table of contents 0

Section 01
SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
0
SERVICE TOOLS....................................................................................................................
01-02-1
SERVICE PRODUCTS ............................................................................................................
01-03-1
VMR2004_033_01_01ATOC.FM
01-01-1
Section 01
SERVICE TOOLS
SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
0
This is a list of tools to properly service ATV vehicles. If you need to replace or add to your tool inventory,
these items can be ordered through the regular parts channel.
NEW
Following mention points out new tool:
VMR2004_002_01_02A.FM
01-02-1
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Small Hose Pincher
295 000 076
All Models
MANDATORY
Valve Spring Compressor
529 035 724
Insertion Jig Handle
420 877 650
All Models
RECOMMENDED
Large Hose Pincher
529 032 500
Fuel System Pressure Tester
529 033 100
Vacuum/Pressure Pump
529 021 800
All Models
Float Level Gauge
529 035 520
RECOMMENDED
1
2
3
4
Low Speed Screw Adjuster
529 035 732
Leak Down Tester
529 035 661
Carburetor Kit
404 112 000
01-02-2
VMR2004_002_01_02A.FM
Section 01
SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Terminal Remover
Snap-On TT660-4
Shock Tool
529 035 636
Multimeter
529 035 868
All Models
Oil Pressure Adapter
529 035 652
RECOMMENDED
All Models
RECOMMENDED
NEW
Handle Grip Insertion Tool
529 035 897
NEW
Crimp Plier
529 035 730
Oil Pressure Gauge
529 035 709
Connection Tool
529 035 714
VMR2004_002_01_02A.FM
01-02-3
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Caillau Pliers
295 000 054
Ring Compressor
Snap-On RC980
CV Boot Clamp Installation and
Removal Tool
295 000 069
DS 650/Baja/X
Outlander 330
Outlander 400
Quest 500/650
Traxter
Cable Luber
529 035 738
DS 650/Baja/X
Outlander 330
Outlander 400
Quest 500/650
Rally 200
MANDATORY
Valve Stem Seal Pliers
Snap-On YA 8230
Crankshaft Protector
420 876 557
DS 650/Baja/X
Outlander 330
Outlander 400
Quest 500/650
Rally 200
RECOMMENDED
Crankshaft Locking Bolt
529 035 617
MANDATORY
DS 650/Baja/X
Youth models
Outlander 330
Outlander 400
Quest 500/650
Traxter
RECOMMENDED
Digital/Inductive Type Tachometer
529 014 500
Flywheel Puller
529 035 748
Valve Spring Compressor Cup
529 035 764
01-02-4
VMR2004_002_01_02A.FM
Outlander 330
Outlander 400
Quest 500/650
Rally 200
Traxter
RECOMMENDED
41 mm Socket
PROTO 5541
Outlander 330
Outlander 400
Quest 500/650
Traxter
MANDATORY
Exhaust Spring Installer/Remover
529 035 401
Outlander 330
Outlander 400
Quest 500/650
Traxter
RECOMMENDED
DS 650/Baja/X
Outlander 330
Outlander 400
Quest 500/650
Traxter
SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
RECOMMENDED
Section 01
Hub Puller
529 035 612
Outlander 330
Outlander 400
Quest 500/650
Rally 200
Needle Bearing Installer
(main shaft in crankcase)
529 035 762
RECOMMENDED
Shock Spring Disassembly Tool
529 035 504
Differential Spanner Socket
529 035 649
Backlash Measurement Tool
529 035 665
Choke Nut Tool
529 035 660
VMR2004_002_01_02A.FM
01-02-5
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Outlander 330
Outlander 400
Quest 500/650
MANDATORY
Oil Seal Installer
(crankshaft oil seal
on magneto cover)
529 035 759
Outlander 330
Outlander 400
Quest 500/650
RECOMMENDED
Bevel Gear Lock Pin/Driven Clutch
Expander
529 035 747
Oil Seal Installer
(shift shaft oil seal
on magneto cover)
529 035 758
Outlander 330
Outlander 400
Quest 500/650
Traxter
RECOMMENDED
Drive Clutch Puller
529 035 746
Torque Angle
Snap-On TA 36
DS 650/Baja/X
Outlander 330
Quest 500/650
RECOMMENDED
DS 650/Baja/X
Outlander 330
Outlander 400
MANDATORY
Water Pump Ceramic Seal Installer
529 035 766
Engine Installation and
Removal Tool
529 035 619
Driven Clutch Holding Tool
529 035 771
Oil Seal Installer
(crankshaft oil seal on crankcase)
529 035 760
Needle Bearing Installer
(starter drive pinion in crankcase)
529 035 756
Valve Stem Seal Installer
529 035 687
01-02-6
VMR2004_002_01_02A.FM
SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
46 mm Socket for Crankshaft/
Driven Pulley
529 035 648
MANDATORY
Section 01
Rally 200
Traxter
Outlander 330
Outlander 400
Quest 500/650
Crankcase Support (CVT side)
529 035 754
RECOMMENDED
Needle Bearing Installer
(bevel gear shaft in crankcase)
529 035 763
Magneto Cover Removal Tool
529 035 622
UP to 2003 models
64 mm (2-1/2 in) Crow-foot
Rear Axle Nut
529 035 729
NEW
DS 650/Baja/X
MANDATORY
NEW
Valve Guide Installer
529 035 853
Quest 500/650
Rally 200
RECOMMENDED
Output Shaft Oil Seal Installer
529 035 941
Blind Hole Bearing Puller
Snap-On
VMR2004_002_01_02A.FM
MANDATORY
Clutch Basket Holder
529 035 618
Quest 500/650
Traxter
6 Pin Harness for Magneto
529 035 604
Rear Axle Key
529 035 951
01-02-7
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Front Knuckle Wear Ring Installer
529 035 637
UP to 2003 models
Front Hub Seal Installer
529 035 632
Brake Hub Remover
529 035 695
Clutch Shaft Bearing Installer
529 035 691
DS 650/Baja/X
Ball Joint Guide
529 035 705
RECOMMENDED
Shock Charging Tool
529 035 570
NEW
DS 650/Baja/X
RECOMMENDED
Clutch Shaft Seal Installer
529 035 693
Gas fill tool kit (needle type)
503 190 102
Ball Joint Drive
529 035 706
UP to 2003 models
Swing Arm Key
529 035 696
Rear Axle Wear Ring Installer
529 035 694
Rear Hub Seal Installer
529 035 634
01-02-8
VMR2004_002_01_02A.FM
SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Magneto Puller
(4-stroke engines)
529 035 798
DS 650/Baja/X
Primary Crankshaft Gear Puller
529 035 624
RECOMMENDED
Crankshaft Bushing Installer
529 035 689
ILLUSTRATION
NOT AVAILABLE
Valve Seat Remover/Installer
(4-stroke engines)
529 035 794
Oil Filter Rotor Puller
(4-stroke engines)
529 035 795
VMR2004_002_01_02A.FM
Youth models
MANDATORY
Flywheel Puller
(4-stroke engines)
529 035 792
Youth models
RECOMMENDED
Crankshaft Bearing Puller
(4-stroke engines)
529 035 791
Crankshaft Bushing Remover
529 035 688
Valve Gap Adjuster
(4-stroke engines)
529 035 793
MANDATORY
Section 01
Crankcase Puller
(2-stroke engines)
529 035 796
Crankcase Installer
(2-stroke engines)
529 035 797
01-02-9
Crankshaft Puller
(2-stroke engines)
529 035 799
Youth models
RECOMMENDED
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Bearing Puller Kit
(2-stroke engines)
529 035 800
Camshaft Locking Tool
529 035 926
Valve Guide Remover
529 035 924
Outlander 330
Outlander 400
Trailing Arm Socket
529 035 925
MANDATORY
Piston Circlip Installer
529 035 921
Outlander 330
Outlander 400
RECOMMENDED
Piston Ring Compressor
529 035 919
Crankshaft Plain Bearings
Remover/Installer
529 035 917
Engine Lifting Tool
529 035 898
Crankshaft Support (MAG side)
529 035 916
Clutch Holding Tool
529 006 400
01-02-10
VMR2004_002_01_02A.FM
Section 01
SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Oil Seal Protector
529 035 935
Outlander 330
Outlander 400
RECOMMENDED
Wear Ring Installer
(rear drive shafts)
529 035 915
RECOMMENDED
Starter drive needle bearing
installer
529 035 934
Outlander 330
Outlander 400
Quest 500/650
MANDATORY
Wear Ring Installer
(front drive shafts)
529 035 927
Balancer Shaft Oil Seal Installer
529 035 933
Adaptor Kit for Shock Spring
Remover (P/N 529 035 504)
529 035 928
Trailing Arm Bearing
Remover/Installer (wheel side)
529 035 918
Drive Clutch Holding Tool
529 035 745
Trailing Arm Bearing
Remover/Installer (frame side)
529 035 920
Bearing Alignment Tool
529 035 806
Trailing Arm Bearing Removal
Support
529 035 922
VMR2004_002_01_02A.FM
01-02-11
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Quest 500/650
RECOMMENDED
Rally 200
MANDATORY
Crankcase Plain Bearing
Remover/Installer (MAG side)
529 035 753
Lifting Ring
529 035 770
Oil Seal Installer
(main shaft oil seal on crankcase)
529 035 761
Quest 500/650
RECOMMENDED
Crankcase Support
(MAG side)
529 035 755
Clutch Holding Tool
529 035 862
Oil Seal Installer
(water pump shaft oil seal)
529 035 757
Piston Circlip Installer
529 035 765
Clutch Support
529 035 863
51 mm (2 in) Open Wrench
529 035 866
Crankcase Plain Bearing
Remover/Installer (CVT side)
529 035 752
51 mm (2 in) Crow-Foot
529 035 884
01-02-12
VMR2004_002_01_02A.FM
Section 01
SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Clutch Holding Support
529 035 864
Crankshaft Oil Seal Installer
529 035 847
Needle Bearing Installer
529 035 858
Rally 200
Water Pump Oil Seal Installer
529 035 849
Rally 200
Shifter Oil Seal Installer
529 035 851
RECOMMENDED
Piston Circlip Installer
529 035 859
RECOMMENDED
Crankshaft Plain Bearing
Remover/Installer
529 035 855
Allen Wrench
529 035 861
Valve Guide Remover
529 035 852
Rear Axle Bearing Puller
420 276 930
Gearbox Oil Seal Installer
529 035 854
Magneto Puller
(use bolt from magneto puller
P/N 529 035 748)
529 035 883
VMR2004_002_01_02A.FM
01-02-13
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 02 (SERVICE TOOLS)
Lifting Bar
529 035 610
Crimping Tool
(for AMP connectors)
295 100 164
Crankshaft Locking Bolt
529 035 645
Spanner Tool for Clutch Basket
529 035 647
T-Harness for Solenoids Dianosis
529 035 653
01-02-14
Traxter
Lifting Ring
529 035 644
UP to 2000
RECOMMENDED
Traxter
MANDATORY
Jumper for Self Diagnosis
529 035 605
Front Suspension Spacer Bar
529 035 611
Valve Spring Compressor Cup
529 035 725
VMR2004_002_01_02A.FM
Section 01
SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
SERVICE PRODUCTS
0
This is a list of products to properly service ATV vehicles. If you need to replace or add to your tool inventory, these
items can be ordered through the regular parts channel.
Following mention points out new tool:
VMR2004_003_01_03A.FM
NEW
01-03-1
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
Loctite® 567
Pipe Sealant
(250 mL)
293 800 013
Loctite® 243
Medium-Strength Threadlocker
(10 mL) (blue)
293 800 060
Suspension Synthetic Grease
(400 g)
293 550 033
Synthetic Grease
(400 g)
293 550 010
Loctite® 609
Retaining Compound Loctite RC
(10 mL) (green)
413 703 100
All Models
All Models
Bombardier ATV Tire Sealant
(946 mL)
715 000 130
Loctite® Primer
Primer N
128 g (5 oz)
293 800 041
Brake Fluid DOT 4
(354 mL)
293 600 062
Loctite® Anti-Seize Lubricant
(236 mL)
293 800 070
01-03-2
VMR2004_003_01_03A.FM
Section 01
SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
BOMBARDIER LUBE
(12 x 14 oz)
293 600 016
Bombardier Fuel Stabilizer
(12 x 8 oz)
413 408 600
All Models
All Models
Bombardier Premixed Coolant 50/50
- 37°C (- 35°F)
(16 x 1 L)
293 600 038
Bombardier Storage Oil
(350 g spray can)
(12 x 350 g)
Canada: 413 711 600
U.S.:
413 711 900
VMR2004_003_01_03A.FM
Bombardier Pulley Flange Cleaner
(320 g)
413 711 809
Bombardier Heavy Duty Cleaner
293 110 001 (400 g)
293 110 002 (4 L)
01-03-3
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
DS 650/Baja/X
Quest 500/650
Traxter
Loctite® 271
High Strength Threadlocker
(10 mL) (red)
293 800 005
Bombardier Plastic & Vinyl Cleaner
(6 x 1 L)
413 711 200
All Models
Bombardier Synthetic
4-Stroke Oil 5W-40
(12 x 1 L)
293 600 039
Air Filter Cleaner
(2 L)
293 600 059
Loctite® 277
High Strength Retaining Compound
(10 mL) (red)
293 800 073
Loctite® 518
Paste Gasket
Gasket Eliminator (50 mL)
293 800 038
Rally 200
Air Filter Oil
(1 L)
293 600 058
Silicone Dielectric Grease
(3 oz)
293 550 004
Loctite® 384
Thermally Conductive Adhesive
(300 mL)
293 800 099
CAUTION: This product must be
stored at 5°C (41°F).
Loctite® 5150
Clear Silicone Sealant
(300 mL)
293 800 086
01-03-4
VMR2004_003_01_03A.FM
Section 01
Bombardier Chaincase Oil
(16 x 250 mL)
413 801 900
SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
Rally 200
Loctite® Chisel
Gasket/Paint Remover
510 g (18 oz)
413 708 500
DS 650/Baja/X
Quest 500/650
Rally 200
Traxter
Bombardier Synthetic Chaincase Oil
(12 x 355 mL)
413 803 300
Cable Lubricant
(400 g)
293 600 041
DS 650/Baja/X
Outlander 330
Outlander 400
Rally 200
Traxter
Synthetic Grease
(60 g)
293 550 019
DS 650/Baja/X
Outlander 330
Outlander 400
Quest 500/650
Traxter
Loctite® 648
High Temperature and Strength
Retaining Compound
(5 mL) (green)
413 711 400
VMR2004_003_01_03A.FM
01-03-5
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
High Temp RTV Silicone
ULTRA COPPER
(85 g)
413 800 090
Loctite® 406
Instant Adhesive
(must be used with tapered tip)
(20 g)
293 800 095
Quest 500/650
Traxter
DS 650/Baja/X
Kayaba shock absorber oil
293 600 035
Smoothflow Tapered Tips
16ga #511 rtt-b
(not sold by Bombardier),
call EFD Inc, 1 800 556-3484
Loctite® 5900
RTV Silicone Sealant
(300 mL)
293 800 066
Marvin shock absorber oil
Outlander 330
Outlander 400
503 190 103
Loctite® Maxi-Coat
Heavy Duty Rustproofing
(340 g)
293 800 105
01-03-6
VMR2004_003_01_03A.FM
Section 01
Loctite®
5910
Flange Sealant
(300 mL)
293 800 081
Loctite® 515
Paste Gasket
Gasket Eliminator
(50 mL)
413 702 700
SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 03 (SERVICE PRODUCTS)
Outlander 330
Outlander 400
Quest 500/650
Rally 200
Traxter
Molykote G-n Paste
(50 g)
711 297 433
DS 650/Baja/X
Traxter
Outlander 330
Outlander 400
Traxter
Molykote PG 54
(10 g)
420 899 763
111
Outlander 330
Outlander 400
Quest 500/650
Traxter
Bombardier Differential Oil
(946 mL)
293 600 043
VMR2004_003_01_03A.FM
Molykote 111
(150 g)
413 707 000
DS 650/Baja/X
Rally 200
Traxter
Super Lube Grease
293 550 030
01-03-7