Can-Am Rally 200 Operator's Manual
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Can-Am Rally 200 Operator's Manual

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  • Page 2 (BRP) In USA, products are distributed by BRP US Inc. The following trademarks are the property of Bombardier Recreational Prod- ucts Inc.: Can-Am™ Rally XP-S Printed in Canada. (vmo2007-016 DR) ®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.
  • Page 3 FOREWORD Congratulations on your purchase of a The information and components/ new Can-Am™ ATV. It is backed by the system descriptions contained in this BRP warranty and a network of autho- document are correct at the time of publication. BRP, however, maintains...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. NOTICE................7 INTRODUCTION ..
  • Page 5 2) Front Brake Lever ............67 3) Rear Brake Lever.
  • Page 6 Coolant Replacement ............104 Air Filter Housing Draining .
  • Page 7 STORAGE AND PRESEASON PREPARATION ....... 124 WARRANTY BRP LIMITED WARRANTY NORTH AMERICA: 2007 CAN-AM ATV . .. 126 BRP INTERNATIONAL LIMITED WARRANTY: 2007 CAN-AM ATV .
  • Page 8 _______________________...

  • Page 9: Notice

    NOTICE This Operator's Guide has been pre- pared to acquaint the owner/operator of a new vehicle with the various ve- hicle controls, maintenance and safe operating instructions. It is indispens- able for the proper use of the product. This Operator's Guide uses the follow- ing symbols.

  • Page 10: Introduction

    INTRODUCTION Your dealer should have provided you The contents of this Operator's Guide provide riding information which has with some basic information on the been proven reliable by other users. particular controls and features of your new vehicle. Please take the time to They are not intended as a definitive study this Operator's Guide and all means of avoiding accidents.

  • Page 11: Safety Information

    SAFETY INFORMATION ____________ ____________ SAFETY INFORMATION...

  • Page 12: Special Safety Messages

    Operator's Guide. instructor. Contact an authorized Always keep both hands on the Can-Am dealer to find out about handlebars and both feet on the available training course nearest footpegs of the vehicle during op- you or call the Specialty Vehicle In- eration.
  • Page 13 Never operate this vehicle on hills Always use proper procedures if too steep for the vehicle or for your you stall or roll backwards when climbing a hill. To avoid stalling, abilities. Practice on smaller hills before attempting larger hills. use proper gear and maintain a steady speed when climbing a hill.
  • Page 14 Specialty Vehicle Institute of Amer- ica (SVIA) at 1 800 887-2887 or in Canada, the Canada Safety Council (CSC) at 1 (613) 739-1535 ext. 227 or contact an authorized Can-Am dealer to find out about available training courses nearest you. ___________...

  • Page 15: Operation Warnings

    They should then regularly practice the skills learned in the course and the operating techniques described in this Operator's Guide. For more information about the training course, contact an authorized Can-Am dealer or call BRP at 1 (819) 566-3366. ____________ ___________...
  • Page 16 WARNING V00A01Q POTENTIAL HAZARD Failure to follow the age recommendations for this vehicle. WHAT CAN HAPPEN A lack of respect for this age recommendation can lead to severe injury or death of the child. Even though a child may be within the age group for which this vehicle is recommended, he may not have the skills, abilities, or judgment needed to operate this vehicle safely and may be involved in a serious accident.
  • Page 17 WARNING V00A02Q POTENTIAL HAZARD Carrying a passenger on this vehicle. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this vehicle. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 18 WARNING V00A03Q POTENTIAL HAZARD Operating this vehicle on paved surfaces. WHAT CAN HAPPEN The tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of this vehicle, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Never operate this vehicle on any paved surfaces, including sidewalks, driveways, parking lots and streets.
  • Page 19 WARNING V00A04Q POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, even a dirt or gravel one.
  • Page 20 WARNING V00A06Q POTENTIAL HAZARD Riding this vehicle without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN The following items concern all ATV's operator: – riding without an approved helmet increases the chances of a severe head injury or death in the event of an accident –...
  • Page 21 WARNING V00A07Q POTENTIAL HAZARD Riding this vehicle 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 or death. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while riding this vehicle.
  • Page 22 WARNING V00A08Q POTENTIAL HAZARD Operating this vehicle at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the vehicle, which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and op- erating conditions, and your experience.
  • Page 23 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. Do not try to show off. ____________ ___________ SAFETY INFORMATION...
  • Page 24 WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition.
  • Page 25 WARNING V00A0BQ POTENTIAL HAZARD Removing hands from handlebar or feet from the footrests during opera- tion. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the vehicle or could cause you to lose your balance and fall off the vehicle. If you remove a foot from the footrests, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.
  • Page 26 WARNING V00A0CQ POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the vehicle overturning or loss of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain.
  • Page 27 WARNING V00A0DQ POTENTIAL HAZARD 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 this vehicle on such terrain.
  • Page 28 WARNING V00A0EQ POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Vehicle could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described further in this Operator's Guide. Practice turning at low speeds before attempting to turn at faster speeds.
  • Page 29 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 this vehicle on hills too steep for the vehicle or for your abil- ities.
  • Page 30 WARNING V00A0FQ POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described further in this Operator's Guide. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
  • Page 31 WARNING V00A0GQ POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described further in this Operator's Guide. NOTE: A special technique is required when brak- ing as you go down a hill.
  • Page 32 WARNING V00A0HQ POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the vehicle around on any hill until you have mas- tered the turning technique as described further in this Operator's Guide on level ground.
  • Page 33 WARNING V00A0IQ POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in vehicle overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Keep your weight uphill.
  • Page 34 WARNING V00A0JQ POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the vehicle 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.
  • Page 35 WARNING V00A0KQ POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this vehicle. You may also regain traction unexpectedly, which may cause the vehicle to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain.
  • Page 36 WARNING V00A0LQ POTENTIAL HAZARD Operating this vehicle 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 vehicle in fast flowing water or in water deeper than that specified further in this Operator's Guide.
  • Page 37 WARNING V00A0MQ POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind the vehicle, resulting in serious injury. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no obstacles or people behind the vehicle.
  • Page 38 WARNING V00A0OQ POTENTIAL HAZARD Operating this vehicle with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this vehicle, or operation of this vehicle with im- proper or uneven tire pressure, may cause loss of control, tire blow outs, tire to move around on its rim and increases the risk of an accident.
  • Page 39 All parts and accessories added to this vehicle should be approved by BRP and should be installed and used according to instructions. If you have questions, consult an authorized Can-Am dealer. NEVER install passenger seat or use the racks to carry a passenger.
  • Page 40 WARNING V00A0PQ POTENTIAL HAZARD Overloading this vehicle 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 vehicle including operator, as well as other loads and added accessories.
  • Page 41 WARNING V03M01Q POTENTIAL HAZARD Transporting flammable or dangerous material can lead to explosions. WHAT CAN HAPPEN This can cause serious injury or death. HOW TO AVOID THE HAZARD Never transport flammable or dangerous material. While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death.

  • Page 42: Riding The Vehicle

    RIDING THE VEHICLE To fully appreciate the pleasures and excitement of riding this vehicle, there are some basic rules and tips that you MUST follow. Some may be new to you while others may be common sense or obvious. Nonetheless, we ask that you take a few minutes to read this Operator's Guide completely before you operate this vehicle.

  • Page 43: Pre-Operation Check

    Correct any problem you may have wear and damage. found before riding. See an autho- • Check location of controls and en- rized Can-Am dealer as necessary. sure they work properly. • Verify if steering operates freely. • Activate throttle control lever sever- al times to ensure it operates freely.

  • Page 44: Clothing

    Clothing Actual weather conditions should help you decide how to dress. However, it is important that the operator always wear the appropriate protective clothing and apparel, including an approved helmet, eye protection, boots, gloves, long sleeved shirt and pants. This type of clothing will provide you protection from some of the minor hazards you may encounter en route.

  • Page 45: Carrying Loads

    Your vehicle can help you perform a number of different LIGHT tasks ranging from snow removal to pulling wood or carrying cargo. A variety of accessories are available from your authorized Can-Am dealer. However, always respect the load and capacities of the vehicle. Overloading of the vehicle can overstress the components and cause failure.

  • Page 46: Environment

    Always keep a safe distance from other riders. Your judgment of speed, ter- rain conditions, weather, mechanical condition of your vehicle and the “trust in judgment” you have in others around you will help you make a better choice of appropriate safe distance.

  • Page 47: General Operating And Safety Precautions

    An operator who takes a vehicle off-road should always exercise the utmost care in selecting the safest path and keeping close watch on the terrain ahead of him. On no account should the vehicle be operated by anyone who is not completely familiar with the driving instructions applicable to the vehicle, nor should it be operated on steep or treacherous terrain.

  • Page 48: Side Hilling

    Side Hilling Whenever possible, such operation should be avoided. If necessary, do so with extreme caution. Side hilling on steep inclines could result in rollover. In addi- tion, slippery or unfirm surfaces could result in uncontrollable side sliding. Do not attempt to turn the vehicle downhill with the slide. Avoid all objects or de- pressions that will intensify the raising of one side of the vehicle higher than the other, thus causing rollover.
  • Page 49 V00A0UL Even though there is an adequate suspensions system on this vehicle there are “washboard” or rough terrain conditions that will make you feel uncomfortable and even cause back injury. “Posting” or riding in a crouched position will often be required. Slow down and allow your flexed legs to absorb impact. This vehicle is not designed for riding on roads or highways.
  • Page 50 Water can be a unique hazard. If it is too deep the vehicle may “float” and topple. Check the water depth and current before you attempt to cross any water. Water should not go above the footrest. Be wary of slippery surfaces such as rocks, grass, logs, etc., both in the water and on its banks.
  • Page 51 Sand and riding on sand dunes or on snow is another unique experience but there are some basic precautions that should be observed. Wet, deep or fine sand/snow may create a loss of traction and cause the vehicle to slide, drop off or become “bogged”...
  • Page 52 Obstacles in the “trail” should be traversed with caution. This includes loose rocks, fallen trees, slippery surfaces, fences, posts, and embankments and de- pressions. You should avoid them whenever possible. Remember that some obstacles are too large or dangerous to cross and should be avoided. Small rocks or fallen trees may be safely crossed...
  • Page 53 Downhill Keep your body weight rearwards. Apply the brake gradually to prevent skidding. Do not “coast” down the slope using solely engine compression or in neutral gear. V00A0YL Side Hilling This is one of the most risky types of riding since it may drastically change the balance of the vehicle.

  • Page 54: Routine Maintenance

    Part of your responsibility towards safety is to respect the contents of this Op- erator's Guide. It provides valuable advice on how to properly take care of your vehicle. If further assistance is required your authorized Can-Am dealer is always willing to help.

  • Page 55: Hang Tag

    HANG TAG This vehicle comes with a hang tag and labels containing important safety infor- mation. Any person who rides this vehicle should read and understand this information before riding. V07M11L 704901107 vmo2006-005-009_en ____________ ___________ SAFETY INFORMATION...

  • Page 56: On-Product Labels

    The following labels are on your vehicle and they should be considered perma- nent parts of the vehicle. If missing or damaged, they can be replaced free of charge. See an authorized Can-Am dealer. NOTE: The following illustrations used in this Operator's Guide are a general representation only.
  • Page 57 Label 1 Label 3 V01M07Z Label 4 V01M01Z Label 2 V01M02Z V06M0AY Label 5 704901094 ____________ ___________ SAFETY INFORMATION...
  • Page 58 Label 6 Label 9 V06M0DY Label 7 V00M0AY INTERNATIONAL MODELS ONLY V06M0EY Label 8 vmo2006-005-012 ___________ ___________ SAFETY INFORMATION...

  • Page 59: Vehicle Information

    VEHICLE INFORMATION _____________________...

  • Page 60: How To Identify Your Vehicle

    It may sometimes become necessary to locate these num- bers for warranty purposes or to trace your vehicle in the event of loss. These numbers are required by the authorized Can-Am dealer to complete warranty claims properly. No warranty will be allowed by BRP. if the engine identification number (EIN) or vehicle identification number (VIN) is removed or mutilated in any way.
  • Page 61 vmo2006-002-001 VIN (VEHICLE IDENTIFICATION NUMBER) ALSO STAMPED ON FRAME _____________________...
  • Page 62 Engine Identification Number Location V06A18L ______________________...

  • Page 63: Compliance Label

    Compliance Label This label indicates vehicle's compliance in many countries. LABEL LOCATION All Rally 200 On frame between front suspension A-arms V00M02Y USA AND CANADA V00M03Y OTHER COUNTRIES IN THE WORLD _____________________...

  • Page 64: Noise Emission Control System Regulation

    NOISE EMISSION CONTROL SYSTEM REGULATION Tampering with Noise Control System Is 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...

  • Page 65: Emission Requirements

    EMISSION REQUIREMENTS The California Air Resources Board (CARB) requires that your vehicle complies 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.

  • Page 66: Break-In Period

    (125 mi) or 30 days after the pur- chase, whichever comes first, your vehicle be inspected by an authorized Can-Am dealer. This inspection will give you the opportunity to discuss the unanswered questions you may have encountered during the first hours of operation.

  • Page 67: Controls/Instruments/Equipment

    CONTROLS/INSTRUMENTS/EQUIPMENT NOTE: Some controls/instruments/equipment are optional. V06A12L _____________________...
  • Page 68 V06A13L ______________________...

  • Page 69: Throttle Lever

    While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. NOTE: This section gives basic func- tions of the various controls of your ve- hicle. For more details of how to op- erate one control in conjunction with some others, refer to OPERATING IN- STRUCTIONS further in this section.

  • Page 70: Parking Brake

    4) Parking Brake To release mechanism: Squeeze brake lever. Lever lock should auto- Located on left side of handlebar on matically return to its original position. the rear brake lever. When applied, Brake lever should return to rest po- it prevents the vehicle from moving. sition.

  • Page 71: Multi-Function Switch

    This selects the high speed range of WARNING the transmission in the gearbox. It is Before moving vehicle in reverse, the normal driving speed range. It al- ensure the path behind is clear of lows the vehicle to reach its maximum obstacles or bystanders.
  • Page 72 NOTE: Place ignition switch to ON Engine Start Button “without light” position to close the Located below engine stop switch. headlamp. To start engine: place the engine stop switch to RUN. Press and hold the engine start button. Release immediately after engine is started.

  • Page 73: Indicator Lamps

    If engine overheats, refer to ENGINE OVERHEAT in SPECIAL PROCEDURES. CAUTION: If the light does not turn off right after engine starting, stop engine. See an authorized Can-Am dealer. Do not use the vehicle until repaired. V06F0PY Reverse Lamp (red)

  • Page 74: Fuel Tank Cap

    WARNING Always stop engine before re- fueling. Open cap slowly. If a differential pressure condition is noticed (whistling sound heard when loosening fuel tank cap) have vehicle inspected and/or re- paired before further operation. Fuel is flammable and explosive under certain conditions. Never use an open flame to check fuel level.

  • Page 75: Rear Brake Pedal

    11) Rear Brake Pedal Located on the right footrest. When pressed down, the rear brake is ap- plied. When released, it should return to its original position. Braking effect is proportional to the force applied on the pedal and to the type and condition of the terrain.

  • Page 76: Front/Rear Cargo Racks

    15) Radiator Cap Located under front fender. It pro- vides access to the radiator filling neck. WARNING In order to avoid potential burns, do not remove the radiator cap if the engine is hot. vmo2006-001-009_a Turn radiator cap counterclockwise to 1.
  • Page 77 V06G01Y 1. Fuse holder _____________________...

  • Page 78: Liquids

    LIQUIDS While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. NOTE: This section specifies the rec- Fuel Level ommended liquids and procedures to WARNING check their levels. Refer to MAINTE- NANCE for procedures to replace the Always stop engine before refu- liquids.
  • Page 79 NOTE: For improved overall perfor- mance and all season application, use XP-S 5W40 synthetic oil (P/N 293 600 039). XP-S 5W40 Synthetic Oil (P/N 293 600 039) SAE 0W30 SAE 5W30 SAE 10W30 XP-S 10W40 Mineral Oil V06C2DY (P/N 219 700 346) RH SIDE OF ENGINE SAE 15W40 With vehicle on a level surface and...

  • Page 80: Gearbox Oil

    Gearbox Oil Level CAUTION: Check level and refill if necessary. Do not overfill. Oper- ating the gearbox with an improp- er level may severely damage gear- box. Wipe off any spillage. Place the vehicle on a level surface. Select NEUTRAL position then apply parking brake.
  • Page 81 362) or with distilled water and an- tion of leaks or engine problems. See tifreeze solution (50% water, 50% an- an authorized Can-Am dealer. tifreeze). To gain access to the radiator, proceed as follows: Coolant Level –...

  • Page 82: Brake Fluid

    NOTE: A low level may indicate leaks add distilled water. or worn brake pads. See an autho- rized Can-Am dealer. Refilling Brake Lever Fluid Reservoir Place battery on a level surface. Turn steering in the straight-ahead Unscrew caps and add distilled water position to ensure reservoir is level.
  • Page 83 V06G02Y 1. Upper mark 2. Lower mark Properly retighten caps. While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. _____________________...

  • Page 84: Operating Instructions

    Correct any problem you may have • Verify if steering operates freely. found before riding. See an autho- • Activate throttle control lever sever- rized Can-Am dealer as necessary. al times to ensure it operates freely. It must return to idle position when released.

  • Page 85: Starting The Engine

    Starting the Engine When the engine is warm, push the choke lever to OFF and release brakes. Initial Cold Starting Warm Engine Starting Insert key in ignition switch and turn to ON position. Start the engine as explained above but without the choke. If the engine NOTE: Do not forget, place the engine does not start after two 5-second at- stop switch to RUN position.

  • Page 86: Stopping The Engine

    Stopping the Engine WARNING Avoid parking vehicle on slope. Release throttle and completely stop the vehicle. Apply the parking brake by using brake lever lock on brake lever. Set transmission lever in NEUTRAL position. Push the engine stop switch in OFF position.

  • Page 87: Special Procedures

    Use the vehicle In order to avoid potential burns, as little as possible and see an autho- do not remove the radiator cap or rized Can-Am dealer as soon as possi- refill cooling system when engine ble. is hot.

  • Page 88: Vehicle Immersion

    Vehicle Immersion Should the vehicle become immersed, it will be necessary to take it to an authorized Can-Am dealer as soon as possible. DO NOT START THE EN- GINE! Immersion of the vehicle can cause serious damage if the correct restart procedure is not followed.

  • Page 89: Cargo And Transportation

    CARGO AND TRANSPORTATION While reading this Operator’s Guide, remember that: WARNING Indicates a potential hazard that, if not avoided, could result in serious in- jury or death. Cargo WARNING The vehicle handling, stability and braking distance are affected when load- ing racks and using the vehicle.
  • Page 90 CAUTION: Attaching vehicle at oth- er locations may damage the vehi- cle. Unload racks before transporting the vehicle. Front Location vmo2006-001-006 TYPICAL Rear Location vmo2006-001-007 TYPICAL WARNING Do not tow this vehicle behind a car or other vehicle. Use a trailer. ______________________...

  • Page 91: Troubleshooting

    4. Weak battery or loose connections. – Check charging system fuse. – Check connections and terminals condition. – Have the battery checked. – Contact an authorized Can-Am dealer. ENGINE TURNS OVER BUT FAILS TO START 1. Burnt fuse. – Check main fuse condition.
  • Page 92 – Start engine with spark plug grounded to the engine away from spark plug hole. If no spark appears, replace spark plug. – If trouble persists, contact an authorized Can-Am dealer. 6. Engine compression. – If no pulsating resistance is felt, it suggests a major loss of compression.
  • Page 93 1. Oil filter and/or oil pressure regulator plugged. – Change oil filter and engine oil. – Clean oil pressure regulator. 2. Valve adjustment. – Contact an authorized Can-Am dealer. 3. Chain tensioner plugged. – Contact an authorized Can-Am dealer. 4. Timing chain wear.
  • Page 94 THE RPM INCREASES BUT THE VEHICLE DOES NOT MOVE 1. The transmission is in NEUTRAL position. – Set transmission in REVERSE or HI. 2. CVT dirty or wear. – Contact an authorized Can-Am dealer. 3. Water in the CVT housing. – Contact an authorized Can-Am dealer. ______________________...

  • Page 95: Specifications

    SPECIFICATIONS MODEL RALLY™ 200 ENGINE 4 stroke. Single overhead camshaft Type engine, liquid cooled Number of cylinder Single cylinder Number of valves 4 valves with mechanical lifters (adjustable) Displacement 176.3 cc (10.76 cu. in) Bore Standard 62 mm (2.4 in) Stroke 58.4 mm (2.3 in) Compression ratio...
  • Page 96 MODEL RALLY™ 200 ELECTRICAL Magneto generator 260 W @ 6000 RPM Ignition type CDI (Capacitor Discharge Ignition) Ignition timing Not adjustable Engine RPM limiter 10 500 RPM (any gear in forward) Vehicle speed limiter 15 km/h (9 MPH) in reverse Make Spark plug Type...
  • Page 97 MODEL RALLY™ 200 WHEELS Front 10 x 5.5 Size Rear 10 x 8 70 N•m Wheel nuts torque (52 lbf•ft) BRAKES Front Hydraulic, 2 discs Rear Hydraulic, 1 disc Parking device LH brake lever includes a parking brake LOADING CAPACITY Front racks 16 kg (35 lb) Rear racks...
  • Page 98 MODEL RALLY™ 200 LIQUIDS and GREASES SAE 5W30. API classification SM, SL or SJ. Engine oil type Refer to OIL VISCOSITY CHART for other grade Gearbox oil 80W-90 Ethylene-glycol/water mix (50% coolant, 50% distilled water). Use BRP premixed Coolant coolant or a coolant specially designed for aluminum engines Type Regular unleaded gasoline...

  • Page 99: Maintenance Information

    MAINTENANCE INFORMATION _____________________...

  • Page 100: Maintenance Chart

    Can-Am dealer. PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 200 km (125 mi) (To be performed by an authorized Can-Am dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST...
  • Page 101 PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 200 km (125 mi) (To be performed by an authorized Can-Am dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST C: CLEAN 25 H OR 500 km (310 mi)
  • Page 102 PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 200 km (125 mi) (To be performed by an authorized Can-Am dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST C: CLEAN 25 H OR 500 km (310 mi)
  • Page 103 PERIODIC MAINTENANCE CHART INITIAL INSPECTION 10 H OR 30 DAYS OR 200 km (125 mi) (To be performed by an authorized Can-Am dealer. The initial maintenance is very important and must not be neglected.) A: ADJUST C: CLEAN 25 H OR 500 km (310 mi)

  • Page 104: General

    The following covers the maintenance items that can be performed by the cus- tomer if desired. Other items found in maintenance chart must be performed by an authorized Can-Am dealer. NOTE: Among other things, this section gives the procedures to replace the liq- uids.

  • Page 105: Engine

    ENGINE 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. In order to avoid potential burns, do not remove the engine drain plug V06C04Y or the oil filter cover if the engine is...

  • Page 106: Oil Pressure Regulator

    Reinstall oil strainer plug with a new gasket. Change gasket on drain plug. Clean gasket area on engine and drain plug then reinstall plug. Refill engine at the proper level with the recommended oil. Refer to SPECIFICATIONS for ca- pacity. Start engine and let idle for a few min- utes.
  • Page 107 V06C07Y Lift the front of vehicle high enough to have front wheels off the ground. V06C2FZ Fill the radiator until the coolant comes out by the thermostat housing bleed- 1. Cooling drain plug ing hole. Install the bleeding screw Unscrew the bleeding screw on the then remove the hose pincher.

  • Page 108: Air Filter Housing Draining

    Air Filter Housing Draining Air Filter CAUTION: Never remove or mod- Removal ify any component in the air filter housing. The engine carburation CAUTION: Never remove or mod- is calibrated to operate specifically ify any component in the air filter with these components.

  • Page 109: Drive Belt

    1. Spark arrester 2. Muffler Drive Belt Remove carbon deposits from the See an authorized Can-Am dealer to spark arrester using a brush. inspect and/or replace the drive belt. NOTE: Use a soft brush and be careful to avoid damaging spark arrester.
  • Page 110 The fins are purposely thin parts to allow effi- cient cooling. WHEN HOSING, USE LOW PRESSURE ONLY. NEVER USE A HIGH PRESSURE WASHER. See an authorized Can-Am dealer to check the performance of the cooling system. _____________________...

  • Page 111: Gearbox

    GEARBOX Oil Change Place the vehicle on a level surface. Remove the left footrest. Clean drain plug area and oil level plug then remove the gearbox drain plug. V06C2GY 1. Gearbox drain plug 2. Gearbox oil level plug NOTE: To completely drain the gear- box, place a jack under the right footrest and tilt the vehicle toward the left side.

  • Page 112: Carburetor

    CARBURETOR See an authorized Can-Am dealer each year to verify and clean the fuel sys- tem. _____________________...

  • Page 113: Fuel System

    FUEL SYSTEM Throttle Cable Lubrication The throttle cable must be lubricated with silicone cable lubricant (P/N 293 600 041) or an equivalent. WARNING Always use a silicone-based lu- bricant. Using another lubricant (like water-based lubricant) could cause the throttle lever/cable stick- ing or stiffness.

  • Page 114: Throttle Lever Adjustment

    With the transmission lever on NEU- WARNING TRAL position, start the engine. Always wear eye protection and Check if the throttle cable is adjusted gloves when you lubricate a cable. correctly by turning handlebar fully right then fully left. If the engine RPM increases, readjust the throttle lever NOTE: Place a rag around the cable free play.

  • Page 115: Electrical

    ELECTRICAL CAUTION: Should any electrolyte WARNING spillage occur, immediately wash Unless otherwise informed, al- off with a solution of baking soda ways turn ignition switch to the and water. OFF position before performing any maintenance or repair on elec- Cleaning trical system.

  • Page 116: Bulb Replacement

    Headlamp CAUTION: Never touch glass por- tion 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. To unplug connector, release outer edge of rubber protector from head- lamp housing, then pull on connector using a wiggle movement.
  • Page 117 V06G0RY TYPICAL V06G0TY Lift and hold the spindle then remove TYPICAL the bulb. 1. Headlamp housing 2. Beam height adjustment 3. Beam side adjustment Taillight Unscrew lens screws to expose bulb. V06G0SY TYPICAL V06G0UY Properly reinstall removed parts in the reverse order of their removal.
  • Page 118 Indicator Lamp Remove the cluster by unscrewing the screws. V06G0WY 1. Indicator lamp bulb 2. Rubber protector Pull the bulb to remove it. V06G0OZ For installation, reverse the removal 1. Cluster's screws instructions. Pull the indicator lamp lens out of its location.

  • Page 119: Drive Train

    DRIVE TRAIN Lubrication Cleaning and Lubrication Lubricate front knuckles. Use syn- CAUTION: Never wash the chain thetic grease (P/N 293 550 033) or an with a high pressure washer or equivalent. There is a grease fitting gasoline. Damage to the O-ring on each knuckle.

  • Page 120: Drive Chain Slider

    See an authorized Can-Am dealer for top of the chain. The bottom part of replacement. the chain should be taught during ad- justment.

  • Page 121: Wheel

    Push and pull the wheels from the up- TIRE PRESSURE per edge to feel the play. See an au- FRONT/REAR thorized Can-Am dealer if there is any play. UP to 24 kPa RECOMMENDED 175 kg (3.5 PSI)
  • Page 122 At installation, it is recommended to apply anti-seize lubricant on threads. Gently tighten nuts in a criss-cross se- quence then apply a final torque of 70 N•m (52 lbf•ft). V06H05Y 1. Taper side of nut CAUTION: Always use the recom- mended wheel nuts (P/N 250 100 039).

  • Page 123: Suspension

    V06J0GY Check swing arm for distortion, cracks or bending. See an autho- FRONT SUSPENSION rized Can-Am dealer if any problem is A. Same length on both sides detected. A-Arms Check A-arms for cracks, bending or other damages. See an authorized Can-Am dealer as necessary.

  • Page 124: Brake

    WARNING Any brake system repair should WARNING be performed by an authorized Can-Am dealer. See an authorized Can-Am deal- er to repair or replace any compo- nents of the brake system. Front Brake The front brakes are hydraulic disc Check the following to keep the types.

  • Page 125: Body/Frame

    BODY/FRAME Engine Area CAUTION: Never clean plastic parts with strong detergent, degreasing Check engine area for any damage agent, paint thinner, acetone, etc. and leaks. Ensure all hose clamps are properly secured and no hose is cracked, kinked or otherwise dam- aged.

  • Page 126: Storage And Preseason Preparation

    CHART. When a vehicle is not in use for more than one month, proper storage is a necessity. See an authorized Can-Am dealer for proper procedures. When using your vehicle after storage, a preparation is required. See an au- thorized Can-Am dealer for proper pro- cedures.

  • Page 127: Warranty

    WARRANTY _____________________...

  • Page 128: Brp Limited Warranty North America: 2007 Can-Am

    All genuine Can-Am ATV parts and accessories, installed by an authorized Can-Am dealer (as hereinafter defined) at the time of delivery of the 2007 Can-Am ATV, carry the same warranty as that of the Can-Am ATV. Use of the product for racing or any other competitive activity, at any point, even by a previous owner, will render this warranty null and void.
  • Page 129 3) CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on 2007 Can-Am ATVs purchased as new and unused by its first owner from a Can-Am dealer authorized to distrib- ute Can-Am ATV products in the country in which the sale occurred (“Can-Am dealer”), and then only after the BRP specified pre-delivery inspection process...
  • Page 130 Can-Am dealer and gives the coordinates of the new owner; or b) BRP or an authorized Can-Am dealer receives a proof that the former owner agreed to the transfer of ownership, in addition to the coordinates of the new owner.
  • Page 131 If the issue has not yet been resolved, please submit your complaint in writing or call the appropriate number below: IN CANADA IN USA BOMBARDIER RECREATIONAL BRP US Inc. PRODUCTS INC. CAN-AM ATV CAN-AM ATV CONSUMER SERVICES GROUP CONSUMER SERVICES GROUP 7575 BOMBARDIER COURT VALCOURT QC J0E 2L0 WAUSAU WI 54401...

  • Page 132: Tm Atv

    Can-Am distributor/dealer (as hereinafter defined) at the time of delivery of the 2007 Can-Am ATV, carry the same warranty as that of the Can-Am ATV. Use of the product for racing or any other competitive activity, at any point, even by a previous owner;...
  • Page 133 BRP’s obligations under this warranty are limited to, at its sole discretion, repair- ing parts found defective under normal use, maintenance and service; or replac- ing such parts with new genuine Can-Am ATV parts without charge for parts and labour, at any authorized Can-Am distributor/dealer.
  • Page 134 If the ownership of a product is transferred during the warranty coverage period, this warranty shall also be transferred and be valid for the remaining coverage period provided BRP or an authorized Can-Am distributor/dealer receives a proof that the former owner agreed to the transfer of ownership, in addition to the coordinates of the new owner.
  • Page 135 9) CONSUMER ASSISTANCE a) In the event of a controversy or a dispute in connection with this limited war- ranty, BRP 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.

  • Page 136: Privacy Obligation/Disclaimer

    PRIVACY OBLIGATION/DISCLAIMER We wish to inform you that your coordinates will be used for safety and warranty purposes. Sometimes, we also use the coordinates of our clients to inform them about our products and to present them offers. Should you prefer not to receive information on our product, services and offers, please let us know by writing to the address below.

  • Page 137: Change Of Address/Ownership

    (715) 848-4957 (USA) or (819) STOLEN UNITS: If your personal ATV 566–3366 (Canada); is stolen, you should notify BRP or an authorized Can-Am dealer. We – notifying an authorized Can-Am will ask you to provide your name, dealer. address, phone number, the vehicle...
  • Page 138 _____________________...
  • Page 139 ATV MODEL No. VEHICLE IDENTIFICATION NUMBER (V.I.N.) ENGINE IDENTIFICATION NUMBER (E.I.N.) Owner: NAME STREET CITY STATE/PROVINCE ZIP/POSTAL CODE Purchase Date YEAR MONTH Warranty Expiry Date YEAR MONTH To be completed by the dealer at the time of the sale. DEALER IMPRINT AREA V00A2IL Please verify with your dealer to ensure your vehicle has been registered with BRP.

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