2005 Bombardier Rally 200 ATV Repair Manual

2005 Shop Manual RALLY™ 200 BOMBARDIER RECREATIONAL PRODUCTS INC.

Legal deposit: National Library of Quebec National Library of Canada 2004 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. © Bombardier Recreational Products Inc. 2004 Technical Publications Bombardier Recreational Products Inc. Valcourt (Québec) Canada Printed in Canada ®TM Registered trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates. † Bombardier and sprocket design are trademarks of Bombardier Inc. used under license. BOMBARDIER LUBE ® Rally™ This document contains the trademarks of the following companies: Loctite ® is a registered trademark of Loctite Corporation Molykote © is a registered trademark of Dow Corning Corporation Snap-on © is a registered trademark of Snap-on Tools Corporation Simple Green © is a registered trademark of Sunshine Markets Inc.

TABLE OF CONTENTS SAFETY NOTICE .................................................................................. VIII INTRODUCTION ................................................................................... IX VEHICLE SERIAL NUMBER LOCATION ......................................................................... IX ENGINE SERIAL NUMBER LOCATION .......................................................................... IX ARRANGEMENT OF THE MANUAL ............................................................................. IX LIST OF ABBREVIATIONS USED IN THIS MANUAL ........................................................... X GENERAL INFORMATION........................................................................................ XIII ILLUSTRATIONS AND PROCEDURES ......................................................................... XIII SELF-LOCKING FASTENERS PROCEDURE ................................................................... XIII LOCTITE ® APPLICATION PROCEDURE ........................................................................ XIII TIGHTENING TORQUES ......................................................................................... XVI 01 MAINTENANCE 01 – MAINTENANCE CHART ....................................................................................... 1 NOISE EMISSION CONTROL SYSTEM REGULATION ................................................... 1 EMISSION REQUIREMENTS......................................................................................... 1 MAINTENANCE CHART ....................................................................................... 2 02 – MAINTENANCE ................................................................................................ 5 SPECIAL PROCEDURES.............................................................................................. 5 AIR BOX................................................................................................................ 6 AIR FILTER ............................................................................................................. 6 BOLTS, FASTENERS AND NUTS .................................................................................... 7 ENGINE OIL AND FILTER ............................................................................................ 7 ENGINE OIL PRESSURE REGULATOR .............................................................................. 9 OIL STRAINER......................................................................................................... 9 SPARK ARRESTER .................................................................................................... 9 TIRES AND WHEELS ................................................................................................ 10 ENGINE AREA ........................................................................................................ 10 VEHICLE CLEANING ................................................................................................. 10 03 – STORAGE/PRESEASON PREPARATION ................................................................. 11 STORAGE ..................................................................................................... 11 FUEL STABILIZER .................................................................................................... 11 ENGINE LUBRICATION .............................................................................................. 11 RAGS INTO INLET AND OUTLET HOSES OF CVT ................................................................ 12 VEHICLE CLEANING AND PROTECTION .......................................................................... 12 COOLANT DENSITY ................................................................................................. 13 PRESEASON PREPARATION ............................................................................... 14 02 ENGINE 01 – TROUBLESHOOTING........................................................................................ 17 COOLING SYSTEM .......................................................................................... 17 MAGNETO SYSTEM......................................................................................... 17 LUBRICATION ................................................................................................ 18 CYLINDER AND HEAD ...................................................................................... 19 CRANKSHAFT ................................................................................................ 20 GEARBOX ..................................................................................................... 20 CVT ............................................................................................................. 21 ENGINE GENERAL ........................................................................................... 23 02 – LEAK TEST .................................................................................................... 27 VERIFICATION ........................................................................................................ 27 LEAK TEST PROCEDURE ........................................................................................... 27 I

TABLE OF CONTENTS 03 – REMOVAL AND INSTALLATION........................................................................... 31 ENGINE SYSTEM ............................................................................................ 32 EXHAUST SYSTEM.......................................................................................... 33 GENERAL ............................................................................................................. 34 ENGINE ............................................................................................................... 34 ENGINE SPROCKET ................................................................................................. 41 ANTI-VIBRATION SYSTEM .......................................................................................... 41 EXHAUST PIPE ...................................................................................................... 42 MUFFLER ............................................................................................................. 42 TRANSMISSION LEVER ............................................................................................. 43 04 – COOLING SYSTEM .......................................................................................... 45 WATER PUMP ................................................................................................ 46 COOLING SYSTEM .......................................................................................... 47 GENERAL ............................................................................................................. 48 COOLING SYSTEM LEAK TEST..................................................................................... 48 INSPECTION.......................................................................................................... 48 DRAINING THE SYSTEM ............................................................................................ 49 COOLANT REPLACEMENT ......................................................................................... 49 THERMOSTAT ........................................................................................................ 50 WATER TEMPERATURE SWITCH .................................................................................. 51 WATER PUMP HOUSING ........................................................................................... 52 WATER PUMP OIL SEAL ............................................................................................ 54 WATER PUMP IMPELLER ........................................................................................... 55 WATER PUMP SHAFT ............................................................................................... 55 RADIATOR CAP ...................................................................................................... 56 RADIATOR ............................................................................................................ 56 COOLANT TANK ..................................................................................................... 56 BLOCK HEATER ...................................................................................................... 57 05 – MAGNETO SYSTEM......................................................................................... 61 MAGNETO SYSTEM......................................................................................... 62 GENERAL ............................................................................................................. 63 MAGNETO COVER................................................................................................... 63 STATOR AND TRIGGER COIL ....................................................................................... 64 ROTOR ................................................................................................................ 65 SPRAG CLUTCH...................................................................................................... 67 STARTER .............................................................................................................. 68 06 – LUBRICATION SYSTEM ..................................................................................... 71 ENGINE OIL FLOW CHART ......................................................................................... 73 GENERAL ............................................................................................................. 74 ENGINE OIL PRESSURE TEST ...................................................................................... 74 OIL AND OIL FILTER CHANGE ..................................................................................... 74 OIL STRAINER........................................................................................................ 76 ENGINE OIL PRESSURE REGULATOR ............................................................................. 76 OIL PUMP ............................................................................................................ 77 07 – CYLINDER AND HEAD ...................................................................................... 81 GENERAL ............................................................................................................. 84 SPARK PLUG ......................................................................................................... 84 THERMOSTAT ........................................................................................................ 84 VALVE COVER ........................................................................................................ 85 VALVE ADJUSTMENT................................................................................................ 85 CHAIN TENSIONER .................................................................................................. 86 BREATHER............................................................................................................ 86 II

TABLE OF CONTENTS CAMSHAFT TIMING GEAR.......................................................................................... 87 ROCKER ARM ........................................................................................................ 88 TIMING CHAIN ....................................................................................................... 90 CYLINDER HEAD..................................................................................................... 90 CAMSHAFT ........................................................................................................... 92 VALVE SPRING ....................................................................................................... 93 VALVE ................................................................................................................. 95 VALVE GUIDE ......................................................................................................... 97 CYLINDER ............................................................................................................ 99 PISTON.............................................................................................................. 101 PISTON RINGS ..................................................................................................... 104 08 – CRANKSHAFT ............................................................................................... 107 CRANKCASE........................................................................................................ 109 GENERAL ........................................................................................................... 110 CRANKSHAFT LOCKING PROCEDURE .......................................................................... 110 TIMING CHAIN ..................................................................................................... 111 CRANKSHAFT ...................................................................................................... 112 CRANKCASE........................................................................................................ 116 OIL SEAL............................................................................................................ 118 PLAIN BEARING.................................................................................................... 118 BALL BEARING..................................................................................................... 119 09 – GEARBOX .................................................................................................... 121 GEARBOX .................................................................................................... 122 GENERAL ........................................................................................................... 123 OIL CHANGE ....................................................................................................... 123 OIL SEALS .......................................................................................................... 124 BEARINGS .......................................................................................................... 126 GEARBOX COVER ................................................................................................. 127 GEARBOX........................................................................................................... 128 SHIFTING INDICATOR SWITCH .................................................................................. 134 10 – CONSTANT VELOCITY TRANSMISSION (CVT)........................................................ 137 GENERAL ........................................................................................................... 139 DRIVE BELT REPLACEMENT ..................................................................................... 139 CVT COVER......................................................................................................... 140 CVT COVER BEARING ............................................................................................. 141 DRIVE PULLEY ..................................................................................................... 141 DRIVEN PULLEY ................................................................................................... 145 03 FUEL SYSTEM 01 – FUEL CIRCUIT ............................................................................................... 151 GENERAL ........................................................................................................... 153 FUEL LINE .......................................................................................................... 153 FUEL TANK ......................................................................................................... 153 FUEL VALVE ........................................................................................................ 154 02 – CARBURETOR ............................................................................................... 157 GENERAL ........................................................................................................... 159 CARBURETOR...................................................................................................... 159 CARBURETOR ADJUSTMENTS .................................................................................. 161 THROTTLE CABLE ................................................................................................. 161 CHOKE CABLE ..................................................................................................... 163 03 – AIR INTAKE SILENCER ..................................................................................... 165 GENERAL ........................................................................................................... 167 III

TABLE OF CONTENTS AIR FILTER AND CLEANING ...................................................................................... 167 AIR BOX............................................................................................................. 167 AIR FILTER HOUSING ............................................................................................. 168 04 ELECTRICAL 01 – OVERVIEW ................................................................................................... 171 GENERAL OPERATION INFORMATION ................................................................. 171 CHARGING SYSTEM............................................................................................... 171 STARTING SYSTEM ................................................................................................ 171 IGNITION SYSTEM................................................................................................. 172 GENERAL TESTING/TROUBLESHOOTING INFORMATION.......................................... 172 FUSE LOCATION ................................................................................................... 173 SERVICING CONNECTORS ....................................................................................... 173 02 – CHARGING SYSTEM ....................................................................................... 175 TESTING PROCEDURE ............................................................................................ 175 03 – STARTING SYSTEM ........................................................................................ 179 BATTERY ..................................................................................................... 180 TROUBLESHOOTING .............................................................................................. 180 BATTERY TESTING................................................................................................. 180 REMOVAL .......................................................................................................... 181 CLEANING .......................................................................................................... 182 INSPECTION........................................................................................................ 182 BATTERY STORAGE ............................................................................................... 182 ACTIVATION OF A NEW BATTERY ............................................................................... 183 TIPS FOR CHARGING A USED BATTERY ........................................................................ 184 INSTALLATION ..................................................................................................... 185 CABLE TERMINAL INSTALLATION ............................................................................... 185 STARTING SYSTEM TROUBLESHOOTING ............................................................. 188 STARTING SYSTEM TESTS ............................................................................... 190 GENERAL ........................................................................................................... 190 ELECTRIC STARTER ........................................................................................ 191 REMOVAL .......................................................................................................... 191 INSTALLATION ..................................................................................................... 191 04 – IGNITION SYSTEM ......................................................................................... 193 IGNITION SYSTEM TESTING PROCEDURE ............................................................ 193 GENERAL ........................................................................................................... 193 IGNITION SYSTEM TEST .......................................................................................... 195 IGNITION TIMING .................................................................................................. 197 SPARK PLUG................................................................................................. 197 REMOVAL .......................................................................................................... 197 HEAT RANGE ....................................................................................................... 198 FOULING............................................................................................................ 198 SPARK PLUG ANALYSIS ........................................................................................... 198 INSTALLATION ..................................................................................................... 198 NGK SPARK PLUG SYMBOL EXPLANATION .......................................................... 200 05 – INSTRUMENTS AND ACCESSORIES .................................................................... 201 GENERAL ..................................................................................................... 202 HEADLAMP......................................................................................................... 202 HEADLAMP BEAM AIMING ...................................................................................... 204 TAILLIGHT .......................................................................................................... 204 IGNITION SWITCH ................................................................................................. 205 INDICATOR LAMP ................................................................................................. 206 IV

TABLE OF CONTENTS ELECTRONIC MODULE ........................................................................................... 206 TEST........................................................................................................... 206 MULTIFUNCTION SWITCH........................................................................................ 206 INDICATOR LIGHTS................................................................................................ 208 05 DRIVE TRAIN 01 – FRONT DRIVE................................................................................................ 209 GENERAL ........................................................................................................... 211 FRONT WHEEL HUB .............................................................................................. 211 WEAR RING ........................................................................................................ 212 BALL BEARING..................................................................................................... 212 02 – REAR AXLE................................................................................................... 215 GENERAL ........................................................................................................... 217 DRIVE CHAIN ....................................................................................................... 217 REAR WHEEL HUB ................................................................................................ 218 REAR AXLE ......................................................................................................... 219 SPROCKET AND SPROCKET HUB ............................................................................... 219 CHAIN TENSIONER ................................................................................................ 220 CHAIN TENSIONER SEAL ......................................................................................... 221 CHAIN TENSIONER BEARINGS .................................................................................. 221 SLIDER-SHOE ...................................................................................................... 222 CHAIN GUARD ..................................................................................................... 222 CHAIN ROLLER .................................................................................................... 222 06 STEERING SYSTEM 01 – STEERING SYSTEM ........................................................................................ 223 GENERAL ........................................................................................................... 225 HANDLEBAR GRIP................................................................................................. 225 HANDLEBAR ....................................................................................................... 225 STEERING COLUMN .............................................................................................. 225 STEERING COLUMN BEARING................................................................................... 226 TIE-ROD............................................................................................................. 226 KNUCKLE ........................................................................................................... 228 MULTIFUNCTION SWITCH........................................................................................ 229 THROTTLE HANDLE ............................................................................................... 230 LH HANDLE BRAKE ............................................................................................... 231 RH HANDLE BRAKE ............................................................................................... 231 07 SUSPENSION 01 – FRONT SUSPENSION ...................................................................................... 233 GENERAL ........................................................................................................... 235 FRONT SHOCK ..................................................................................................... 235 LH/RH A-ARM ...................................................................................................... 236 A-ARM CUSHIONS................................................................................................. 238 02 – REAR SUSPENSION ........................................................................................ 241 GENERAL ........................................................................................................... 243 REAR SHOCK....................................................................................................... 243 SWING ARM........................................................................................................ 244 08 BRAKES 01 – HYDRAULIC BRAKES....................................................................................... 247 FRONT BRAKES ............................................................................................. 248 V

TABLE OF CONTENTS REAR BRAKE................................................................................................. 249 GENERAL ........................................................................................................... 250 BRAKE FLUID ...................................................................................................... 250 MASTER CYLINDER ............................................................................................... 252 BRAKE CALIPERS .................................................................................................. 253 BRAKE PADS ....................................................................................................... 255 BRAKE DISC ........................................................................................................ 257 FRONT BRAKE LEVER............................................................................................. 259 REAR BRAKE LEVER .............................................................................................. 259 BRAKE PEDAL...................................................................................................... 259 REAR BRAKE CABLE .............................................................................................. 259 BRAKE HOSES/BRAKE TUBE ..................................................................................... 260 09 BODY/FRAME 01 – BODY .......................................................................................................... 261 BODY PARTS................................................................................................. 262 SEAT .......................................................................................................... 263 GENERAL ........................................................................................................... 264 SEAT................................................................................................................. 264 STEERING COVER ................................................................................................. 264 AIR FILTER BOX COVER .......................................................................................... 265 FUEL TANK COVER ................................................................................................ 265 FRONT FASCIA ..................................................................................................... 265 RH/LH FOOTREST ................................................................................................. 266 FRONT FENDER.................................................................................................... 266 REAR FENDER ..................................................................................................... 266 DECALS ............................................................................................................. 267 PLASTIC MAINTENANCE ......................................................................................... 267 PLASTIC REPAIR ................................................................................................... 267 02 – FRAME ........................................................................................................ 269 GENERAL ........................................................................................................... 270 FRONT BUMPER................................................................................................... 270 REAR BUMPER .................................................................................................... 270 FRONT RACK ....................................................................................................... 271 REAR RACK......................................................................................................... 271 FENDER SUPPORT BRACKET .................................................................................... 271 FRONT FASCIA SUPPORT ........................................................................................ 272 FRONT PLATE ...................................................................................................... 272 FRAME .............................................................................................................. 272 10 TECHNICAL DATA 01 – TECHNICAL DATA........................................................................................... 273 INTERNATIONAL METRIC INFORMATION GUIDE .................................................... 273 RALLY 200 .................................................................................................... 274 11 WIRING DIAGRAM 01 – WIRING DIAGRAM.......................................................................................... 285 WIRING CONNECTORS CODING......................................................................... 285 WIRE COLORS ..................................................................................................... 285 WIRE GAUGE....................................................................................................... 285 CONNECTOR HOUSING AREA ................................................................................... 285 CONNECTOR IDENTIFICATION................................................................................... 285 VI

TABLE OF CONTENTS CONNECTOR LOCATION IN HOUSING .......................................................................... 286 VII

2005 Bombardier Rally 200 ATV Repair Manual

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