BOMBARDIER RALLY 200 2003 Shop Manual page 67

SYMPTOM GEAR INDICATION FAILS.
CONDITION NORMAL USE.
Test/Inspection
SYMPTOM GEAR(S) IS (ARE) HARD TO SHIFT.
CONDITION NORMAL USE.
Test/Inspection
VMR2003_006_03_02A.FM
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. Contact(s) is (are) corroded and/or contact screw for wire harness got loose.
Clean contact surface and retighten contact screw(s) with recommended torque.
c. Wire harness has broken cables.
Replace wire harness.
2. Check connector condition and/or electronical system.
a. Connector contact(s) is (are) corroded and/or otherwise damaged.
Clean connector(s) and/or replace wire harness if damaged.
b. Electrical system failed and/or otherwise damaged.
Repair and/or replace damaged part(s).
3. Check index spring placed on gearbox cover.
a. Indexation fails due to broken and/or damaged index spring.
Clean gearbox from metal particles, replace index spring and/or damaged part(s).
1. Check shift plate and/or shift forks for wear and/or damages.
a. Shift plate has worn out and/or damaged tracks.
Replace shift plate.
b. Shift fork(s) is (are) worn out and/or engagement pins are damaged.
Replace shift fork(s).
c. Shift fork(s) is (are) worn out and/or fork(s) is (are) damaged.
Replace shift fork(s).
d. Shift gear(s) is (are) worn out.
Replace shift gear(s).
e. High gear worn and/or otherwise damaged.
Replace high gear.
f. Index spring worn in front area (stops intermediate gear in idle).
Replace index spring.
2. Check engine idle speed (choke in use).
a. Idle speed is to high (CVT starts to work).
Adjust idle speed.
b. Choke is in use and increases the engine RPM.
Release choke.
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
03-02-7