Can-Am Bombardier Rally 200 2003-2005 Service Repair Manual

2003 Shop Manual RALLY™ 200

Legal deposit: National Library of Quebec 2 nd trimester 2002 National Library of Canada 2002 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 2002 Technical Publications Bombardier Inc. Valcourt (Quebec) Canada Printed in Canada ® Registered trademarks of Bombardier Inc. TM Trademarks of Bombardier Inc. This document contains the registered trademarks of the following companies: Kimtowels ® is a registered trademark of Kimberly-Clark 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 Makers Inc.

VMR2003_001_00_02A.FM I SECTION SUBSECTION PAGE SAFETY NOTICE ................................................................................................................................... III INTRODUCTION .................................................................................................................................. IV 01 SERVICE TOOLS AND SERVICE PRODUCTS 01 – Table of contents...................................................................... 01-01-1 02 – Service tools ............................................................................. 01-02-1 03 – Service products....................................................................... 01-03-1 02 MAINTENANCE 01 – Table of contents...................................................................... 02-01-1 02 – Maintenance chart.................................................................... 02-02-1 03 – Maintenance/lubrication ........................................................... 02-03-1 04 – Storage/preseason preparation ................................................ 02-04-1 03 ENGINE 01 – Table of contents...................................................................... 03-01-1 02 – Troubleshooting........................................................................ 03-02-1 03 – Leak test................................................................................... 03-03-1 04 – Removal and installation........................................................... 03-04-1 05 – Cooling system......................................................................... 03-05-1 06 – Magneto system ...................................................................... 03-06-1 07 – Lubrication system ................................................................... 03-07-1 08 – Cylinder and head ..................................................................... 03-08-1 09 – Crankshaft ................................................................................ 03-09-1 10 – Gearbox .................................................................................... 03-10-1 11 – CVT ........................................................................................... 03-11-1 04 FUEL SYSTEM 01 – Table of contents...................................................................... 04-01-1 02 – Fuel circuit ................................................................................ 04-02-1 03 – Carburetor ............................................................................... 04-03-1 04 – Air intake silencer ..................................................................... 04-04-1 05 ELECTRICAL 01 – Table of contents...................................................................... 05-01-1 02 – Overview .................................................................................. 05-02-1 03 – Charging system ...................................................................... 05-03-1 04 – Starting system ........................................................................ 05-04-1 05 – Ignition system......................................................................... 05-05-1 06 – Instruments and accessories ................................................... 05-06-1 06 DRIVE TRAIN 01 – Table of contents...................................................................... 06-01-1 02 – Rear axle................................................................................... 06-02-1 07 STEERING/CONTROL SYSTEMS 01 – Table of contents...................................................................... 07-01-1 02 – Steering/control systems ......................................................... 07-02-1 08 SUSPENSION 01 – Table of contents...................................................................... 08-01-1 02 – Front suspension ...................................................................... 08-02-1 03 – Rear suspension ....................................................................... 08-03-1 09 BRAKES 01 – Table of contents...................................................................... 09-01-1 02 – Hydraulic brakes ....................................................................... 09-02-1 TABLE OF CONTENTS

II VMR2003_001_00_02A.FM 10 BODY/FRAME 01 – Table of contents ..................................................................... 10-01-1 02 – Body ......................................................................................... 10-02-1 03 – Frame ....................................................................................... 10-03-1 11 TECHNICAL DATA 01 – SI metric information guide...................................................... 11-01-1 02 – Technical data (engine and vehicle) ......................................... 11-02-1 12 WIRING DIAGRAM 01 – Wiring diagram......................................................................... 12-01-1 SECTION SUBSECTION PAGE TABLE OF CONTENTS

VMR2003_001_00_02A.FM III SAFETY NOTICE 0 This manual has been prepared as a guide to correctly service and repair 2003 ATVs. This edition was primarily published to be used by ATV mechanical technicians who are already familiar with all service procedures relating to Bombardier made vehicles. Mechanical technicians should attend continuous training courses given by Bombardier Training Department. Please note that the instructions will apply only if proper hand tools and special service tools are used. This Shop Manual uses technical terms which may be slightly different from the ones used in Parts Catalog. It is understood that this manual may be translated into another language. In the event of any discrepancy, the english version shall prevail. The content depicts parts and/or procedures applicable to the particular product at time of writing. Service and Warranty Bulletins may be published to update the content of this manual. Make sure to read and understand these. It does not include dealer modifications, whether authorized or not by Bombardier, after manufacturing the product. In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas of the parts. The use of Bombardier parts is most strongly recommended when considering replacement of any com- ponent. Dealer and/or distributor assistance should be sought in case of doubt. The engines and the corresponding components identified in this document should not be utilized on product(s) other than those mentioned in this document. This manual emphasizes particular information denoted by the wording and symbols: CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components. NOTE: Indicates supplementary information needed to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your understanding of the information will promote its correct use. Always use common shop safety practice. This information relates to the preparation and use of Bombardier ATV and has been utilized safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing federal, provincial and state regulations.  WARNING Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death. SAFETY NOTICE

IV VMR2003_001_00_02A.FM INTRODUCTION 0 This Shop Manual covers the following Bombardier made 2003 ATV: Models TYPICAL — VEHICLE SERIAL NUMBER LABEL 1. Model number VEHICLE SERIAL NUMBER LOCATION 1. V.I.N. (Vehicle Identification Number) ENGINE SERIAL NUMBER LOCATION E.I.N. (ENGINE IDENTIFICATION NUMBER) ARRANGEMENT OF THE MANUAL The manual is divided into 12 major sections: 01 SERVICE TOOLS AND SERVICE PRODUCTS 02 MAINTENANCE 03 ENGINE 04 FUEL SYSTEM 05 ELECTRICAL 06 DRIVE TRAIN 07 STEERING/CONTROL SYSTEMS 08 SUSPENSION 09 BRAKES 10 BODY/FRAME 11 TECHNICAL DATA 12 WIRING DIAGRAM Each section is divided in various subsections, and again, each subsection has one or more division. Rally TM 200 (red) ..................................... 7550 Rally TM 200 (green) ................................. 7551 Rally TM 200 (yellow) ................................ 7552 Rally TM 200 (red international) ............... 7591 Rally TM 200 (green international)........... 7592 Rally TM 200 (yellow international) ......... 7593 TM Trademark of Bombardier Inc.      INTRODUCTION

VMR2003_001_00_02A.FM V LIST OF ABBREVIATIONS USED IN THIS MANUAL A ampere amp ampere A•h ampere-hour AC alternate current BDC bottom dead center BTDC before top dead center °C degree Celsius CDI Capacitor discharge ignition cm centimeter cm² square centimeter cm³ cubic centimeter CVT Continuously variable transmission DC direct current °F degree Fahrenheit fl. oz fluid ounce ft foot GRD ground hal. halogen I.D. inside diameter IDI induction discharge ignition imp. oz imperial ounce in inch in² square inch in³ cubic inch k kilo (thousand) kg kilogram km/h kilometer per hour kPa kilo pascal l liter lbf/in² pound per square inch LH left hand lb pound lbf pound (force) m meter MAG magneto Max. maximum Min. minimum ml milliliter mm millimeter MPH mile per hour N newton N.A. not applicable no. number 00.0 continuity 0.L overload (open circuit) O.D. outside diameter OHC Over head camshaft OPT optional oz ounce P/N part number PSI pound per square inch PTO power take off RPM revolution per minute Sp. Gr. specific gravity TDC top dead center U.S. oz ounce (United States) USFD U.S. Forest Service V volt Vac volt (alternative current) INTRODUCTION

VI VMR2003_001_00_02A.FM                                                                                                                                         INTRODUCTION

VMR2003_001_00_02A.FM VII                                                                              INTRODUCTION

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Can-Am Bombardier Rally 200 2003-2005 Service Repair Manual

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