

COUNTRY

NAME

______________________________________________

NO. STREET APT

STOLEN UNITS

In the event that your ATV is stolen, you should notify your area’s distributor
warranty department of such.

Please provide your name, address, phone number, vehicle identification num­ber and date it was stolen.

Bombardier will provide a list of stolen units to all ATV dealers on a monthly basis
to aid in recovery of such units to their owners.

______________________________________________

CITY STATE/PROVINCE ZIP/POSTAL CODE

______________________________________________

COUNTRY

81

CHANGE OF ADDRESS

N

OTE: This card is strictly for change of address only.

CHANGE OF ADDRESS



AFFIX

PROPER

POSTAGE

BOMBARDIER

Recreational Products
ATV Warranty
Valcourt (Quebec)
Canada J0E 2L0

CHANGE OF ADDRESS

If your address has changed, be sure to fill out and mail the card provided on this
page.

Such notification is likewise necessary for your own safety even after expiration
of the original warranty, since Bombardier will be in a position to contact you if
correction to your ATV becomes necessary.

NOTE: This card is strictly for change of address only.



CHANGE OF ADDRESS

VEHICLE IDENTIFICATION NUMBER

Model Number Vehicle Identification Number (V.I.N.)

OLD ADDRESS: ______________________________________________

NEW ADDRESS: ______________________________________________



NAME

______________________________________________

NO. STREET APT

______________________________________________

CITY STATE/PROVINCE ZIP/POSTAL CODE

______________________________________________

COUNTRY

NAME

______________________________________________

NO. STREET APT

STOLEN UNITS

In the event that your ATV is stolen, you should notify your area’s distributor
warranty department of such.

Please provide your name, address, phone number, vehicle identification num­ber and date it was stolen.

Bombardier will provide a list of stolen units to all ATV dealers on a monthly basis
to aid in recovery of such units to their owners.

______________________________________________

CITY STATE/PROVINCE ZIP/POSTAL CODE

______________________________________________

COUNTRY

83

CHANGE OF ADDRESS

N

OTE: This card is strictly for change of address only.

CHANGE OF ADDRESS



AFFIX

PROPER

POSTAGE

BOMBARDIER

Recreational Products
ATV Warranty
Valcourt (Quebec)
Canada J0E 2L0

CHANGE OF ADDRESS

If your address has changed, be sure to fill out and mail the card provided on this
page.

Such notification is likewise necessary for your own safety even after expiration
of the original warranty, since Bombardier will be in a position to contact you if
correction to your ATV becomes necessary.

NOTE: This card is strictly for change of address only.



CHANGE OF ADDRESS

VEHICLE IDENTIFICATION NUMBER

Model Number Vehicle Identification Number (V.I.N.)

OLD ADDRESS: ______________________________________________

NEW ADDRESS: ______________________________________________



NAME

______________________________________________

NO. STREET APT

______________________________________________

CITY STATE/PROVINCE ZIP/POSTAL CODE

______________________________________________

COUNTRY

NAME

______________________________________________

NO. STREET APT

STOLEN UNITS

In the event that your ATV is stolen, you should notify your area’s distributor
warranty department of such.

Please provide your name, address, phone number, vehicle identification num­ber and date it was stolen.

Bombardier will provide a list of stolen units to all ATV dealers on a monthly basis
to aid in recovery of such units to their owners.

______________________________________________

CITY STATE/PROVINCE ZIP/POSTAL CODE

______________________________________________

COUNTRY

85

CHANGE OF ADDRESS

N

OTE: This card is strictly for change of address only.

CHANGE OF ADDRESS



AFFIX

PROPER

POSTAGE

BOMBARDIER

Recreational Products
ATV Warranty
Valcourt (Quebec)
Canada J0E 2L0

CHANGE OF ADDRESS

If your address has changed, be sure to fill out and mail the card provided on this
page.

Such notification is likewise necessary for your own safety even after expiration
of the original warranty, since Bombardier will be in a position to contact you if
correction to your ATV becomes necessary.

NOTE: This card is strictly for change of address only.



CHANGE OF ADDRESS

VEHICLE IDENTIFICATION NUMBER

Model Number Vehicle Identification Number (V.I.N.)

OLD ADDRESS: ______________________________________________

NEW ADDRESS: ______________________________________________



NAME

______________________________________________

NO. STREET APT

______________________________________________

CITY STATE/PROVINCE ZIP/POSTAL CODE

______________________________________________

COUNTRY

NAME

______________________________________________

NO. STREET APT

STOLEN UNITS

In the event that your ATV is stolen, you should notify your area’s distributor
warranty department of such.

Please provide your name, address, phone number, vehicle identification num­ber and date it was stolen.

Bombardier will provide a list of stolen units to all ATV dealers on a monthly basis
to aid in recovery of such units to their owners.

______________________________________________

CITY STATE/PROVINCE ZIP/POSTAL CODE

______________________________________________

COUNTRY

87

CHANGE OF ADDRESS

N

OTE: This card is strictly for change of address only.

CHANGE OF ADDRESS



AFFIX

PROPER

POSTAGE

BOMBARDIER

Recreational Products
ATV Warranty
Valcourt (Quebec)
Canada J0E 2L0

WARNING



Indicates a potential hazard that could result in serious injury or death.