BOMBARDIER RALLY 200 2003 User Manual

Details mandatory special tools for all models and Traxter.

Lists recommended special tools for all models, including ring compressor and carburetor kit.

Lists mandatory service products like paste gasket, threadlocker, and primer.

Details regular maintenance tasks for noise emission control systems and lubrication.

Provides a chart detailing lubrication and maintenance intervals for various components.

Continues the chart for rear suspension, brakes, and body/frame maintenance.

Covers special procedures for flipped over ATVs, water immersion, and air box maintenance.

Details tire pressure, tire/wheel condition, and engine area inspection.

Provides guidance on storing the ATV for extended periods and preparing it for seasonal use.

Covers vehicle cleaning, protection, and coolant density checks for storage.

Outlines a checklist of preseason preparation tasks for customers and dealers.

Provides diagnostic charts for engine mechanical components, starting with the cooling system.

Details troubleshooting steps for the magneto system, focusing on "No Spark" symptoms.

Addresses lubrication issues like low/no oil pressure and high oil consumption, and checks for leaks.

Continues lubrication troubleshooting for oil pump issues and oil contamination, including checking for particles.

Covers troubleshooting for unusual engine noise/vibration and oil contamination related to the cylinder and head.

Addresses troubleshooting for crankshaft vibrations and gearbox noises or shifting issues.

Continues gearbox troubleshooting for gear indication failures and shifting difficulties.

Details troubleshooting for CVT issues like slow acceleration, high RPM, and top speed limitations.

Covers CVT troubleshooting for belt side wear and belt disintegration, including flex cracks between cogs.

Addresses general engine problems like backfires, intake manifold leaks, and exhaust leaks.

Focuses on troubleshooting "No Spark" conditions, including spark plug, ignition coil, and magneto checks.

Provides verification steps and the procedure for performing a cylinder leak test on the engine.

Details the procedure for preparing the engine and performing the leak test using a leak tester.

Explains how to diagnose leaks based on air escaping points and outlines the installation process.

Provides an exploded view and basic steps for removing and installing the engine system.

Details the procedure for removing and installing the exhaust system components.

Provides an exploded view of the cylinder and head assembly, showing component locations and torques.

Shows an exploded view of cylinder head components, including valves, springs, and camshaft parts.

Covers general notes, spark plug removal, ignition system testing, battery condition, and ignition switch testing.

Details the removal and installation of the valve cover and profile sealing ring.

Explains how to perform valve adjustment using feeler gauges and torque specifications.

Covers the removal and installation of the chain tensioner and breather components.

Details the removal and inspection of the camshaft timing gear and related components.

Covers the removal and inspection of the rocker arm assembly, shafts, and related measurements.

Explains the installation of rocker arms and refers to the timing chain section.

Details the removal and installation of the cylinder head, including torquing procedures and chain guide checks.

Covers the removal and inspection of the camshaft, including lobe and bearing journal measurements.

Provides camshaft specifications and details the removal of valve springs using specialized tools.

Covers the inspection and installation of valve springs, including free length and squareness checks.

Details the removal and inspection of valves, including stem seals and surface conditions.

Provides specifications for valve stem diameter, guide clearance, and valve face/seat contact width.

Explains the procedure for removing and installing valve guides, including heating and using specific tools.

Covers the removal and inspection of the cylinder, including checks for cracks and wear ridges.

Details how to measure cylinder taper and out of round, and the installation procedure.

Covers the removal and inspection of the piston, including circlips, pin, and measurement specifications.

Details piston measurement, bore gauge usage, and piston pin inspection procedures.

Covers clearance measurements and the installation of the piston pin and connecting rod.

Details the inspection of piston rings, including ring/piston groove clearance and ring end gap.

Explains the correct installation procedure for piston rings, including gap spacing and orientation.

Provides an exploded view of the carburetor assembly and its components.

Covers general carburetor notes, cleaning, and the procedure for adjusting the float level.

Details carburetor installation, cap replacement, and float level adjustment procedures.

Explains pilot screw and idle speed adjustments for the carburetor.

Covers throttle cable removal, installation, adjustment, and lubrication procedures.

Provides troubleshooting steps for battery issues and details unloaded and loaded battery testing procedures.

Explains the load test procedure for battery condition and details the steps for removing the battery.

Covers procedures for storing batteries and activating new batteries, including charging and electrolyte handling.

Provides advice on charging used batteries, emphasizing temperature and state of charge considerations.

Details procedures for charging severely discharged batteries and reinstalling the battery.

Provides a troubleshooting table for common starting system problems, listing causes and remedies.

Details tests for fuses, battery, starting solenoid, ignition switch, and multi-function switch.

Covers the removal and installation of the electric starter motor, including cable connections and torque specifications.

Outlines the general approach to diagnosing ignition problems, listing components to check in order.

Presents a flowchart for diagnosing ignition system issues, starting with "No spark or poor spark".

Details tests for main fuse, spark occurrence, battery condition, ignition switch, trigger coil, and ignition coil.

Covers ignition coil resistance checks and primary/secondary winding tests, including peak voltage.

Discusses the electronic module and notes the impossibility of checking ignition timing with a lamp.

Explains spark plug analysis based on face condition and details spark plug installation procedures.