BOMBARDIER Rally 200 Operator's Manual
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BOMBARDIER Rally 200 Operator's Manual

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  • Page 2 The following trademarks are the property of Bombardier Recreational Prod- ucts Inc.: Rally Printed in Canada. (vmo2005-002 AP) ®™Trademarks of Bombardier Recreational Products Inc. or its affiliates. ©2004 Bombardier Recreational Products Inc. All rights reserved. * Bombardier and the sprocket design are trademarks of Bombardier Inc., used under license.
  • Page 3 SAE U.S. equiva- experience problems which cannot be lent in parenthesis. Where precise ac- resolved by an authorized Bombardier curacy is not required, some conver- ATV dealer. sions are rounded off for easier use.

  • 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................INTRODUCTION ..
  • Page 5 3) Rear Brake Lever............. . 62 4) Brake Lever Lock ..
  • Page 6 SPECIFICATIONS ..............109 INTERNATIONAL SYSTEM METRIC INFORMATION ......113 WARRANTY BRP LIMITED WARRANTY NORTH AMERICA: 2005 BOMBARDIER † ATV . 116 †...

  • Page 7: 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 8: Introduction

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

  • Page 9: Safety Information

    SAFETY INFORMATION ____________ ____________ SAFETY INFORMATION...

  • Page 10: Special Safety Messages

    Beginners should receive nance procedures and schedules training from a certified instructor. described in this Operator's Guide. Contact an authorized Bombardier Always keep both hands on the ATV dealer to find out about avail- handlebars and both feet on the...
  • Page 11 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 abilities. Practice on smaller hills climbing a hill. To avoid stalling, before attempting larger hills. use proper gear and maintain a steady speed when climbing a hill.
  • Page 12 Never modify this vehicle through improper installation or use of ac- cessories. Only use BRP's ap- proved accessories. Do not install passenger seat or use the racks to carry a passenger. Never exceed the stated load limits for this vehicle including operator, all other loads and added acces- sories.

  • Page 13: Operation Warnings

    BRP. 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 Bombardier ATV dealer or call BRP at 1 (819) 566–3366. ____________ ___________ SAFETY INFORMATION...
  • Page 14 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 15 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 16 WARNING V00A03Q POTENTIAL HAZARD Operating this vehicle on paved surfaces. WHAT CAN HAPPEN The ATV's tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of 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 17 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 18 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 19 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 20 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 21 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 22 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 23 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 24 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 25 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 26 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 27 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 28 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 29 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 30 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 31 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 32 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 33 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 34 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 35 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 36 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, and increases the risk of an accident.
  • Page 37 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 Bombardier ATV dealer. Do not install passenger seat or use the racks to carry a passenger.
  • Page 38 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 39 WARNING V03M01Q POTENTIAL HAZARD Transporting inflammable or dangerous material can lead to explosions. WHAT CAN HAPPEN This can cause serious injury or death. HOW TO AVOID THE HAZARD Never transport inflammable 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 40: Safety Warning

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

  • Page 41: Pre-Operation Check

    Correct any problem you may have e) Verify if steering operates freely. found before riding. See an autho- f) Activate throttle control lever sev- rized Bombardier ATV dealer as nec- eral times to ensure it operates essary. freely. It must return to idle posi- tion when released.

  • Page 42: 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 43: 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 Bombardier ATV dealer. However, always re- spect the load and capacities of the vehicle. Overloading of the vehicle can over- stress the components and cause failure.

  • Page 44: 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 45: 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 46: 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 47 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 48 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 49 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 50 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 51 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 52: 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 Bombardier ATV dealer is always willing to help.

  • Page 53: Location Of The Important 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 Bombardier ATV dealer. NOTE: The following illustrations used in this Operator's Guide are a general representation only.
  • Page 54 Label 1 Label 4 V01M07Z Label 5 V01M01Z Label 2 V01M02Z V06M0AY Label 3 V01M050 ___________ ___________ SAFETY INFORMATION...
  • Page 55 Label 6 V06M0BY Label 7 V06M0CY Label 8 V06M0DY Label 9 V06M0EY ____________ ___________ SAFETY INFORMATION...

  • Page 56: Vehicle Information

    VEHICLE INFORMATION _____________________...

  • Page 57: How To Identify Your Atv

    These numbers are required by the authorized Bombardier ATV dealer to complete war- ranty claims properly. No warranty will be allowed by BRP . if the engine identifi- cation number (EIN) or vehicle identification number (VIN) is removed or mutilated in any way.

  • Page 58: Engine Identification Number Location

    Engine Identification Number Location V06A18L _____________________...

  • Page 59: 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 60: Emission Requirements

    EMISSION REQUIREMENTS The California Air Resources Board (CARB) requires that your ATV 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 61: Controls/Instruments/Equipment

    CONTROLS/INSTRUMENTS/EQUIPMENT NOTE: Some controls/instruments/equipment are optional. V06A12L ______________________...
  • Page 62 V06A13L _____________________...

  • Page 63: 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 ATV. 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 64: Brake Lever Lock

    4) Brake Lever Lock 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 posi- it prevents the vehicle from moving.

  • Page 65: Multi-Function Switch

    WARNING Before moving vehicle in reverse, ensure the path behind is clear of obstacles or bystanders. Remain seated. N: Neutral V06I0ZY controls located this multi-function switch are: Headlamp Switch It is located on top of the multi-func- tion switch. Place switch to LO for the low beam and taillight.
  • Page 66 Press and hold the start button. Re- lease immediately after engine is started. V06A1AY 1. OFF 2. ON position “without light” 3. ON position “with light” V06I12Y 1. Start button Engine Stop Switch Located on the top of multi-func- To stop engine, fully release throttle tion switch, at the right of headlamp lever then use the engine stop switch.

  • Page 67: Indicator Lamps

    7) Indicator Lamps WARNING Never activate the override button Engine Temperature/Oil while throttle is open as loss of Pressure Lamp (red) control may result, causing severe personal injury or death. This light turns on when the ignition switch is turned ON and remains on until engine is Choke Lever running.

  • Page 68: 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 69: 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 70: 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. Turn radiator cap counterclockwise to V06A0SY remove.
  • Page 71 V06G01Y 1. Fuse holder ______________________...

  • Page 72: 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 check their levels. Refer to MAINTE- WARNING NANCE for procedures to replace the Always stop engine before refu-...
  • Page 73 Oil Viscosity SAE 5W30 is recommended for all seasons. However, during the hottest days of the summer and bitter cold days of the winter, refer to the following chart to select the proper viscosity. °C °F V06C2DY RH SIDE OF ENGINE With vehicle on a level surface and engine cold, not running, check the oil level as follows:...

  • Page 74: Gearbox Oil

    Gearbox Oil level hole. To change gearbox oil, refer to MAIN- Recommended Oil TENANCE section. Use BOMBARDIER chaincase oil (P/N 413 801 900) or an equivalent. Engine Coolant CAUTION: Do not use unrecom- mended other types of oil when ser- Recommended Coolant vicing.
  • Page 75 (P/N 219 700 362) or with distilled tion of leaks or engine problems. See water and antifreeze solution (50% an authorized Bombardier ATV dealer. water, 50% antifreeze). To gain access to the radiator, proceed as follows: Coolant Level –...

  • Page 76: Brake Fluid

    NOTE: A low level may indicate leaks add distilled water. or worn brake pads. See an autho- rized Bombardier ATV dealer. Refilling Place battery on a level surface. Brake Lever Fluid Reservoir Unscrew caps and add distilled water Turn steering in the straight-ahead up to upper mark as required.
  • Page 77 V06G02Y 1. Upper mark 2. Lower mark Properly retighten caps. ______________________...

  • Page 78: Break-In Period

    BREAK-IN PERIOD Engine Belt A break-in period of 10 operating hours A new belt requires a break-in period is required before running the vehicle of 50 km (30 miles). Avoid strong ac- at sustained full throttle. celeration/deceleration, pulling a load or high speed cruising.

  • Page 79: Pre-Operation Check

    Correct any problem you may have e) Verify if steering operates freely. found before riding. See an autho- f) Activate throttle control lever sev- rized Bombardier ATV dealer as nec- eral times to ensure it operates essary. freely. It must return to idle posi- tion when released.

  • Page 80: Operating Instructions

    OPERATING INSTRUCTIONS General NOTE: Throttle assist may be use to help engine starting faster. Press Transmission lever must be on NEU- the throttle lever slightly. If too much TRAL to allow engine starting. throttle is used the choke system will To start engine, place the engine stop not be activated.

  • Page 81: Shifting The Transmission

    Shifting the Transmission Let engine idle to warm up. Apply brakes and select the desired gear range H. Release brakes. CAUTION: Make sure parking brake is fully disengaged before operating the ATV. Gradually press the throttle lever to in- crease engine speed and thus engag- ing the continuously variable transmis- sion (CVT).

  • Page 82: Special Procedures

    Start engine as explained above. If en- gine continues to flood, see an autho- rized Bombardier ATV dealer. Engine Overheat If engine overheats and indicator light turns on, try the following: –...

  • Page 83: Post-Operation Care

    Stop engine immediately. will be necessary to take it to an autho- Otherwise, if the light turn off and the rized Bombardier ATV dealer as soon engine is cold or warm, not hot, a po- as possible. DO NOT START THE...

  • Page 84: 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 85 Place the fuel valve to OFF position. Select the NEUTRAL position and set the parking brake. Secure the vehicle by the front and rear bumpers. CAUTION: Attaching vehicle at other locations may damage the vehicle. Unload racks before transporting the vehicle.

  • Page 86: Maintenance Information

    MAINTENANCE INFORMATION _____________________...

  • Page 87: Maintenance Chart

    MAINTENANCE CHART The maintenance is very important, if you are not familiar with safe service prac- tices and adjustment procedures, see your authorized Bombardier ATV dealer. I: Inspect, verify, clean, adjust, lubricate or replace if EVERY Initial necessary inspection To be...
  • Page 88 I: Inspect, verify, clean, adjust, lubricate or replace if EVERY Initial necessary inspection To be C: Clean 10 h or 200 h or performed 100 h or 30 days L: Lubricate 25 h or 50 h or 2 years 1 year or or 200 km 500 km 1000 km...
  • Page 89 Customer EVERY RIDE Vehicle cleaning and protection Customer (1) To be performed by an authorized Bombardier ATV dealer. The initial maintenance is very important and must not be neglected. (2) Pre-ride inspection item. (3) Every 100 hours, check coolant strength.

  • Page 90: Maintenance

    MAINTENANCE 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. WARNING WARNING Unless otherwise specified, engine The engine oil can be very hot. should not be running for all main- Wait until engine oil is warm.
  • Page 91 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 92 4. Oil pressure valve port place the vehicle on the ground. NOTE: Oil coming out will push out Refill gearbox, using BOMBARDIER spring loaded ball; take care not to lose chaincase oil (P/N 413 801 900) or an spring and ball.
  • Page 93 Check if the carburetor heater is pincher (P/N 529 032 500). warm. If not, redo the bleeding pro- cedure. Reinstall front facia. Drive Belt See an authorized Bombardier ATV dealer to inspect and/or replace the drive belt. ______________________...

  • Page 94: Carburetor

    Valve Adjustment Reinstall the spark arrester in muffler. See an authorized Bombardier ATV Radiator dealer for valves adjustment. Periodically check the radiator area for Insufficient clearance will cause loss cleanliness. of power and possibly damage the valves. Excessive clearance will Inspect radiator fins.
  • Page 95 Air Box Draining Periodically inspect air box drain tube for liquid or deposits. V06L0VY 1. Air box cover Remove air filter. V06C2IY TYPICAL 1. Air box 2. Drain tube 3. Clamp NOTE: If vehicle is used in dusty area, inspect more frequently than specified in MAINTENANCE CHART.

  • Page 96: Electrical

    Air Filter Installation WARNING Properly reinstall removed parts in the Electrolyte is poisonous and dan- reverse order of their removal. gerous. Avoid contact with eyes, skin and clothing. Wear protective Reinstall the air filter with the grey part eyeglasses and a suitable pair of on top.
  • Page 97 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 iso- propyl alcohol which will not leave a film on the bulb. Unplug connector from headlamp. V06G01Y 1.
  • Page 98 V06G0RY Lift and hold the spindle then remove V06G0TY the bulb. 1. Headlamp housing 2. Beam height adjustment 3. Beam side adjustment Taillight Unscrew lens screws to expose bulb. V06G0SY Properly reinstall removed parts in the reverse order of their removal. V06G0UY Adjust beam aiming as follows: 1.

  • Page 99: Drive Train

    V06G0WY V06G0OZ 1. Indicator lamp bulb 1. Cluster's screws 2. Rubber protector Pull the indicator lamp lens out of its Pull the bulb to remove it. location. For installation, reverse the removal instructions. Drive Train Lubrication Lubricate front knuckles. Use syn- thetic grease (P/N 293 550 033) or an equivalent .
  • Page 100 WARNING Place ignition switch to OFF before checking, adjusting or lubricating the drive chain. CAUTION: Never operate this vehi- cle with the drive chain too loose or too tight as severe damage to the drive components can occur. Inspection V06H0QY This ATV is equipped with O-ring 1.
  • Page 101 Replace the drive chain slider when it Push and pull the wheels from the is worn. upper edge to feel the play. See an See an authorized Bombardier ATV authorized Bombardier ATV dealer if dealer for replacement. there is any play.

  • Page 102: Steering System

    Tire/Wheel Condition Check tire for damage and wear. Re- place if necessary. Do not rotate tires. The front and rear tires have a different size. The tires are directional and their rotation must be kept in a specific direction for proper operation.
  • Page 103 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. Open the throttle lever housing. V06I04Y 1. Throttle handle housing 2. Throttle cable NOTE: Slide cable in clip slot and re- move the end of cable from clip.

  • Page 104: Suspension

    Loosen lock nut then turn the adjuster Shorten the spring for a firmer ride and to obtain correct throttle lever free rough road condition. play. Lengthen the spring for a light load and NOTE: Measure throttle free play at a smooth road condition. the tip of throttle lever.

  • Page 105: Brake

    Inspect shock absorbers for oil leaks ble lubricant (P/N 293 600 041) or and and fasteners for tightness. See an equivalent then press the brake pedal authorized Bombardier ATV dealer as to move the brake cable. Repeat this necessary. procedure until the silicone lubricant exits the other end of the cable.

  • Page 106: Body/Frame

    When required, wash the body with any brake system repairs should hot water and soap (only use mild de- be performed by an authorized tergent). Apply non-abrasive wax. Bombardier ATV dealer. CAUTION: Never clean plastic parts with strong detergent, de- Body/Frame greasing agent, paint thinner, ace- tone, etc.

  • Page 107: Troubleshooting

    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 Bombardier ATV dealer. 6. Engine compression. – If no pulsating resistance is felt, it suggests a major loss of compression.
  • Page 108 Contact an authorized Bombardier ATV dealer. 4. Engine is overheating. – Check ENGINE OVERHEATING in SPECIAL PROCEDURES. – If overheating persists, contact an authorized Bombardier ATV dealer. 5. Air filter/box plugged or dirty. – Check air filter and clean if necessary. –...
  • Page 109 3. Chain tensioner plugged. – Contact an authorized Bombardier ATV dealer. 4. Timing chain wear. – Contact an authorized Bombardier ATV dealer. Vehicle cannot reach full speed 1. Engine. – See ENGINE LACKS ACCELERATION OR POWER. 2. Parking brake. –...

  • Page 110: Specifications

    SPECIFICATIONS VEHICLE 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) 11.37:1...
  • Page 111 VEHICLE MODEL Rally™ 200 ELECTRICAL Make SEEC Magneto generator Type 260 W @ 6000 RPM Ignition type Ignition timing Not adjustable Engine RPM limiter 10 200 RPM (any gear in forward) Vehicle speed limiter 15 km/h (9 MPH) in reverse Make Type Spark plug...
  • Page 112 VEHICLE MODEL Rally™ 200 WHEELS Front 10 x 5.5 Size Rear 10 x 8 Wheel nuts torque 70 N•m (52 lbf•ft) BRAKES Front Hydraulic, 2 discs Rear Hydraulic, 1 disc Parking device LH brake lever includes a lock. LOADING CAPACITY Front racks 16 kg (35 lb) Rear racks...
  • Page 113 VEHICLE MODEL Rally™ 200 LIQUIDS and GREASES SAE 4–stroke mineral-based. API Engine oil type classification SG, SH or SJ or Bombardier (engine and transmission) synthetic oil 5W40. Refer to OIL VISCOSITY CHART for other grade Gearbox oil 80W-90 Ethylene-glycol/water mix (50% coolant, 50% distilled water).

  • Page 114: International System Metric Information

    INTERNATIONAL SYSTEM METRIC INFORMATION BASE UNITS DESCRIPTION UNIT SYMBOL length ..........meter ........ mass ..........kilogram ......force........... newton......liquid ..........liter ........temperature ........Celsius ......°C pressure ..........kilo pascal......torque ..........newton-meter ....land velocity ........kilometer per hour..... km/h navigation velocity ......

  • Page 115: Warranty

    WARRANTY _____________________...

  • Page 116: Brp Limited Warranty North America: 2005 Bombardier Atv

    ATVs are warranted separately by the tire and winch manufacturer. If such tire or winch are installed on your Bombardier ATV, please contact the manufacturer or ask your authorized Bombardier ATV dealer for warranty coverage and assistance.
  • Page 117 3) CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on 2005 Bombardier ATVs purchased as new and unused by its first owner from a Bombardier dealer authorized to distrib- ute Bombardier ATV products in the country in which the sale occurred (“Bom- bardier ATV dealer”), and then only after the BRP specified pre-delivery inspection...
  • Page 118 Bombardier ATV dealer and gives the coordinates of the new owner; or b) BRP or an authorized Bombardier ATV dealer receives a proof that the former owner agreed to the transfer of ownership, in addition to the coordinates of the new owner.
  • Page 119 VALCOURT, QC, J0E 2L0 WAUSAU WI 54401 Tel : (819) 566-3366 Tel : (715) 848-4957 * In the USA, products are distributed and serviced by Bombardier Motor Corpo- ration of America. © 2004 Bombardier Recreational Products Inc. All rights reserved.

  • Page 120: Brp International Limited Warranty: 2005 Bombardier Atv

    3) CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on 2005 Bombardier ATVs purchased as new and unused by its first owner from a Bombardier dealer authorized to distrib- ute Bombardier ATV products in the country in which the sale occurred (“Bom- bardier ATV distributor/dealer”...
  • Page 121 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 Bombardier parts without charge for parts and labor, at any authorized Bombardier ATV distributor/dealer.
  • Page 122 YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM STATE TO STATE, OR PROVINCE TO PROVINCE. Neither the distributor, any Bombardier ATV dealer nor any other person has been authorized to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against BRP.
  • Page 123 BOMBARDIER RECREATIONAL PRODUCTS INC. BOMBARDIER ATV CUSTOMER ASSISTANCE CENTER VALCOURT, QC, J0E 2L0 Tel : (819) 566-3366 * In the USA, products are distributed and serviced by Bombardier Motor Corpo- ration of America. © 2004 Bombardier Recreational Products Inc. All rights reserved. †...

  • Page 124: Privacy Obligation/Disclaimer

    If you prefer not to have your name and ad- dress released, please let us know by writing to the address below. Bombardier Recreational Products Inc. Warranty Department 75 J.A. Bombardier Street Sherbrooke, Québec J1L 1W3 Canada Fax Number: (819) 566 –...

  • Page 125: Change Of Address/Ownership

    STOLEN UNITS: If your personal ATV is stolen, you should notify BRP or an au- thorized Bombardier ATV dealer. We will ask you to provide your name, address, phone number, the vehicle identification number and the date it was stolen.
  • Page 126 AFFIX PROPER POSTAGE Bombardier Recreational Products Inc. WARRANTY DEPARTMENT 75, J.A. Bombardier Sherbrooke, QC Canada J1L 1W3 V00A2G _____________________...
  • Page 127 STOLEN UNITS: If your personal ATV is stolen, you should notify BRP or an au- thorized Bombardier ATV dealer. We will ask you to provide your name, address, phone number, the vehicle identification number and the date it was stolen.
  • Page 128 AFFIX PROPER POSTAGE Bombardier Recreational Products Inc. WARRANTY DEPARTMENT 75, J.A. Bombardier Sherbrooke, QC Canada J1L 1W3 V00A2G _____________________...
  • Page 129 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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