Bombardier Rally 200 ATV (Specs and Review)

A robust off-road machine by BRP, the Bombardier Rally 200 has gained acclaim for its durability and versatility in the early 2000s. In this guide, I will be delving into its specifications and lowdowns. I aim to offer a brief but comprehensive review of its engine performance, handling capabilities, and overall design while answering the questions: “What kind of ORV is the Bombardier Rally 200?” and “What does it offer?”

The Bombardier Rally 200 is a spunky 176cc ATV, predominantly utilitarian by design but doubles as a sport quad for budget-conscious enthusiasts. It is a full-featured, gas-fed four-wheeler with liquid cooling and (then) industry-leading Rotax engine finished in Yellow or Viper Red.

Nowadays, these features are standard. But during its time, the Rally 200 was one of the most technologically advanced quads in (and even beyond) its class. Are you curious to know more about this specific small-displacement four-wheeler? Then, stick around and read on.

The Off-Road Marvel of the Early 2000s

The Bombardier Rally 200 was conceptualized as an off-road powerhouse, combining rugged design with dynamic performance. Manufactured by BRP, this thumper hit the market in the early 2000s — catering to ATV enthusiasts seeking a versatile and reliable machine.

The model’s production was relatively short-lived, spanning from 2003 to 2007 (with some online sources suggesting it lasted until around 2012). Nonetheless, the Rally gained popularity for its durability and adaptability across varied terrains. That said, it is no surprise that its legacy endures despite its discontinuation — earning it a loyal following that appreciates its off-road prowess and the OEM’s commitment to crafting enduring ATVs.

2003 Bombardier Rally 200 Specs & Features

Engine

Powering the Bombardier Rally 200 is a liquid-cooled, single-cylinder, 4-stroke SOHC Rotax engine. It has a bore-stroke ratio of 62 x 58.4 mm (2.441 x 2.299 inches) and boasts a displacement of 176.3cc (10.76 in3). Fuel delivery is handled by a Mikuni VM24 carburetor with manual choke, while the engine operates at a full-stroke compression ratio of 11.37:1. Air filter element is a 2-stage foam filter.

This configuration yields the following performance figures:

Description	Performance Figure
Top Speed	53 mph (85 km/h)
Horsepower	10.7 kW (14.3 HP)
Maximum Torque	14.5 Nm @ 6,500 RPM, CanAm TV

Fuel & Lubrication

The Rally has a wet sump lubrication system with an oil capacity of 1.35 L (1.43 U.S. quarts) of SAE 5W-40 synthetic 4-stroke oil. I recommend using premium-quality oil variants without molybdenum additives or their equivalent. Ensure that your engine oil meets OEM specs, a minimum API classification of SJ, and ACEA/DIN/JASO T 903 MA standards.

Fuel-wise, the ATV mandates 18.3 L (4.8 USgal, with an approximate reserve of 3.7 L/1 USgal) of unleaded gasoline. For optimal performance, it is imperative to avoid using lower-octane fuel to prevent knocking, which could eventually result in engine failure.

Drivetrain

A Continuously Variable Transmission (CVT) and sub-transmission with forward, neutral & reverse — with a chain-driven, solid axle drivetrain — controls the Rally 200. The latter transfers power from the engine to the rear wheels. The whole powertrain setup is supplemented by engine braking.

Ignition & Electricals

A fully-transistorized CDI (Capacitor Discharge Ignition) system with an electric start and a non-adjustable ignition timing wakes the 200-class thumper. Meanwhile, its charging system is a magneto generator with a rated output of 260 W @ 6,000 RPM.

A YTX14AH-BS battery (view on Amazon) powers up lighting and accessories. As for spark ignition, it employs an NGK CR8E plug. If you do not wish to use 10-mm spacers, a 12V 14 Ah/(10 HR) YB14A-A2 battery format would better fit the quad.

The quad has a 35-watt HS1 headlight, a 5-watt taillight, and a 21-watt brake light. To achieve superior light distribution and enhance aesthetics, you can incorporate a night light on the Bombardier Rally 200 or switch to LED lighting.

Tires & Brakes

Stamped steel wheels come fitted with tubed, front-and-rear tires measuring 21 x 7-10 and 22 x 10-10, respectively. These may be Maxxis®, Duro, ITP, or Kenda Bear Claw tires (view on Amazon), depending on personal preference — although the latter is best if going one size up from stock knobbies.

The tires should be maintained at a cold-tire pressure of 24 kPa (0.24 kgf/cm2, 3.5 psi) with flexibility for adjustment within ± 2-4 psi, considering the terrain, driving speed, and payload. For its tire-and-wheel assembly, the Rally is complemented by triple inboard hydraulic discs on all fours, alongside an LH brake lever featuring a lock mechanism, ensuring effective stopping power.

Suspension

Nestled within an SST frame, the Bombardier Rally 200 features a single A-arm for independent suspension at the front. This is accompanied by dual oil-damped shocks, while a mono-shock rigid swingarm graces the rear. These front and rear suspension units offer 5.4 inches (137 mm) and 6.4 inches (163 mm) of wheel travel.

This meticulously designed suspension layout provides a smooth ride and improves the turning radius of 6.4 feet (1.950 m, 77 inches). This seamlessly aligns with the quad’s 46-inch (1,180-mm) wheelbase and substantial ground clearance, measuring 235 mm (9 inches) at the front and under the engine and 167 mm (6.6 inches) at the rear axle.

Dimensions & Capacities

The Rally 200’s comprehensive measurements are 81 x 41.5 x 43 inches (2,057 x 1,054 x 1,092 mm — L x W x H). Its saddle sits at a height of 33 inches (838 mm), and it maintains a dry weight of 417 lbs. (189 Kg). Considering variables like passenger weight, front-rear rack capacity, cargo, and accessories, the quad’s Gross Vehicle Weight Rating (GVWR) reaches 822 lbs. (373 Kg).

Compared to same-class counterparts, the four-wheeler is relatively longer and heavier. Its length, for instance, is at least 15 inches longer than small-displacement ATVs. This length can be likened to the Honda Foreman 500 — a mid-size quad at least two tier sizes larger than the Rally 200.

Exterior

The quad features a rugged, compact design for durability across diverse terrains. Its dynamic front end combines sporty aesthetics with optimal visibility for thrilling adventures. Meanwhile, front and rear racks offer ample cargo space for leisure or work-related tasks.

You can personalize your ride with various graphics, vibrant colors, and brand logos — although it already has a nice metallic paint finish out of the crate. Combined with the four-wheeler’s robust suspension and frame construction, these elements and more ensure durability and enable the Bombardier Rally 200 to withstand varied off-roading challenges.

Bombardier Rally 200 Price

The 2003 Bombardier Rally 200 had an MSRP of $3,199, while its final year iteration was $3,349. Per JD Power data, the current resale average of this base model ranges from $465 to $585. However, trader and auction sites show a higher average closer to the four-wheeler’s original list price.

Bombardier Rally 200 Problems

Try searching online for problems linked to this 20-year-old quad, and I am sure you will find at least ten issues. These include poor acceleration, backfiring/misfiring, weird noises, and electrical hiccups. But for purposes of this guide, let us cover the four most prevalent and troublesome problems associated with this 200cc quad.

Starting Difficulties

Difficulty starting the Bombardier Rally 200 can be from a discharged battery, faulty starter motor, or fuel system issues. These scenarios are typically caused by poor upkeep or deteriorated components and may occur regardless of weather conditions.

To address this, routinely maintain your ATV battery, clean and tighten terminals, and inspect the solenoid, spark plug, and starter motor. Replace faulty components and address fuel system problems for reliable starting. Additionally, clean the Bombardier Rally 200 carburetor and promptly replace worn or defective spark plugs to prevent potential starting issues.

Stalling

Engine stalling, on the other hand, usually results from compromised ignition (often traced back to a faulty plug or water seeping into the engine). This, in turn, leads to inconsistency or misfires during combustion. Proper upkeep and using high-quality fuel should keep this issue at bay.

Transmission Issues

The Rally 200 is also not safe from transmission issues, such as misfires during gear shifts, getting stuck in high gear, or power transfer difficulties. This propensity is mainly due to the quad’s age and the fact that it can only be procured as a secondhand unit nowadays. However, even some brand-new Rallies reportedly had the same problem in 2003.

Several factors can contribute to these tranny issues, namely:

• Broken gear shift components: Wear or breakage in gear shift components leading to difficulties in engaging or disengaging gears
• Malfunctioning gear transfer levers: Issues with gear transfer levers disrupt the smooth transition between gears, causing misfires during shifts or getting stuck in high gear
• Transmission seal problems: Worn or damaged transmission seals leading to fluid leakage
• Fluid level irregularities: Insufficient or contaminated transmission fluid hindering proper lubrication and cooling, leading to rough gear changes and potential damage

Potential root causes often extend beyond these factors above. To determine the problem source for the transmission issue encountered, check the owner’s manual for troubleshooting guidance or heed the advice of veterans. If your Rally 200 is stuck in high gear, however, Just Answer suggests ascertaining the condition of specific components:

• Shift plate exhibits wear or damage to its tracks
• Shift forks show signs of wear or are damaged
• Engagement pins may be compromised in any way
• Shift gears are dilapidated
• High gear is worn or otherwise damaged.
• The front index spring (the one that stops intermediate gear in idle) is worn.

Depending on your mechanical savvy, you can attempt a DIY repair or outsource the task to a certified technician.

Timing Chain Tensioner Problem

Some Bombardier Rally 200 parts, like its timing chain tensioner, are reportedly flimsy. The ATV only has plastic chain guides that tend to be easily affected when the four-wheeler’s valves become bent.

This is not to say that the timing chain tensioner is inherently problematic. The issue is often from wear and tear (due to continuous use), use of low-quality or inadequate engine oil, insufficient or irregular maintenance, and misalignment due to improper installation during maintenance or repair.

Fortunately, performing timely, regular checks, replacing the affected tensioner, and using the correct engine oil effectively address the issue when done early on. However, more experienced riders wish there was an aftermarket chain tensioner that could permanently eradicate the problem.

Pros and Cons

Pros

• Versatility: The Bombardier Rally 200 is suitable for various terrain and riding conditions. Its design allows for effortless navigation of both trails and off-road environments.
• Smooth Suspension: Equipped with a well-tuned suspension system, the quad provides a smooth and comfortable ride, particularly beneficial when traversing uneven surfaces or rough terrain.
• Reliable Engine: The Rally 200 features a stalwart power mill, offering a good balance of power and fuel efficiency.
• User-Friendly Controls: With user-friendly controls and handling, the ATV is accessible for riders of different skill levels.
• Sturdy Build: The Rally 200 is known for its robust construction, capable of withstanding the rigors of off-road adventures and challenging riding conditions.
• Ample Storage Space: The quad has sufficient storage space, enhancing its practicality and allowing riders to carry essential gear and belongings during their journeys.

Cons

• Outdated Technology: This 20-year-old four-wheeler may lack advanced controls and safety features found in newer ATVs. This can impact performance, efficiency, rider safety, and overall riding experience.
• Deep Whoops: Because the quad’s front end is heavy, many riders find that the machine cannot instantly respond when faced with whoops.
• Limited Speed: The Bombardier Rally 200 top speed is restricted to 53 mph (85 km/h) compared to more modern ATVs. This limitation can be a deal-breaker for those seeking higher speeds and performance.
• Parts Availability: Finding replacement parts for older Rally 200 models may pose a challenge due to Bombardier’s recent shift in focus.
• Noise Levels: Being an older model, the ATV might exhibit higher noise levels during operation.
• Resale Value: Due to its age and potential tech shortcomings, its resale value may not be as competitive as newer, more advanced ATV models.

About BRP

Founded in 1942 by Joseph-Armand Bombardier in Quebec, Canada, Bombardier Recreational Products (or BRP) began as a maker of snow vehicles. The most famous of the firm’s inventions is the iconic Ski-Doo snowmobile, which revolutionized winter recreation when it debuted in 1959.

Since then, Bombardier diversified into various industries, including aerospace and transportation. It became a global leader in manufacturing trains, planes, and ATVs like the Bombardier Rally 200. The company encountered financial challenges in the early 21st century. Despite this, Bombardier’s impact on mobility and transportation remains significant.

Conclusion — Bombardier RallyTM 200 ATV

The Bombardier Rally 200 is a remarkable off-road companion, blending durability, versatility, and power seamlessly. With its robust engine, advanced suspension, and an unintimidating but capable design for various terrains, it continues to be a favorite among ATV enthusiasts.

I hope referencing this guide enables you to judge this small but powerful quad better. Now, all you have to do is search up available preloved Rallies in your area and get your hands on one!