Segment:
Youth/Entry-Level Sport ATV
Target Demographic:
Beginner riders, recreational users, younger enthusiasts.
Competitors:
Yamaha Warrior 350, Suzuki LT-Z250/LT-Z400, Honda TRX300EX/TRX350.
Vehicle Focus:
Ease of use, reliability, approachable performance for recreational riding.
Manual Value Proposition:
Provides essential repair and maintenance information to keep the Can-Am Rally 200 operational and well-maintained.
Vehicle Systems:
Engine, Fuel System, Drivetrain, Suspension, Steering, Brakes, Electrical System, Chassis, Bodywork, Maintenance, Troubleshooting, Specifications
Type:
Workshop Service Manual
Engine Mechanical:
Detailed engine disassembly, inspection, repair, and reassembly procedures for the 200cc engine.
Fuel System:
Carburetor adjustment, cleaning, and repair; fuel pump operation and testing; fuel tank and lines.
Drivetrain:
Clutch operation, adjustment, and replacement; CVT (Continuously Variable Transmission) belt inspection and replacement; final drive and chain maintenance.
Suspension:
Front and rear suspension component inspection, repair, and adjustment; shock absorber servicing.
Steering:
Handlebar and steering column components, linkage inspection and adjustment.
Braking System:
Hydraulic brake system service, including bleeding, pad replacement, caliper and master cylinder maintenance.
Electrical System:
Ignition system, charging system (stator, rectifier/regulator), battery service, lighting, and starter motor troubleshooting.
Chassis And Frame:
Frame inspection for damage, fastener torque specifications, component mounting.
Bodywork And Trim:
Panel removal and installation, seat, fenders, and graphics.
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, lubrication points, valve adjustments.
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues with flowcharts and symptom-based guidance.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly.
Component Replacement:
Guidance on replacing wear items and major components.
Diagnostic Capabilities:
Covers basic to intermediate diagnostic procedures for mechanical and electrical systems, including common fault identification.
Rebuild Instructions:
Detailed instructions for engine and transmission component rebuilding.
Special Tools:
Lists and descriptions of special tools required for specific repair procedures.
Engine Type:
4-stroke, single-cylinder
Bore X Stroke:
65.5 mm x 57.8 mm
Cooling System:
Air-cooled
Valve Train:
SOHC, 2 valves
Horsepower:
Approximately 15-17 HP (estimated, specific figures not readily available for this model variant)
Torque:
Not specified, but typical for its class.
Fuel Delivery:
Carburetor (specific model typically Keihin or Mikuni, e.g., VM24 or similar)
Fuel Type:
Unleaded gasoline
Ignition System:
CDI (Capacitor Discharge Ignition)
Length:
Approximately 1700 mm (66.9 in)
Width:
Approximately 1050 mm (41.3 in)
Height:
Approximately 1000 mm (39.4 in)
Wheelbase:
Approximately 1120 mm (44.1 in)
Dry Weight:
Approximately 150 kg (330 lbs)
Fuel Capacity:
Approximately 10 Liters (2.6 Gallons)
Front Tire Size:
AT 22 x 7-10 (typical)
Rear Tire Size:
AT 22 x 10-10 (typical)
Wheel Bolt Pattern:
4x110 mm (common ATV pattern)
Crash Test Ratings:
N/A (ATVs are not typically subject to automotive crash testing standards)
Braking:
Hydraulic disc brakes front and rear.
Parking Brake:
Yes (typically lever-actuated)
Throttle Limiter:
Often present on youth ATVs for speed control.
Footwells:
Full-coverage floorboards with heel guards for rider protection.
Oil Change Interval:
Typically every 3 months or 1500 km / 1000 miles, or as per manual recommendation (refer to manual for exact interval).
Air Filter Cleaning:
Regular inspection and cleaning, especially in dusty conditions. Replacement as needed.
Spark Plug Replacement:
Typically recommended every 3,000-6,000 km or annually.
Valve Adjustment Interval:
Initial check at 1000 km, then every 3000 km or as specified in the manual.
Engine Oil Type:
API SG or higher, SAE 10W-40 recommended (verify with manual for specific viscosity).
Engine Oil Capacity:
Approximately 1.8 Liters (1.9 US Quarts) with filter change (verify with manual).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Gear Oil Type:
Typically SAE 80W-90 hypoid gear oil for final drive (verify with manual).
Common Wear Items:
CVT belt wear, brake pad wear, suspension bushings.
Potential Electrical Issues:
Age-related degradation of wiring, rectifier/regulator failure are possible on older units.
Carburetor Tuning:
Can be sensitive to altitude and fuel quality, requiring periodic adjustment or cleaning.
Manufacturer History:
Can-Am is a brand of BRP (Bombardier Recreational Products), a Canadian company with a long history in snowmobiles, jet skis (Sea-Doo), and ATVs/SSVs.
Model Lineage:
The Rally series was positioned as an entry-level and youth-oriented ATV line for Can-Am in the early 2000s, before BRP focused more on larger displacement models and their Commander/Maverick side-by-side vehicles.
Production Period:
The Rally 200 was produced for a relatively short period, with these model years representing its core market presence.
Manufacturing Location:
Likely manufactured in North America by BRP.
