Bombardier Rally 200 ATV 2003 Factory Shop Manual (P/N 704 100 019)

• 309-page PDF of Bombardier’s 2003 Rally 200 factory shop manual, cover number 704 100 019, copyrighted in 2002 and organized into 12 sections. It covers red, green, and yellow standard/international model codes 7550, 7551, 7552, 7591, 7592, and 7593.
• Engine repair procedures cover troubleshooting, cylinder leak-down testing, engine removal and installation, cooling-system pressure testing and bleeding, oil-pressure checks, valve adjustment, cam timing, cylinder-head work, piston and ring inspection, and crankshaft service.
• Gearbox, CVT, and fuel-system chapters detail internal shaft and shift-mechanism service, belt replacement, drive and driven pulley teardown, centrifugal and one-way clutch inspection, and carburetor cleaning and adjustment.
• Electrical diagnostics address charging, starting, ignition, interlocks, lighting, switches, and indicators, with output and resistance tests, connector repair, a major connector-pin chart, and the complete Rally 200 wiring diagram.
• Chassis coverage includes the chain-driven solid rear axle, steering and toe adjustment, front and rear suspension, hydraulic front brakes, mechanical rear brake, and frame/body repair.
• Factory reference data provides component-specific torque tables, approved service products, capacities, adjustment data, electrical test values, inspection and wear limits, exploded assembly views, and Rally-specific special tools with part numbers.

Exact Model Coverage

This is not a general Bombardier ATV manual. Bombardier lists all six model codes individually, including separate international versions. That makes it easier to verify the manual against the model tag before ordering parts or beginning a repair.

Factory data identifies the engine as a 176.3 cc Bombardier-Rotax liquid-cooled OHC single with four mechanically adjusted valves, a Mikuni VM-24 carburetor, and a high/neutral/reverse CVT driving a solid rear axle by chain. Coverage reflects factory-built 2003 machines at the time of publication. Later dealer modifications are outside this edition, and Bombardier Service and Warranty Bulletins may supersede individual procedures or specifications.

Engine, Gearbox, and CVT Repair

The troubleshooting section separates cooling faults, no-spark conditions, lubrication problems, abnormal cylinder-head or crankshaft noise, gearbox complaints, hard shifting, starting faults, and recognizable CVT belt or pulley failure patterns. Leak-down diagnosis helps isolate sealing problems at the intake valves, exhaust valves, cooling system, piston rings, and head gasket.

Cooling-system content includes pressure testing, draining, refilling and bleeding, thermostat and temperature-switch checks, radiator and cap service, plus water-pump housing, impeller, shaft, and seal repair. The lubrication chapter adds an engine oil-flow chart, oil-pressure testing, pump and regulator inspection, filter and strainer service, and final checks.

Internal engine work covers the timing chain and tensioner, rocker arms, camshaft, cylinder head, valves and guides, cylinder, piston, rings, crankshaft, crankcase, and plain bearings. Gearbox repair goes inside the case, covering the main, output, and intermediate shafts, shift fork and plate, thrust washers, bearings, seals, axial play, and neutral/reverse switches. CVT procedures address the belt, cover bearing, drive and driven pulleys, centrifugal clutch, one-way clutch, spring, wear checks, and reassembly.

Fuel, Electrical, and Chassis Systems

The fuel section covers the tank, valve, lines, VM-24 carburetor, air box, filter housing, and intake silencer. Carburetor procedures include removal, cleaning, float-level inspection and adjustment, pilot-screw setup, idle adjustment, and throttle-cable service.

Electrical chapters explain the charging, starting, inductive-discharge ignition, interlock, lighting, and accessory circuits. They provide charging tests, battery and starter diagnosis, ignition-component checks, switch and lamp tests, Packard and Deutsch connector service, wire-color coding, connector locations, and pin identification.

Rear-drive repair covers the O-ring chain, sprockets, hubs, axle, chain tensioner, bearings, slider shoe, and roller. Steering and suspension sections handle the steering column, tie rods, ball joints, toe-out alignment, shocks, A-arms, bushings, and rear swing arm. The brake chapter distinguishes the hydraulic twin-disc front system from the cable-operated rear disc and includes bleeding, master-cylinder and caliper repair, hose service, pads, discs, controls, and rear-cable adjustment.

Body/frame procedures address the seat, fascia, footwells, racks, bumpers, decals, plastics, frame inspection, and welding-related electrical isolation.

Diagrams, Tools, and Repair Cautions

Among the most useful visual references are the engine oil-flow chart, water-pump exploded view, cylinder-head and valve-train assembly view, gearbox exploded assembly, major connector-pin chart, and complete wiring diagram. The tool section lists the crankshaft locking bolt P/N 529 035 617, leak-down tester P/N 529 035 661, Rally clutch fixtures P/Ns 529 035 862–864, valve-guide tools P/Ns 529 035 852/853, and rear-axle bearing puller P/N 420 276 930.

Two cautions matter during a major rebuild: incorrect crankshaft/camshaft indexing can damage engine components, while misaligned crankcase plain-bearing oil passages can interrupt crankshaft lubrication. Brake, fuel, cooling, rotating-drive, and electrical repair work should be performed with the specified tools and standard shop safety practices.