A friend of my brother's rolled one of his Rally's and did some damage. The handlebars and steering shaft or rod need to be replaced. I have 2 questions.

1. Is there a website with a parts diagram or list with pricing?

2. What would you guess a dealer would charge to fix that kind of damage. We are planning on fixing it ourselves, but time is an issue, as both of us are very busy with our jobs and we have a planned trip to Coal Creek coming up soon.

Any help or suggestions would be greatly appreciated. He rolled it down a big hill and it landed hard on the handlebars. Fortunately, there wasn't any other damage.

 

Website: No, but the dealer will sell you a service manual for $70. I have it and didn't like paying the money, but did not have any options beside paying the dealer everytime I couldn't figure something out on my own.

 

We fixed it. We replaced the handle bar and the steering shaft. It took us about 2 hours to take it apart and about an hour to put it back together. We also straightened the front bumper and its mounts. The bent plastic on the nose regained its shape on its own after a couple of days.

We just returned from over 90 miles of riding at Windrock. I'm convinced that there is no 2wd machine that can do what that little thing does. It was astounding even when rock crawling. The only change we are going to make is to add the optional sprocket to gain low end power on two of the three. One of them already had it and it helped enough to make it worth it. I only had to winch a Rally out of a ravine once, and it was due to an inexperienced rider more than anything else. These guys made muddy, rocky hills almost look easy. These same hills stopped other 2wd machines in their tracks, including Honda Ranchers. One guy on a Yamaha 4wd (Timberwolf?) got hung up on a steep hill and had to be winched out by one of my Cats. Right after that, my brother-in-law rode right up the same spot with ease. What a machine.

The only drawback on the Rally is the lousy brakes. They were a major handicap in the mountains on all three machines. The rear brakes were only useable with the foot pedal. The handlebar caliper was worthless. They have been adjusted as much as they can be and they still stink. Put some good brakes on this thing and it would be almost faultless.

 

What model years do you have in the Rally?
What type rear brakes are on them?
The newer ones have the one large disc brake on the axle. Is this the upgrade?
When did they go to the adjustable shocks and SST frame?
I would appreciate the info, because I am looking at an 04 or an 05 used, for my wife.

 

In 2005 the Rally was upgraded. They put the rear brake on the axle were it belongs and added steel racks. The Rally has always had the sst frame.

 

Got the Rally 05 for the wife 2 months ago. She was very happy with it until yesterday.
Had same issue that I read about in other threads. Intake hose coming partly off the carb. Hit water and it stalled. Start it up, hit water and stall again. Put hose back on and tightened clamp as mush as possible, but still kind of loose. Seems like hose is too big for carb outlet. Hose at an angle to carb outlet isn't helping either. Any suggestions.

 

Unfortunately it is just a bad configuration between the air box, carb, motor, ect. The rotox is a good motor and the carb is fine. They just engineered a bad design to fit it in the chassis. I considered replacing the manifold(s) with some kind of flexible tubing. I poked around a plumbing supply store and a NAPA but never got around to it. Not sure if it would work or not. I think it might be worth trying?