Can-Am Rally 200 Manual

vmo2007 RALLY 200 ang.FH10 Thu May 11 15:47:01 2006 Page 1
Composite
C M Y CM MY CY CMY K

This Operator’s Guide utilizes the following symbols to emphasize particular in-
formation:
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.
CAUTION: Denotes an instruction which, if not followed, could severely
damage vehicle components.
NOTE: Indicates supplementary information needed to fully complete an instruc-
tion.
WARNING
YOUR VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rollover
can occur quickly, even during routine maneuvers such as turning and driv-
ing 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 VIDEO and on-product labels could cause injury
including the possibility of death!
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 pos-
sibility of death.
In Canada, products are distributed by Bombardier Recreational Products Inc.
(BRP)
In USA, products are distributed by BRP US Inc.
The following trademarks are the property of Bombardier Recreational Prod-
ucts Inc.:
Can-Am™
RallyTM
XP-STM
Printed in Canada.(vmo2007-016 DR)
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.
©2006 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.

FOREWORD
Congratulations on your purchase of a
new Can-Am™ ATV. It is backed by the
BRP warranty and a network of autho-
rized Can-Am dealers ready to provide
the parts, service or accessories you
may require.
Your dealer is committed to your satis-
faction. He has taken training to per-
form the initial setup and inspection
of your vehicle as well as completed
the final adjustment before you took
possession. At delivery, your dealer
would have explained the operation,
maintenance and safety features of
the vehicle. We trust you have tak-
en full advantage of this! If you need
more complete servicing information,
please ask your dealer.
Atdelivery,youwerealsoinformedof
the warranty coverage and completed
the Warranty Registration Form which
is to be sent to us for processing. In
the near future you should be receiv-
ing a warranty card which will confirm
our receipt of the registration as well
as be used for warranty or recall pur-
poses.
You are invited to contact our cus-
tomer assistance center should you
experience problems which cannot
be resolved by an authorized Can-Am
dealer.
It is understood that this Operator’s
Guide may be translated into another
language. In the event of any discrep-
ancy, the English version shall prevail.
Throughout this document the mascu-
line is used to denote the masculine or
feminine.
If you want to view and/or print an
extra copy of your Operator's Guide,
simply visit the following website
www.operatorsguide.brp.com.Al-
so note that the guide is available in
several languages.
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 differ-
ences 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 equip-
ment without incurring any obligation
upon itself.
The illustrations in this document
show the typical construction of the
different assemblies and may not re-
produce 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 indica-
tions in the text always refers to driv-
ing position (when sitting on vehicle).
Specifications are given in the SI met-
ric system with the SAE U.S. equiva-
lent in parenthesis. Where precise ac-
curacy is not required, some conver-
sions are rounded off for easier use.
We recommend genuine BRP prod-
ucts for replacement parts and acces-
sories. They’ve been especially de-
signed for your vehicle and manufac-
tured to meet BRP’s demanding stan-
dards.
ASHOP MANUAL can be obtained for
complete service and maintenance in-
formation and more repair information.
______________________ 1

TABLE OF CONTENTS
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious in-
jury or death.
NOTICE................................................................................ 7
INTRODUCTION ..................................................................... 8
SAFETY INFORMATION
SPECIAL SAFETY MESSAGES................................................... 10
OPERATION WARNINGS.......................................................... 13
RIDING THE VEHICLE.............................................................. 40
Pre-Operation Check ........................................................... 41
Clothing.......................................................................... 42
Carrying Loads .................................................................. 43
Hauling a Trailer (if so equipped) .............................................. 43
Working with your Vehicle ..................................................... 43
Recreational Riding ............................................................. 43
Environment..................................................................... 44
Design Limitation ............................................................... 44
Off-Highway Operation......................................................... 44
General Operating and Safety Precautions .................................. 45
Uphill Driving .................................................................... 45
Downhill Driving ................................................................ 45
Side Hilling....................................................................... 46
Drop-Offs ........................................................................ 46
Riding Techniques .............................................................. 46
Routine Maintenance........................................................... 52
HANG TAG .......................................................................... 53
ON-PRODUCT LABELS............................................................ 54
VEHICLE INFORMATION
HOW TO IDENTIFY YOUR VEHICLE............................................. 58
NOISE EMISSION CONTROL SYSTEM REGULATION ....................... 62
EMISSION REQUIREMENTS ..................................................... 63
BREAK-IN PERIOD.................................................................. 64
CONTROLS/INSTRUMENTS/EQUIPMENT .................................... 65
1) Throttle Lever ................................................................ 67
2_______________________

2) Front Brake Lever............................................................ 67
3) Rear Brake Lever............................................................. 67
4) Parking Brake................................................................. 68
5) Transmission Lever .......................................................... 68
6) Multi-Function Switch ....................................................... 69
7) Indicator Lamps.............................................................. 71
8) Ignition Switch ............................................................... 71
9) Fuel Tank Cap ................................................................ 72
10) Fuel Valve ................................................................... 72
11) Rear Brake Pedal ........................................................... 73
12) Footpeg...................................................................... 73
13) Tool Kit....................................................................... 73
14) Front/Rear Cargo Racks.................................................... 74
15) Radiator Cap ................................................................ 74
16) Fuse.......................................................................... 74
LIQUIDS.............................................................................. 76
Fuel............................................................................... 76
Engine Oil........................................................................ 76
Gearbox Oil...................................................................... 78
Engine Coolant.................................................................. 78
Brake Fluid....................................................................... 80
Battery ........................................................................... 80
OPERATING INSTRUCTIONS..................................................... 82
General........................................................................... 82
Pre-Operation Check ........................................................... 82
Starting the Engine ............................................................. 83
Shifting the Transmission ...................................................... 83
Stopping the Engine............................................................ 84
Post-Operation Care............................................................ 84
SPECIAL PROCEDURES........................................................... 85
Engine Overheat ................................................................ 85
Turn Over ........................................................................ 85
Vehicle Immersion.............................................................. 86
CARGO AND TRANSPORTATION ............................................... 87
TROUBLESHOOTING.............................................................. 89
SPECIFICATIONS ................................................................... 93
MAINTENANCE INFORMATION
MAINTENANCE CHART........................................................... 98
GENERAL .......................................................................... 102
ENGINE ............................................................................ 103
Oil Change and Oil Filter Replacement..................................... 103
Oil Pressure Regulator ....................................................... 104
______________________ 3

Coolant Replacement ........................................................ 104
Air Filter Housing Draining................................................... 106
Air Filter........................................................................ 106
Drive Belt ...................................................................... 107
Valve Adjustment ............................................................. 107
Spark Arrester................................................................. 107
Radiator........................................................................ 107
GEARBOX ......................................................................... 109
Oil Change..................................................................... 109
CARBURETOR .................................................................... 110
FUEL SYSTEM .................................................................... 111
Throttle Cable Lubrication.. .................................................. 111
Throttle Lever Adjustment................................................... 112
ELECTRICAL....................................................................... 113
Battery ......................................................................... 113
Fuse............................................................................ 113
Bulb Replacement ............................................................ 114
DRIVE TRAIN...................................................................... 117
Lubrication ..................................................................... 117
Drive Chain .................................................................... 117
Drive Chain Slider............................................................. 118
Sprocket and Pinion .......................................................... 118
Wheel .......................................................................... 119
Wheel Bearing/Bushings Condition ......................................... 119
Tires/Wheels .................................................................. 119
SUSPENSION..................................................................... 121
Adjustment .................................................................... 121
Lubrication ..................................................................... 121
Inspection...................................................................... 121
BRAKE.............................................................................. 122
Front Brake .................................................................... 122
Rear Brake..................................................................... 122
Brake Cable Lubrication ...................................................... 122
Inspection...................................................................... 122
Brake Fluid Replacement .................................................... 122
BODY/FRAME..................................................................... 123
Engine Area ................................................................... 123
Hitch/Trailer Ball Condition (if so equipped) ................................ 123
Chassis Fasteners . ........................................................... 123
Seat Fasteners ................................................................ 123
Vehicle Cleaning and Protection............................................. 123
4_______________________

STORAGE AND PRESEASON PREPARATION ............................... 124
WARRANTY
BRP LIMITED WARRANTY NORTH AMERICA: 2007 CAN-AMTM ATV . . . 126
BRP INTERNATIONAL LIMITED WARRANTY: 2007 CAN-AMTM ATV .... 130
PRIVACY OBLIGATION/DISCLAIMER......................................... 134
CHANGE OF ADDRESS/OWNERSHIP ........................................ 135
______________________ 5

6_______________________

NOTICE
This Operator's Guide has been pre-
pared to acquaint the owner/operator
of a new vehicle with the various ve-
hicle controls, maintenance and safe
operating instructions. It is indispens-
able for the proper use of the product.
This Operator's Guide uses the follow-
ing symbols.
WARNING
Indicates a potential hazard that, if
not avoided, could result in serious
injury or death.
CAUTION: Denotes an instruction
which, if not followed, could se-
verely damage vehicle compo-
nents.
NOTE: Indicates supplementary infor-
mation needed to fully complete an in-
struction.
Although the mere reading of such in-
formation does not eliminate the haz-
ard, the understanding and application
of the information will promote the
correct use of this vehicle.
To fully appreciate the pleasures, en-
joyment and excitement of using this
vehicle, there are some basic rules
that MUST be observed and followed
by any user.
______________________ 7

INTRODUCTION
Your 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 VIDEO that came with
this vehicle. They more completely
describe what you should know about
this vehicle before riding it.
Whether you are a new user or an ex-
perienced rider, it is important for your
personal safety as well as passenger
safety that you know the controls and
features of this vehicle. Equally impor-
tant 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 avail-
ability in your area. If you are a com-
pletely new rider, this should be done
before your first ride. Your instructor
should be able to provide advice on lo-
cal 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 rid-
ing on snow or through forests or
marshes. Each location may require a
greater degree of awareness and skill
may not be suitable with a passen-
ger. Show good judgement. Always
proceed with caution. Please do not
take any unnecessary risks that could
leave you or your passenger 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 condi-
tion, 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 pre-
pared to acquaint the owner/operator
of a new vehicle with the various ve-
hicle controls, maintenance and safe
operating instructions. They are indis-
pensable 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
VIDEO or on-product warnings labels.
8_______________________

SAFETY
INFORMATION
____________ SAFETY INFORMATION ____________ 9

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 ma-
neuvers such as turning and driving on
hills or over obstacles, if you fail to take
proper precautions.
SEVERE INJURY OR DEATH can re-
sult if you do not follow these instruc-
tions:
Read this Operator's Guide and all
on-product warning labels careful-
ly and follow the operating proce-
dures described. Watch and pay at-
tention to the SAFETY VIDEO be-
fore operation.
Never operate this vehicle without
proper instruction. Takeatrain-
ing course. All operators should
receive training from a certified
instructor. Contact an authorized
Can-Am dealer to find out about
available training course nearest
you or call the Specialty Vehicle In-
stitute of America (SVIA) at 1 800
877-2887 or in Canada, the Cana-
da safety Council (CSC) at 1 (613)
739-1535 ext. 227.
Always follow this age recommen-
dation: A person under 16 years old
should never operate this vehicle.
Never carry a passenger on this ve-
hicle.
Never operate this vehicle on any
paved surfaces, including side-
walks, driveways, parking lots and
streets.
Never operate this vehicle on any
public street, road or highway, even
a dirt or gravel one.
Never take place on this vehicle
without wearing an approved hel-
met 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 be-
fore or while riding this vehicle.
Never operate at excessive speeds.
Always go at a speed that is prop-
er for the terrain, visibility, and op-
erating conditions, and your experi-
ence.
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 mainte-
nance 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 op-
eration.
Always go slowly and be extra
careful when operating on unfa-
miliar terrain. Always be alert to
changing terrain conditions when
operating this vehicle.
Never operate on excessively
rough, slippery or loose terrain un-
til you have learned and practiced
the skills necessary to control this
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 at-
tempting to turn at faster speeds.
Do not turn at excessive speed.
10 ___________ SAFETY INFORMATION ___________

Never operate this vehicle on hills
too steep for the vehicle or for your
abilities. Practice on smaller hills
before attempting larger hills.
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 excessively slippery or
loose surfaces. Shift your weight
forward. Never open the throt-
tle 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 brak-
ing 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 un-
til you have mastered the turning
technique described in this Opera-
tor'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 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 at-
tempt to operate over large obsta-
cles, such as large rocks or fallen
trees. Always follow proper proce-
dures when operating over obsta-
cles as described further in this Op-
erator'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 sur-
faces, 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 in this Opera-
tor's Guide. Remember that wet
brakes may have reduced stopping
ability. Test your brakes after leav-
ing water. If necessary, apply them
several times to let friction dry out
the pads.
Always be sure there are no ob-
stacles or people behind the vehi-
cle when you operate in reverse.
When it is safe to proceed in re-
verse, 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
Operator's Guide.
____________ SAFETY INFORMATION ___________ 11

Never modify this vehicle through
improper installation or use of ac-
cessories. Only use BRP's ap-
proved accessories. NEVER install
passenger seat or use the racks to
carry a passenger.
Never exceed the stated load lim-
its for this vehicle including opera-
tor, all other loads and added acces-
sories. Cargo should be properly
distributed and securely attached.
Reduce speed and follow instruc-
tions in this manual for carrying car-
go or pulling a trailer. Allow greater
distance for braking.
FOR MORE INFORMATION
ABOUT ATV SAFETY, call the
Specialty Vehicle Institute of Amer-
ica (SVIA) at 1 800 887-2887 or in
Canada, the Canada Safety Council
(CSC) at 1 [phone] ext. 227
or contact an authorized Can-Am
dealer to find out about available
training courses nearest you.
12 ___________ SAFETY INFORMATION ___________

OPERATION WARNINGS
While reading this Operator’s Guide, remember that:
WARNING
Indicates a potential hazard that, if not avoided, could result in serious in-
jury or death.
The following warning and their format have been requested by the United States
Consumer Product Safety Commission and are required to be in the Operator's
Guide for all ATVs.
NOTE: The following illustrations are general representations only. Your model
may differ.
WARNING
V00A0AQ
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 a training course.
They should then regularly practice the skills learned in the course and the
operating techniques described in this Operator's Guide.
For more information about the training course, contact an authorized
Can-Am dealer or call BRP at 1 [phone].
____________ SAFETY INFORMATION ___________ 13

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

WARNING
V00A02Q
POTENTIAL HAZARD
Carrying a passenger on this vehicle.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and control this vehicle.
Could cause an accident, resulting in harm to you and/or your passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. Even with a long seat that provides unrestricted
operator movement, it is not designed nor intended to carry passenger(s).
____________ SAFETY INFORMATION ___________ 15

WARNING
V00A03Q
POTENTIAL HAZARD
Operating this vehicle on paved surfaces.
WHAT CAN HAPPEN
The tires are designed for off-road use only, not for use on pavement.
Paved surfaces may seriously affect handling and control of this vehicle,
and may cause the vehicle to go out of control.
HOW TO AVOID THE HAZARD
Never operate this vehicle on any paved surfaces, including sidewalks,
driveways, parking lots and streets.
16 ___________ SAFETY INFORMATION ___________

WARNING
V00A04Q
POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate this vehicle on any public street, road or highway, even a
dirt or gravel one. In many states or provinces it is illegal to operate this
vehicle on public streets, roads or highways.
____________ SAFETY INFORMATION ___________ 17

WARNING
V00A06Q
POTENTIAL HAZARD
Riding this vehicle without wearing an approved helmet, eye protection
and protective clothing.
WHAT CAN HAPPEN
The following items concern all ATV's operator:
– riding without an approved helmet increases the chances of a severe
head injury or death in the event of an accident
– 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 in-
jury 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
–Iongpants.
18 ___________ SAFETY INFORMATION ___________