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

Bombardier’s factory shop manual (P/N 704 100 019) covers the standard and international 2003 Rally 200 ATV in red, green, and yellow. The 12-section edition carries a 2002 copyright. Match the ATV’s model number to the coverage list before using the manual to plan a repair or identify parts for replacement.

PDF Search, Bookmarks, and Wiring Detail

Finding text and tracing circuits: The service text is searchable, and embedded bookmarks jump to the main sections and the wiring diagram. The cover and the small circuit labels are outside the searchable text. Zoom in to read the connector identifiers, terminal markings, and wire codes on the diagram.

The ZIP download contains one printable PDF with 309 pages. The total includes the cover, title page, two pages for the publisher’s feedback form, 24 blank pages, and the foldout wiring diagram.

Engine, Drivetrain, and Chassis Service

The topics below are selected highlights. The manual also covers storage and preseason preparation, including coolant density checks.

• Scheduled maintenance: Service intervals, air-filter cleaning, oil and filter changes, oil-strainer cleaning, and spark-arrester service.
• Engine diagnosis and repair: Cylinder leak-down testing, engine removal and installation, cooling-system pressure testing, oil-pressure checks, valve adjustment, and crankshaft service.
• Gearbox and CVT: Shaft and shift-mechanism service, belt replacement, drive and driven pulley teardown, and centrifugal and one-way clutch inspection.
• Fuel system: Fuel tank and valve service, carburetor cleaning and adjustment, throttle-cable service, and air intake silencer removal.
• Electrical troubleshooting: Charging-output tests, battery and starter diagnosis, ignition and interlock checks, connector service, and a foldout wiring diagram.
• Chassis and brakes: Rear axle and chain service, steering alignment, front and rear suspension, hydraulic front brakes, and mechanical rear brake adjustment.
• Shop reference: Exploded assembly views, component-specific torque tables, service products, fluid capacities, wear limits, and numbered special tools.

Bombardier wrote this edition for ATV technicians familiar with its service procedures and equipped with the specified shop tools. The procedures cover factory-built machines. Later dealer modifications fall outside this edition, and Bombardier Service and Warranty Bulletins may update procedures or specifications.

Engine Tests and Internal Repairs

The Rally 200 uses a 176.3 cc liquid-cooled Bombardier-Rotax OHC single with four mechanically adjusted valves. The leak-down section explains how the path of escaping air helps distinguish leaking intake or exhaust valves from a head-gasket leak or cylinder and ring wear.

Cooling procedures cover draining, refilling and bleeding, thermostat and temperature-switch tests, radiator and cap service, and water-pump shaft and seal work. The oil-flow chart complements pressure testing and inspection of the pump and regulator.

Internal engine work includes the timing chain and tensioner, rocker arms, camshaft, valves and guides, piston and rings, and crankcase bearings. Timing-chain installation calls for correct crankshaft and camshaft indexing. Misaligned crankcase plain bearings can interrupt the oil supply to the crankshaft.

Gearbox, CVT, and Carburetor

The gearbox section covers the main, intermediate, and output shafts, shift fork and plate, thrust washers, seals, shaft end play, and neutral and reverse switches. The CVT section provides step-by-step procedures for pulley disassembly and reassembly, with wear checks for rollers, clutch linings, and springs.

The Mikuni VM-24 carburetor section covers float-level checks, pilot-screw and idle adjustment, and throttle-cable service. The intake section also covers the air box and filter housing.

Electrical Tests, Chassis, and Shop Tools

The electrical section includes battery load testing, starter and interlock checks, and stator, regulator/rectifier, and ignition-coil tests. Packard and Deutsch connector service, the major connector-pin chart, and the wire-color key help trace faults through the harness.

Rear-drive procedures cover the O-ring chain, sprockets, hubs, axle bearings, tensioner, slider shoe, and roller. Steering and suspension coverage includes tie rods, ball joints, toe-out, shocks, A-arms, bushings, and the rear swing arm. Brake procedures cover bleeding, master-cylinder and caliper repair, hose and pad service, disc inspection, and rear cable adjustment.

The body and frame sections cover the seat, fascia, footwells, racks, bumpers, decals, and plastics. They also describe front plate inspection and electrical isolation for welding. Use the specified tools and shop safety practices for brake, fuel, cooling, CVT, and electrical work.

The tool catalog identifies the crankshaft locking bolt 529 035 617, leak-down tester 529 035 661, clutch fixtures 529 035 862–864, valve-guide tools 529 035 852 and 529 035 853, and rear-axle bearing puller 420 276 930.

Valve Clearance and Charging Test Examples

For valve adjustment at top dead center on the compression stroke, the manual specifies 0.05–0.09 mm intake clearance and 0.10–0.14 mm exhaust clearance.

In the dynamic charging test, the manual identifies a battery-terminal reading above 15 V at approximately 3,500 RPM as a regulator/rectifier fault.