Can-Am Bombardier Rally 200 2003-2005 Factory Service Manual

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Mots clés: 2003 2004 2005 Atv Bombardier Bombardier Rally 200 Can-am

Variantes de produits

Description

Introducing the Rally 200, an all-terrain vehicle produced for the 2003, 2004, and 2005 model years. Manufactured by a recreational products company, this ATV is engineered for recreational riders and light utility tasks, offering sport-oriented handling and a robust 197 cc liquid-cooled engine. Known for a reputation for performance and build quality in the powersports segment, the Rally 200 provides an accessible entry into the world of ATVs, designed to handle various terrains with its reliable drivetrain and capable suspension. This comprehensive Factory Service Manual provides essential information for the maintenance and repair of your Rally 200. It covers a wide range of systems, including detailed procedures for the engine, fuel, ignition, cooling, drivetrain, suspension, steering, braking, and electrical systems. The manual includes guidance on preventive maintenance, troubleshooting, disassembly, reassembly, and technical specifications such as torque values and fluid capacities. Whether you are an owner performing routine upkeep or a technician undertaking complex repairs, this manual serves as an indispensable resource for ensuring the optimal performance and longevity of your vehicle.

🏷️ Basic Information

Identification

Make:

Can-Am

Manufacturer:

Bombardier Recreational Products (BRP)

Model:

Rally 200

Model Years Covered:

2003, 2004, 2005

Vehicle Type:

ATV (All-Terrain Vehicle)

👋 Introduction

Market Position

Segment:

Entry-level to mid-range sport/utility ATV

Target Audience:

Recreational riders, trail riding, light utility work

Competitive Analysis

Competitors:

Yamaha Warrior, Suzuki LT-Z250, Honda TRX250EX (approximate displacement and market segment)

Key Features

Design Philosophy:

Sport-oriented handling with a robust engine for its class.

Unique Selling Points:

Can-Am's reputation for performance and build quality in the ATV segment.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF Download

Page Count:

Hundreds (specific count not provided, but implies comprehensive)

Completeness:

Complete Official Factory Manual

📖 Manual Coverage

Systems Covered

Engine Service:

Detailed overhaul, inspection, and repair procedures for the engine.

Fuel System:

Carburetor adjustment, cleaning, fuel pump, fuel lines, and tank service.

Ignition System:

Spark plug, ignition coil, CDI unit, timing checks, and troubleshooting.

Cooling System:

Radiator, fan, coolant, thermostat, and related plumbing.

Exhaust System:

Muffler, header pipe inspection and replacement.

Drivetrain:

Clutch operation, centrifugal clutch inspection, belt drive service, rear axle assembly.

Suspension System:

Front and rear suspension components, shock absorber adjustment and replacement, control arms, ball joints.

Steering System:

Handlebar assembly, steering shaft, tie rods, steering linkage geometry.

Braking System:

Front and rear brake calipers, master cylinders, brake lines, pads, rotors, fluid bleeding procedures.

Electrical System:

Battery, charging system (stator, regulator/rectifier), lighting, starter motor, wiring diagrams, fuses, relays.

Frame And Bodywork:

Chassis inspection, body panel removal and installation, seats, fenders, racks.

Procedures Included

Preventive Maintenance:

Scheduled maintenance tasks, lubrication points, inspections.

Troubleshooting:

Diagnostic charts and procedures for identifying and resolving common problems.

Disassembly Reassembly:

Step-by-step instructions for removing and reinstalling components.

Specifications Data:

Torque values, clearances, fluid capacities, electrical resistance values.

Adjustments:

Carburetor, chain tension, brake levers, clutch engagement.

Engine Rebuild:

Detailed instructions for engine teardown, component inspection, and rebuilding.

Electrical Diagnostics:

Use of multimeters, troubleshooting circuits, and component testing.

Technical Depth

Depth:

Comprehensive, covering all aspects from basic maintenance to complex repairs and diagnostics.

Detail Level:

Includes specific measurements, tolerances, and schematics.

Illustrations:

Likely includes diagrams, exploded views, and illustrations to aid in repair.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Typically searchable PDF, allowing for quick access to information.

Print Quality:

Printable, designed for use in a workshop environment.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC

Displacement:

197 cc

Bore X Stroke:

62.5 mm x 64 mm (typical for this engine family)

Cooling System:

Liquid-cooled

Compression Ratio:

10.0:1 (typical for this engine family)

Performance

Horsepower:

Approx. 18-20 HP (estimated, specific figures often vary by region and tune)

Torque:

Approx. 12-14 lb-ft (estimated)

Fuel System

Carburetor:

Keihin CVK34 (typical specification)

Fuel Type:

Unleaded gasoline (minimum 87 octane)

Fuel Tank Capacity:

Approx. 2.5 gallons (10 liters)

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Drive System:

2WD (Rear Wheel Drive)

Features

Gear Selection:

Forward, Neutral, Reverse

Clutch Type:

Centrifugal dry clutch

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 70-72 inches (1778-1829 mm)

Width:

Approx. 43-45 inches (1092-1143 mm)

Height:

Approx. 42-44 inches (1067-1118 mm)

Weights

Dry Weight:

Approx. 300-320 lbs (136-145 kg)

Ground Clearance:

Approx. 6-7 inches (152-178 mm)

Wheelbase:

Approx. 47-48 inches (1194-1219 mm)

🛡️ Safety Features

Ratings

Safety Compliance:

Designed to meet applicable ATV safety standards for its production era.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Throttle Limiter:

Potential for adjustable throttle limiter on some models/configurations.

Passive Features

Footwells:

Full floorboards with integrated heel guards for foot protection.

Handlebar Design:

Grip-oriented handlebars with protective pads.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic recreational ATV, no advanced infotainment typically)

Driver Assistance

Stability Control:

N/A (No electronic stability control)

Connectivity

Connectivity Features:

N/A (No Bluetooth or smartphone integration)

Lighting

Headlights:

Dual halogen headlights (typical for the era)

Taillight:

Single LED or incandescent taillight/brakelight

🔧 Maintenance

Service Intervals

Initial Service:

First service typically recommended around 20 hours or 3 months (refer to manual for exact details).

Engine Oil Change:

Every 100 hours or 6 months (typical interval, verify in manual).

Air Filter Cleaning:

Frequent checks recommended, cleaning/replacement as needed based on operating conditions (e.g., dusty environments).

Spark Plug Inspection:

Every 100 hours or annually.

Brake Fluid Flush:

Every 2 years or as recommended by manual.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 motorcycle-specific or ATV engine oil, API SG or higher, JASO MA certified (verify in manual for exact specification).

Engine Oil Capacity:

Approx. 1.5-1.8 liters (1.6-1.9 US quarts) with filter change (verify in manual).

Coolant Type:

Ethylene glycol-based antifreeze coolant (50/50 mix with distilled water).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (verify in manual).

Final Drive Oil:

Specific gear oil for chain case/differential if applicable (verify in manual).

Known Issues

Carburetor Cleaning:

Carburetors can become clogged with fuel varnish if left with fuel for extended periods or if poor quality fuel is used.

Cvt Belt Wear:

CVT belts can wear over time and require replacement; proper belt alignment and sheave maintenance are crucial.

Electrical Connections:

Corrosion or loose connections in electrical connectors can lead to intermittent issues.

Suspension Bushings:

Rubber bushings in suspension components can degrade over time, leading to play and clunking noises.

📚 Vehicle History

Brand Heritage

Parent Company:

Bombardier Recreational Products (BRP) is a Canadian company with a long history in snowmobiles and jet skis, expanding into ATVs and other powersports vehicles.

Model Evolution

Rally Series:

The Rally series was Can-Am's offering in the recreational/sport ATV segment during the early 2000s, focusing on accessible performance and handling.

Production

Manufacturing Location:

Likely manufactured in North America by BRP.

Production Period:

Covering the 2003-2005 model years, indicating a specific generation or iteration.

🏆 Awards & Recognition

Recognitions

Atv Awards:

No specific widely publicized awards found for this particular model year/variant, but generally well-regarded within its class for its performance and Can-Am's reputation.