BOMBARDIER rally 200 Manual

This Operator’s Guide utilizes the following symbols to emphasize particular information:
CAUTION: Denotes an instruction which, if not followed, may damage the vehicle and/or com-
ponents.
All safety documentation should remain with the vehicle at the time of sale.
All content of the Safety Information section should be interpreted by the reader as a warning
which if not followed, may result in injury including the possibility of death.
The following trademarks are the property of Bombardier Recreational Products Inc.:
RALLY™
XP-S™
Printed in the E.U. (ATV RALLY EN CE 2006.fm)
®™ Trademarks of Bombardier Recreational Products Inc. or its affiliates.
©2006 Bombardier Recreational Products Inc. All rights reserved.
* Bombardier and the sprocket design are trademarks of Bombardier Inc., used under license.
The Safety Alert Symbol indicates a potential personal injury hazard.
WARNING Indicates a potential hazard that, if not avoided, could result in serious
injury or death.
WARNING
YOUR VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rollover can occur
quickly, even during routine maneuvers such as turning and driving on hills or over obstacles,
if you fail to take proper precautions.
For your safety, understand and follow all the warnings contained in this Operator’s Guide and
the labels on your vehicle. Failure to follow these warnings can result in SEVERE INJURY
OR DEATH.
Keep this Operator’s Guide with the vehicle at all times.
WARNING
Disregarding any of the safety precautions and instructions contained in this Operator’s
Guide, Safety Videocassette and on-product labels could cause injury including the possibility
of death!

1
FOREWORD
Congratulations on your purchase of a new Bombardier *recreational vehicle. It is backed by the
BRP warranty and a network of authorized Bombardier ATV dealers ready to provide the parts,
service or accessories you may require.
Your dealer is committed to your satisfaction. He has taken training to perform the initial setup
and inspection of your vehicle as well as completed the final adjustment before you took pos-
session. At delivery, your dealer would have explained for the operation, maintenance and safety
features of the vehicle. We trust you have taken full advantage of this! If you need more complete
servicing information, please ask your dealer.
At delivery, you were also informed of the warranty coverage and completed the Warranty Reg-
istration Form which is to be sent to us for processing. In the near future you should be receiving
a warranty card which will confirm our receipt of the registration as well as be used for warranty
or recall purposes.
You are invited to contact our customer assistance center should you experience problems which
cannot be resolved by an authorized Bombardier ATV dealer.
It is understood that this Operator’s Guide may be translated into another language. In the event
of any discrepancy, the English version shall prevail. Throughout this document, the masculine
is used to denote the masculine or feminine.
The information and components/system descriptions contained in this document are correct at the
time of publication. BRP however, maintains a policy of continuous improvement of its products
without imposing upon itself any obligation to install them on products previously manufactured.
Due to late changes, some differences between the manufactured product and the descriptions
and/or specifications in this Guide may occur. BRP reserves the right at any time to discontinue
or change specifications, designs, features, models or equipment without incurring any obliga-
tion upon itself.
The illustrations in this document show the typical construction of the different assemblies and
may not reproduce the full detail or exact shape of the parts. However, they represent parts that
have the same or similar function.
The use of RIGHT and LEFT indications in the text, always refers to driving position (when sitting
on vehicle).
Specifications are given in the SI metric system with the SAE U.S. equivalent in parenthesis.
Where precise accuracy is not required, some conversions are rounded off for easier use.
We recommend genuine BRP products for replacement parts and accessories. They’ve been
especially designed for your vehicle and manufactured to meet of BRP’s demanding standards.
A Shop Manual can be obtained for complete service and maintenance information and more
repair information.

2
TABLE OF CONTENTS
While reading this Operator’s Guide, remember that:
NOTICE ............................................................................................................... 6
European Community.............................................................................. 6
INTRODUCTION ................................................................................................. 7
SAFETY INFORMATION
SPECIAL SAFETY MESSAGES......................................................................... 10
OPERATION WARNINGS................................................................................... 12
SAFETY WARNING ............................................................................................ 38
Pre-Operation Check............................................................................... 39
Clothing ................................................................................................... 40
Carrying Loads ........................................................................................ 41
Hauling a Trailer ...................................................................................... 41
Working with your vehicle........................................................................ 41
Recreational Riding ................................................................................. 41
Environment ............................................................................................ 42
Design Limitation ..................................................................................... 42
Off-Highway Operation ............................................................................ 43
General Operating and Safety Precautions............................................. 43
Uphill Driving ........................................................................................... 43
Downhill Driving....................................................................................... 44
Side hilling ............................................................................................... 44
Drop-Offs ................................................................................................. 44
Riding Techniques................................................................................... 44
Routine Maintenance............................................................................... 50
HANG TAG.......................................................................................................... 51
LOCATION OF THE IMPORTANT LABELS ...................................................... 52
VEHICLE INFORMATION
HOW TO IDENTIFY YOUR ATV ......................................................................... 58
Vehicle Identification Number Location ................................................... 58
Engine Identification Number Location.................................................... 60
CONTROLS/COMPONENTS/INSTRUMENTS................................................... 61
1) Throttle Lever.................................................................................... 63
2) Front/Rear Brake Lever .................................................................... 63
3) Rear Brake Lever.............................................................................. 64
4) Brake Lever Lock .............................................................................. 64
5) Transmission Lever........................................................................... 64
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.

3
6) Multi-function Switch ........................................................................ 65
7) Indicator Lamps................................................................................ 68
8) Ignition Switch .................................................................................. 68
9) Fuel Tank Cap.................................................................................. 69
10) Fuel Valve ........................................................................................ 69
11) Front/Rear Brake Pedal ................................................................... 70
12) Footpeg ............................................................................................ 70
13) Tool Box ........................................................................................... 70
14) Front/Rear Cargo Racks .................................................................. 71
15) Radiator Cap .................................................................................... 71
16) Fuse ................................................................................................. 71
17) Vehicle Lock ..................................................................................... 72
18) Direction Indicator Switch................................................................. 72
19) Horn Button ...................................................................................... 72
20) Hazard Warning Switch.................................................................... 72
LIQUIDS............................................................................................................... 73
Fuel......................................................................................................... 73
Engine/Transmission Oil ........................................................................ 73
Gearbox Oil............................................................................................. 75
Engine Coolant ....................................................................................... 76
Coolant Replacement ............................................................................. 77
Brake Fluid.............................................................................................. 77
Battery .................................................................................................... 78
BREAK-IN PERIOD ............................................................................................. 79
Engine..................................................................................................... 79
Belt.......................................................................................................... 79
10-Hour Inspection ................................................................................. 79
OPERATING INSTRUCTIONS ............................................................................ 80
General ................................................................................................... 80
Pre-Operation Check .............................................................................. 80
Initial Cold Starting.................................................................................. 80
Warm Engine Starting............................................................................. 81
Stopping the Engine ............................................................................... 81
Shifting the Transmission ....................................................................... 81
SPECIAL PROCEDURES ................................................................................... 82
Flooded Engine....................................................................................... 82
Engine Overheat..................................................................................... 82
Post-Operation Care............................................................................... 83
Turn Over................................................................................................ 83
ATV Immersion ....................................................................................... 83
Storage and Preseason Preparation ...................................................... 83
CARGO AND TRANSPORTATION ..................................................................... 84
Transportation......................................................................................... 84

4
TROUBLESHOOTING ........................................................................................ 86
SPECIFICATIONS............................................................................................... 89
MAINTENANCE INFORMATION
MAINTENANCE CHART..................................................................................... 94
GENERAL ........................................................................................................... 97
ENGINE............................................................................................................... 98
Oil Change and Oil Filter Replacement ................................................... 98
Oil Pressure Regulator ............................................................................ 99
Gearbox Oil Replacement ....................................................................... 100
Coolant Replacement .............................................................................. 100
Drive Belt ................................................................................................. 101
Valve Adjustment..................................................................................... 101
Spark Arrester ......................................................................................... 101
Radiator ................................................................................................... 102
CARBURETOR ................................................................................................... 103
AIR INTAKE SYSTEM ........................................................................................ 104
Air Box Draining....................................................................................... 104
Air Filter Cleaning .................................................................................... 104
ELECTRICAL ...................................................................................................... 106
Battery ..................................................................................................... 106
Fuse......................................................................................................... 106
Bulb Replacement ................................................................................... 107
DRIVE TRAIN ...................................................................................................... 109
Lubrication ............................................................................................... 109
Drive Chain.............................................................................................. 109
Drive Chain Slider.................................................................................... 110
Sprocket and Pinion ................................................................................ 110
Wheel ...................................................................................................... 111
Wheel Bearing/Bushings Condition ......................................................... 111
Tires/Wheels ........................................................................................... 111
STEERING SYSTEM........................................................................................... 113
Throttle Cable Lubrication ....................................................................... 113
Throttle Lever Adjustment ....................................................................... 114
SUSPENSION ..................................................................................................... 115
Adjustment............................................................................................... 115
Lubrication ............................................................................................... 115
Inspection ................................................................................................ 115
BRAKE................................................................................................................ 116
Front Brake.............................................................................................. 116
Rear Brake .............................................................................................. 116
Brake Cable Lubrication .......................................................................... 116
Inspection ................................................................................................ 116
Brake Fluid Replacement ........................................................................ 116

5
BODY/FRAME ..................................................................................................... 117
Engine Area ............................................................................................ 117
Hitch/Trailer Ball Condition (if so equipped) ........................................... 117
Fasteners................................................................................................ 117
Seat Fasteners ....................................................................................... 117
Vehicle Cleaning and Protection............................................................. 117
WARRANTY
BRP INTERNATIONAL LIMITED WARRANTY: 2006 BOMBARDIER*
ATV PRODUCTS ................................................................................................. 120
PRIVACY OBLIGATION/DISCLAIMER............................................................... 123
CHANGE OF ADDRESS/OWNERSHIP .............................................................. 125

6
NOTICE
This Operator’s Guide has been prepared to
acquaint the owner/operator of a new vehicle
with the various vehicle controls, mainte-
nance and safe operating instructions. It is in-
dispensable for the proper use of the product.
This Operator’s Guide uses the following
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 informa-
tion does not eliminate the hazard, the under-
standing and application of the information
will promote the correct use of this vehicle.
To fully appreciate the pleasures, enjoyment
and excitement of using this vehicle, there are
some basic rules that MUST be observed and
followed by any user.
European Community
This warning applies only in the European
Countries where on road usage is allowed.
WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.
WARNING
On road use:
This vehicle is built for OFF-ROAD pur-
poses only. It may be used for short dis-
tances on paved surfaces at reduced
speed, in order to move the vehicle from
an off-road location to another.
When driving this vehicle on roads, always
refrain from speeding and substantially re-
duce vehicle speed when turning.
Failure to do so can cause a loss of vehicle
control, possibly resulting in serious injury.
Front winch:
The front winch hook of the so equipped
vehicle must be removed and stored when
riding the vehicle on public trails and/or
roads.
Failure to do so can increase the risk of
injury to bystanders.

7
INTRODUCTION
Your selling dealer should have provided you with some basic information on the particular
controls and features of your new vehicle. Please take the time to study this Operator’s Guide
and all on-product warning labels as well as the Safety Videocassette that came with the ATV.
They more completely describe what you should know about this vehicle before riding it.
Whether you are a new user or an experienced rider, it is important for your personal safety that
you know the controls and features of the this vehicle. Equally important is knowing how to
properly ride.
Irrespective of your age, experience or state regulations, it is always prudent for you or any other
person who may ride your vehicle, to take an approved safe riding course. Please check with
your dealer or local authorities for availability in your area. If you are a completely new rider, this
should be done before your first ride. Your instructor should be able to provide advice on local
conditions and safe riding practices particular to the area.
Riding conditions vary from place to place. Each is subject to weather conditions which may
radically change from time to time and from season to season. Riding on sand is different than
riding on snow or through forests or marshes. Each location may require a greater degree of
awareness and skill. Show good judgement. Always proceed with caution. Please do not take
any unnecessary risks that could leave you stranded or possibly injured.
The contents of this Operator's Guide provide riding information which has been proven reliable
by other users. They are not intended as a definitive means of avoiding accidents. How you
apply this information, coupled with your mental and physical condition, the particular terrain
hazard and your risk acceptance level will have an effect on your riding experience. Have fun...
and ride responsibly.
This Operator's Guide has been prepared to acquaint the owner/operator of a new vehicle with
the various vehicle controls, maintenance and safe operating instructions. They are indispens-
able for the proper use of the product.
We would be pleased to receive any comments on the content and format of this Operator's
Guide, the Safety Videocassette or on-product warnings labels.

8

9
SAFETY
INFORMATION

10
SPECIAL SAFETY MESSAGES
THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
This vehicle handles differently from other vehicles including motorcycles and cars. A collision
or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills
or over obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this Operator’s Guide and all on-product warning labels carefully and follow the oper-
ating procedures described. Watch and pay attention to the Safety Videocassette before
operation.
Never operate this vehicle without proper instruction. Take a training course. Beginners
should receive training from a certified instructor. Contact an authorized Bombardier ATV
dealer to find out about the available training course nearest you.
Always follow this age recommendation: A person under 16 years old should never operate
this vehicle.
Never carry a passenger on this vehicle.
Never operate this vehicle on any paved surfaces unless it is for short distances, at reduced
speed and in order to move the vehicle from an off-road location to another.
Always respect the road traffic law when you operate this vehicle on the roadway, even a dirt
or gravel road.
Never take place on this vehicle without wearing an approved helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, long sleeved shirt or
jacket, and long pants.
Never consume alcohol or drugs before or while riding this vehicle.
Never operate at excessive speeds. Always go at a speed that is proper for the terrain,
visibility, and operating conditions, and your experience.
Never attempt wheelies, jumps, or other stunts.
Always inspect your vehicle each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in this
Operator’s Guide.
Always keep both hands on the handlebars and both feet on the footpegs of the vehicle during
operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert
to changing terrain conditions when operating the vehicle.
Never operate on excessively rough, slippery or loose terrain until you have learned and
practiced the skills necessary to control the vehicle on such terrain. Always be especially
cautious on these kinds of terrain.
Always follow proper procedures for turning as described further in this Operator’s Guide.
Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at
excessive speed.
Never operate the vehicle on hills too steep for the vehicle or for your abilities. Practice on
smaller hills before attempting larger hills.

11
Always follow proper procedures for climbing hills as described further in this Operator’s
Guide. Check the terrain carefully before you start up any hill. Never climb hills with exces-
sively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly
or make sudden gear changes. Never go over the top of any hill at high speed.
Always follow proper procedures for going down hills and for braking on hills as described
further in this Operator’s Guide. Check the terrain carefully before you start down any hill.
Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at
an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill
where possible.
Always follow proper procedures for crossing the side of a hill as described further in this
Operator’s Guide. Avoid hills with excessively slippery or loose surfaces. Shift your weight to
the uphill side of the vehicle. Never attempt to turn the vehicle around on any hill until you
have mastered the turning technique described in this Operator’s Guide on level ground.
Avoid crossing the side of a steep hill if possible.
Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid
stalling, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll
backwards, follow the special procedure for braking described further in this Operator’s
Guide. Dismount on the uphill side or to a side if pointed straight uphill. Turn the vehicle
around and remount, following the procedure described further in this Operator’s Guide.
Always check for obstacles before operating in a new area. Never attempt to ride over large
obstacles, such as large rocks or fallen trees. Always follow proper procedures when riding
over obstacles as described further in this Operator’s Guide.
Always be careful when skidding or sliding. Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such
as ice, go slowly and be very cautious in order to reduce the chance of skidding out of control.
Never operate this vehicle in fast flowing water or in water deeper than that specified further
in this Operator’s Guide. Remember that wet brakes may have reduced stopping ability. Test
your brakes after leaving water. If necessary, apply them several times to let friction dry out
the pads.
Always be sure there are no obstacles or people behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly.
Always use the size and type tires specified further in this Operator’s Guide. Always maintain
proper tire pressure as described further in this guide.
Never modify this vehicle through improper installation or use of accessories. Only use BRP's
approved accessories. Do not install passenger seat or use racks to carry a passenger.
Never exceed the stated load limits for this vehicle including operator, all other loads and
added accessories. Cargo should be properly distributed and securely attached. Reduce
speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater
distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, contact an authorized ATV dealer to find
out about the training courses nearest you.

12
OPERATION WARNINGS
While reading this Operator’s Guide, remember that:
NOTE: The following illustrations are general representations only. Your model may differ.
WARNING
Indicates a potential hazard that, if not avoided, could result in serious injury or death.
WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does not know how to operate this
vehicle properly in different situations and on different types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the training course offered by BRP.
They should then regularly practice the skills learned in the course and the operating tech-
niques described in this Operator’s Guide.
For more information about the training course, contact an authorized Bombardier ATV
dealer.
V00A0AQ

13
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this vehicle.
WHAT CAN HAPPEN
A lack of respect for this age recommendation can lead to severe injury or death of the child.
Even though a child may be within the age group for which this vehicle is recommended, he
may not have the skills, abilities, or judgment needed to operate the ATV safely and may be
involved in a serious accident.
HOW TO AVOID THE HAZARD
No one under 16 should operate this vehicle.
V00A01Q

14
WARNING
POTENTIAL HAZARD
Carrying a passenger on this vehicle.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and control this vehicle.
Could cause an accident, resulting in harm to you and/or your passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. Even with a long seat that provides unrestricted operator move-
ment, it is not designed nor intended to carry passenger(s).
V00A02Q

15
WARNING
POTENTIAL HAZARD
Operating this vehicle on public streets or roads.
WHAT CAN HAPPEN
You can collide with another vehicle. Paved surfaces may seriously affect handling and con-
trol of this vehicle, and may cause the vehicle to go out of control.
HOW TO AVOID THE HAZARD
If an on-road usage is allowed in your area, operate your vehicle on paved surface only for
short distance and for the only purpose of moving the vehicle from an off-road usage to
another.
Always operate this vehicle at low speed (never exceed 65 km/h (40 MPH)) and reduce the
speed before making a turn.
Always respect all road traffic laws when operating your vehicle on public streets or roads.
V00A04Q

16
WARNING
POTENTIAL HAZARD
Riding this vehicle without wearing an approved helmet, eye protection and protective cloth-
ing.
WHAT CAN HAPPEN
The following items concern all ATV's operator:
– riding without an approved helmet increases the chances of a severe head injury or death
in the event of an accident
– riding without eye protection can result in an accident and increases the chances of a
severe injury in the event of an accident
– riding without protective clothing increases the chances of severe injury in the event of an
accident.
HOW TO AVOID THE HAZARD
Always wear an approved helmet that fits properly. You should also wear:
– eye protection (goggles or face shield)
– gloves and boots
– Iong sleeved shirt or jacket
– Iong pants.
V00A06Q

17
WARNING
POTENTIAL HAZARD
Riding this vehicle after consuming alcohol or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident or death.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while riding this vehicle.
V00A07Q

18
WARNING
POTENTIAL HAZARD
Operating this ATV at excessive speeds.
WHAT CAN HAPPEN
Increases your chances of losing control of the vehicle, which can result in an accident.
HOW TO AVOID THE HAZARD
Always travel at a speed which is proper for the terrain, visibility and operating conditions,
and your experience. The maximum speed authorized with this vehicle is 65 km/h (40 MPH).
Always reduce speed before making a turn
V00A08Q