BOMBARDIER RALLY 200 2003 Install guide

2003
Shop Manual
RALLY™ 200

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

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

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

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

IV VMR2003_001_00_02A.FM
INTRODUCTION 0
This Shop Manual covers the following Bombardier
made 2003 ATV:
Models
TYPICAL — VEHICLE SERIAL NUMBER LABEL
1. Model number
VEHICLE SERIAL NUMBER
LOCATION
1. V.I.N. (Vehicle Identification Number)
ENGINE SERIAL NUMBER
LOCATION
E.I.N. (ENGINE IDENTIFICATION NUMBER)
ARRANGEMENT OF THE
MANUAL
The manual is divided into 12 major sections:
01 SERVICE TOOLS AND SERVICE PRODUCTS
02 MAINTENANCE
03 ENGINE
04 FUEL SYSTEM
05 ELECTRICAL
06 DRIVE TRAIN
07 STEERING/CONTROL SYSTEMS
08 SUSPENSION
09 BRAKES
10 BODY/FRAME
11 TECHNICAL DATA
12 WIRING DIAGRAM
Each section is divided in various subsections, and
again, each subsection has one or more division.
RallyTM 200 (red) ..................................... 7550
RallyTM 200 (green) ................................. 7551
RallyTM 200 (yellow)................................ 7552
RallyTM 200 (red international)............... 7591
RallyTM 200 (green international)........... 7592
RallyTM 200 (yellow international) ......... 7593
TM Trademark of Bombardier Inc.
1
V06M05A
V06M06A
1
V06M09A
INTRODUCTION

VMR2003_001_00_02A.FM V
LIST OF ABBREVIATIONS USED
IN THIS MANUAL
Aampere
amp ampere
A•h ampere-hour
AC alternate current
BDC bottom dead center
BTDC before top dead center
°C degree Celsius
CDI Capacitor discharge ignition
cm centimeter
cm²square centimeter
cm³cubic centimeter
CVT Continuously variable transmission
DC direct current
°F degree Fahrenheit
fl. oz fluid ounce
ft foot
GRD ground
hal. halogen
I.D. inside diameter
IDI induction discharge ignition
imp. oz imperial ounce
in inch
in²square inch
in³cubic inch
k kilo (thousand)
kg kilogram
km/h kilometer per hour
kPa kilo pascal
lliter
lbf/in²pound per square inch
LH left hand
lb pound
lbf pound (force)
m meter
MAG magneto
Max. maximum
Min. minimum
ml milliliter
mm millimeter
MPH mile per hour
Nnewton
N.A. not applicable
no. number
00.0 continuity
0.L overload (open circuit)
O.D. outside diameter
OHC Over head camshaft
OPT optional
oz ounce
P/N part number
PSI pound per square inch
PTO power take off
RPM revolution per minute
Sp. Gr. specific gravity
TDC top dead center
U.S. oz ounce (United States)
USFD U.S. Forest Service
Vvolt
Vac volt (alternative current)
INTRODUCTION

VI VMR2003_001_00_02A.FM
Page heading
indicates section
and subsection
detailed.
Bold face number
indicates special
procedure
concerning this
part.
Tightening torque
nearby fastener. In this
case, nut must be
torqued to
10 Nm or 9 lbfin.
This Shop Manual uses technical terms wich may be
slightly different from the ones in the parts catalog.
Exploded view
assists you in
identifying parts and
related positions.
TYPICAL PAGE
V01A39S
Illustration
number for
publishing
process.
Subsection title
indicates
beginning of the
subsection.
Drop represents a
liquid product to
be applied to
a surface.
Page numbering system:
03: ENGINE section
04: REMOVAL AND INSTALLATION
subsection
1: First page of this subsection
CAUTION: Pay attention
to torque spe ifi
ations.
Some of these are in
lbfin instead of lbfft.
Use appro
priate torque
wren h.
Document
number for
publishing
process.
VMR2001-037_03-04A.FM
V04C0VS
10 Nm
(89 lbfin)
26
23
22
21
524
6
11 Nm
(97 lbfin)
13 Nm
(115 lbfin)
19
18
19
13 Nm
(115 lbfin)
24 Nm
(18 lbfft)
13 Nm
(115 lbfin)
20
4
48 Nm
(35 lbfft)
8
24 Nm
(18 lbfft)
10 Nm
(89 lbfin)
24 Nm
(18 lbfft)
24 Nm
(18 lbfft)
13
13
11
10 Nm
(89 lbfin)
1
27
10 17
16
48 Nm
(35 lbfft)
2
29 10 Nm
(89 lbfin)
28
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
3
9
48 Nm
(35 lbfft)
11 24 Nm
(18 lbfft)
17
16
17 11
24 Nm
(18 lbfft)
14
15
26
25
Syntheti
grease
Syntheti
grease
03-04-1
Section 03 ENGINE
Subse tion 04 (REMOVAL AND INSTALLATION)
REMOVAL AND INSTALLATION
INTRODUCTION

VMR2003_001_00_02A.FM VII
TYPICAL PAGE
Title indicates
main procedure
to be carried-out.
Bold face number
following part
name refers to
exploded view
at beginning of
subsection.
V01A3AS
m
Section 03 ENGINE
Subse tion 06 (MAGNETO SYSTEM)
03-06-6
BEARING
1. Ball bearing
Call-outs for
above illustration.
Reference to look
up a certain section
and subsection.
In this case it
concerns
IGNITION SYSTEM.
VMR2002_010_03-06A.FM
Inspe tion
Ball bearing no. 10 must rotate freely. Othewise,
replace it.
Removal
 Heat up the magneto housing cover to about
1
R610motr12A
Installation
For installation also heat the magneto housing
up to about 100oC (212oF) to put ball bearing in
place.
Place new ball bearing in freezer for 10 minutes
approximately.
Reinstall other removed parts in the reverse order.
STATOR AND TRIGGER COIL
Removal
Remove.
 m agneto housing cover no. 7
100oC (212oF) for an easy ball bearing removal.
 screw no. 11 and 12
 stator with trigger coil no. 13.
1. Stator
2. Stator screws
3. Trigger coil
4. Trigger coil screws
Inspe tion
Check stator and trigger coil condition. If damaged
replace the faulty part.
For electrical inspection, refer to CHARGING SYS-
TEM for the stator and IGNITION SYSTEM for the
trigger coil.
4
1
R610motr20A
43
2
INTRODUCTION