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BOMBARDIER
Offroad Vehicle
RALLY 200 2003
BOMBARDIER RALLY 200 2003 User Manual
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Table of Contents
Table of Contents
4
Service Tools and
7
Engine
9
Table of Contents
17
Service Tools
18
Fuel System
18
Recommended Special Tool
25
Service Products
42
Mandatory Special Tool
18
Mandatory Service Products
42
Recommended Service Products
43
Table of Contents
46
Noise Emission Control System Regulation
47
Tampering with Noise Control System Is Prohibited
47
Among those Acts Presumed to Constitute Tampering Are the Acts
47
Maintenance Chart
47
Lubrication and Maintenance Chart
48
Steering/Control
48
Suspension
49
Maintenance/Lubrication
50
Air Box
50
Air Filter
50
Special Procedures
50
Bolts, Fasteners and Nuts
51
Engine Oil and Filter
51
Brakes
53
Engine Area
54
Tires and Wheels
54
Storage/Preseason Preparation
55
Oil Strainer
53
Spark Arrester
53
Engine Lubrication
55
Fuel Stabilizer
55
Rags into Inlet and Outlet Hoses of Cvt
55
Storage
55
Coolant Density
56
Vehicle Cleaning and Protection
56
Preseason Preparation
57
Table of Contents
58
Troubleshooting
61
Cooling System
61
Magneto System
62
Lubrication
63
Cylinder and Head
65
Gearbox
66
Crankshaft
66
Cvt
68
Engine General
72
Leak Test
78
Verification
78
Leak Test Procedure
78
Engine System
81
Removal and Installation
81
Exhaust System
82
General
83
Engine
83
Engine Sprocket
89
Front Anti-Vibration System
90
Exhaust Pipe
90
Muffler
91
Transmission Lever
91
Cooling System
92
Water Pump
92
Cooling System
93
General
94
Cooling System Leak Test
94
Inspection
94
Draining the System
94
Coolant Replacement
95
Thermostat
96
Water Temperature Switch
97
Water Pump Housing
97
Water Pump Impeller
100
Water Pump Shaft
101
Pressure Cap
101
Radiator
101
Coolant Tank
102
Block Heater
102
Magneto System
106
General
107
Magneto Cover
107
Stator and Trigger Coil
108
Rotor
109
Sprag Clutch
111
Starter
112
Lubrication System
114
Engine Oil Flow Chart
115
General
116
Engine Oil Pressure Test
116
Oil Change
116
Oil Filter
117
Oil Strainer
118
Engine Oil Pressure Regulator
119
Oil Pump
120
Cylinder and Head
123
General
125
Spark Plug
125
Thermostat
125
Valve Cover
125
Valve Adjustment
126
Chain Tensioner
127
Breather
127
Camshaft Timing Gear
128
Rocker Arm
129
Timing Chain
131
Cylinder Head
131
Camshaft
133
Valve Spring
134
Valve
136
Valve Guide Procedure
138
Cylinder
139
Piston
141
Piston Rings
144
Crankshaft
146
General
148
Crankshaft Locking Procedure
148
Timing Chain
149
Crankshaft
150
Crankcase
159
General
160
Oil Change
160
Oil Seals
160
Crankcase
162
Gearbox
165
Shifting Indicator Switch
172
Cvt
173
General
174
Drive Belt Replacement
174
Cvt Cover
175
Cvt Cover Bearing
176
Drive Pulley
176
Driven Pulley
179
Table of Contents
184
Fuel Circuit
185
General
186
Fuel Line
186
Fuel Tank
186
Fuel Valve
187
Carburetor
189
General
190
Carburetor
190
Carburetor Adjustments
192
Throttle Cable
192
Air Intake Silencer
194
General
195
Air Filter and Cleaning
195
Air Box
195
Air Filter Housing
197
Table of Contents
198
Overview
200
General Operation Information
200
Charging System
200
Starting System
200
Ignition System
201
General Testing/Troubleshooting Information
201
Fuse Location
202
Servicing Packard Connectors
202
Servicing Deutsch Connectors
203
Identification of Major Connector Pins
204
Charging System
205
Testing Procedure
205
Starting System
207
Battery
207
Troubleshooting
207
Battery Testing
207
Removal
208
Cleaning
208
Inspection
208
Battery Storage
209
Activation of a New Battery
209
Tips for Charging a Used Battery
210
Installation
211
Starting System Troubleshooting
212
Starting System Tests
213
General
213
Electric Starter
214
Removal
214
Installation
214
Ignition System Testing Procedure
215
General
215
Ignition System Test
217
Ignition Timing
219
Ignition System
215
Spark Plug
219
Disassembly
219
Heat Range
219
Fouling
220
Spark Plug Analysis
220
Spark Plug Installation
220
Ngk Spark Plug Symbol Explanation
221
General
222
Headlight
222
Headlight Beam Aiming
223
Taillight
224
Ignition Switch
224
Indicator Lamp
224
Electronic Module
225
Instruments and Accessories
222
Test
225
Multi-Function Switch
225
Indicator Lights
226
Table of Contents
227
Rear Axle
228
Drive Chain
229
General
229
Rear Sprocket
230
Rear Sprocket Hub
231
Rear Axle
232
Rear Wheel Hub
232
Chain Tensioner
233
Chain Tensioner Bearings
233
Chain Roller
235
Slider-Shoe
235
Table of Contents
236
Steering/Control Systems
237
Handlebar
238
Steering Column
238
Tie-Rod
238
Multi-Function Switch
240
Steering Column Bearing
240
Throttle Handle
241
Lh Handle Brake
242
Rh Handle Brake
243
Front Suspension/Rear Suspension
244
Front Suspension
245
General
246
Front Shock
246
Lh/Rh A-Arm
247
A-Arm Bushings
247
Rear Suspension
249
General
250
Rear Shock
250
Swing Arm
251
Table of Contents
253
Hydraulic Brakes
254
Front Brakes
254
Rear Brake
255
Brake Fluid
256
General
256
Master Cylinder
257
Front Brake Calipers
258
Brake Pads
260
Rear Brake Caliper
260
Brake Disc
262
Front Brake Lever
263
Rear Brake Cable
263
Rear Brake Pedal
263
Brake Hoses
264
Table of Contents
265
Body
266
Body Parts
266
General
267
Seat
267
Dash Board Cover
267
Dash Board/Steering Cover
268
Front Bumper/Luggage Rack
268
Front Fascia
269
Rh/Lh Footwells
269
Rear Luggage Rack/Rear Bumper
270
Seat Cover Replacement
271
Seat Cleaning
271
Decals Replacement
271
Plastic Maintenance
272
Maintenance
272
Plastic Repair
272
Frame
274
General
274
Front Plate
274
Frame
280
4
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BOMBARDIER RALLY 200 2003 Specifications
General
Brand
BOMBARDIER
Model
RALLY 200 2003
Category
Offroad Vehicle
Language
English
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