Can-Am Rally 200 Operator'S Manual Download

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GEARBOX

Oil Change

Place the vehicle on a level surface.

Remove the left footrest.

Clean drain plug area and oil level plug
then remove the gearbox drain plug.

V06C2GY

1. Gearbox drain plug
2. Gearbox oil level plug

NOTE:

To completely drain the gear-

box, place a jack under the right
footrest and tilt the vehicle toward
the left side. When the gearbox is
empty, install the drain plug and re-
place the vehicle on the ground.

Refill gearbox, using XP-S chaincase
oil (P/N 413 801 900) or an equivalent.

CAUTION:

Do not use other unrec-

ommended types of oil when ser-
vicing. Do not mix with other types
of oil.

The oil should be level with the bottom
of the oil level hole. Refill as required
until gearbox oil level flows through oil
level hole.

Reinstall oil level plug.

_____________________

109

Summary of Contents for Rally 200

Page 1: ...vmo2007 RALLY 200 ang FH10 Thu May 11 15 47 01 2006 Page 1 Composite C M Y CM MY CY CMY K ...

Page 2: ...low these warnings can result in SEVERE INJURY OR DEATH Keep this Operator s Guide with the vehicle at all times WARNING Disregarding any of the safety precautions and instructions contained in this Operator s Guide SAFETY VIDEO and on product labels could cause injury including the possibility of death All safety documentation should remain with the vehicle at the time of sale All content of the ...

Page 3: ...opy of your Operator s Guide simply visit the following website www operatorsguide brp com Al so note that the guide is available in several languages The information and components system descriptions contained in this document are correct at the time of publication BRP however maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them...

Page 4: ...railer if so equipped 43 Working with your Vehicle 43 Recreational Riding 43 Environment 44 Design Limitation 44 Off Highway Operation 44 General Operating and Safety Precautions 45 Uphill Driving 45 Downhill Driving 45 Side Hilling 46 Drop Offs 46 Riding Techniques 46 Routine Maintenance 52 HANG TAG 53 ON PRODUCT LABELS 54 VEHICLE INFORMATION HOW TO IDENTIFY YOUR VEHICLE 58 NOISE EMISSION CONTROL...

Page 5: ...ne Oil 76 Gearbox Oil 78 Engine Coolant 78 Brake Fluid 80 Battery 80 OPERATING INSTRUCTIONS 82 General 82 Pre Operation Check 82 Starting the Engine 83 Shifting the Transmission 83 Stopping the Engine 84 Post Operation Care 84 SPECIAL PROCEDURES 85 Engine Overheat 85 Turn Over 85 Vehicle Immersion 86 CARGO AND TRANSPORTATION 87 TROUBLESHOOTING 89 SPECIFICATIONS 93 MAINTENANCE INFORMATION MAINTENAN...

Page 6: ...4 DRIVE TRAIN 117 Lubrication 117 Drive Chain 117 Drive Chain Slider 118 Sprocket and Pinion 118 Wheel 119 Wheel Bearing Bushings Condition 119 Tires Wheels 119 SUSPENSION 121 Adjustment 121 Lubrication 121 Inspection 121 BRAKE 122 Front Brake 122 Rear Brake 122 Brake Cable Lubrication 122 Inspection 122 Brake Fluid Replacement 122 BODY FRAME 123 Engine Area 123 Hitch Trailer Ball Condition if so ...

Page 7: ...PARATION 124 WARRANTY BRP LIMITED WARRANTY NORTH AMERICA 2007 CAN AMTM ATV 126 BRP INTERNATIONAL LIMITED WARRANTY 2007 CAN AMTM ATV 130 PRIVACY OBLIGATION DISCLAIMER 134 CHANGE OF ADDRESS OWNERSHIP 135 ______________________ 5 ...

Page 8: ...6 _______________________ ...

Page 9: ...rious injury or death CAUTION Denotes an instruction which if not followed could se verely damage vehicle compo nents NOTE Indicates supplementary infor mation needed to fully complete an in struction Although the mere reading of such in formation does not eliminate the haz ard the understanding and application of the information will promote the correct use of this vehicle To fully appreciate the...

Page 10: ...s vary from place to place Each is subject to weather conditions which may radically change from time to time and from season to season Riding on sand is different than rid ing on snow or through forests or marshes Each location may require a greater degree of awareness and skill may not be suitable with a passen ger Show good judgement Always proceed with caution Please do not take any unnecessar...

Page 11: ...SAFETY INFORMATION ____________ SAFETY INFORMATION ____________ 9 ...

Page 12: ...cle on any public street road or highway even a dirt or gravel one Never take place on this vehicle without wearing an approved hel met that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs be fore or while riding this vehicle Never operate at excessive speeds Always go at a speed that i...

Page 13: ...wards when climbing a hill To avoid stalling use proper gear and maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this Operator s Guide Dismount on the uphill side or to a side if pointed straight uphill Turn the vehicle around and remount following the procedure described further in this Operator s Guide Always check...

Page 14: ... should be properly distributed and securely attached Reduce speed and follow instruc tions in this manual for carrying car go or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Specialty Vehicle Institute of Amer ica SVIA at 1 800 887 2887 or in Canada the Canada Safety Council CSC at 1 613 739 1535 ext 227 or contact an authorized Can Am dealer...

Page 15: ...AQ POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate this vehicle properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete a training course They should then regularly practice the skills l...

Page 16: ...o severe injury or death of the child Even though a child may be within the age group for which this vehicle is recommended he may not have the skills abilities or judgment needed to operate this vehicle safely and may be involved in a serious accident HOW TO AVOID THE HAZARD No one under 16 should operate this vehicle 14 ___________ SAFETY INFORMATION ___________ ...

Page 17: ... balance and control this vehicle Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger Even with a long seat that provides unrestricted operator movement it is not designed nor intended to carry passenger s ____________ SAFETY INFORMATION ___________ 15 ...

Page 18: ... use only not for use on pavement Paved surfaces may seriously affect handling and control of this vehicle and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Never operate this vehicle on any paved surfaces including sidewalks driveways parking lots and streets 16 ___________ SAFETY INFORMATION ___________ ...

Page 19: ...APPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street road or highway even a dirt or gravel one In many states or provinces it is illegal to operate this vehicle on public streets roads or highways ____________ SAFETY INFORMATION ___________ 17 ...

Page 20: ...event of an accident riding without eye protection can result in an accident and increases the chances of a severe injury in the event of an accident riding without protective clothing increases the chances of severe in jury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly You should also wear eye protection goggles or face shield gloves and boo...

Page 21: ... HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while riding this vehicle ____________ SAFETY INFORMATION ___________ 19 ...

Page 22: ... CAN HAPPEN Increases your chances of losing control of the vehicle which can result in an accident HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain visibility and op erating conditions and your experience 20 ___________ SAFETY INFORMATION ___________ ...

Page 23: ...wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Do not try to show off ____________ SAFETY INFORMATION ___________ 21 ...

Page 24: ... follow the inspection and maintenance procedures and schedules described further in this Operator s Guide WARNING POTENTIAL HAZARD Riding on frozen waterways WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or operator break through the ice HOW TO AVOID THE HAZARD Never ride this vehicle on a frozen surface before you are sure the ice is thick enough and sound enough to suppor...

Page 25: ...ol the vehicle or could cause you to lose your balance and fall off the vehicle If you remove a foot from the footrests your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebar and both feet on the footrests during vehicle operation ____________ SAFETY INFORMATION ___________ 23 ...

Page 26: ...ome upon hidden rocks bumps or holes without enough time to react Could result in the vehicle overturning or loss of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the vehicle 24 ___________ SAFETY INFORMATION ___________ ...

Page 27: ...ion or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control this vehicle on such terrain Always be especially cautious on these kinds of terrain ____________ SAFETY INFORMATION ___________ 25 ...

Page 28: ...ol causing a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described further in this Operator s Guide Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed 26 ___________ SAFETY INFORMATION ___________ ...

Page 29: ...can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate this vehicle on hills too steep for the vehicle or for your abil ities Practice on smaller hills before attempting larger hills ____________ SAFETY INFORMATION ___________ 27 ...

Page 30: ... s Guide Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ve hicle could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hil...

Page 31: ...ribed further in this Operator s Guide NOTE A special technique is required when brak ing as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible ____________ SAFETY INFOR...

Page 32: ...s tered the turning technique as described further in this Operator s Guide on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as described further in this Operator s Guide Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the vehi...

Page 33: ...ock parking brake after you are stopped Dismount on uphill side or to a side if pointed straight uphill If you begin rolling backwards Keep your weight uphill Never open the throttle suddenly or make sudden gear changes The vehicle could flip over backwards Never apply the rear brake while rolling backwards Apply the front brake gradually When fully stopped apply rear brake as well and lock parkin...

Page 34: ... cause the vehicle to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as de scribed further in this Operator s Guide 32 ___________ SAFETY INFORMATION ___________ ...

Page 35: ...edly which may cause the vehicle to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control ____________ SAFETY INFORMATION ___________ 33 ...

Page 36: ...operate this vehicle in fast flowing water or in water deeper than that specified further in this Operator s Guide Check water depth and current before you attempt to cross any water Wa ter should not go above footrests Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the pads 34 __________...

Page 37: ... You could hit an obstacle or person behind the vehicle resulting in serious injury HOW TO AVOID THE HAZARD When you select reverse gear make sure there are no obstacles or people behind the vehicle When it is safe to proceed go slowly ____________ SAFETY INFORMATION ___________ 35 ...

Page 38: ...n tire pressure may cause loss of control tire blow outs tire to move around on its rim and increases the risk of an accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified further in this Operator s Guide for this vehicle Always maintain proper tire pressure as described further in this Opera tor s Guide Always replace wheels or tires that are damaged 36 ___________ SAFET...

Page 39: ...d lead to an acci dent HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of acces sories All parts and accessories added to this vehicle should be approved by BRP and should be installed and used according to instructions If you have questions consult an authorized Can Am dealer NEVER install passenger seat or use the racks to carry a passenger ____________ SAF...

Page 40: ... Never exceed the stated load capacity for this vehicle including operator as well as other loads and added accessories Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater dis tance for braking Always follow the instructions in this Operator s Guide for carrying cargo or pulling a trailer 38 ___________ SAFETY INFORMATION _...

Page 41: ...HAPPEN This can cause serious injury or death HOW TO AVOID THE HAZARD Never transport flammable or dangerous material While reading this Operator s Guide remember that WARNING Indicates a potential hazard that if not avoided could result in serious in jury or death ____________ SAFETY INFORMATION ___________ 39 ...

Page 42: ...e risks and operate a vehicle safely Persons with cognitive or physical impairments or who are high risk takers have an increased exposure to overturns or collisions which may result in injury includ ing death Become completely familiar with the operational controls and the general oper ation of the vehicle before venturing into off road conditions Practice driving in a suitable area free of hazar...

Page 43: ...n reset in NEUTRAL position Check drive chain for adjustment and lubrication Check sprockets for wear and dam ages Check fuel oil and coolant levels Check for oil leaks on the engine and the transmission Ensure fuel valve is in fully open position ON Clean headlamps and taillight Ensure seat is properly latched If you transport cargo respect load capacity Ensure cargo is properly secured to the ra...

Page 44: ... you may encounter en route Operator must never wear loose clothing such as a scarf that may get entangled in the vehicle or on tree branches and shrubs Depending on conditions antifogging goggles or sun glasses may be required Different colored lenses available for goggles or sun glasses help you distinguish terrain variations Sunglasses should only be worn during the daytime Boots Long sturdy pa...

Page 45: ...e careful not to skid or slide When stopped or parked block the vehicle and trailer wheels from possible movement Always make sure load is evenly distributed on the trailer Use caution when disconnecting a loaded trailer it or its load may topple on you or others Do not turn at high speeds Working with your Vehicle Your vehicle can help you perform a number of different LIGHT tasks ranging from sn...

Page 46: ...vehicle If you encounter animals on the trail stop and observe quietly and with caution It will be one of the better memories of your life Observe the rule what you take in carry out Do not litter Do not start campfires unless you have permission to do so and then only away from dry areas The hazards you may create on the trail may cause injury to others or yourself even at a later date Respect fa...

Page 47: ... especially im portant when parking on a slope On very steep inclines or if the vehicle is car rying cargo the wheels should be blocked using rocks or bricks Remember to turn the fuel valve to the closed position Uphill Driving Due to configuration this vehicle has excellent climbing ability so much so that tipover is possible before traction is lost For example its common to encounter terrain sit...

Page 48: ...ons may result in injury Apply only enough throttle to proceed safely Statistics show that high speed turns usually result in mishaps and injury Always remember that this vehicle is heavy Its pure weight alone may entrap you should it fall and pin you down This vehicle is not designed for jumping nor can it or you absorb the energy of high impacts such as jumping Performing wheelies can cause the ...

Page 49: ... your vehicle on roads or highways could cause a collision to occur with another vehicle The tires of this vehicle are not suited for paved road use Pavement may seriously affect the handling and control of the vehicle Riding on roads or soft shoulders may confuse other road users especially if your lights are on If you have to cross a road the lead driver should get off his vehicle then observe a...

Page 50: ...ed for sudden holes or changes in depth Similarly so be watchful of hazards such as rocks logs etc partially covered by vegetation If your trip crosses frozen waterways make sure that the ice is thick enough and sound enough to support the total weight of yourself the vehicle and its load Be ever watchful of open water it is a sure indication that the ice thickness will vary If in doubt do not att...

Page 51: ...na type safety flag can snag and rebound on your body if caught do not use it in areas where there are low hanging branches or obstacles Riding on loose stones or gravel is very similar to riding on ice They will affect the steering of vehicle possibly causing it to slide and tipover especially at high speeds In addition braking distance may be a effected Remember that gunning the throttle or slid...

Page 52: ...and use proper body positioning Uphill Keep your body weight forward towards the top of the hill Keep your feet on the footpegs and shift into low gear then accelerate and when necessary change gear quickly as you climb Do not over speed since this may cause the front of the vehicle to lift from the ground and fall back on you If the hill is too steep and you cannot proceed or the vehicle begins t...

Page 53: ... risky types of riding since it may drastically change the balance of the vehicle It should be avoided wherever possible If it is necessary to do so however it is important that you ALWAYS keep your body weight on the upside of the slope and be prepared to dismount on that side should the vehicle begin to topple Do not try to stop or save the vehicle from damage ____________ SAFETY INFORMATION ___...

Page 54: ...ents of this Op erator s Guide It provides valuable advice on how to properly take care of your vehicle If further assistance is required your authorized Can Am dealer is always willing to help Modification of the vehicle to increase speed and performance may violate the terms and conditions of your vehicle limited warranty In addition certain modifi cations including the removal of engine or exha...

Page 55: ...hang tag and labels containing important safety infor mation Any person who rides this vehicle should read and understand this information before riding V07M11L 704901107 vmo2006 005 009_en ____________ SAFETY INFORMATION ___________ 53 ...

Page 56: ...d they can be replaced free of charge See an authorized Can Am dealer NOTE The following illustrations used in this Operator s Guide are a general representation only Your model may differ vmo2007 009 006_a vmo2007 009 001_a vmo2007 009 002_c vmo2007 009 003_b vmo2007 009 004_a vmo2007 009 005_a 54 ___________ SAFETY INFORMATION ___________ ...

Page 57: ...Label 1 V01M01Z Label 2 V01M02Z Label 3 V01M07Z Label 4 V06M0AY Label 5 704901094 ____________ SAFETY INFORMATION ___________ 55 ...

Page 58: ...Label 6 V06M0DY Label 7 V06M0EY Label 8 vmo2006 005 012 Label 9 V00M0AY INTERNATIONAL MODELS ONLY 56 ___________ SAFETY INFORMATION ___________ ...

Page 59: ...VEHICLE INFORMATION _____________________ 57 ...

Page 60: ... required by the authorized Can Am dealer to complete warranty claims properly No warranty will be allowed by BRP if the engine identification number EIN or vehicle identification number VIN is removed or mutilated in any way We strongly recommend that you take note of all the serial numbers on your vehicle and supply them to your insurance company Vehicle Identification Number Location V06A19 L 2...

Page 61: ...vmo2006 002 001 VIN VEHICLE IDENTIFICATION NUMBER ALSO STAMPED ON FRAME _____________________ 59 ...

Page 62: ...Engine Identification Number Location V06A18L 60 ______________________ ...

Page 63: ...l This label indicates vehicle s compliance in many countries LABEL LOCATION All Rally 200 On frame between front suspension A arms V00M02Y USA AND CANADA V00M03Y OTHER COUNTRIES IN THE WORLD _____________________ 61 ...

Page 64: ...e ultimate purchaser or while it is in use or 2 The use of the vehicle after such device or element of design has been re moved or rendered inoperative by any person Among those Acts Presumed to Constitute Tampering Are the Acts Listed Below 1 Removal or alteration or the puncturing of the muffler or any engine compo nent which conducts removal of engine exhaust gases 2 Removal or alteration or th...

Page 65: ...structions supplied A non compliance Red Label as well as a Green Label is obtained annually during California Vehicle registration The appropriate label is denoted by the vehicle identification number in the 8th character detailed herein VEHICLE CATEGORY VIN 8TH CHARACTER Non complying Red Label Must denote a C or 3 Complying Green Label Any alphanumeric designation other than a C or 3 __________...

Page 66: ...heating are detrimental during the break in period Belt A new belt requires a break in period of 50 km 30 miles Avoid strong acceleration deceleration pulling a load or high speed cruising 10 Hour Inspection NOTE The 10 hour inspection is at the expense of the vehicle owner As with any precision piece of me chanical equipment we suggest that after the first 10 hours 200 km 125 mi or 30 days after ...

Page 67: ...CONTROLS INSTRUMENTS EQUIPMENT NOTE Some controls instruments equipment are optional V06A12L 14 9 6 14 2 15 16 11 12 5 14 1 9 3 14 13 10 12 _____________________ 65 ...

Page 68: ...1 9 8 6 2 7 4 3 V06A13L 66 ______________________ ...

Page 69: ...tically to idle and the vehicle will gradually slow down V06I0YY 1 2 3 1 Throttle lever 2 To accelerate 3 To decelerate 2 Front Brake Lever Located on the right side of handle bar When compressed the brake is applied When released it should au tomatically return to its original posi tion Braking effect is proportional to the force applied on the lever and to the type and condition of the terrain V...

Page 70: ...K10Y 1 2 1 Brake lever lock 2 Press to apply parking brake To release mechanism Squeeze brake lever Lever lock should auto matically return to its original position Brake lever should return to rest po sition Always release parking brake before riding 5 Transmission Lever Located on the right side of vehicle at the rear of engine A 3 position lever R N and H To change the transmission position com...

Page 71: ...mission in the gearbox It is the normal driving speed range It al lows the vehicle to reach its maximum speed 6 Multi Function Switch The multi function switch is located on the left side of the handlebar V06I0ZY The controls located on this multi function switch are Headlamp Switch It is located on top of the multi function switch Place switch to LO for the low beam and taillight Place switch to ...

Page 72: ... OFF we recom mend the engine be stopped by the engine stop switch V06I11Y 1 1 Engine stop switch Engine Start Button Located below engine stop switch To start engine place the engine stop switch to RUN Press and hold the engine start button Release immediately after engine is started V06I12Y 1 1 Engine start button To stop engine fully release throttle lever then use the engine stop switch Overri...

Page 73: ...ps Engine Temperature Oil Pressure Lamp red This light turns on when the ignition switch is turned ON and remains on until engine is running When this indicator light is ON it indicates the engine is overheating or a low oil pressure condition of the engine If engine overheats refer to ENGINE OVERHEAT in SPECIAL PROCEDURES CAUTION If the light does not turn off right after engine starting stop eng...

Page 74: ...ly tighten clockwise WARNING Always stop engine before re fueling Open cap slowly If a differential pressure condition is noticed whistling sound heard when loosening fuel tank cap have vehicle inspected and or re paired before further operation Fuel is flammable and explosive under certain conditions Never use an open flame to check fuel level Never smoke or allow flame or spark in vicinity Alway...

Page 75: ...is empty When down to the reserve refuel as soon as possible Ensure to turn the valve back to the ON position after re fuelling CAUTION Improper opening of fu el valve will restrict the flow of fu el Make sure valve is fully opened while running 11 Rear Brake Pedal Located on the right footrest When pressed down the rear brake is ap plied When released it should return to its original position Bra...

Page 76: ...load does not interfere with visibil ity and or steering Do not carry passenger s Refer to SPECIFICATIONS for carry ing loads and cargo weight distribution recommendations 15 Radiator Cap Located under front fender It pro vides access to the radiator filling neck WARNING In order to avoid potential burns do not remove the radiator cap if the engine is hot Turn radiator cap counterclockwise to remo...

Page 77: ...V06G01Y 1 1 Fuse holder _____________________ 75 ...

Page 78: ...uel This vehicle has a 4 stroke engine Oil must be added to engine base only Fuel Level WARNING Always stop engine before refu eling Open cap slowly If a dif ferential pressure condition is no ticed whistling sound heard when loosening fuel tank cap have ve hicle inspected and or repaired before further operation Fuel is flammable and explosive under certain conditions Never use an open flame to c...

Page 79: ... 10 C 14 F 20 C 4 F 30 C 22 F Oil Level CAUTION Check level frequently and refill if necessary Do not over fill Operating the engine with an improper level may severely dam age engine Wipe off any spillage V06C2DY RH SIDE OF ENGINE With vehicle on a level surface and engine cold not running check the oil level as follows 1 Unscrew dipstick then remove it and wipe clean 2 Reinstall dipstick screw i...

Page 80: ...verfill Oper ating the gearbox with an improp er level may severely damage gear box Wipe off any spillage Place the vehicle on a level surface Select NEUTRAL position then apply parking brake Check the gearbox oil level by remov ing the gearbox oil level plug V06E01Y 1 1 Oil level plug WARNING In order to avoid potential burns do not remove gearbox oil level plug if the exhaust is hot The oil shou...

Page 81: ...uired Use a funnel to avoid spillage Do not overfill Properly reinstall and tighten filler cap If the coolant is added in the coolant reservoir check the level in the radia tor too Add coolant if necessary WARNING In order to avoid potential burns do not remove the radiator cap if the engine is hot NOTE A cooling system that fre quently requires coolant is the indica tion of leaks or engine proble...

Page 82: ...See an autho rized Can Am dealer Brake Lever Fluid Reservoir Turn steering in the straight ahead position to ensure reservoir is level Check the brake fluid level the reser voir is full when the fluid reaches of the top of window Visually inspect lever boot condition Check for cracks tears etc Replace if damaged V06K05Y Battery This vehicle is equipped with an elec trolyte type battery that requir...

Page 83: ...per mark 2 Lower mark Properly retighten caps While reading this Operator s Guide remember that WARNING Indicates a potential hazard that if not avoided could result in serious in jury or death _____________________ 81 ...

Page 84: ...ensure it operates freely It must return to idle position when released Activate the brake levers and brake pedal to make sure the brakes fully apply Levers and pedal must fully return when released Ensure transmission lever is work ing then reset in NEUTRAL position Check drive chain for adjustment and lubrication Check sprockets for wear and dam ages Check fuel oil and coolant levels Check for o...

Page 85: ...CEDURES if it occurs When the engine is warm push the choke lever to OFF and release brakes Warm Engine Starting Start the engine as explained above but without the choke If the engine does not start after two 5 second at tempts with the electric starter move the choke lever and place it half way position Start the engine without ac tivating the throttle lever After a few seconds push the choke le...

Page 86: ... area launching loading boats etc rinsing the vehi cle with fresh water is necessary to preserve vehicle and its components Metallic parts lubrication is highly rec ommended Use XP S Lube P N 293 600 016 or an equivalent This must be performed at the end of each op erating day When vehicle is operated in muddy conditions rinsing the vehicle is rec ommended to preserve vehicle and its components an...

Page 87: ...ight after engine start ing stop engine and disconnect the temperature sensor 1 V06C2EY 2 1 Temperature sensor 2 Thermostat housing Restart engine If the light stays on a low oil pressure of the engine must be considered Stop engine immediately Otherwise if the light turn off and the engine is cold or warm not hot a po tential problem with the sensor or en gine part is possible Use the vehicle as ...

Page 88: ...e immersed it will be necessary to take it to an authorized Can Am dealer as soon as possible DO NOT START THE EN GINE Immersion of the vehicle can cause serious damage if the correct restart procedure is not followed 86 ______________________ ...

Page 89: ...to follow the rec ommendations here could cause changes in vehicle handling which could lead to an accident resulting in severe injuries including the possibility of death When transporting cargo on the vehi cle respect these maximum loads MAXIMUM LOADS Total load allowed 175 kg 386 lb Includes operator all other loads and added accessories Front load 16 kg 35 lb Evenly distributed Rear load 30 kg...

Page 90: ...may damage the vehi cle Unload racks before transporting the vehicle Front Location vmo2006 001 006 TYPICAL Rear Location vmo2006 001 007 TYPICAL WARNING Do not tow this vehicle behind a car or other vehicle Use a trailer 88 ______________________ ...

Page 91: ...s the engine may be fuel flooded Proceed as follows Turn ignition switch to ON position and ensure choke is not applied Ensure the transmission lever is on NEUTRAL Fully press throttle lever and hold while starting the engine As soon as the engine starts release throttle lever Do not race engine If it does not work Clean the spark plug cap area then remove it Remove the spark plug tools are suppli...

Page 92: ...AILS TO START 2 Lack of fuel to engine Check item ENGINE TURNS OVER BUT FAILS TO START 3 Carburetor adjustments Contact an authorized Can Am dealer 4 Engine is overheating Check ENGINE OVERHEATING in SPECIAL PROCEDURES If overheating persists contact an authorized Can Am dealer 5 Air filter housing plugged or dirty Check air filter and clean if necessary Check deposits in air filter housing drain ...

Page 93: ...See ENGINE LACKS ACCELERATION OR POWER 2 Parking brake Ensure brake lever lock is completely removed 3 Air filter housing plugged or dirty Check air filter and clean if necessary Check deposits in air filter housing drain Check the position of the air intake tube 4 CVT dirty or wear Contact an authorized Can Am dealer TRANSMISSION LEVER IS HARD TO MOVE 1 Transmission gears are in a position that p...

Page 94: ... DOES NOT MOVE 1 The transmission is in NEUTRAL position Set transmission in REVERSE or HI 2 CVT dirty or wear Contact an authorized Can Am dealer 3 Water in the CVT housing Contact an authorized Can Am dealer 92 ______________________ ...

Page 95: ...n Compression ratio 11 3 1 Engine power 10 7 kW 14 3 HP Lubrication Wet sump with replaceable oil filter without oil filter bypass Decompressor N A Exhaust system Screen type Spark arrestor approved by USDA Forest Service Air filter 2 stage foam filter TRANSMISSION Transmission Continuously Variable Transmission CVT COOLING Type Liquid cooled Radiator Front mounted CARBURETION Carburetor VM24 with...

Page 96: ...lt 12 volts 14 Ah Starting system Electric start Headlamp bulb 2 x 35 W HS1 Taillight bulb 5 21 W Solenoids 15 A Fuses Main 15 A DRIVE TRAIN Rear axle Chain driven solid axle Turning radius 1 950 m 77 in at low speed SUSPENSION Type Independent suspension single A arm 2 shock absorbers oil Front Travel 137 mm 5 4 in Type Rigid swing arm 1 shock absorber oil Rear Travel 163 mm 6 4 in TIRES Front 24...

Page 97: ...or all other loads and added accessories GVWR Gross Vehicle Weight Rating 373 kg 822 lb Towing capacity 227 kg 500 lb Tongue capacity 14 kg 30 lb included with rear racks DIMENSIONS Dry mass 189 kg 417 lb Overall length 2 05 m 81 in Overall width 1 06 m 41 5 in Overall height 1 09 m 43 in Seat height 0 84 m 33 in Wheel base 1 18 m 46 in Front 880 mm 35 in Wheel track Rear 810 mm 32 in Front and un...

Page 98: ...PACITIES Fuel tank 18 3 L 4 8 U S gal including an approximate reserve of 3 7 L 1 U S gal Engine oil 1 35 L 1 43 U S quarts Gearbox oil 400 mL 13 5 U S oz Coolant 2 5 L 2 64 U S quarts A Ampere Ah Ampere hour HP horsepower kW kilowatt RPM revolution per minute USDA United States Department of Agriculture W watt Because of our ongoing commitment to product quality and innovation BRP re serves the r...

Page 99: ...MAINTENANCE INFORMATION _____________________ 97 ...

Page 100: ...ASK LEGEND ENGINE TRANSMISSION Engine oil and filter 2 R R Customer Engine oil strainer C Dealer Oil pressure regulator I C Customer Gearbox oil I R Customer Valve adjustment I T I T Dealer Engine mounting fasteners I I Dealer Exhaust system I I Dealer Spark arrester C Customer Condition of engine seals I I Dealer Coolant 2 I I 3 R Customer Radiator cap cooling system pressure test I I Dealer Radi...

Page 101: ...ssion related component 2 Pre ride inspection item 4 More often under severe use such dusty area sand snow wet or muddy conditions ELECTRICAL Spark plug 5 I R Customer Battery electrolyte level and connections I I Customer Wiring harnesses cables and lines I I Dealer Condition of ignition switch engine start button and engine stop switch 2 I I Customer Condition of lighting system HI LO intensity ...

Page 102: ...aring etc I I 4 Dealer Tie rod ends I I Dealer Wheel nuts studs 2 I I Customer Tires pressure and wear 2 EVERY RIDE Customer Front wheels alignment I I Dealer 2 Pre ride inspection item 4 More often under severe use such dusty area sand snow wet or muddy conditions SUSPENSION Swing arm 2 I Customer Shock absorbers 2 I Customer A arms I Customer 2 Pre ride inspection item BRAKE Brake fluid front an...

Page 103: ...200 H OR 2 YEARS OR 4000 km 2485 mi A ADJUST C CLEAN I INSPECT L LUBRICATE R REPLACE T PROCEED WITH TASK TO BE PERFORMED BY PART TASK LEGEND BODY FRAME Engine compartment C C Customer Frame I Dealer Hitch trailer ball condition if installed EVERY RIDE Customer Chassis Fasteners I Customer Seat fasteners EVERY RIDE Customer Vehicle cleaning and protection C 4 Customer 4 More often under severe use ...

Page 104: ...t have cooled down to avoid potential burns WARNING Should removal of a locking device e g lock tabs self locking fasteners etc be required when undergoing disassembly assembly always replace with a new one The following covers the maintenance items that can be performed by the cus tomer if desired Other items found in maintenance chart must be performed by an authorized Can Am dealer NOTE Among o...

Page 105: ...pstick Clean the drain plug area Place a drain pan under the engine drain plug area Unscrew drain plug V06C1WY 1 1 Oil drain plug Allow enough time for oil to flow out of oil filter Unscrew the oil filter cover V06C04Y Remove oil filter and replace with a new filter NOTE Check the cover O ring and change it if necessary Wipe out any oil spillage on engine Remove oil strainer plug then clean oil st...

Page 106: ... plug 1 V06C2FY 2 1 Cooling drain plug 2 Oil pressure regulator plug Clean plug area then remove it Remove valve housing compression spring and ball 4 R175motr135Y 3 2 1 1 Valve housing 2 Compression spring 3 Ball 4 Oil pressure valve port NOTE Oil coming out will push out spring loaded ball take care not to lose spring and ball Clean all parts and oil pressure regula tor port Check compression sp...

Page 107: ...hose pincher NOTE If no coolant comes out by the bleeding hole squeeze the lower ra diator hose several times until coolant comes out Complete the radiator filling Check the level in the coolant reservoir and refill if necessary Run engine at idle with the radiator cap off Slowly add additional coolant if necessary At this point wait until engine reach es normal operating temperature De press the ...

Page 108: ...ty it CAUTION Do not start engine when liquid deposits are found in the drain tube When liquid deposits are found the air filter must be inspected dried replaced depending on its condition Air Filter Removal CAUTION Never remove or mod ify any component in the air filter housing The engine carburation is calibrated to operate specifically with these components Other wise engine performance degra d...

Page 109: ...ce will cause noise Spark Arrester The muffler must be periodically purged of accumulated carbon WARNING Never perform this operation im mediately after the engine has been run because exhaust system is very hot Wear eye protection and gloves Respect all applicable laws and regulations Place transmission on NEUTRAL posi tion and apply parking brake Remove the spark arrester from the muffler V06C2H...

Page 110: ...o dam age the radiating fins when clean ing Do not use any object tool that could damage the fins The fins are purposely thin parts to allow effi cient cooling WHEN HOSING USE LOW PRESSURE ONLY NEVER USE A HIGH PRESSURE WASHER See an authorized Can Am dealer to check the performance of the cooling system 108 _____________________ ...

Page 111: ... and tilt the vehicle toward the left side When the gearbox is empty install the drain plug and re place the vehicle on the ground Refill gearbox using XP S chaincase oil P N 413 801 900 or an equivalent CAUTION Do not use other unrec ommended types of oil when ser vicing Do not mix with other types of oil The oil should be level with the bottom of the oil level hole Refill as required until gearb...

Page 112: ...CARBURETOR See an authorized Can Am dealer each year to verify and clean the fuel sys tem 110 _____________________ ...

Page 113: ...tor to expose the cable adjuster Unscrew the lock nut of the cable ad juster then screw in the adjuster to re lease the cable tension V06I0TY 1 2 1 Rubber protector 2 Cable adjuster Remove the cable from the throttle lever V06I04Y 2 1 1 Throttle handle housing 2 Throttle cable NOTE Slide cable in clip slot and re move the end of cable from clip Remove the carburetor cap on top of the carburetor Pl...

Page 114: ...e rubber protector back to expose throttle cable adjuster Loosen lock nut then turn the adjuster to obtain correct throttle lever free play NOTE Measure throttle free play at the tip of throttle lever Tighten lock nut and reinstall protector V06A0WY 1 4 3 2 A 1 Throttle lever 2 Protector 3 Cable adjuster 4 Lock nut A 3 to 8 mm 1 8 to 5 16 in With the transmission lever on NEU TRAL position start t...

Page 115: ...ous and dan gerous Avoid contact with eyes skin and clothing Wear protective eyeglasses and a suitable pair of non absorbent gloves when re moving the battery by hand CAUTION Should any electrolyte spillage occur immediately wash off with a solution of baking soda and water Cleaning Clean battery battery casing cables and battery posts using a solution of baking soda and water Remove corrosion fro...

Page 116: ...ng life If glass is touched clean it with isopropyl alcohol which will not leave a film on the bulb To unplug connector release outer edge of rubber protector from head lamp housing then pull on connector using a wiggle movement NOTE The rubber protector is a one piece component encapsulating the connector vmo2006 001 008_a 1 Release outer edge of rubber protector 2 Pull on connector using a wiggl...

Page 117: ...ht and side orientation to your convenience Adjust both headlamps evenly V06G0TY 1 2 3 TYPICAL 1 Headlamp housing 2 Beam height adjustment 3 Beam side adjustment Taillight Unscrew lens screws to expose bulb V06G0UY 1 2 TYPICAL 1 Lens 2 Screws Push bulb in and hold while turning counterclockwise to release Install the new bulb by first pushing in while turning clockwise Reinstall lens _____________...

Page 118: ...f its location V06G0VY Turn the cluster and pull the rubber protector of the defective indicator lamp Turn round the rubber protector to ex pose the indicator lamp bulb V06G0WY 1 2 1 Indicator lamp bulb 2 Rubber protector Pull the bulb to remove it For installation reverse the removal instructions 116 _____________________ ...

Page 119: ... free play of drive chain and adjust if necessary Check for damage or missing O ring or rollers Cleaning and Lubrication CAUTION Never wash the chain with a high pressure washer or gasoline Damage to the O ring will result causing premature wear and drive chain failure Clean the side surfaces of the chain with a dry cloth NOTE Do not brush chain Lubricate only with an approved O ring chain lubrica...

Page 120: ...hain too loose or too tight as severe damage to the drive components can occur When the adjustment is done repeat the above procedure to check the deflection several times at different spots on the chain Replacement With the chain installed on vehicle measure the distance between a span of 13 links from pin center to pin cen ter Change drive chain if the distance exceeds the service limit see an a...

Page 121: ...te and rotate on wheel Overpres sure may burst the tire Always follow recommended pressure Since tires are low pressure types a manual pump should be used Check pressure when tires are cold before using the vehicle Tire pres sure changes with temperature and altitude Recheck pressure if one of these conditions has changed For your convenience a pressure gauge is supplied in tool kit TIRE PRESSURE ...

Page 122: ...reads Gently tighten nuts in a criss cross se quence then apply a final torque of 70 N m 52 lbf ft V06H05Y 1 1 Taper side of nut CAUTION Always use the recom mended wheel nuts P N 250 100 039 Using a different nut could cause damages to the rim 120 _____________________ ...

Page 123: ...A FRONT SUSPENSION A Same length on both sides Lubrication A Arm Lubricate front A arms Use synthetic grease P N 293 550 033 or an equiv alent There is two grease fittings on each A arm V06J01Y 1 1 Grease fittings Swing Arm Lubricate swing arm pivots Use syn thetic grease P N 293 550 033 or an equivalent Inspection Front and Rear Suspension Inspect shock absorbers for oil leaks and fasteners for t...

Page 124: ... 041 or and equivalent then press the brake ped al to move the brake cable Repeat this procedure until the silicone lubri cant exits the other end of the cable WARNING Always use a silicone based lu bricant Using another lubricant like water based lubricant could cause brake cable sticking or stiff ness Inspection WARNING See an authorized Can Am deal er to repair or replace any compo nents of the...

Page 125: ... if worn Chassis Fasteners Check fastener condition and tight ness on the vehicle Retighten as required Seat Fasteners Check tightness of seat fasteners Retorque or replace if necessary Vehicle Cleaning and Protection Never use the high pressure washer to clean the vehicle USE LOW PRES SURE ONLY like a garden hose The high pressure can cause electrical or mechanical damages Painted parts which are...

Page 126: ...pecified in MAINTENANCE CHART When a vehicle is not in use for more than one month proper storage is a necessity See an authorized Can Am dealer for proper procedures When using your vehicle after storage a preparation is required See an au thorized Can Am dealer for proper pro cedures 124 _____________________ ...

Page 127: ...WARRANTY _____________________ 125 ...

Page 128: ...o the first retail consumer or the date the product is first put into use whichever occurs first and for a period of SIX 6 CONSECUTIVE MONTHS for private use or commercial use owners The emission related components included in the chart below that are installed on EPA certified Can Am ATV s see list below registered in the USA are covered for thirty 30 consecutive months The EPA certified Can Am A...

Page 129: ...duct and reasonable opportunity to repair it The customer must also present to the authorized Can Am dealer proof of purchase of the product and must sign the repair work order prior to starting the repair in order to validate the warranty repair All parts replaced under this limited warranty become the property of BRP 5 WHAT BRP WILL DO BRP s obligations under this warranty are limited to at its ...

Page 130: ... YOU THIS WARRANTY GIVES YOU SPECIFIC RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM STATE TO STATE OR PROVINCE TO PROVINCE Neither the distributor any Can Am dealer nor any other person has been autho rized to make any affirmation representation or warranty regarding the product other than those contained in this limited warranty and if made shall not be en forceable against ...

Page 131: ...omplaint in writing or call the appropriate number below IN CANADA IN USA BOMBARDIER RECREATIONAL PRODUCTS INC CAN AM ATV CONSUMER SERVICES GROUP VALCOURT QC J0E 2L0 Tel 819 566 3366 BRP US Inc CAN AM ATV CONSUMER SERVICES GROUP 7575 BOMBARDIER COURT WAUSAU WI 54401 Tel 715 848 4957 In the USA products are distributed and serviced by BRP US Inc 2006 Bombardier Recreational Products Inc All rights ...

Page 132: ... service under this war ranty does not extend the life of this warranty beyond its original expiration date 3 CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on 2007 Can Am ATVs purchased as new and unused by its first owner from a Can Am distributor dealer authorized to dis tribute Can Am ATV products in the country in which the sale occurred Can Am distributor deale...

Page 133: ...om time to time without assuming any obligation to modify products previously manufactured 6 EXCLUSIONS ARE NOT WARRANTED The following are not warranted under any circumstances Normal wear and tear Routine maintenance items tune ups adjustments Damage caused by failure to provide proper maintenance and or storage as described in the Operator s Guide Damage resulting from removal of parts improper...

Page 134: ...PLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM COUNTRY TO COUNTRY Neither the distributor any BRP dealer nor any other person has been authorized to make any affirmation representation or warranty regarding the product other than those contained in this limited warranty and if made shall not be enforce able against BRP BRP reserves t...

Page 135: ...r owner b If further assistance is required the distributor s service department should be contacted in order to resolve the matter c If the matter still remains unresolved then contact BRP by writing to us at the address listed below BRP EUROPE N V Consumer Service Center Belgium Tel 32 0 9 272 63 30 2006 Bombardier Recreational Products Inc All rights reserved TM Trademark of Bombardier Recreati...

Page 136: ...rthy organiza tions may be permitted to use the coordinates of our clients to promote quality products and services If you prefer not to have your name and address released lease let us know by writing to the address below IN CANADA IN USA Bombardier Recreational Products Inc Warranty Department 75 J A Bombardier Street Sherbrooke Québec J1L 1W3 Fax Number 819 566 3590 BRP US Inc Warranty Departme...

Page 137: ... your personal ATV is stolen you should notify BRP or an authorized Can Am dealer We will ask you to provide your name address phone number the vehicle identification number and the date it was stolen IN NORTH AMERICA OTHER COUNTRIES IN THE WORLD Bombardier Recreational Products Inc Warranty Department 75 J A Bombardier Street Sherbrooke Québec J1L 1W3 Canada BRP European Distribution Warranty Dep...

Page 138: ...136 _____________________ ...

Page 139: ... completed by the dealer at the time of the sale DEALER IMPRINT AREA NAME No STREET APT CITY STATE PROVINCE ZIP POSTAL CODE V00A2IL Please verify with your dealer to ensure your vehicle has been registered with BRP While reading this Operator s Guide remember that WARNING Indicates a potential hazard that if not avoided could result in serious in jury or death ...

Page 140: ...vmo2007 RALLY 200 ang FH10 Thu May 11 15 47 01 2006 Page 1 Composite C M Y CM MY CY CMY K ...

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