Yes some have been corrected, they moved the brake out on the rear axle where it belongs. So it now has a more conventional rotor and disk brake out on the rear axle. That was the only major change that I can see.

If you are looking for one for someone that is just going to putter around the yard a little, nothing serious, they might hold up. But if you are looking for something to do some serious trail riding, I would look else where. That is just my opinion and I have been burned by the rally so I am obviously biased. Based on durability I think there are a lot better choices out there for the money. While they have some nice features, no ATV is fun if it is always broke down, and you can not trust it. That has been my experience with the Rally.

 

Just as an update, I sold mine last fall for $1,500. I was happy that I got some cash for it and the new owner seemed happy that he was getting a low hour adult owned quad for a reasonable price. He bought it for his wife so she could tag along with him and his kids when they go riding. I went over with the new owner the situation with the rear brake (use foot lever not hand lever) and to check the connections around the carb manifold before and after each ride. Got a call a couple weeks later that he was pissed and that the quad was a POS. I think he just called to vent and he never asked for his money back or anything like that.

The moral of the story is that most of the manufacturers make a good product. Some manufacturers do put forward what they call a "price-point" product. Basically the Rally was designed to be the best it could be and fit into a particular price range. Learn to recognize these price point products and don't buy them. Most dealer will be honest if the machine is not the same quality and up to the same standards as the rest of the manufacturers products. A Rally aint an Outlander. When in doubt, buy a Honda.

 

ctPaddler2000 makes a good point. It is something I have always felt about the Rally. It was originally constructed to sell for 3000 (well 2995) dollars. So you had a liquid cooled CVT machine for under 3000. It was engineered to hit that price point. The other funny thing is where I puchased my Rally they also sell Honda's. I was deciding between a Recon with electric shift, or the Rally. Should have bought the Recon.

 

Classic!!![img]i/expressions/face-icon-small-happy.gif[/img] LMAO

 

I´ve had my Rally for 5months. It has now 4000km behind. Model is 2005/06 Europe version.
Problems i had :
- Rear brakes, even though it is nowadays disc brake. Brake caliper/disc/pads had to be replaced.
- shift lever broke down. One metal clip inside the gear box
These were repaired by the dealer at no cost to me.

- carburetor hoses won´t stay in place,same thing still as it was on 2003 models. Why they have not repaired yet?
- it looses coolant 1,2l/4000km, no leaks at sight. IS THIS SERIOUS?

Mine also had first tickling noise, that came from the CVT. Not any more.

How it is possible to check if there is gasoline mixed with the oil?The engine makes metallic sound, could that be the reason?It has done that from the beginning. Dealer says : that is the normal sound of ROTAX engine.I doubt that.



Text

 

Just an update to my 2005 Rally. A few of you had said that you had a ticking noise, which sounded like it was coming from the CVT. I had the same thing and it got worse, much worse, until I thought my clutch was toasted.

One day, I pulled the oil check plug for the gearbox and there was all sorts of nasty water, dirt and oil in there. It was way overfull. I immediately drained and refilled it, but the sound was as hideous as ever.

So I took the gearbox apart and found 2 splines with numerous teeth ground off and lots of metal in the bottom of the gearbox. The gears will cost me almost $600 US just for parts, so it was an expensive mistake. I believe if I had checked this much earlier, I would have saved the gears. I didn't even know there was a gearbox (I didn't understand the whole CVT and Belt Drive until I tore the gearbox apart).

Hopefully this will help others. The check plug is on the left side, right below the CVT cover. It is mentioned in the owner's manual, I don't know how I missed that one!!!!

 

Things have gone ahead. I replaced drive chain at 4600km.They were out of the adjusting range.I just could not adjust them anymore.
- Carburetor hose came, not replaced yet
- Cylinder gasket will also have to be replaced, because it looses coolant.
- Rear brake cylinder-still waiting for it-4 weeks now!
- new fault is that rear axle bearings are at the end of their road (4600km!)
Those faults will be repaired at free of charge to me.
I wonder, there is still 1,5 year guarantie left, what else there is to be broken...[img]i/expressions/face-icon-small-sad.gif[/img]

 

its amazing Bomb is willing to put their name on such a junk machine with so many issues and unhappy customers!!

here's my take on a few of the issues I hear mentioned -
water in oil - either water pump seal or head gasket.

missing coolant with no signs of external leak - its either in the crankcase from same soruces just mentioned or it is being burnt in combustion and going out the pipe from head gasket leak but typically head gaskets leaks pressurize the coolant system and cause overflow of expansion tank.

gas in oil - only possible source of this is carburetor bowl overfilling and gas leaking down intake manifold into cylinder and seeping around piston rings into crankcase, creating a molitoff cocktail between your legs!! the overfilling is from either a leaking float valve and/or seat, or improper float level adjustment from factory inside carb bowl.

all of the above is basic standard knowledge that any dealer should know without even having to read a service bulletin from Bomb, but there lies part of the problem - Bomb allows anybody to be a dealer regardless of the level of competence when it comes to warranty work. That sucks serious @ss, few dealers are really qualified to do little more than change oil, and some not even that!!!! But I'll tell ya, plenty of honda mechanics fall into that same category, good thing they don't worked on as often as these rallys do!

 

stacker2001 I wonder how you got water in the gear box? Did you check for cracks? Our gear box cracked when the reverse chain broke. It should be a sealed case. I also wonder if the bearing on the inside of the top gear shaft survived? It was not a roller bearing, but rather just a pocket for the shaft to sit in with an oiler access on the top, ours still squeals terrible when we ride it due to damage when we had problems with the case. Just wondering about these things....

 

I could list what all has broke on ours but that is a sad story :-(

we replaced 2 shafts that come out of the gear box (160 each), all bearings several times, of course brake pads several times, timing gear and chain, reverse chain.....I hope you do not have all the issues we had.

Actually we took the Rally on about a 15 mile ride the other day, since both on boys went, I didn't even have to tow it home. That was the first big ride we ever remembered that it survived. Although it was making a very strange noise by the time we made it home, I really haven't investigated it yet.