Segment:
Entry-level to mid-range sport/utility ATV
Target Audience:
Recreational riders, trail riding, light utility work
Competitors:
Yamaha Warrior, Suzuki LT-Z250, Honda TRX250EX (approximate displacement and market segment)
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.
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.
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.
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.
Engine Type:
Four-stroke, SOHC
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)
Horsepower:
Approx. 18-20 HP (estimated, specific figures often vary by region and tune)
Torque:
Approx. 12-14 lb-ft (estimated)
Carburetor:
Keihin CVK34 (typical specification)
Fuel Type:
Unleaded gasoline (minimum 87 octane)
Fuel Tank Capacity:
Approx. 2.5 gallons (10 liters)
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.
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).
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.
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.
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.
Manufacturing Location:
Likely manufactured in North America by BRP.
Production Period:
Covering the 2003-2005 model years, indicating a specific generation or iteration.
