BOMBARDIER RALLY 200 2003, Shop Manual

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Section 11 TECHNICAL DATA
Subsection 02 (ENGINE AND VEHICLE)
11-02-2
VMR2003_031_11_02A.FM
VEHICLE MODEL RALLY TM 200
ENG
INE
Rocker arm bore diameter
New minimum mm (in) 10.036 (.3951)
New maximum mm (in) 10.050 (.3957)
Wear limit mm (in) 10.060 (.3961)
Rocker arm shaft diameter
New minimum mm (in) 10.006 (.3939)
New maximum mm (in) 10.015 (.3943)
Wear limit mm (in) 9.950 (.3917)
Cylinder bore
New mm (in) 62.000 to 62.014 (2.4409 to 2.4415)
Wear limit mm (in) 62.030 (2.4417)
Cylinder taper
New maximum mm (in) 0.052 (.002)
Wear limit mm (in) 0.090 (.004)
Cylinder out of round
New maximum mm (in) 0.015 (.0006)
Wear limit mm (in) 0.02 (.0008)
Camshaft bearing
journal
PTO side
New minimum mm (in) 19.959 (.7857)
New maximum mm (in) 19.980 (.7866)
Wear limit mm (in) 19.940 (.7850)
Magneto side
New minimum mm (in) 31.950 (1.2578)
New maximum mm (in) 31.975 (1.2588)
Wear limit mm (in) 31.930 (1.2571)
Camshaft bore
PTO side
New minimum mm (in) 20.000 (.7874)
New maximum mm (in) 20.021 (.7882)
Wear limit mm (in) 20.035 (.7888)
Magneto side
New minimum mm (in) 32.000 (1.2598)
New maximum mm (in) 32.025 (1.2608)
Wear limit mm (in) 32.040 (1.2614)
Cam lobe
Intake
New minimum mm (in) 30.887 (1.216)
New maximum mm (in) 31.087 (1.224)
Wear limit mm (in) 30.800 (1.252)
Exhaust
New minimum mm (in) 30.887 (1.216)
New maximum mm (in) 31.087 (1.224)
Wear limit mm (in) 30.800 (1.252)
Crankshaft axial clearance
New minimum mm (in) 0.2 (.0078)
New maximum mm (in) 0.4 (.0157)
Crankshaft deflection
MAG side New nominal mm (in) 0.04 (.0024)
PTO side New nominal mm (in) 0.04 (.0024)
Crankshaft pin diameter
New minimum mm (in) 26.037 (1.0250)
New maximum mm (in) 26.040 (1.0252)
Wear limit mm (in) 26.020 (1.0244)
Crankshaft journal
diameter
MAG side
New minimum mm (in) 32.010 (1.2602)
New maximum mm (in) 32.025 (1.2608)
Wear limit mm (in) 32.000 (1.2598)
PTO side
New minimum mm (in) 32.010 (1.2602)
New maximum mm (in) 32.025 (1.2608)
Wear limit mm (in) 32.000 (1.2598)
Crankshaft radial
clearance
MAG side
Service limit mm (in) 0.07 (.0028)
PTO side
Connecting rod big end diameter
New minimum mm (in) 26.050 (1.0256)
New maximum mm (in) 26.078 (1.0267)
Service limit 26.090 (1.0272)
Connecting rod big end clearance Service limit 0.07 (.0028)
Connecting rod big end axial play
New minimum mm (in) 0.3 (.012)
New maximum mm (in) 0.627 (.025)
Wear limit mm (in) 0.8 (.03)
Connecting rod small end diameter
New minimum mm (in) 15.005 (.5908)
New maximum mm (in) 15.015 (.5911)
Wear limit mm (in) 15.060 (.5929)
Piston pin diameter
New minimum mm (in) 14.997 (.5904)
New maximum mm (in) 15.000 (.5906)
Wear limit mm (in) 14.990 (.5902)
Piston pin bore clearance Wear limit mm (in) 0.03 (.0012)