This is a photo from the web..  Same yellow Rally..  just all together.

This is the one I bought.  The foot well was taken of to better access the motor.   A bunch of other bits are in a box too.  But it’s all there, and this was a running quad before the valve decided to say hello to the piston.  Tires are worn .  .. but holding air.   The plastics are great, the seat has some stitching coming apart on one side.   Everything else seams to be in fine shape.  So I’m thinking it’s worth fixing the motor..

2003  vs 2005

Bombardier made the Rally 200 for a few years only.  Designed as an entry level quad with some big quad features.   Water cooled 4 stroke Rotax motor,  hydraulic disc brakes.  CVT drive .  These are good stuff to have.  2003 was the first year, and the design was pretty cool for then.   Instead of racks they molded in trays front and back.  I like that.. but they quickly went back to racks the next year ?   also the 2003 has a manual disc brake on the transmission .. and the 2005 has a hydraulic disc on the rear axle.   Some little changes like moving the key and indicator lights up on a handle bar pod.   Later I will take some photos of the two side by side..

It’s later !  Here’s the two together.  See the wheel size.   Which changes the height a bit.   The racks make the red one look much taller.

So there are no plans for this quad YET..   I parked it and covered it in a safe place for now…

February 26 2017:

It’s seams impossible to find the top motor parts to repair the motor..  They just don’t make that size motor anymore and no one has even a used motor..  It is said that these are a weak motor and easily drop a valve.  SO I have another plan.

1994 Yamaha Timber Wolf 250 4×4

This sad quad has been hanging out in the yard waiting to see if it’s worth fixing..   And there is one big question ?  Does the motor run ?

So we dragged in into the shop..  I removed all the wheels , plastics and racks.  Today I’ll clean the carb,  check the wiring and see if we have at least a motor..

Well it runs.. but not well enough to go through all the work to transplant the motor.   so back to trying to get the motor parts.

Well this came up for sale ..  at what I’m going to say was a very good price..  Seems not to much interest because it’s a two wheel drive Quad. 

So what !  It runs great..  Has NO damage .  Aside from 4 wheel drive .. it has all the good stuff.  4 stroke 200 cc water cooled motor. CVT drive.  three hydraulic disc brakes.  newish tires.  Above is the photo in my yard before I even cleaned it..   It’s not perfect.. there are things to do.  The battery needed to be charged.. the racks need new paint.  and they have by-passed the starter solenoid with a big button ?  So I’m going to take a few days and go over the Rally and adjust … fix …  and add a few goodies.

Into the shop and start removing bits and pieces..  So far I’ve got a list of things that need fixing and things that bug me.  And one thing that I did not see at first..  :

• The front brake reservoir window is missing.  Therefore no fluid .. no front brakes !
• That hokey start button..  it’s wired directly to the starter, bypassing the solenoid.  Why ?
• The foam air filter is shot..  I’ll make a new one.
• The front clip on the seat is loose.  You can lift the seat there.
• Battery could be bad..
• The chain needs to be adjusted.
• The rear wheels ..  they have been mounted backwards to make the wheels wider ?  not needed…  Kids !

It’s not that big considering the price we paid.  The first thing I did was cosmetic.. I removed the racks .. sanded them and welded a hook on each end.

There’s no plans to put a winch on this quad.  And the paint was all scratched of the front and back bars.. so I installed these hooks to use for pulling on.

Then the four pieces got a new gray paint job.   I removed even more parts from the Rally so I can get to some of the cleaning and wiring.  Because first on my mind was the hard wired start button.  I needed to know what was wrong with the factory start button.  So I took it apart and found a broken solder connection. Simple fix.   Meanwhile I’ve had the battery on charge .. three times and it tests out just on the verge of bad..  so a new battery was bought.. something we thought was going to happen anyway.  Ok a little “pimpin”  while things are apart.

What to do with that hole where the start button was ?  A horn button of coarse..  And why not a power plug too.  !

Routing the wires is easy when this much of the quad was apart.

And lets not forget the all important LED running light.

I’ve got the quad all back together now..  Replaced the window in the brake reservoir,  Found out the chain has been adjusted to the limit.. so maybe a new chain.   The rear wheels have to stay as they are ..  the rims are not the original ones.. so the offset is too much inward if you turn them around.   New battery installed.  New foam air filter.  I even replaced the gas line.  I don’t like those clear hoses.  It’s running good.

And Mo is liking the new ride..  just the right fit for her..   Remember the chain had a lot of play.. I bought a new chain.. made it the proper size and it fits perfect ..  with the adjustment set back.  So it will be easy to take up any slack.   We now have a 100% working quad.   Time to take it out for a run..

While I was looking for parts for the 2005 Rally, I came across a 2003 Rally being sold very cheap.   The motor had a broken valve which also wrecked the piston.   It looks fixable.. so I bought it and brought it home… See the new post   HERE.

Sept 28 2016… and we finally got to take out the two quads.. mostly to see if Mo likes this as a activity..   we had NO troubles.. BUT she feels that this is not her “thing”…  so she want’s to sell it ..  no need for two..

Aug 2016:

Realizing that ramps were not working good for lawn tractors.. I needed a small tilt deck trailer that could be towed by the Carry.

I bought this off a fella for $100.  a few months back.  It’s an old tent trailer frame.  Which does not tilt,  the tongue is a little bent, but the wheels and springs are like new..

And it has new lights !  BUT it’s seven feet wide..  I want the trailer to be only five feet wide.  So time for some mods.

Here’s the frame after removing the wood.  There is jack stands on all four corners.. Some are bent up, but all of them haft to go.  I can use the bits I cut off to make the frame a bit stronger.   I need the rear to be tapered and slim so it comes close to the ground when tilted.  So I’m cutting off the rear bumper.  The main frame is four feet wide. The wheels are another eight inches on both sides.  So I will need narrow fenders..  and the lights will have to move forward so they don’t hit the ground.

Cut Cut Cut .. Weld Weld Weld…

I plan as I go.  And so far it looks good.. I fear I’m adding more weight with all the extra metal..   But I don’t want a flimsy trailer.

I moved the axle to the top of the springs..  and that lowered the trailer by 4 or 5 inches.  Now I’m concerned that the deck will hit the wheels..  Once I flip it back over I will see.

This took awhile to figure out..  and a few trips to the metal stash to find the right bits.  But I got it.. very “over built ” tilt system for the hitch tongue.  Then I flipped the trailer back on it’s wheels and could see two things..   The wheels are close to the deck..  So maybe small shallow fenders?  And the deck is just a touch heavier on the front so it won’t stay in the tilt position.   I was thinking of all kinds of ways to fix this..  adding weight to the rear.. no..   Finally I thought to tighten the hinge bolt  !  Now it stays wherever you put it.

Here’s a view of the hinge.  I purposely located it forward of the axle so the deck would drop down..  DUH.. the real hinge point is the wheels.   So with the bolt tight things work fine.

Here’s the right side up view of my pin and pocket for the tongue.  Very sturdy..   There’s a few more things to do before the deck wood goes back on..  Like these…

Tail light holders !   And a mount for the hand winch…

Yes a hand winch will sit atop this platform.  Keep it simple and light ..   I’ve got the tongue all fixed up with a spare tire mount a hoop for the safety chain..   And I used the best jack stand  and welded it on the bottom of the tongue ..  CAUSE I CAN.

Looks like this now..  The jack stand is adjustable for height and folds up to the tongue.  The wiring is done too.

So now we have lights..   Oh and here’s what the winch looks like.

Just needs bolts and the strap… simple.   So I’m ready for the plywood to go back on..

It’s a perfect 5 ft x 8 ft.  and I had enough of the plywood .  I also mounted the tie down rails that were in the box of the Carry.   So it’s all done !

It’s sits level hooked up to the little truck.  Good

And tilts nicely to the ground with only a 3/4 ” lip

A winch for the dead tractors & spare.. We are styln…  I have the registration now and a new plate.

Aug 2016:

The Extra Stuff:

That makes the little guy mine..  OR.. Rob’s creative corner..  where I “pimp” my ride.  I’ve already done some “pimpin”  like the keyless locks, the new stereo.  But.. I’ve got all the supplies to build a covered canopy for the back.  Also I’ve got a new winch, the wiring and the metal for building a plug-in winch / bush bar.

Here’s is some of the stuff for the winch set up.  The winch will be mounted to a hitch extension.  This allows for a snow plow to still be plugged in..  or whatever ?  This winch could be used on any vehicle with a 2 ” receiver.  It will be operated by wireless remote, and just needs power.

And this is what I’ve come up with.  looks a bit strange, but it’s designed to ….  1 – not hide the front license plate.   2- not sick out from the truck any further that necessary.  3- bush bar side extensions are plug-in and can be removed.   The roller fair head mounts to the front, and of coarse you can still plug in a hitch.

Aug 2016:

Well I’ve put about 100 or more kms on the little bugger..  and there is a tiny oil leak .. I think from the oil filter..  Everything was on hold while we had our Camping / family reunion..  And the Carry was there..

But not pulling the fifth wheel..   Before I get back to finishing the Carry up..  I need my little trailer built so I can fetch tractors with the Carry..   So I’m pausing to do that …      Tilt Trailer Bolg

So I’m in no hurry to do those extras like the winch..  I’m using the truck every day for work..  I’ve done a new oil change and that fixed the little leak.  Checked the timing , the hoses.. everything is good.  And it’s running good too.   This weekend my little truck will be in the car show at the City Park..

Here it is..  no prizes..  However someone saw it that wanted to buy it from me..  And a month later I have sold my little truck to a very happy guy.   So on Sept  27 th 2016 I watched it drive away.. Going to miss it for sure.. was really handy.  But time to move on..

Work on the BOX:

Time to improve the box…

Well here it is..  with the tie – down rails removed.  First thing.. weld the many holes up.

Color Scheme:

On the first page I had a mock-up of what I would like to see.. Since then I worked on the plan a bit more.  And of coarse the frame ended up black.  But I still would like some gray too.  So the head rack, hitches, winch mount and stake pockets will be grey.  The bottom of the truck will be Orange as planed.   Like this….

The plan is to build a removable winch for the front that incorporates a bush guard.  It could be moved to the rear as well if needed there.  The winch will be wireless remote.  Better get back to working on the box..

Using a combination of Por 15 and undercoating, I sealed up the underside.  In the photo you can see I have primed the parts that get the orange paint.

And this is the first coat of orange.  I will flip the bed over to second coat.  The weather was not cooperating ,  It was cool and the paint took forever to cure.  so it’s an overnight job now.   also the paint is very thin for covering..  even after 4 coats you can see through it.  Very frustrating.

So I fought with the paint..  wasted a bunch..  got a fifth coat on there.. but it’s not smooth..  I said enough and will leave it like this..  It’s a truck..  I like the color of this Orange..  so I’ll buy more and carry on.

I’m using spray on box liner that comes in a spray can..  it’s great stuff, and I can do the job quickly.  I did run out with only a small patch left to go..  GRRR.   Off to get another can.

With the bed of the box done.. we got busy and put it back on the truck.  The wiring was all improved and a new trailer harness was installed.  I’ve drove it around a bit and it seams the smoke has cleared.  Once the rings and other bits get seated in this should be the case.  I still hate the orange paint job on the side of the bed.  I’m switching over to good old enamel paint.  And I’m taking the time to brush it on carefully.  Same for the orange.. I had a quart mixed to a bit lighter orange, and that’s what is going on the truck… by brush… carefully..

Here’s the tailgate with the first coat of orange.  The white is done, three coats.  I have also taken most of the dents out..  so it’s looking good.   I’m thinking a black pin stripe dividing the orange and white.

Ok the box sides are done the stake sides are done..

The black pin stripe on the line between orange & white looks great.  The spare tire is back in the proper place.  Both batteries are hooked up.  Still some little things to do..  but it’s useable now.

In fact there goes two bags of garbage…  I can hardly wait to get going on the canopy.. But first there is more details.

The rear trailer hitch has been reworked. Lowered so the spare can be accessed,  painted grey and mounted with heavier metal.  Six bolts instead of Four.  There’s my handy bumper / step plugged back in.  Today I also got the aluminum plate cut and mounted to the tailgate.

Nice eh !  easier to load and unload over the tailgate now.

At this point the truck is done..  drives… got it’s bits and pieces back..  So everything now is fluff.. just stuff I would like to do but not really necessary.   Like:  tarp canopy,  winch,  I plan to finish the orange paint  next month.  I’m starting to build the winch mount..  We will CARRY on..  to a new page for this “extra”  stuff.

PAGE 5

Motor Install & Frame Paint:

Well not quite the same as the other projects.   I have the good paint for the frame..  And it’s black.  yup decided to keep it simple..  If I was to change to grey I would have to do a lot more painting.  And the black undercoating that is all over could be a problem.   As for the box..  need to fix the dents , paint the bottom orange,  paint box liner inside,  install stake pockets.   I have also purchased new rims and tires for my little friend..

With a new motor and these..   we will be stylin.

Update on Motor:

So as it turns out it’s not easy getting parts for the motor in this truck.  Apparently several of the internal parts were changed over the years …so..  the pistons I have take a longer connecting rod,  narrow rings and a pressed in pin.  The ring set that came with the truck are the wider / newer type.  So I ordered a new set of pistons that the rings fit..  BUT  the rods I have won’t work with the new pistons.  Solution !   Get my old pistons machined to fit the new rings.  And that only took an hour and $30.  Wow !  Now it’s going back together..   So a new plan is to get the motor ready for install .. then do the frame.  and today we got quite far.

Here’s the motor so far..  Still more bits to go on..  but it coming together quickly.

June 26 2016:

It really is time to get this truck back on the road.. So I’ve backed it into the shop and I’ve removed the fuel tank …getting ready for painting the frame.  I’m using Por15 paint..  it’s the best at sealing the rust.  Plus it’s a hard finish..

Here’s just the first coat.  And with that I concentrated on the rusty parts.  The important thing is to get the motor & trans back in.

Here’s the new battery box for the right side.  This will hold another tractor battery and give me extra power for the winch.  I’m installing a tube across the frame after the trans is back to hold the cables.  No more attaching them to the underside of the box.

All painted now..  with the new wheels on the back.  And the fuel tank back home , ( with four bolts instead of three).   Ready for the motor…   and the motor….

Is ready for the truck..  Tomorrows job !  The transmission is back on and most things ready..

The motor is in and running !  Ya hoo.  Took a bit of fussing with the timing to get it running , but it’s all good now.  Will it smoke ?  Will it leak ?  we will see.  Here’s a new video..

Now there’s a few vent lines to hook up and some electrical stuff to do.

Electrical Stuff:

I had to remove the dash… which was a good thing..  Not only easier to get the wiring proper.. but the nut had come off the washer nozzle and very hard to reach.  So that is fixed.  I’ve installed a new stereo, a switch for the running lights , and new 12 volt power outlet..  and my favorite “keyless” locking.

I still need the find speakers that will work.  I’m thinking motorcycle / ATV speakers would be a good choice.  Because the space in the cab is tight..  And I decided not to put them on the door.  So they have to be found.  But for now everything is back in working order..  We even improved the battery hook -up wires.  And better ground.   So the box is next…  New page for that…  Here PAGE 4

Motor Work:

Now that the motor is out and in the work stand..  time to talk about that..

Wow that’s a huge motor !  And.. it was very easy to pull the motor out the rear.. onto a piece of plywood..  once you remember to disconnect all the hoses.   In fact it was faster than I thought.. Took longer to get it mounted to the work stand.   And so I did a lot of careful removing of the bits..

Here’s a short Video on the progress…

So the motor sat there on the stand for a week… maybe a bit longer..  Seems I’m busier than I want to be..

June 7 th  2016:

Finally got at the motor..  Dave came and in a few hours we had nothing but a naked engine block.   Everything is laid out carefully on a table.   It’s sure hard to tell there is anything wrong with the motor..  The cylinders are perfect.  All we did was a quick honing to take the shine off.   Dave’s gone away for the week, so the plan is when he comes back I will have all the parts clean and painted.. ready for re-assembly.  All new gaskets / seals/ rings and main bearings.   The top of the motor was done so not touching that.

As you can see I’ve cleaned and painted the block.   Yup Orange.  !  That’s part of the color theme for the truck.

Here’s my table full of goodies..  And …

Here’s the new & improved oil pan..  Grey.. once again following the color scheme.  A lot of cleaning , polishing and painting.. but look at the bits & pieces !

As before the whole motor block is orange.  The exhaust is completely painted with extreme high heat silver ( better than rust) . I decided not to paint the transmission..  It’s aluminum.. but I did paint the rusty steel parts.  I am ready for re- assembly on Monday.

Monday June 13 2016:

We got the crank back in with the new bearings and seals..  But when we were changing the rings we ran into problems.  The new rings do not fit the pistons. !  So I did some phoning and will have to wait now for genuine Suzuki rings to come.  So The motor will have to wait once more ..  But if I’ve gone this far I only want it done properly.   I’ll switch gears on the truck and fix up the frame  and box.

New page for that work…   Page 3

Painting the Exterior…   RED !

Back to the first page.   Back to page 4

All Primed and ready for the color.  I had trouble getting the color I wanted.  So I settled for a Honda Civic color ..  interestingly a slight orangey kind of red..  very different.  Lots of pearl in this red.. so I’m hoping I like it.

So far I do !   Have to wait 30 min and then the clear coat..

This is where I realize I’m not a good painter..  In my lust for laying the clear on .. I got a few runs !  Damit.. !  On the second coat.  So Hopefully they will polish out..

This color is going to look different… in different light.  looks orange here..  after I turned off the halogen work lights.   Going to be interesting to see it outside.

Anyway It’s looks good with the black trim.  You would have to take apart stuff to know it was once white.

May 10 2016:

The Suzuki got kicked out of the shop for a month while the lawn tractor repairs were happening..  And now I have sold the blue Tracker.. and have potential buyers for this one too.. So !  Finally got the Suzuki back in the shop.

Welcome back..  time to Get R Done.   I’ve transferred the insurance from the sold Tracker to this guy..  so once we are on the road I can get a new window.   and I’m determined to keep the momentum up on the finishing.  I’ve now got the exterior all back together.

Bumpers, grill, rocker panels and mud flaps on done.   And the mirrors too.  So now I’m moving to the interior.  The power locks are first..  The carpets and the rear door panel all done now to..  I’ve been working on the dash.

Had to wire in the locking system.. and install the new muti-media stereo.  The ash tray is going back.  Only a USB port and a 12 volt power plug.  I’m keeping it simple.

May 19 th 2016:

I’ve been busy..  Got most of the interior back in..  and the locks working good…  just the door panels and the seats to go..   When I tested the electrical I found that none of the rear lights work..  Then I remembered I skipped over the broken wire behind the left tail light..  sure enough the connector was in bad shape..  So I rewired that and all is good..   Here’s a new video..

All Done !

I really put in a full day and got all the rest of the Sidekick finished up.  All that’s left is to take it to Kelowna and get a new windshield.

Looks good runs good.. time to sell it..   and move on..

Painting the interior:   Black !

Back one page.   Back to the first page.

Half way through March now..  Still waiting for the power locks to show up.. but I can carry on with the interior.  Big job changing the all white to all black.  Well not all..  but lots.  what’s not covered with a panel or trim.

Needs a second coat but you get the idea..  I don’t want any white showing..

Here you see the black panel that surrounds the door and windows..  I like this accent, it justifies the black interior.  Again once this paint is cured the doors go back on and the side windows too..  I now have the power locks to install in the doors..  I can put the headliner back as well..

Here’s the headliner back where it belongs…  All clean and the two little rips repaired.  And it smells better too..  I found mouse poop up behind the liner and yucky batting for sound proofing..  All good now.

I have tinted the rear windows and they are also back where they go..   The plan here is to seal out the dust and make it easier to mask off the windows.   There is still lots to do inside .. but it’s time to get to the last of the body work and get the Zook painted.

March 23 2016:    Exterior fixing.

Today I got busy and installed the rear door gasket, and the door sill moldings.   Then set to work on the fenders.  The new left side fender went on without a hitch.. fits great… no more binding on the door.

It’s always a pleasure working with new parts that FIT !   The right side fender however was a bit of a challenge.  There was too much gap on the lower part of the door.  I made the bolt holes a bit more oval.. and got that gap to a reasonable one.  Banged out some dents and it fit good..  The hood did not fit good.  So I removed it and made some adjustments to the hinges..  Fixed the hood prop too..  I can now move on to the yucky stuff.

Turned out not too bad.  In two days I had all the bodywork done..  I’m not being fussy with the rocker panels because they are covered with the plastic trim.  And the rest was easy too.   Talk about color change !

I decided to paint the yuckyness inside the fuel filler.  Normally I would have used the black here…  But I had some red spray paint… so it may not be a perfect match to the red I have mixed for the body… but I can live with a little difference.   I saw a nice yellow Tracker for sale .  Nice until you open the door and the original light blue color was everywhere.  Not Cool !  One more video before painting

Time for a new page..   Painting    Page 5