Page 2 2003 Shop Manual RALLY™ 200...
Page 3 National Library of Quebec 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.
Page 4: Table Of Contents
TABLE OF CONTENTS SECTION SUBSECTION PAGE SAFETY NOTICE ........................... INTRODUCTION ..........................SERVICE TOOLS AND 01 – Table of contents..............01-01-1 SERVICE PRODUCTS 02 – Service tools................01-02-1 03 – Service products............... 01-03-1 MAINTENANCE 01 – Table of contents..............02-01-1 02 – Maintenance chart..............02-02-1 03 –...
Page 5 TABLE OF CONTENTS SECTION SUBSECTION PAGE BODY/FRAME 01 – Table of contents ..............10-01-1 02 – Body..................10-02-1 03 – Frame..................10-03-1 TECHNICAL DATA 01 – SI metric information guide............11-01-1 02 – Technical data (engine and vehicle) ......... 11-02-1 WIRING DIAGRAM 01 –...
Page 6 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.
Page 7: Service Tools And
INTRODUCTION INTRODUCTION ENGINE SERIAL NUMBER This Shop Manual covers the following Bombardier made 2003 ATV: LOCATION Models Rally 200 (red) ........7550 Rally 200 (green) ......... 7551 Rally 200 (yellow)........ 7552 Rally 200 (red international)....7591 Rally 200 (green international)... 7592 Rally 200 (yellow international) ..
Page 8 INTRODUCTION LIST OF ABBREVIATIONS USED left hand IN THIS MANUAL pound ampere pound (force) ampere meter A•h ampere-hour magneto alternate current Max. maximum bottom dead center Min. minimum BTDC before top dead center milliliter °C degree Celsius millimeter Capacitor discharge ignition mile per hour centimeter newton...
Page 9: Engine
INTRODUCTION This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. Page heading indicates section and subsection detailed. Section 03 ENGINE REMOVAL AND INSTALLATION Subsection title indicates beginning of the subsection. Exploded view assists you in identifying parts and related positions.
Page 10 INTRODUCTION Section 03 ENGINE Title indicates main procedure to be carried-out. Ball bearing must rotate freely. Othewise, Remove replace it. Bold face number – magneto housing cover following part – screw name refers to – stator with trigger coil – Heat up the magneto housing cover to about exploded view C (212 F) for an easy ball bearing removal.
Page 11 Due to late changes, it may have some differences between the manufactured product and the descrip- tion and/or specifications in this document. Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation.
Page 12 INTRODUCTION Threadlocker 1. Clean threads (bolt and hole) with solvent. 2. Apply Loctite Primer N (P/N 293 800 041) on Uncovered Holes (bolts and nuts) threads (bolt and nut) and allow to dry for 30 sec- onds. 3. Choose proper strength Loctite threadlocker. 4.
Page 13 INTRODUCTION Adjusting Screw NOTE: Retaining compound is always forced out when applied on shaft. 3. DO NOT use anti-seize Loctite or any similar product. 4. No curing period is required. Mounting in Tandem 1. Apply retaining compound on internal element bore.
Page 14 INTRODUCTION TIGHTENING TORQUES Tighten fasteners to torque mentioned in exploded views and text. When they are not specified refer to following table.The table also gives the metric conversion. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones where specified.
Page 15 Page______ ❏ ❏ Machine___________________ Report of error Suggestion ____________________________________________________________ We would be pleased if you could ____________________________________________________________ communicate to Bombardier any sug- gestions you may have concerning our publications. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ____________________________________________________ City and State/Prov. ________________________...
Page 16 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0...
Page 17 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS SERVICE TOOLS........................01-02-1 MANDATORY SPECIAL TOOL ..................01-02-1 RECOMMENDED SPECIAL TOOL ..................01-02-8 SERVICE PRODUCTS ......................01-03-1 MANDATORY SERVICE PRODUCTS ................01-03-1 RECOMMENDED SERVICE PRODUCTS ................01-03-2 01-01-1 VMR2003-033_01-01ATOC.FM...
Page 18: Service Tools
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) SERVICE TOOLS MANDATORY SPECIAL TOOL All Models TOOL DESCRIPTION Small Hose Pincher 295 000 076 A01B2IY Large Hose Pincher 529 032 500 F01B23Y Fuel System Pressure Tester 529 033 100 Traxter —...
Page 19 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) DS 650/Baja — Quest 500/650 — Traxter TOOL DESCRIPTION Caillau Pliers 295 000 054 CV Boot Clamp 295 000 069 Installation and Removal Tool Crankshaft Protector 420 876 557 Flywheel Puller 529 035 748 01-02-2...
Page 20 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Rally TOOL DESCRIPTION Clutch Holding Tool 529 035 862 Clutch Support 529 035 863 51 mm (2 in) Open Wrench 529 035 866 51 mm (2 in) Crow Foot 529 035 884 01-02-3 VMR2003-002-01-02A.FM...
Page 21 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Traxter TOOL DESCRIPTION Lifting Bar 529 035 610 Jumper for Self Diagnostics 529 035 605 Crankshaft Locking Bolt 529 035 645 Spanner Tool for Clutch Basket 529 035 647 T-Harness for Diagnoses of 529 035 653 Solenoids...
Page 22 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) DS 650/Baja TOOL DESCRIPTION Magneto Cover Removal Tool 529 035 622 Engine Installation and 529 035 619 Removal Tool 64 mm (2-1/2 in) Crow Foot 529 035 729 Rear Axle Nut Clutch Basket Holder 529 035 618 01-02-5...
Page 23 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Quest 500/650 TOOL DESCRIPTION Bevel Gear Lock Pin/Driven 529 035 747 Clutch Expander Drive Clutch Puller 529 035 746 Driven Clutch Holding Tool 529 035 771 Drive Clutch Colding Tool 529 035 745 Bearing Aligment Tool 529 035 806...
Page 24 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Quest 500/650 — Traxter TOOL DESCRIPTION 6 Pin Harness for Magneto 529 035 604 41 mm Socket for Swing Arm Nut PROTO 5541 Hub Puller 529 035 612 DS 650/Baja — Quest 500/650 — Rally TOOL DESCRIPTION Crankshaft Locking Bolt...
Page 25: Recommended Special Tool
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) RECOMMENDED SPECIAL TOOL All Models TOOL DESCRIPTION Ring Compressor Snap-On RC980 Low Speed Screw Adjuster 529 035 732 Float Level Gauge 529 035 520 Carburetor Kit 404 112 000 Valve Spring Compressor 529 035 724 Insertion Jig Handle...
Page 26 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) All Models (Continued) TOOL DESCRIPTION Vacuum/Pressure Pump 529 021 800 Cable Luber 529 035 738 Leak Down Tester 529 035 661 Multimeter 529 035 868 01-02-9 VMR2003-002-01-02A.FM...
Page 27 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Quest 500/650 — Rally TOOL DESCRIPTION Blind Hole Bearing Puller Snap-On Needle Bearing Installer 529 035 762 (Main Shaft in Crankcase) Quest 500/650 — Traxter TOOL DESCRIPTION Ball Joint Remover 529 035 873 Differential Spanner Socket 529 035 649...
Page 28 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Quest 500/650 — Traxter (Continued) TOOL DESCRIPTION Choke Nut Tool 529 035 660 Ball Joint Installer Support 529 035 875 Ball Joint Installer 529 035 874 Terminal Remover Snap-On TT660-4 Shock Spring Disassembly Tool 529 035 504 01-02-11...
Page 29 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) DS 650/Baja — Quest 500/650 — Rally TOOL DESCRIPTION Valve Spring Compressor Cup 529 035 764 DS 650/Baja — Quest 500/650 TOOL DESCRIPTION Valve Stem Seal Pliers Snap-On YA 8230 DS 650/Baja —...
Page 30 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) DS 650/Baja — Quest 500/650 — Traxter (Continued) TOOL DESCRIPTION Exhaust Spring Installer/Remover 529 035 401 Oil Pressure Gauge 529 035 709 Connection tool 529 035 714 01-02-13 VMR2003-002-01-02A.FM...
Page 31 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) DS 650/Baja TOOL DESCRIPTION Front Hub Seal Installer 529 035 632 Ball Joint Guide 529 035 705 Ball Joint Drive 529 035 706 01-02-14 VMR2003-002-01-02A.FM...
Page 32 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) DS 650/Baja (Continued) TOOL DESCRIPTION Swing arm key 529 035 696 Shock Tool 529 035 636 Rear Hub Seal Installer 529 035 634 Front Knuckle Wear Ring Installer 529 035 637 Shock Charging Tool 529 035 570 Brake Hub Remover...
Page 33 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) DS 650/Baja (Continued) TOOL DESCRIPTION Rear Axle Wear Ring Installer 529 035 694 Crankshaft Bushing Installer 529 035 689 Primary Crankshaft Gear Puller 529 035 624 01-02-16 VMR2003-002-01-02A.FM...
Page 34 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) DS 650/Baja (Continued) TOOL DESCRIPTION Clutch Shaft Bearing Installer 529 035 691 Clutch Shaft Seal Installer 529 035 693 Crankshaft Bushing Remover 529 035 688 Quest 500/650 TOOL DESCRIPTION Water Pump Ceramic Seal Installer 529 035 766 Valve Stem Seal Installer...
Page 35 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Quest 500/650 (Continued) TOOL DESCRIPTION Lifting Ring 529 035 770 Torque Angle Snap-On TA 362 Oil Seal Installer 529 035 760 (Crankshaft Oil Seal on Crankcase) Needle Bearing Installer 529 035 756 (Starter Drive Pinion in Crankcase) 01-02-18...
Page 36 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Quest 500/650 (Continued) TOOL DESCRIPTION Oil Seal Installer 529 035 761 (Main Shaft Oil Seal on Crankcase) Oil Seal Installer 529 035 757 (Water Pump Shaft Oil Seal) Oil Seal Installer (Crankshaft Oil Seal on 529 035 759 Magneto Cover)
Page 37 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Quest 500/650 (Continued) TOOL DESCRIPTION Oil Seal Installer (Shift Shaft Oil Seal on 529 035 758 Magneto Cover) Needle Bearing Installer 529 035 763 (Bevel Gear Shaft in Crankcase) Piston Circlip Installer 529 035 765 Crankcase Plain Bearing...
Page 38 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Quest 500/650 (Continued) TOOL DESCRIPTION Crankcase Plain Bearing Remover/Installer 529 035 753 (MAG Side) Crankcase Support 529 035 754 (CVT Side) Crankcase Support 529 035 755 (MAG Side) 01-02-21 VMR2003-002-01-02A.FM...
Page 39 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Traxter TOOL DESCRIPTION Crimping Tool 295 100 164 (for AMP Connectors) Lifting Ring 529 035 644 Front Suspension Spacer Bar 529 035 611 (Model Year 1999/2000) Valve Spring Compressor Cup 529 035 725 01-02-22 VMR2003-002-01-02A.FM...
Page 40 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Rally TOOL DESCRIPTION Clutch Holding Support 529 035 864 Crankshaft Oil Seal Installer 529 035 847 Water Pump Oil Seal Installer 529 035 849 Shifter Oil Seal Installer 529 035 851 Valve Guide Remover 529 035 852 Valve Guide Installer...
Page 41 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE TOOLS) Rally (Continued) TOOL DESCRIPTION Magneto Puller (used bolt from 529 035 883 magneto puller P/N 529 035 748) Crankshaft Plain Bearing 529 035 855 Remover/Installer Needle Bearing Installer 529 035 858 Piston Circlip Installer 529 035 859 Allen Wrench...
Page 42: Service Products
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 03 (SERVICE PRODUCTS) SERVICE PRODUCTS MANDATORY SERVICE PRODUCTS Paste gasket Loctite ® primer High strength retaining compound (P/N 293 800 038) (P/N 293 800 041) (P/N 293 800 073) Loctite ® 518: Primer N 128 g (5 oz) Loctite 277 (10 ml) (red) Gasket eliminator (50 ml)
Page 43: Recommended Service Products
Loctite 384 (300 ml) V00B1I4 Fuel stabilizer (P/N 413 408 600) (12 x 8 oz) A00B5Z4 A00B5Y4 BOMBARDIER LUBE Storage oil (P/N 293 600 016) (P/N 413 711 600) (12 x 14 oz) (350 g spray can) (12 x 350 g) A00B604 Premixed coolant 50/50 - 37°C (- 35°F)
Page 44 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 03 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Anti-seize lubricant Heavy duty cleaner High temperature and strength retaining compound (P/N 293 800 070) (P/N 293 110 001) (400 g) (P/N 413 711 400) Loctite anti-seize lubricant 236 ml (8 oz) (P/N 293 110 002)
Page 45 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 03 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Bombardier Cleaner Super Lube grease Bombardier Cable Lubricant (P/N 293 110 001) (400 g) (P/N 293 550 030) (P/N 293 600 041) (400 g) (P/N 293 110 002) (4 l)
Page 46 Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS MAINTENANCE CHART ......................02-02-1 NOISE EMISSION CONTROL SYSTEM REGULATION ........... 02-02-1 TAMPERING WITH NOISE CONTROL SYSTEM IS PROHIBITED ........02-02-1 AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS ..02-02-1 LUBRICATION AND MAINTENANCE CHART ..............
Page 47: Maintenance Chart
Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART) MAINTENANCE CHART 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 there of: 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 2.
Page 48: Lubrication And Maintenance Chart
Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART) LUBRICATION AND MAINTENANCE CHART Some items may not apply to your particular model. EVERY I: Inspect, verify, clean, adjust, lubricate, replace if necessary C: Clean L: Lubricate R: Replace Engine oil and filter Engine oil strainer Maintenance/ Lubrication...
Page 49: Suspension
Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART) EVERY I: Inspect, verify, clean, adjust, lubricate, replace if necessary C: Clean L: Lubricate R: Replace Swing arm Front and rear Shock absorber suspension A-arm Brake fluid Brake cable Hydraulic brakes Brake system (discs, hoses, etc.) Brake pads Engine area Chassis fastener...
Page 50: Maintenance/Lubrication
Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) MAINTENANCE/LUBRICATION SPECIAL PROCEDURES Flipped Over When vehicle has flipped over or stays tilted on the side, wait around 5 minutes before starting engine. Check oil level and adjust if necessary. Do not start the engine if the oil level is lower than the minimum recommended.
Page 51: Bolts, Fasteners And Nuts
Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) Remove cluster cover. Reinstall the air filter with the grey part on top. NOTE: Check if the air filter broach is properly located before installing air filter. BOLTS, FASTENERS AND NUTS Check that all fasteners, bolts and nuts are tightened to the proper torque.
Page 52 Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) Oil Level Place a drain pan under the engine magnetic drain plug area. Using the following procedure, check the engine Clean the magnetic drain plug area. oil level. Unscrew magnetic drain plug. Place the vehicle on a level surface. CAUTION: Pay attention not to lose gasket ring NOTE: The engine must be cold, not running.
Page 53: Oil Strainer
Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) WARNING Never run engine in an enclosed area. Never perform this operation immediately af- ter the engine has been run because exhaust system is very hot. Make sure that there are no combustible ma- terials in the area.
Page 54: Tires And Wheels
Section 02 MAINTENANCE Subsection 03 (MAINTENANCE/LUBRICATION) TIRES AND WHEELS NOTE: Do not make a tire rotation. The front and rear tires have a different size. Besides, these tires are directional and their rotation must be kept in a Tire Pressure specific direction for proper operation.
Page 55: Storage/Preseason Preparation
Section 02 MAINTENANCE Subsection 04 (STORAGE/PRESEASON PREPARATION) STORAGE/PRESEASON PREPARATION STORAGE – Inject storage oil until the engine stalls or until a sufficient quantity of oil has entered the en- If the ATV is to be stored for an extended period gine (approximately a quarter of can).
Page 56: Vehicle Cleaning And Protection
Inspect the vehicle and repair any damage. Touch up all metal spots where paint has been scratched off. Spray all metal parts with BOMBARDIER LUBE (P/N 293 600 016). NOTE: Protect the vehicle with a cover to prevent dust accumulation during storage.
Page 57: Preseason Preparation
Section 02 MAINTENANCE Subsection 04 (STORAGE/PRESEASON PREPARATION) PRESEASON PREPARATION TO BE PERFORMED BY SYSTEM PRESEASON OPERATIONS REFER TO SECTION CUSTOMER DEALER Test Run Vehicle ➁➃. Check Clutch and Transmission ✔ N.A. Operation Engine Oil and Filter Oil Replacement ➀ ✔ ✔...
Page 58 Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS TROUBLESHOOTING ......................03-02-1 COOLING SYSTEM ......................03-02-1 MAGNETO SYSTEM ......................03-02-2 LUBRICATION........................03-02-3 CYLINDER AND HEAD ...................... 03-02-5 CRANKSHAFT........................03-02-6 GEARBOX .......................... 03-02-6 CVT ............................. 03-02-8 ENGINE GENERAL ......................03-02-11 LEAK TEST..........................
Page 59 Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) MAGNETO SYSTEM ......................03-06-1 MAGNETO SYSTEM ......................03-06-1 GENERAL..........................03-06-2 MAGNETO COVER......................03-06-2 STATOR AND TRIGGER COIL ................... 03-06-3 ROTOR ..........................03-06-4 SPRAG CLUTCH ......................... 03-06-6 STARTER..........................03-06-7 LUBRICATION SYSTEM......................03-07-1 ENGINE OIL FLOW CHART....................03-07-2 GENERAL..........................
Page 60 Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) GEARBOX ..........................03-10-1 GEARBOX .......................... 03-10-1 CRANKCASE ........................03-10-2 GENERAL ........................... 03-10-3 OIL CHANGE ........................03-10-3 OIL SEALS.......................... 03-10-3 CRANKCASE ........................03-10-5 GEAR BOX ......................... 03-10-8 SHIFTING INDICATOR SWITCH ..................03-10-15 CVT............................03-11-1 GENERAL ...........................
Page 61: Troubleshooting
Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) TROUBLESHOOTING The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. This section pertains to engine mechanical components only. Some related problems can come from other systems such as ignition system, fuel system etc.
Page 62: Magneto System
Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) MAGNETO SYSTEM SYMPTOM NO SPARK. CONDITION NORMAL USE. Test/Inspection 1. Check spark plug electrode condition. a. Gap is too big. Readjust gap (refer to TECHNICAL DATA). 2. Check ignition coil for damage and/or electrical failure. a.
Page 63: Lubrication
Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) LUBRICATION SYMPTOM LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION. CONDITION NORMAL USE. Test/Inspection 1. Check oil level and search for leakage on crankcase and/or defective sealing ports. a. Crankcase is leaking due to damage. Rebuild engine with new crankcase and gasket parts.
Page 64 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION. CONDITION NORMAL USE. Test/Inspection 8. Check oil orifice(s) on the oil pump suction side. a. Oil orifice(s) is (are) clogged. Clean from contamination. Replace oil and oil filter if necessary (refer to MAINTE- NANCE or LUBRICATION).
Page 65: Cylinder And Head
Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) CYLINDER AND HEAD SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATION IN IDLE SPEED. CONDITION NORMAL USE. Test/Inspection 1. Check oil pressure regulator valve (spring) function. a. Valve fixed due contamination and/or spring damaged (valve remains open). Clean and/or replace spring and/or mechanism.
Page 66: Crankshaft
Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) CRANKSHAFT SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATIONS. CONDITION NORMAL USE. Test/Inspection 1. Check thrust washer(s) on crankshaft MAG/PTO side. a. Thrust washer(s) is (are) missing on MAG and/or PTO side. Fit thrust washer(s). GEARBOX SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATIONS.
Page 67 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM GEAR INDICATION FAILS. CONDITION NORMAL USE. Test/Inspection 1. Check contact screws on PTO side (gearbox area) for damage and/or wear. a. Shifting indicator switch(es) pin(s) is (are) worn and/or otherwise damaged. Replace shifting indicator switch(es). b.
Page 68: Cvt
ENGINE MAXIMUM RPM IS TOO HIGH AND TOP SPEED IS NOT REACHED. CONDITION NORMAL USE. Test/Inspection 1. Check items 1 to 3 of THE ATV ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED. 2. Check driven pulley spring tension. a. Spring tension is too stiff. Replace spring (recommended Bombardier spring). 03-02-8 VMR2003_006_03_02A.FM...
Page 69 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM DRIVE PULLEY NOISE IN IDLE SPEED. CONDITION NORMAL USE. Test/Inspection 1. Check slide pieces (drive pulley). a. Worn slide pieces (increased clearance to drive pulley inner half). Replace all slide pieces at the same time (slide piece kit). 2.
Page 70 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM VIBRATIONS ORIGINATING FROM DRIVEN PULLEY. CONDITION NORMAL USE. Test/Inspection 1. Check centrifugal clutch on driven pulley. a. Centrifugal clutch out of round after replacement. Reinstall centrifugal clutch turned by 180°. SYMPTOM PULLEYS DO NOT DOWN SHIFT PROPERLY. CONDITION NORMAL USE.
Page 71 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM BELT SIDES WORN CONCAVE. CONDITION NORMAL USE. Test/Inspection 1. Check pulley half surfaces. a. Rough or scratched pulley half surfaces. Repair or replace. 2. Check drive belt identification number. a. Unspecified type of belt. Replace belt with an appropriate drive belt (refer to TECHNICAL DATA).
Page 72: Engine General
Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) ENGINE GENERAL SYMPTOM ENGINE BACKFIRES. CONDITION NORMAL USE. Test/Inspection 1. Check spark plug and/or electrical system. a. Carbon accumulation caused by defective spark plug. Clean carbon accumulation and replace spark plug. b. Electrical system has failure. Replace defective part(s).
Page 73 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. Test/Inspection 1. Check condition of spark plug (blue spark ideal). a. Red, jumping spark means a damaged spark plug. Replace spark plug with appropriate heat range (refer to TECHNICAL DATA). 2.
Page 74 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. Test/Inspection 6. Cracked or broken piston. a. Cracked or broken piston due to excessive piston/cylinder clearance or engine overreving. Replace piston. Check piston/cylinder clearance (refer to CYLINDER AND HEAD). 7.
Page 75 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH SYMPTOM MAXIMUM OPERATING RPM. CONDITION NORMAL USE. Test/Inspection 1. Check items 1 and 2 of ENGINE SUDDENLY TURNS OFF. 2. Check air intake system. a.
Page 76 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM ENGINE TURNS OVER BUT FAILS TO START. CONDITION NORMAL USE. Test/Inspection 1. Check items of ENGINE DOES NOT START — NO SPARK AT SPARK PLUG. 2. Check spark plug. a. Define spark plug (no spark) or wrong spark plug gap. Readjust gap and clean spark plug or replace.
Page 77 Section 03 ENGINE Subsection 02 (TROUBLESHOOTING) SYMPTOM ENGINE DOES NOT START — NO SPARK AT SPARK PLUG (SEE MAGNETO SYSTEM). CONDITION AT ENGINE CRANKING. Test/Inspection 1. Verify spark plug condition. a. Defective, improperly set, worn out, fouled. Identify source of problem and correct. Replace spark plug. 2.
Page 78: Leak Test
Section 03 ENGINE Subsection 03 (LEAK TEST) LEAK TEST VERIFICATION Remove: – radiator cap Before performing the cylinder leak test, verify the – CVT hose inlet. following: NOTE: To ease reaching cylinder head area it is – intake port/air filter contaminated (glogged) recommended to disconnect CVT hose inlet.
Page 79 Section 03 ENGINE Subsection 03 (LEAK TEST) Rotate crankshaft until piston is at TDC. 1. Crankshaft locking bolt 2. Thread in the area of electrical starter Test 1. Cylinder bore axle (arrow middle of the timing gear bore) 2. Groove in the camshaft Connect leak tester (P/N 529 035 661) to adequate 3.
Page 80 Section 03 ENGINE Subsection 03 (LEAK TEST) Note the amount of leaking or percentage (depending on tester). LEAKAGE ENGINE PERCENTAGE CONDITION 0% to 7% Excellent condition. Fair condition; 8% to 15% proceed with tuned up or adjustment. Poor condition; engine will run and 16% to 30% performance might be down in some...
Page 81: Removal And Installation
Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION ENGINE SYSTEM 03-04-1 VMR2003_008_03_04A.FM...
Page 82: Exhaust System
Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) EXHAUST SYSTEM 03-04-2 VMR2003_008_03_04A.FM...
Page 83: General
Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) GENERAL Always disconnect battery. WARNING Always disconnect battery or starter cables exactly in the specified order, BLACK (-) cable first. At installation, use torque values and Loctite prod- ucts from the exploded view. Clean threads before using Loctite products when installing screws.
Page 84 Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) – rear brake caliper/disc/pedal (refer to BRAKES) 1. Drive chain 2. Adjuster lock 3. Sprocket hub 4. Chain tensioner Slacken drive chain tightness. 1. Rear brake caliper 2. Rear brake disc Disconnect: 3.
Page 85 Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) – gearbox vent tube – CVT inlet no. 1 and oulet no. 2 hoses – neutral and reverse switches. 1. CVT inlet hose 1. Gearbox vent tube 2. CVT outlet hose 2. Neutral switch 3.
Page 86 Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) – clamps retaining the carburetor to the engine From the top side, do the following: and to the air box Remove: – seat (refer to BODY) – fuel tank (refer to FUEL CIRCUIT). Unplug the magneto connector.
Page 87 Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) Remove: Lift engine no. 6 approximately 25 mm (1 in) to clear front mounting brackets. – chain roller Turn engine 90°, cylinder head towards right side – drive chain from engine sprocket of vehicle.
Page 88 Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) From bottom side, do the following: Install O-rings between swing arm bushing and washers. One on each side. Install inner bushings into swing arm. Apply Loc- tite anti-seize lubricant on bushing tapers. Position the swing arm at its place then install the swing arm bolt.
Page 89: Engine Sprocket
Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) On right side of vehicle, do the following: Unlook the tab washer no. 18. Connect: Unscrew the sprocket nut then remove the tab washer. – neutral and reverse switches (the neutral switch wire is YELLOW/GREY) Slack the drive chain.
Page 90: Front Anti-Vibration System
Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) FRONT ANTI-VIBRATION Removal SYSTEM Remove the LH footwell. Refer to BODY. Remove clamp no. 9 retaining exhaust pipe no. 4 Removal to muffler no. 10. NOTE: To remove the front anti-vibration bush- Unscrew exhaust pipe nuts no.
Page 91: Muffler
Section 03 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) MUFFLER Removal Remove cotter pin no. 14 and washer no. 15. Unscrew the clamp no. 9. Remove muffler no. 10. 1. Clamp 2. Exhaust pipe 3. Muffler Inspection Check muffler for cracks or other damages. Replace if necessary.
Page 92: Cooling System
Section 03 ENGINE Subsection 05 (COOLING SYSTEM) COOLING SYSTEM WATER PUMP 03-05-1 VMR2003_009_03_05A.FM...
Page 93: Cooling System
Section 03 ENGINE Subsection 05 (COOLING SYSTEM) COOLING SYSTEM 03-05-2 VMR2003_009_03_05A.FM...
Page 94: General
Section 03 ENGINE Subsection 05 (COOLING SYSTEM) GENERAL INSPECTION The engine removal is not necessary when work- Check general condition of hoses and clamp tight- ing on water pump, thermostat or temperature ness. switch. Check the weep hole if there is oil and/or water and replace oil seals in water pump housing if nec- WARNING essary (refer to WATER PUMP HOUSING further).
Page 95: Coolant Replacement
Section 03 ENGINE Subsection 05 (COOLING SYSTEM) To drain cooling system, partially unscrew cooling Pinch engine outlet hose no. 25 between radiator drain plug no. 23 on the left side of engine and and thermostat housing with a large hose pincher drain the coolant into a suitable container.
Page 96: Thermostat
Section 03 ENGINE Subsection 05 (COOLING SYSTEM) At this point, wait until engine reaches normal op- erating temperature. Depress the throttle lever two or three times; then add coolant if required. Install the radiator cap. Inspect all connections for leaks and recheck coolant in the reservoir. Once year, check coolant concentration (freezing point) with proper tester.
Page 97: Water Temperature Switch
Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Install the thermostat cover then torque screws to NOTE: Cylinder head has a tapper thread. 5 N•m (44 lbf•in). Test NOTE: Do not forget to place shim no. 7. To check temperature switch, put in water and heat water.
Page 98 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) – retaining ring no. 10 (discard), shim no. 11 and – needle pin no. 13 and thrust washer no. 14 water pump gear no. 12 1. Needle pin 2. Thrust washer – screw no. 9 retaining water pump housing no. 15 1.
Page 99 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) NOTE: Using pliers, pull the water pump housing Inspect water pump gear for wear and damage on out of crankcase. See the following illustration. the snap mechanism to the needle pin. Replace if necessary.
Page 100: Water Pump Impeller
Section 03 ENGINE Subsection 05 (COOLING SYSTEM) – Place distance ring no. 16. – Push outer oil seal no. 1. Sealing lip has to point towards the impeller. 1. Shim 2. Water pump gear 3. Shim Install a new retaining ring. CAUTION: Never use the retaining ring a second time.
Page 101: Water Pump Shaft
Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Inspection Inspection Check impeller for cracks, fitting on water pump Water pump shaft must rotate freely. Otherwise, shaft or other damage. Replace impeller if dam- replace it. aged. NOTE: When removing water pump shaft, always NOTE: Use appropriate punch to remove spring pin replace together retaining ring, oil seals, water no.
Page 102: Coolant Tank
Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Removal – mounting bolts on the top of radiator. Remove overflow hose no. 21. Using a 3/16 drill, remove the rivets retaining the coolant tank support no. 30 to the frame. Remove the coolant tank no. 26. Empty coolant tank.
Page 103 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Install hose pinchers (P/N 295 000 076) on inlet Come out the carburetor overflow drain hose from hose no. 32 and outlet hose no. 33 of block heater. its location. 1. Carburetor overflow drain hose Unplug the carburetor vent hose.
Page 104 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Remove the block heater outlet hose no. 33. Unscrew the valve piston assembly then remove the block heater inlet hose no. 32. 1. Block heater outlet hose 2. Fuel line NOTE: Catch any coolant spillage. 1.
Page 105 Section 03 ENGINE Subsection 05 (COOLING SYSTEM) Using a flat screwdriver, gently pry the block heater Install the block heater in accordance with the fol- until the glue is braked. Only use the location lowing illustration. showed in the following illustration. Install the block heater lock and torque screw.
Page 106: Magneto System
Section 03 ENGINE Subsection 06 (MAGNETO SYSTEM) MAGNETO SYSTEM MAGNETO SYSTEM 03-06-1 VMR2003_010_03_06A.FM...
Page 107: General
Section 03 ENGINE Subsection 06 (MAGNETO SYSTEM) GENERAL Remove magneto cover screws no. 1. Always disconnect battery. WARNING Always disconnect battery or starter cables exactly in the specified order, BLACK (-) cable first. Always perform the electric tests before removing or installing whatever component.
Page 108: Stator And Trigger Coil
NOTE: Clean all metal component in a non-ferrous metal cleaner. Use Bombardier gasket remover (P/N 413 708 500), or suitable equivalent. WARNING Wear safety glasses and work in a well venti- lated area when working with strong chemical products.
Page 109: Rotor
Section 03 ENGINE Subsection 06 (MAGNETO SYSTEM) 1. Notch for stator ROTOR Removal 1. Stator 2. Stator screws Lock crankshaft with locking bolt (P/N 529 035 617). 3. Trigger coil 4. Trigger coil screws Refer to CRANKSHAFT/BALANCER SHAFT. Inspection Check stator and trigger coil condition. If damaged replace the faulty part.
Page 110 Section 03 ENGINE Subsection 06 (MAGNETO SYSTEM) Remove the RH footwell and the seat (refer to Remove: BODY). – rotor no. 9 together with sprag clutch gear Lift up the fuel tank (refer to FUEL CIRCUIT). no. 11,distance sleeve no. 4 and starter inter- mediate gear no.
Page 111: Sprag Clutch
Section 03 ENGINE Subsection 06 (MAGNETO SYSTEM) Turn sprag clutch gear counterclockwise for easily CAUTION: Use protector on the vise jaws to fit in the sprag clutch rollers. avoid damaging the sprag clutch housing. 1. Rotor 2. Direction of rotation from sprag clutch gear 1.
Page 112: Starter
Section 03 ENGINE Subsection 06 (MAGNETO SYSTEM) Check bushing of sprag clutch gear for service lim- it and replace sprag clutch gear no. 11 if neces- sary. 1. Push until snap mechanism works 2. Thread to be clean STARTER Removal Remove: –...
Page 113 Section 03 ENGINE Subsection 06 (MAGNETO SYSTEM) Inspection Check if O-ring is brittle, hard or otherwise dam- aged. Replace if necessary. Installation For installation, reverse the removal procedure. However, pay attention to the following. Always apply the anti-seize lubricant on the sup- port of the starter which is shown in the exploded view.
Page 114: Lubrication System
Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) LUBRICATION SYSTEM 03-07-1 VMR2003_011_03_07A.FM...
Page 115: Engine Oil Flow Chart
Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) ENGINE OIL FLOW CHART Following illustration gives a general overview regarding the oil supply through the engine. 1. Oil pump 9. Cylinder stud screw bore as oil supply to camshaft 2. Oil strainer 10.
Page 116: General
Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) GENERAL The engine oil pressure should be as following value at warm engine condition (80°C (176°F) approxi- The engine removal is not necessary when work- mately). ing on the oil pressure switch, oil filter, pressure regulator valve, magnetic plug and/or oil strainer.
Page 117: Oil Filter
Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) OIL FILTER Clean the magnetic drain plug from metal shav- ings and dirt. Presence of debris gives an indica- tion of failure inside the engine. Check engine to Removal correct the problem. Remove: Change gasket ring on magnetic drain plug if dam- –...
Page 118: Oil Strainer
Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) Installation The installation is the opposite of the removal pro- cedure. Pay attention to the following details. Install O-ring no. 6 on oil filter cover. 1. Oil strainer 2. Gasket ring 3. Plug screw Cleaning and Inspection Clean oil strainer with a part cleaner then use an air gun to dry it.
Page 119: Engine Oil Pressure Regulator
Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) ENGINE OIL PRESSURE REGULATOR The oil pressure regulator is located on the engine PTO side underneath the water inlet port. 1. Valve housing 2. Compression spring 3. Ball 4. Oil pressure regulator port Clean and Inspection 1.
Page 120: Oil Pump
Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) OIL PUMP The oil pump is located on the engine MAG side near water pump housing (refer to COOLING SYSTEM). Removal Remove: – RH footwell and seat – engine oil NOTE: No need to drain cooling system. –...
Page 121 Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) 1. Suction side of the oil pump (oil coming from oil strainer) 2. Oil outlet to pressure regulator valve/oil filter NOTE: Following illustration shows the oil flow from engine inside. 1. Bore of oil pump outer rotor 2.
Page 122 Section 03 ENGINE Subsection 07 (LUBRICATION SYSTEM) If difference exceeds service limit, replace the OUTER AND INNER ROTORS CLEARANCE complete oil pump assembly. mm (in) NOTE: When the axial clearance of the oil pump SERVICE LIMIT shaft assembly increases, the oil pressure de- creases (less discharge).
Page 123: Cylinder And Head
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) CYLINDER AND HEAD NOTE: For cylinder head, cylinder and piston removal, it is not necessary to remove engine from vehicle. •in 03-08-1 VMR2003_012_03_08A.FM...
Page 124 Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) 03-08-2 VMR2003_012_03_08A.FM...
Page 125: General
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) GENERAL NOTE: When diagnosing an engine problem, always perform a cylinder leak test. This will help pin-point a problem. Refer to the instructions included with your leak tester and LEAK TEST section for procedures. Always place the vehicle on level surface.
Page 126: Valve Adjustment
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Installation For installation, reverse the removal procedure. NOTE: Install the valve cover screws in a criss-cross sequence. VALVE ADJUSTMENT Lock crankshaft at the TDC compression position (refer to CRANKSHAFT). Remove valve cover (refer to VALVE COVER above).
Page 127: Chain Tensioner
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) CHAIN TENSIONER BREATHER Removal Removal Remove: WARNING – valve cover Chain tensioner is spring loaded. – breather no. 4 with V-ring no. 5. Remove: NOTE: Use flat screwdriver to remove breather as per following illustration.
Page 128: Camshaft Timing Gear
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) CAMSHAFT TIMING GEAR Removal Lock crankshaft at the TDC compression position, refer to CRANKSHAFT. Remove: – valve cover – chain tensioner – chain guide no. 22 – bolt no. 6, washer no. 7 and camshaft timing gear no.
Page 129: Rocker Arm
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) ROCKER ARM Removal Lock crankshaft at the TDC compression position, refer to CRANKSHAFT. Remove: – valve cover – chain tensioner – breather no. 4 – camshaft timing gear no. 8 – Allen screws no. 9 and camshaft retaining plate no.
Page 130 Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Inspection Rocker Arm Inspect each rocker arm for cracks and scored friction surfaces. If so, replace rocker arm assembly. Check the rocker arm rollers for free movement, wear and excessive radial play. Replace rocker arm assembly if necessary.
Page 131: Timing Chain
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Installation Disconnect: – spark plug cable For installation, reverse the removal procedure. Pay attention to the following details. – temperature sensor connector. Apply engine oil on rocker arm shaft. Remove: Install the rocker arm shafts with the chamfered –...
Page 132 Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Torque cylinder head nuts no. 23 in criss-cross se- quence at half of the recommended torque value in the exploded view. Finish tightening hexagonal nuts no. 23 criss- cross with the recommended values in the explod- ed view.
Page 133: Camshaft
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) CAMSHAFT Removal The camshaft can be removed with the cylinder head installed. Remove: – valve cover (see VALVE COVER above) – chain tensioner (see CHAIN TENSIONER above) – breather (see BREATHER above) –...
Page 134: Valve Spring
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Installation For installation, reverse the removal procedure. Pay attention to the following details. Install camshaft in the opposite way of the removal then place the camshaft retaining plate in the slot. A. Cylinder head — camshaft bore MAG side B.
Page 135 Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) A. Valve spring length VALVE SPRING FREE LENGTH NEW NOMINAL 33.6 mm (1.323 in) SERVICE LIMIT 33.0 mm (1.299 in) 1. Valve spring compressor clamp (P/N 529 035 724) 2. Valve spring compressor cup (P/N 529 035 725) Installation 3.
Page 136: Valve
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) VALVE Inspection Valve Stem Seal Removal Inspection of valve stem seals is not needed because Remove valve spring. new seals should always be installed whenever cylinder head is removed. Push valve stem then pull valves no. 32 and no. 33 out of valve guide no.
Page 137 Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Check valve face and seat for burning or pittings VALVE STEM DIAMETER mm (in) and replace valve or cylinder head if there are signs of damage. NEW MINIMUM Ensure to seat valves properly. Apply some lapping EXHAUST 3.96 mm (.1559 in) compound to valve face and work valve on its seat...
Page 138: Valve Guide Procedure
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Installation Using valve guide remover (P/N 529 035 852), remove valve guide no. 36. For installation, reverse the removal procedure. Pay attention to the following details. CAUTION: Make sure the thrust washer no. 34 is installed before installing valve stem seal no.
Page 139: Cylinder
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) CYLINDER VALVE GUIDE DIAMETER mm (in) Removal NEW MINIMUM Lock crankshaft at TDC compression position, refer EXHAUST 4.002 mm (.1576 in) to CRANKSHAFT. INTAKE Remove: NEW MAXIMUM – chain tensioner (see CHAIN TENSIONER above) EXHAUST 4.015 mm (.1581 in) –...
Page 140 Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Cylinder Taper Measure cylinder bore and if it is out of specifications, replace cylinder and piston ring set no. 39. Measure cylinder bore at 3 recommended positions. See the following illustration. A. Perpendicular to crankshaft axis B.
Page 141: Piston
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Install cylinder head and the other parts in accor- Detach piston no. 42 from connecting rod. dance with the proper installation procedures. Inspection PISTON Piston Inspect piston for scoring, cracking or other damages. Removal Replace piston and piston rings if necessary.
Page 142 Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Position the dial bore gauge 47 mm (1.85 in) above cylinder base, measuring perpendicularly (90°) to piston pin axis. Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. PISTON/CYLINDER CLEARANCE 0.042 to 0.072 mm NEW NOMINAL...
Page 143 Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Piston Pin/Connecting Rod Bushing Clearance Measure inside diameter of connecting rod. CONNECTING ROD SMALL END DIAMETER NEW MINIMUM 15.005 mm (.5907 in) NEW MAXIMUM 15.015 mm (.5911 in) SERVICE LIMIT 15.06 mm (.593 in) 1.
Page 144: Piston Rings
Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Inspection Ring/Piston Groove Clearance Using a feeler gauge measure each ring/piston groove clearance. If the clearance is too large, the piston and the piston rings should be replaced. RING/PISTON GROOVE CLEARANCE mm (in) NEW MINIMUM RECTANGULAR 0.03 mm (.0012 in)
Page 145 Section 03 ENGINE Subsection 08 (CYLINDER AND HEAD) Ring End Gap RING END GAP NEW MINIMUM RECTANGULAR 0.20 mm (.008 in) TAPER-FACE 0.20 mm (.008 in) OIL SCRAPER RING 0.20 mm (.008 in) NEW MAXIMUM RECTANGULAR 0.35 mm (.014 in) TAPER-FACE 0.35 mm (.014 in) 1.
Page 146: Crankshaft
Section 03 ENGINE Subsection 09 (CRANKSHAFT) CRANKSHAFT 03-09-1 VMR2003_013_03_09A.FM...
Page 147 Section 03 ENGINE Subsection 09 (CRANKSHAFT) 03-09-2 VMR2003_013_03_09A.FM...
Page 148: General
Section 03 ENGINE Subsection 09 (CRANKSHAFT) GENERAL Turn rotor, fixed on crankshaft MAG side, to TDC compression position (refer to CYLINDER AND For installation, use the torque values and Loctite HEAD). products from the exploded views. Clean threads Use a screwdriver to check if groove in crankshaft before using Loctite when installing the screws.
Page 149: Timing Chain
Section 03 ENGINE Subsection 09 (CRANKSHAFT) Double-check camshaft timing gear position (refer If chain is excessively worn or damaged, replace it to CYLINDER AND HEAD). as a set (camshaft timing gear and timing chain). Check chain tensioner guide no. 2 for excessive wear on contact surface to timing chain, replace if necessary.
Page 150: Crankshaft
Section 03 ENGINE Subsection 09 (CRANKSHAFT) Installation The installation is essentially the reverse of the re- moval procedure but, pay attention to the follow- ing details. Ensure to perform proper valve timing. Lock crank- shaft (see TDC procedure below) and place cam- shaft at ignition TDC (refer to CYLINDER AND HEAD).
Page 151 Section 03 ENGINE Subsection 09 (CRANKSHAFT) Measure axial clearance of the crankshaft no. 5 with a feeler gauge on the PTO side between PTO crankcase and shim no. 6. 1. Screws (12) – MAG crankcase (see CRANKCASE below) CAUTION: Pay attention not to damage plain bearing on MAG side with timing gear on crank- shaft.
Page 152 Section 03 ENGINE Subsection 09 (CRANKSHAFT) Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between butting face of connecting rod and crankshaft counterweight. If the distance exceeds specified tolerance, replace the crankshaft. 1. Crankcase MAG side 2.
Page 153 Section 03 ENGINE Subsection 09 (CRANKSHAFT) Connecting Rod/Piston Pin Clearance PISTON PIN BORE CLEARANCE Measure piston pin. Compare to inside diameter of SERVICE LIMIT 0.070 mm (.0028 in) connecting rod. If the connecting rod small end diameter is out of specification, replace crankshaft and piston pin.
Page 154 Section 03 ENGINE Subsection 09 (CRANKSHAFT) Installation For installation, reverse the removal procedure. Pay attention to following details. CAUTION: Never forget shim no. 7 for axial ad- justment on crankshaft MAG side. NOTE: Always degrease taperon crankshaft MAG before reinstalling rotor. 1.
Page 155 Section 03 ENGINE Subsection 09 (CRANKSHAFT) 1. MAG plain bearing with groove 2. Oil bore 3. Split of the plain bearing halves 1. 12 screws 4. Cylinder base direction A. Plain bearing inside diameter to be measured in area of oil bore –...
Page 156 Section 03 ENGINE Subsection 09 (CRANKSHAFT) Bearing Removal Procedure To install the plain bearing turn the plain bearing remover/installer up side down. Always heat crankcase housing up to 100°C NOTE: Apply Molykote grease in crankcase bore to (212°F) before removing ball bearings, needle ease installing the plain bearing halves.
Page 157 Section 03 ENGINE Subsection 09 (CRANKSHAFT) Install a new oil seal no. 14 with the crankshaft oil seal installer (P/N 529 035 847). 1. Crankcase PTO oil seal 2. Crankshaft oil seal installer 3. Insertion jig handle Assembly The assembly of crankcase is the reverse of re- moval procedure.
Page 158 Section 03 ENGINE Subsection 10 (GEARBOX) GEARBOX GEARBOX Engine 03-10-1 VMR2003_014_03_10A.FM...
Page 159: Crankcase
Section 03 ENGINE Subsection 10 (GEARBOX) CRANKCASE 03-10-2 VMR2003_014_03_10A.FM...
Page 160: General
Section 03 ENGINE Subsection 10 (GEARBOX) GENERAL Remove oil level screw no. 3 including O-ring no. 4. To remove gear box cover, the engine removal is necessary. For installation, use the torque values and Loctite products indicated in the exploded views. Clean threads before using Loctite when installing screws.
Page 161 Section 03 ENGINE Subsection 10 (GEARBOX) Inspection NOTE: Use a small, flat screwdriver to remove oil seals from MAG/PTO side. Check bearings behind each oil seal for contami- CAUTION: Pay attention not to damage CVT/ nation and/or metal shavings. main shaft during removal of oil seals. Check surface on CVT/main shaft in oil seal area –...
Page 162: Crankcase
Section 03 ENGINE Subsection 10 (GEARBOX) CRANKCASE Install oil seal no. 5 on PTO side with oil seal in- staller (P/N 529 035 854) as per following illustra- tion. Disassembly Drain gear box oil (see OIL CHANGE above). Remove: – sprocket nut no. 8 –...
Page 163 Section 03 ENGINE Subsection 10 (GEARBOX) Inspection NOTE: To ease lifting the gear box cover no. 11 follow the procedure below while holding the NOTE: To check some parts, it is recommended main shaft in place: to remove all components in both crankcase hous- –...
Page 164 Section 03 ENGINE Subsection 10 (GEARBOX) Check bearings no. 13 and no. 14 as well as nee- Bearing Installation Procedure dle bearing no. 15 for excessive play and smooth Unless otherwise instructed, never use hammer operation. Replace if necessary. to install ball bearings and/or needle bearings. Use press machine only.
Page 165: Gearbox
Section 03 ENGINE Subsection 10 (GEARBOX) GEARBOX CAUTION: Do not forget thrust washer no. 18 and gear box cover gasket no. 12. General Hand-torqued crankcase screws as per following se- quence. Repeat procedure, retightening all screws During and after gear box disassembly, inspect the to 25 N•m (18.5 lbf•ft).
Page 166 Section 03 ENGINE Subsection 10 (GEARBOX) – shift fork shaft no. 19. Remove: – intermediate shaft no. 22 together with output shaft no. 23 1. Shift fork shaft 2. Output shaft 3. Intermediate shaft 4. Main shaft – shift fork no. 20 NOTE: Disengage shift fork no.
Page 167 Section 03 ENGINE Subsection 10 (GEARBOX) NOTE: Following illustration shows gear no. 24 NOTE: Following illustration shows engagement and the respective shifting position. grooves for spring plate no. 26 and the respective shifting position. 1. High gear position 2. Neutral position 1.
Page 168 Section 03 ENGINE Subsection 10 (GEARBOX) – shift shaft plate no. 21. 1. Shift shaft plate 2. Reverse switch 3. Neutral switch Inspection 1. Micrometer A. Shift fork claw thickness Check shift fork for visible damage, wear or bent shift fork claws. Check shift shaft plate track for scouring or heavy wear like rounded engagement slots.
Page 169 Section 03 ENGINE Subsection 10 (GEARBOX) Measure the gap of shift fork engagement groove. Check thrust washer no. 27 on output shaft for wear limit. GAP OF SHIFT FORK ENGAGEMENT GROOVE THRUST WASHER THICKNESS NEW MINIMUM 5.00 mm (.197 in) SERVICE LIMIT NEW MAXIMUM 5.10 mm (.201 in)
Page 170 Section 03 ENGINE Subsection 10 (GEARBOX) NOTE: Check axial measurement of intermediate shaft including thrust washer no. 18 and no. 28. If out of measurement check for wrong and/or miss- ing thrust washers MAG/PTO. AXIAL MEASUREMENT NEW MINIMUM 82.00 mm (.269 ft) NEW MAXIMUM 82.20 mm (.270 ft) 1.
Page 171 Section 03 ENGINE Subsection 10 (GEARBOX) 1. Shift fork shaft Install gearbox cover (see CRANKCASE above). NOTE: Run all gears as a final function check. The 1. Preassembled gears same time check output shaft and main shaft axial 2. Shift fork play.
Page 172: Shifting Indicator Switch
Section 03 ENGINE Subsection 10 (GEARBOX) SHIFTING INDICATOR SWITCH Test Check if shifting indicator switches work properly. NOTE: The engine removal is not necessary to reach the shifting indicator switches. CAUTION: Switch pin has to move freely and must not detach from its housing. Removal Check wiring harness and replace if brittle or hard.
Page 173: Cvt
Section 03 ENGINE Subsection 11 (CVT) NOTE: This is a lubrication free drive pulley. 03-11-1 VMR2003_015_03_11A.FM...
Page 174: General
Never touch CVT while engine is running. Nev- er drive vehicle when CVT cover is removed. WARNING Any drive pulley repairs must be performed by an authorized Bombardier ATV dealer. Sub- component installation and assembly toler- ances require strict adherence to procedures detailed.
Page 175: Cvt Cover
Section 03 ENGINE Subsection 11 (CVT) Installation The maximum drive belt life span is obtained when the drive belt has the proper rotation direction. In- stall it so the printed text on belt is pointing towards front of the vehicle (the text must be legible). 1.
Page 176: Cvt Cover Bearing
Section 03 ENGINE Subsection 11 (CVT) Inspection DRIVE PULLEY Check CVT cover for cracks or other damages. Re- place if necessary. Check if the gasket is brittle, hard or otherwise damaged. Replace if necessary. Check if the CVT cover bearing must turn smooth- ly and freely.
Page 177 Lift ramp plate no. 14 with sliding shoes no. 13. Withdraw spacer no. 9. 1. Faces of drive pulley Reclean mounting surfaces with paper towel and cleaning solvent. Use Bombardier pulley flange cleaner (P/N 413 711 809). Wipe off the mounting surfaces with a clean, dry paper towel.
Page 178 Section 03 ENGINE Subsection 11 (CVT) Measure the roller diameter. If a roller is out of spec- ification, replace roller kit no. 11. ROLLER DIAMETER NEW MINIMUM 20.00 mm (.787 in) NEW MAXIMUM 20.20 mm (.795 in) SERVICE LIMIT 19.50 mm (.768 in) Slider Shoe Check slider shoes kit no.
Page 179: Driven Pulley
Section 03 ENGINE Subsection 11 (CVT) Assembly of Drive Pulley For assembly, reverse the disassembly procedure. Pay attention to following details. Insert slider shoes into ramp plate to properly slide in guides of drive pulley sliding half. Installation of Drive Pulley For installation, reverse the removal procedure.
Page 180 Section 03 ENGINE Subsection 11 (CVT) 1. Driven pulley outer half against clutch assembly 2. Crankshaft locking bolt 1. Lock washer 2. Driven pulley nut Disassembly of Driven Pulley – withdraw clutch drum no. 17 NOTE: The following procedure is not necessary except if clutch no.
Page 181 RPM is needed for centrifugal clutch engagement. Clean pulley faces and shaft with fine steel wool and dry cloth. Use Bombardier pulley flange cleaner (P/N 413 711 809) to clean driven pulley. Clean the CVT crankcase area from contamination. WARNING This procedure must be performed in a well- ventilated area.
Page 182 Section 03 ENGINE Subsection 11 (CVT) Assembly of Driven Pulley Sliding Half Check sliding half of driven pulley for free move- For installation, reverse the removal procedure. ment. Replace driven pulley if necessary. Pay attention to following details Heat ball bearing area up to 100°C (212°F) before installing ball bearing no.
Page 183 Section 03 ENGINE Subsection 11 (CVT) Place spring no. 25, sleeve no. 26 behind sliding half and push the centrifugal clutch assembly no. 18 against driven pulley with clutch holding tool (P/N 529 035 864). WARNING Centrifugal clutch is a spring loaded system. 1.
Page 184 Section 04 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL CIRCUIT........................04-02-1 GENERAL ........................... 04-02-2 FUEL LINE .......................... 04-02-2 FUEL TANK ........................04-02-2 FUEL VALVE ........................04-02-3 CARBURETOR ........................04-03-1 GENERAL ........................... 04-03-2 CARBURETOR ........................04-03-2 CARBURETOR ADJUSTMENTS ..................04-03-4 THROTTLE CABLE ......................
Page 185: Fuel Circuit
Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) FUEL CIRCUIT 04-02-1 VMR2003_016_04_02A.FM...
Page 186: General
When the tank is empty, turn valve OFF. orated fuel lines. Removal When replacing fuel line, be sure to use hoses as available from Bombardier parts department. This Drain fuel tank. will ensure continued proper and safe operation. Remove following items from body. Refer to BODY...
Page 187: Fuel Valve
Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) 1. Special cap on tank 2. Air pump 1. Fuel tank Pressurize fuel system to 21 kPa (3 PSI). That pres- 2. Bolts sure must not drop during 3 minutes. Inspection If pressure drops, locate fuel leak(s) and repair/ Inspect fuel tank for any damage or cracks which replace leaking component(s).
Page 188 Section 04 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) 1. Fuel tank 2. Bolts 3. Fuel valve on OFF position Remove fuel valve. 1. Fuel valve 2. Strainers Inspection Check fuel valve strainers. If one strainer is dam- aged, change fuel valve. Check gasket between fuel valve and fuel tank for damage.
Page 189: Carburetor
Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR ) CARBURETOR 04-03-1 VMR2003_017_04_03A.FM...
Page 190: General
Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR ) GENERAL Remove throttle cable. See THROTTLE CABLE further in this section. Disconnect battery before working on fuel system. Pull out carburetor. WARNING Cleaning and Inspection Always disconnect battery exactly in the The entire carburetor should be cleaned with a specified order, BLACK (-) cable first.
Page 191 Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR ) CARBURETOR FLOAT LEVEL ADJUSTMENT 15 mm ± 1mm Float level (.591 in ± .039 in) Installation To install carburetor on engine, inverse removal procedure, as described: Adjust the throttle cable, then install the carbure- tor cap.
Page 192: Carburetor Adjustments
Section 04 FUEL SYSTEM Subsection 03 (CARBURETOR ) CAUTION: The rubber flanges must be checked Idle Speed Adjustment for cracks and/or damage. At assembly, the rub- Start engine and allow it to warm then adjust idle ber flanges must be perfectly matched with the speed to specifications by turning idle speed air box, carburetor and engine or severe engine screw clockwise to increase engine speed or...
Page 193 Throttle Lever Side Remove both screws on throttle housing. Remove throttle cable. Lubrication The throttle cable must be lubricated with Bombardier cable lubricant (P/N 293 600 041) only. WARNING Using another lubricant could cause sticking or stiffness of throttle lever/cable.
Page 194: Air Intake Silencer
Section 04 FUEL SYSTEM Subsection 04 (AIR INTAKE SILENCER) AIR INTAKE SILENCER 04-04-1 VMR2003_018_04_04A.FM...
Page 195: General
WARNING Then, let the filter dry completely. Always disconnect battery exactly in the When the filter is dried, re-oil it with Bombardier specified order, BLACK (-) cable first. It is rec- air filter oil (P/N 293 600 058). ommended to disconnect electrical connec- tions prior to disconnecting fuel lines.
Page 196 Section 04 FUEL SYSTEM Subsection 04 (AIR INTAKE SILENCER) Removal CAUTION: Never remove or modify any com- ponent in the air box. The engine carburation is calibrated to operate specifically with these components. Otherwise, engine performance degradation or damage can occur. Remove LH and RH side covers to get access to the air box no.
Page 197: Air Filter Housing
Section 04 FUEL SYSTEM Subsection 04 (AIR INTAKE SILENCER) Remove the torx screws no. 2. Remove air box no. 1. NOTE: Air box no. 1 can only be removed through right hand side. Installation Properly reinstall removed parts in the reverse order of their removal.
Page 198 Section 05 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OVERVIEW..........................05-02-1 GENERAL OPERATION INFORMATION ................05-02-1 CHARGING SYSTEM......................05-02-1 STARTING SYSTEM ......................05-02-1 IGNITION SYSTEM......................05-02-2 GENERAL TESTING/TROUBLESHOOTING INFORMATION .......... 05-02-2 FUSE LOCATION ....................... 05-02-3 SERVICING PACKARD CONNECTORS ................05-02-3 SERVICING DEUTSCH CONNECTORS ................
Page 199 Section 05 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) IGNITION SYSTEM ........................ 05-05-1 IGNITION SYSTEM TESTING PROCEDURE..............05-05-1 GENERAL..........................05-05-1 IGNITION SYSTEM TEST ....................05-05-3 IGNITION TIMING ......................05-05-5 SPARK PLUG ........................05-05-5 DISASSEMBLY ........................05-05-5 HEAT RANGE........................05-05-5 FOULING..........................05-05-6 SPARK PLUG ANALYSIS ....................
Page 200: Overview
Section 05 ELECTRICAL Subsection 02 (OVERVIEW) OVERVIEW GENERAL OPERATION Voltage Regulator/Rectifier INFORMATION A 3-phase full-wave series-type voltage regulator/ rectifier receives the AC voltage and rectifies (con- The electrical system consist of different sub- verts) it into DC. The voltage is also regulated to a systems where some are inter-related: maximum of 14.7 ±...
Page 201: Ignition System
Section 05 ELECTRICAL Subsection 02 (OVERVIEW) IGNITION SYSTEM Electronic Module It is basically responsible for interpreting/computing An IDI (Inductive Discharge Ignition) system is uti- information, distribution of information, ignition sys- lized. The ignition system is made up of the follow- tem, the engine RPM limiter and the vehicle speed ing components: limiter.
Page 202: Fuse Location
Section 05 ELECTRICAL Subsection 02 (OVERVIEW) Before replacing any electric or electronic part(s), CAUTION: Do not use a higher rated fuse as this always check electrical connections. Make sure that can cause severe damage. they are very tight and they make good contact and Fuse is located behind front right shock, near cool- that they are corrosion-free.
Page 203: Servicing Deutsch Connectors
Section 05 ELECTRICAL Subsection 02 (OVERVIEW) SERVICING DEUTSCH NOTE: Before extraction, push wire forward to re- lieve pressure on retaining tab. CONNECTORS – Insert a 4.8 mm (0.189 in) wide screwdriver blade inside the front of the contact cavity. Waterproof Connector Housing –...
Page 204: Identification Of Major Connector Pins
Section 05 ELECTRICAL Subsection 02 (OVERVIEW) IDENTIFICATION OF MAJOR CONNECTOR PINS 05-02-5 VMR2003_019_05_02A.FM...
Page 205: Charging System
Section 05 ELECTRICAL Subsection 03 (CHARGING SYSTEM) CHARGING SYSTEM TESTING PROCEDURE DYNAMIC TEST Current Test NOTE: First, ensure that battery is in good condition prior to performing the following test using a current Proceed as follows: inductive ammeter such as Snap-on MT 110. –...
Page 206 Section 05 ELECTRICAL Subsection 03 (CHARGING SYSTEM) NOTE: If the voltage regulator/rectifier is within STATIC TEST: INSULATION the specification, the wiring harness between the With the stator leads disconnected, insert either voltage regulator/rectifier and battery is defective. meter test probe onto AC-1 and ground the other If the voltage regulator/rectifier is out of specifica- meter test probe to the engine or the stator iron tion and the stator test good, the voltage regulator/...
Page 207: Starting System
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) STARTING SYSTEM BATTERY TROUBLESHOOTING SYMPTOM: DISCHARGED OR WEAK BATTERY CAUSE REMEDY 1. Battery posts and/or Clean and coat with cable terminal oxidized. dielectric grease. 2. Loose or bad Check wiring and connections. connector cleanliness, damaged or short circuit.
Page 208: Removal
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) Load Test WARNING This is the best test of battery condition under a Battery electrolyte is a caustic substance that starting load. Use a load testing device that has an burns or destroys organic tissues by chemical adjustable load.
Page 209: Battery Storage
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) In case of accidental premature removal of caps WARNING or sealing tube, battery should be given a full charge. Battery caps do not have vent holes. Make sure Perform the following operations anytime a new that vent tube is not obstructed.
Page 210: Tips For Charging A Used Battery
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) TIPS FOR CHARGING A USED 6. Connect a 2 A battery charger for until the bat- tery is fully charged. BATTERY WARNING WARNING Gases given off by a battery being charged Prior to charging the battery, always remove are highly explosive.
Page 211: Installation
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) Charging a Very Flat or Completely INSTALLATION Discharged Battery Reinstall and fasten the battery, making sure to Unless this procedure is properly followed, a good reinstall the vent tube. battery may be needlessly replaced. WARNING –...
Page 212: Starting System Troubleshooting
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY Starter does not turn. Ignition switch is in the OFF position. Turn switch in the ON position. Burnt fuse. Check main fuse and wiring condition. Transmission is not set on Neutral. Set transmission in Neutral or use the override mode.
Page 213: Starting System Tests
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) STARTING SYSTEM TESTS If solenoid test good, check the electric starter. If starter test good, the NEUTRAL switches can be suspected. GENERAL Ignition Switch First ensure the problem is not related to engine mechanical components.
Page 214: Electric Starter
Section 05 ELECTRICAL Subsection 04 (STARTING SYSTEM) Electrical Cables or Connections Check all connections, cables and wires. Tighten any loose cables. Replace any chafe wires/cables. If wiring and connectors are good, check the elec- tric starter. See below. Electric Starter NOTE: Starter is located in the middle of engine.
Page 215: Ignition System
Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) IGNITION SYSTEM IGNITION SYSTEM TESTING PROCEDURE GENERAL Ignition Problems When dealing with ignition problems, the follow- ing items should be checked in this order. After one item has been checked and it is found not to be the problem, continue with the next item: 1.
Page 216 Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) TROUBLESHOOTING Check that the transmission is in NEUTRAL position and the engine stop switch is in “RUN” position. Check that main fuse is not burned and if battery is fully-charged before diagnosing. Check ignition system connector for poor connections.
Page 217: Ignition System Test
Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) IGNITION SYSTEM TEST Use a multimeter and measure the resistance be- tween the following wires. Safety Precautions POSITION WIRE RESISTANCE WARNING RED and Infinite (0.L) RED/YELLOW To prevent powerful electric shocks while cranking engine, neither touch any electronic RED and Infinite (0.L) RED/VIOLET...
Page 218 Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) NOTE: An ignition coil with good resistance mea- The primary wilding resistance should be between 2.2 ± 0.3 Ω at 20°C (68°F). surement can still be faulty. Voltage leak can occur at high voltage level which is not detectable with For checking the resistance of secondary wind- an ohmmeter.
Page 219: Ignition Timing
Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) NEGATIVE (-) TESTER LINE O.L. 2.985 KΩ 2.567 MΩ 18.41 KΩ 2.481 KΩ 2.540 MΩ 2.539 MΩ 6.37 MΩ 2.538 MΩ 6.23 MΩ 2.983 KΩ O.L. 2.528 MΩ 21.43 KΩ 2.441 MΩ POSITIVE (+) TESTER LINE O.L.
Page 220: Fouling
Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) SPARK PLUG ANALYSIS The “hot” type plug has a longer insulator nose and transfers heat more slowly away from its firing end. It runs hotter and burns off combustion de- posits which might tend to foul the plug during prolonged idle or low speed operation.
Page 221: Ngk Spark Plug Symbol Explanation
Section 05 ELECTRICAL Subsection 05 (IGNITION SYSTEM) NGK SPARK PLUG SYMBOL EXPLANATION 05-05-7 VMR2003_022_05_05A.FM...
Page 222: Instruments And Accessories
Section 05 ELECTRICAL Subsection 06 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES GENERAL WARNING It is recommended to always disconnect the battery when replacing any electric or elec- tronic parts. Always disconnect battery exact- ly in the specified order, BLACK (-) cable first. Do not place tools on battery.
Page 223: Headlight Beam Aiming
Section 05 ELECTRICAL Subsection 06 (INSTRUMENTS AND ACCESSORIES) Installation Measure headlight center distance from ground. Scribe a line at this height on test surface (wall Properly reinstall removed parts in the reverse order or screen). Light beam center should be 131 mm of their removal.
Page 224: Taillight
Section 05 ELECTRICAL Subsection 06 (INSTRUMENTS AND ACCESSORIES) TAILLIGHT Unplug the switch connector. Bulb Replacement Unscrew lens screws to expose bulb. 1. Switch connector Installation For the installation, reverse the removal procedure. 1. Lens 2. Screws INDICATOR LAMP Push bulb in and hold while turning counterclock- wise to release.
Page 225: Electronic Module
Section 05 ELECTRICAL Subsection 06 (INSTRUMENTS AND ACCESSORIES) Installation Headlight Switch Select low beam position on headlight switch. For installation, reverse the removal procedure. Using a multimeter, measure the voltage between ELECTRONIC MODULE GREEN and BLACK wires. The obtained value should be between 12 and Test 14.5 Vdc.
Page 226: Indicator Lights
Section 05 ELECTRICAL Subsection 06 (INSTRUMENTS AND ACCESSORIES) INDICATOR LIGHTS Engine Stop Switch Using a multimeter, measure the resistance be- Remove dash board. tween the following wires. Unplug indicator light connector. SWITCH WIRE RESISTANCE Test each LEDS. The TEMPERATURE/OIL, RE- VERSE and NEUTRAL LEDS can be tested with Engine stop 12 Vdc.
Page 227 Section 06 DRIVE TRAIN Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS REAR AXLE ..........................06-02-1 GENERAL ........................... 06-02-2 DRIVE CHAIN ........................06-02-2 REAR SPROCKET ......................06-02-3 REAR SPROCKET HUB...................... 06-02-4 REAR WHEEL HUB ......................06-02-5 REAR AXLE ........................06-02-5 CHAIN TENSIONER ......................
Page 228: Rear Axle
Section 06 DRIVE TRAIN Subsection 02 (REAR AXLE) REAR AXLE 18 15 06-02-1 VMR2003_024_06-02A.FM...
Page 229: General
Section 06 DRIVE TRAIN Subsection 02 (REAR AXLE) GENERAL Clean the side surfaces of the chain with a dry cloth. NOTE: Do not brush chain. For installation, use the torque values and Loctite Lubricate only with an approved O-ring chain lubri- products from the exploded views.
Page 230: Rear Sprocket
Section 06 DRIVE TRAIN Subsection 02 (REAR AXLE) REAR SPROCKET Adjust chain deflection by slowly moving the ATV forward so any slack that may have previously been on the under part of the chain is now on the Removal top of the chain. The bottom part of the chain Lift rear of vehicle and install jack stands under the should be taught during adjustment.
Page 231: Rear Sprocket Hub
Section 06 DRIVE TRAIN Subsection 02 (REAR AXLE) Remove LH rear wheel and wheel hub. NOTE: The drive pinion must be installed with the lip toward the outside of vehicle. Pull out the rear axle with rear sprocket no. 3 from drive chain tensioner no.
Page 232: Rear Wheel Hub
Section 06 DRIVE TRAIN Subsection 02 (REAR AXLE) REAR WHEEL HUB Install new cotter pin. Both ends of cotter pins must be folded. Removal Install both rear wheels. Lift rear of vehicle and install jack stands under the Put vehicle back on the ground. frame to support the rear of vehicle off the ground.
Page 233: Chain Tensioner
Section 06 DRIVE TRAIN Subsection 02 (REAR AXLE) Using open wrench (P/N 529 035 866) and crow foot (P/N 529 035 884) torque each nut to 140 N•m (103 lbf•ft). Install the rear wheel hubs. See the procedure above. CHAIN TENSIONER Removal Remove the rear axle.
Page 234 Section 06 DRIVE TRAIN Subsection 02 (REAR AXLE) Removal WARNING NOTE: Bearings and seals must be replaced if re- Clean all grease, outside and inside, from ec- moved. centric housing before putting in oven. Remove O-ring no. 14. Press the bearing into the chain tensioner. Pry out drive axle seals no.
Page 235: Slider-Shoe
Section 06 DRIVE TRAIN Subsection 02 (REAR AXLE) SLIDER-SHOE Removal Remove swing arm. Refer to REAR SUSPENSION. Remove slide-shoe no. 16. Installation Installation takes place in the reverse order of re- moval. CHAIN ROLLER Removal Unscrew bolt no. 17 retaining the chain roller no.
Page 236 Section 07 STEERING/CONTROL SYSTEMS Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING/CONTROL SYSTEMS..................07-02-1 HANDLEBAR ........................07-02-2 STEERING COLUMN ......................07-02-2 TIE-ROD..........................07-02-2 STEERING COLUMN BEARING..................07-02-4 MULTI-FUNCTION SWITCH ..................... 07-02-4 THROTTLE HANDLE......................07-02-5 LH HANDLE BRAKE......................07-02-6 RH HANDLE BRAKE ......................07-02-7 07-01-1 VMR2003_033_07_01ATOC.FM...
Page 237: Steering/Control Systems
Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS) STEERING/CONTROL SYSTEMS 07-02-1 VMR2003_025_07_02A.FM...
Page 238: Handlebar
Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS) HANDLEBAR – tie-rods on the steering column side (see further in this section) Removal – hexagonal flange screws no. 11, half bushing no. 12, bushings no. 13, stopper plate no. 14 and Remove: elastic flange nuts no.
Page 239 Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS) Remove cotter pin no. 24 elastic stop nut no. 25, Toe Adjustment washer no. 26, and tie-rod assembly no. 27. Place vehicle on level surface. Check that handlebar is straight. Check pressure in each tires. Always follow recom- mended pressure.
Page 240: Steering Column Bearing
Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS) Measure the distance between the front edge of the front rim and the rope and the distance be- tween the rear edge of the front rim and the rope. 1. Frame support 2.
Page 241: Throttle Handle
Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS) Removal THROTTLE HANDLE – dash board cover and cup (refer to BODY) Removal – tie-rap Remove: – socket screws – throttle cover screws – disconnect connectors. The connectors are locat- – throttle clip screws. ed under the dash board cover.
Page 242: Lh Handle Brake
Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS) Lubrication Refer to CARBURETOR. LH HANDLE BRAKE Removal Remove multi-switch. Remove handlebar grip. Remove cable brake screw. 1. Rubber cap 2. Throttle cable 3. Adjustment screw 4. Throttle cable housing 1. Multi-switch 2.
Page 243: Rh Handle Brake
Section 07 STEERING/CONTROL SYSTEMS Subsection 02 (STEERING/CONTROL SYSTEMS) RH HANDLE BRAKE Removal Remove screws. Remove RH handle brake. Cable Removal Refer to HYDRAULIC BRAKES for specifics in- structions. 1. RH handle brake screws Separate handle brake no. 24 from handlebar no. 10. On some vehicles, unplug connectors under steer- ing cover and cut locking tie.
Page 244 Section 08 SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FRONT SUSPENSION ......................08-02-1 GENERAL ........................... 08-02-2 FRONT SHOCK ........................08-02-2 LH/RH A-ARM ........................08-02-3 A-ARM BUSHINGS......................08-02-3 REAR SUSPENSION......................08-03-1 GENERAL ........................... 08-03-2 REAR SHOCK ........................08-03-2 SWING ARM ........................08-03-3 08-01-1 VMR2003_033_08_01ATOC.FM...
Page 245: Front Suspension
Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION ) FRONT SUSPENSION 08-02-1 VMR2003_026_08_02A.FM...
Page 246: General
Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION ) GENERAL Close and lock the bar. Adjust the handle horizontal position by changing the position of the clevis pin. At installation, use torque values and Loctite products from the exploded view. Clean threads before using Loctite products when installing screws.
Page 247: Lh/Rh A-Arm
Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION ) Installation Installation For assembly, reverse the disassembly and removal Position front A-arm then install bolts and nuts. procedures. Do not torque yet. Install bolt and nut retaining shock absorber to LH/RH A-ARM front A-arm.
Page 248 Section 08 SUSPENSION Subsection 02 (FRONT SUSPENSION ) Inspection Check bushings for wear or other damages. To check bushing wear, use the following procedure: – Lift front of vehicle until front wheels are out of ground. NOTE: Move the tire and check if the knuckle moves with the wheel (at the same time).
Page 249: Rear Suspension
Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) REAR SUSPENSION 08-03-1 VMR2003_027_08_03A.FM...
Page 250: General
Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) GENERAL Push down on handle until it locks. Remove spring stopper and cap then release handle. At installation, use torque values and Loctite prod- ucts from the exploded view. Clean threads before using Loctite products when installing screws. WARNING Torque wrench tightening specifications must strictly be adhered to.
Page 251: Swing Arm
Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) – Oil leakage. Loosen chain tensioner lock bolts. – A gurgling noise, after completing one full com- pression and extension stroke. Renew if any faults are present. Installation Assembly and installation are essentially the re- verse of disassembly and removal procedures.
Page 252 Section 08 SUSPENSION Subsection 03 (REAR SUSPENSION) Remove chain roller. Install the swing arm bolt no. 8 with washers no. 13 then push the O-rings no. 11 between frame and bushings. 1. Brake disc 2. Swing arm bolt 3. Chain roller 4.
Page 253 Section 09 BRAKES Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS HYDRAULIC BRAKES......................09-02-1 FRONT BRAKES ........................ 09-02-1 REAR BRAKE ........................09-02-2 GENERAL ........................... 09-02-3 BRAKE FLUID........................09-02-3 MASTER CYLINDER ......................09-02-4 FRONT BRAKE CALIPERS....................09-02-5 REAR BRAKE CALIPER...................... 09-02-7 BRAKE PADS ........................
Page 254: Hydraulic Brakes
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) HYDRAULIC BRAKES FRONT BRAKES in 12 09-02-1 VMR2003_028_09_02A.FM...
Page 255: Rear Brake
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) REAR BRAKE 09-02-2 VMR2003_028_09_02A.FM...
Page 256: General
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) GENERAL BRAKE FLUID For installation, use the torque values and Loctite Recommended Fluid products from exploded views. Clean threads be- Always use brake fluid meeting the specification fore using Loctite product when installing screws. DOT 4 only.
Page 257: Master Cylinder
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Fluid Replacement Install cover on reservoir. If vacuum pump is not available, use the following WARNING procedure. A contaminated brake disc or pad reduces stop- Install a tube to bleed valve. ping power. Discard contaminated pads and Open bleeder.
Page 258: Front Brake Calipers
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Installation For the installation, reverse the removal procedure, pay attention to the following details. Position cylinder holding bracket with the UP mark upward. Install bolts and tighten loosely. With the handlebar in straight ahead position, po- sition cylinder reservoir parallel to the ground.
Page 259 Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Disassembly Remove brake pads, see the following section. Remove boot kit no. 12 and pad spring. Place rag over piston. Place caliper body with piston down and apply small squirts of air pressure to the fluid inlet to re- move piston.
Page 260: Rear Brake Caliper
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) REAR BRAKE CALIPER Removal Remove RH side footwell. Refer to BODY for re- moval procedure. Remove bolts no. 32 to detach brake cable from rear brake caliper. Remove bolts no. 28 and pull out the rear brake caliper from rear brake disc.
Page 261 Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) Rear Brake Pads CAUTION: Brake pads must always be replaced in pairs. Remove rear brake calipers, see REAR BRAKE CALIPER for removal procedure. Installation Remove rear brake pads no. 30 from the caliper. Front Brake Pads Push caliper pistons inward before installing brake pads.
Page 262: Brake Disc
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES) BRAKE DISC NOTE: Wheel hub has to be removed from vehicle to replace brake disc no.15. Front Brake Disc Inspection Remove cotter pin and unscrew nut. Front brake discs no. 15 can be inspected without removing from the vehicle.
Page 263: Front Brake Lever
Unhook brake pedal spring no. 17. Lubrication Remove stop nut no. 19. The brake cable must be lubricated with Bombardier cable lubricant (P/N 293 600 041) only. Remove cable barrel no. 20. Remove cable from hand lever. To ease this opera- Remove cable no.
Page 264: Brake Hoses
NOTE: Place a rag around cable luber to prevent Remove: lubricant splash. – console Spray a small quantity of Bombardier cable lubri- cant (P/N 293 600 041) then press the brake pedal – front luggage rack. to move the brake cable. Repeat this procedure Refer to BODY for complete procedure.
Page 265 Section 10 BODY/FRAME Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS BODY............................10-02-1 BODY PARTS ........................10-02-1 GENERAL ........................... 10-02-2 SEAT........................... 10-02-2 DASH BOARD COVER ....................... 10-02-2 DASH BOARD/STEERING COVER ..................10-02-3 FRONT BUMPER/LUGGAGE RACK.................. 10-02-3 FRONT FASCIA ........................10-02-4 RH/LH FOOTWELLS......................
Page 266: Body
Section 10 BODY/FRAME Subsection 02 (BODY) BODY BODY PARTS 10-02-1 VMR2003_029_10_02A.FM...
Page 267: General
Section 10 BODY/FRAME Subsection 02 (BODY) GENERAL For installation, use the torque values and Loctite products from exploded views. Clean threads be- fore using Loctite product when installing screws. Plastic Rivet Plastic rivets no. 17 are used in the riveting of the various body parts.
Page 268: Dash Board/Steering Cover
Section 10 BODY/FRAME Subsection 02 (BODY) DASH BOARD/STEERING COVER FRONT BUMPER/LUGGAGE RACK Removal Removal Steering Cover Front Bumper The steering cover no. 26 can be remove by lifting upwards. To remove front bumper no. 1, unscrew screws no. 2. Dash Board NOTE: Console cover must be removed before removing dashboard.
Page 269: Front Fascia
Section 10 BODY/FRAME Subsection 02 (BODY) Pull front luggage rack no. 6 upward. 1. Front fascia 2. Screws 1. Front luggage rack 2. Front fascia Installation 3. Screws 4. Plastic rivets Installation is the reverse order of removal. Installation RH/LH FOOTWELLS Installation is in the reverse order of removal.
Page 270: Rear Luggage Rack/Rear Bumper
Section 10 BODY/FRAME Subsection 02 (BODY) RH Side Footwell Remove the chain cover no. 20 by removing the plastic rivet no. 17. Remove screws no. 15 retaining RH side footwell no. 21. Remove plastic rivets no. 17. Pull out the RH side footwell by detaching the grommet no.
Page 271: Seat Cover Replacement
Section 10 BODY/FRAME Subsection 02 (BODY) Installation SEAT CLEANING Installation is the reverse order of removal. It is recommended to clean the seat with a solution NOTE: Install all screws before torque. of warm soapy water, using a soft clean cloth. CAUTION: Avoid use of harsh detergents such SEAT COVER REPLACEMENT as strong soaps, degreasing solvents, abrasive...
Page 272: Plastic Maintenance
Section 10 BODY/FRAME Subsection 02 (BODY) PLASTIC MAINTENANCE DECALS HAVING A PROTECTIVE FILM ON BOTH SIDES MAINTENANCE These decals usually contain graphics. INSTALLATION ON PLASTIC Clean the vehicle thoroughly, removing all dirt and grease accumulation. Clean surface with isopropyl alcohol. To clean use a soft clean cloth and either soapy Using a pencil and the decal as a template, mark water or isopropyl alcohol.
Page 273 Section 10 BODY/FRAME Subsection 03 (FRAME) FRAME 10-03-1 VMR2003-030_10_03A.FM...
Page 274: Frame
Section 10 BODY/FRAME Subsection 03 (FRAME) GENERAL Installation Installation is the reverse of removal procedure. For installation, use the torque values and Loctite products from exploded views. Clean threads before FRAME using Loctite product when installing screws. CAUTION: Before performing electrical welding Cleaning anywhere on the vehicle, unplug the electronic module connector.
Page 275 Section 11 TECHNICAL DATA Subsection 01 (SI METRIC INFORMATION GUIDE) TECHNICAL DATA SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length ..............meter ............. mass ..............kilogram ..........force ..............newton ........... liquid ..............liter ............temperature ............Celsius ........... °C pressure ..............
Page 276 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) ENGINE AND VEHICLE VEHICLE MODEL RALLY BOMBARDIER-ROTAX, 4 stroke, Engine type Over Head Camshaft (OHC), liquid cooled Starting system Electric Number of cylinder(s) Number of valves 4 valves with mechanical adjustment...
Page 277 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) VEHICLE MODEL RALLY New minimum mm (in) 10.036 (.3951) Rocker arm bore diameter New maximum mm (in) 10.050 (.3957) Wear limit mm (in) 10.060 (.3961) New minimum mm (in) 10.006 (.3939) Rocker arm shaft diameter New maximum mm (in)
Page 278 .591 Type Regular unleaded gasoline Fuel Octane no. 87 (Ron + Mon)/2 SAE 5W30 or 5W40 Bombardier synthetic oil mineral based Lubricant Oil pressure switch 30 to 60 kPa (4.35 to 8.70 PSI) Oil temperature (max.) 120°C (248°F) Oil pressure (min.) 350 kPa (50.76 PSI)
Page 279 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) VEHICLE MODEL RALLY Turning radius 1.85 m (73 in) mm (in) Total toe (vehicle on ground) 0 ± 3 (0 ± .118), each side Camber angle 4° Tie-rod total length mm (in) 320 ±...
Page 280: Frame
Capacity ± 100 1.35 l (1.43 quarts) SAE 5W30, 4 stroke mineral based oil SG, SH or SJ or Engine 5W40 Bombardier synthetic oil. Recommended Refer to the oil viscosity chart in the MAINTENANCE AND LUBRICATION subsection Capacity 200 ml (6.76 U.S. oz)
Page 281 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) SERVICE VEHICLE MODEL RALLY PRODUCT ENGINE Oil filter screw Dipstick tube screw 9 N•m (80 lbf•in) Magneto cover bolts None Starter bolts Engine sprocket nut 95 N•m (70 lbf•ft) Dielectric Starter RED (+) cable 6 N•m (53 lbf•in) grease Rotor bolt...
Page 282 Section 11 TECHNICAL DATA Subsection 02 (ENGINE AND VEHICLE) SERVICE VEHICLE MODEL RALLY PRODUCT DRIVE TRAIN Front wheel hub nut 135 N•m (100 lbf•ft) Rear wheel hub nut None Chain tensioner lock bolt 42 N•m (31 lbf•ft) Rear axle nut 140 N•m (103 lbf•ft) Loctite 277 WHEEL...

BOMBARDIER RALLY 200 2003 Shop Manual

Table of Contents

Table of Contents

Service Tools

Service Products

Table of Contents

Noise Emission Control System Regulation

Maintenance Chart

Lubrication and Maintenance Chart

Maintenance/Lubrication

Storage/Preseason Preparation

Storage

Preseason Preparation

Table of Contents

Troubleshooting

Cooling System

Magneto System

Lubrication

Cylinder and Head

Gearbox

Crankshaft

Cvt

Engine General

Leak Test

Engine System

Removal and Installation

Exhaust System

Cooling System

Water Pump

Cooling System

Magneto System

Lubrication System

Cylinder and Head

Crankshaft

Cvt

Table of Contents

Fuel Circuit

Carburetor

Air Intake Silencer

Table of Contents

Overview

General Operation Information

General Testing/Troubleshooting Information

Charging System

Starting System

Battery

Starting System Troubleshooting

Starting System Tests

Electric Starter

Ignition System Testing Procedure

Ignition System

Spark Plug

Ngk Spark Plug Symbol Explanation

General

Instruments and Accessories

Test

Table of Contents

Table of Contents

Front Suspension/Rear Suspension

Front Suspension

Rear Suspension

Table of Contents

Hydraulic Brakes

Front Brakes

Rear Brake

Table of Contents

Body

Body Parts

Plastic Maintenance

Plastic Repair

Frame

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for BOMBARDIER RALLY 200 2003