Textron Specialized Vehicles TRACKER LX6 EFI Repair And Service Manual Download Page 33

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BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Repair and Service Manual

699324

Figure 6 Body Components (Cargo Box and Seat Foot Rest)

Seat

Bed

Seat Back
Support or
Bed Frame

Summary of Contents for TRACKER LX6 EFI

Page 1: ...REPAIR AND SERVICE MANUAL TRACKER LX6 Gasoline EFI 699324A MODEL YEAR 2020 653635 B...

Page 2: ...this vehicle MANUFACTURER S INTENDED USE This vehicle is designed and manufactured in the United States of America USA The standards and specifications listed in the following text originate in the US...

Page 3: ...other alteration which would adversely affect the safety of the vehicle The manufacturer reserves the right to incorporate engineering and design changes to products in this manual without obligation...

Page 4: ...operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle specifications in order to mainta...

Page 5: ...RS LICENSES AND IN ACCORDANCE WITH APPLICABLE STATE REQUIREMENTS This restriction is important to the SAFE USE AND OPERATION of the product GENERAL Many vehicles are used for a variety of tasks beyond...

Page 6: ...icle Follow all safety rules established in the area where the vehicle is being operated Reduce speed to compensate for poor terrain or conditions Apply service brake to control speed on steep grades...

Page 7: ...e that is not performing as designed is a potential hazard and must not be operated Test drive the vehicle after any repairs or maintenance All tests must be conducted in a safe area that is free of b...

Page 8: ...vi Repair and Service Manual SAFETY INFORMATION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 9: ...NCE 3 BRAKES 4 TIRES 4 TRANSPORTING THE VEHICLE 4 WINTER OR PROLONGED STORAGE 4 CARE AND CLEANING OF THE VEHICLE 4 VEHICLE CARE PRODUCTS 5 HARDWARE 5 TORQUE SPECIFICATIONS 5 SAFETY NOTICE CAUTIONS AND...

Page 10: ...Rod Adjustment 47 PEDAL BOX ADJUSTMENTS 47 Accelerator Pedal Arm Adjustment 47 Micro Switch Adjustment 48 Road Test 48 ENGINE POWERTRAIN MAINTENANCE 51 Checking the Oil Level 51 Changing the Oil 51 AI...

Page 11: ...63 MALFUNCTION INDICATOR LIGHT MIL 64 WALBRO IRIS TSV SERVICE TOOL EFI DIAGNOSTICS 65 Communication Module 65 Jumper Harness 65 Connect to Vehicle 66 Download software file from TSV Connect 66 Connec...

Page 12: ...Installation 78 STORAGE 78 DIRECTION SELECTOR Direction Selector Removal 82 Replacing a Micro Switch 82 Shift Cable Adjustment 82 Neutral Lock Operation 82 ELECTRICAL SYSTEM STARTER 85 GENERATOR 85 WI...

Page 13: ...UID 115 REPLACEMENT OF WEAR ITEMS 116 BLEEDING BRAKES 116 REAR SUSPENSION Shock Absorber Removal 119 Rear Spring Removal 119 REAR AXLE REMOVAL 121 REAR AXLE NEUTRAL LOCK 123 Checking the Lubricant Lev...

Page 14: ...B xii Repair and Service Manual TABLE OF CONTENTS 699324 SCHEDULED MAINTENANCE CHART RECOMMENDED LUBRICANTS AND FLUIDS 147 REPLACEMENT OF MAINTENANCE ITEMS 147...

Page 15: ...B TABLE OF CONTENTS xiii Repair and Service Manual 699324...

Page 16: ...B xiv Repair and Service Manual TABLE OF CONTENTS 699324...

Page 17: ...B TABLE OF CONTENTS xv Repair and Service Manual 699324...

Page 18: ...B xvi Repair and Service Manual TABLE OF CONTENTS 699324...

Page 19: ...of servicing oper ations before reading and understanding all notice cautions and warnings in this manual Any servicing requiring adjustments to be made to the powertrain while the motor is running mu...

Page 20: ...ations may benefit from higher octane gasoline The fuel tank is designed to allow for fuel expansion and does not require space below the bottom of the filler neck Fig 3 Fuel Tank When refueling inspe...

Page 21: ...vate the direction selector pull the neutral lock pin handle out and rotate until the pointed portion of the han dle fits into the hole 3 in the direction selector cam ROUTINE MAINTENANCE This vehicle...

Page 22: ...he engine for winter or a prolonged storage calls for a few simple steps to prevent build up of varnish and gum in the fuel system and corrosion in the engine Place the direction selector in the neutr...

Page 23: ...6 HARDWARE Periodically the vehicle should be inspected for loose fasteners Fasteners should be tightened in accordance with the Torque Specifications table Ref Fig 6 Use care when tightening fastener...

Page 24: ...and Service Manual GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Not...

Page 25: ...hange the weight distribution of the vehicle Changes to the weight distribution or the center of gravity may make the vehicle unstable or prone to roll over which could result in injury or death to th...

Page 26: ...s from the area Exhaust gas carbon monoxide is deadly Carbon monoxide is an odorless gas that is formed as a natural part of the incomplete combustion of hydrocarbon fuels Carbon monoxide is a dangero...

Page 27: ...rocess When lifting the vehicle position jacks and jack stands only on the areas indicated To raise the entire vehicle 1 Install chocks in front and behind each front wheel Ref Fig 2 2 Center the jack...

Page 28: ...10 Repair and Service Manual SAFETY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 29: ...stop will also provide additional protec tion Body components can be replaced with a minimum of special tools Most body components are held in position with standard removable hardware nuts bolts was...

Page 30: ...ll of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699324 Figure 4 Body Components Front 48 144 145 143 16 5 1 8 7 BRUSH GU...

Page 31: ...attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 13 Repair and Service Manual 699324 Figure 5 Body Components Seats and Rear 27 25 34 A A B B 55 49 50 56 26...

Page 32: ...tempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699324 A B A 5 2 7 8 6 9 10 15 14 4 4 1 5 6 3 Seat Bottom Assembly Seat Back Assembly 11 16 7 8 9 10 Front of V...

Page 33: ...mpting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 15 Repair and Service Manual 699324 Figure 6 Body Components Cargo Box and Seat Foot Rest Seat Bed Seat Back Supp...

Page 34: ...1 Drill Bit 7 32 1 Wrench 5 16 1 Phillips Screwdriver 1 Tool List Qty Rivet Gun 1 Duct Tape 1 Allen Key 3 16 1 Drill out the rivets 6 across the top of instrument panel 1 attaching it to the cowl 7 Re...

Page 35: ...seat pod 1 is the reverse order of dis assembly Use new rivets and new hardware where ever required Tighten the nuts 6 11 to a torque of 14 18 ft lbs 19 24 Nm Rear Body Replacement Tool List Qty Elec...

Page 36: ...t to each frame support Leave the bolt in place While supporting the end of the foot rest remove the bolt attaching the vertical bracket to the frame support Replacement of the foot rest is the revers...

Page 37: ...b when in locked position Adjust as necessary by moving tab to the front or back to allow full engagement of latch assembly on tab PAINTING Follow the paint manufacturer s recommendations for specific...

Page 38: ...panels or areas must be painted touch up paint is not recommended In such cases pro fessional painting or panel replacement is called for The manufacturer suggests body panel replacement be con sidere...

Page 39: ...21 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers BODY 699324...

Page 40: ...22 Repair and Service Manual BODY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 41: ...cause personal injury Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for recommended tire inflation pressure For outdoor applica tions with majo...

Page 42: ...llow the cross sequence pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts Finger...

Page 43: ...25 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers WHEELS AND TIRES 699324...

Page 44: ...26 Repair and Service Manual WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 45: ...and Service Manual 699324 FRONT SUSPENSION AND STEERING Figure 1 Axle Mounted Steering and Front Suspension Front of Vehicle Rack Pinion Unit King Pin Tube Thrust Washer Spindle King Pin Bushing Part...

Page 46: ...le injury or death resulting from a vehicle falling from a jack follow the lifting procedure in SAFETY section of this manual Be sure vehicle is on a firm and level surface Never get under a vehicle w...

Page 47: ...the wheel 2 3 more turns to displace excess grease If required tighten castellated nut 3 again until slight resistance is felt If the cotter pin hole in the spindle 5 aligns with a slot in the castel...

Page 48: ...without the flat has conventional right hand threads counter clockwise to loosen To adjust wheel alignment loosen tie rod jam nuts 1 and turn tie rod 2 until correct alignment is achieved Tighten jam...

Page 49: ...31 Repair and Service Manual 699324 FRONT SUSPENSION AND STEERING FRONT SUSPENSION Figure 6 Front Suspension Components 6 13 3 17 16 5 23 21 24 24 14 Part of Frame 7 20 25 Part of Frame 26 28 18 19 11...

Page 50: ...e 1 3 4 long bolts 18 two 1 1 2 long bolts 28 spring plate 24 and five lock nuts 19 secur ing axle to springs and discard lock nuts At the 3 1 2 long bolt 20 securing front of left spring note locatio...

Page 51: ...laced the axle will need to be aligned to the frame Unless the axle has been replaced wheel alignment will not be affected however it is always good practice to check wheel alignment any time the fron...

Page 52: ...to avoid damaging bore of hub Clean outer wheel bearing 6 inner wheel bearing 4 hub and dust cap 7 in solvent and dry thoroughly Inspect for signs of damage Pitting or a blue coloration of the rollers...

Page 53: ...tempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 35 Repair and Service Manual 699324 STEERING Fig 11 Steering Components 1 4 5 8 7 7 6 6 Flat Section 16 20 15 1...

Page 54: ...le arm Tighten castellated nut 3 to 36 ft lbs 50 Nm torque and continue to tighten as needed to insert new cotter pin 2 Maximum torque is 50 ft lbs 70 Nm After replacing or servicing steering componen...

Page 55: ...gnment Check front wheel alignment and adjust if nec essary See the Wheel Alignment on page 29 Jam nut should be tightened to 36 40 ft lbs 49 54 Nm torque Bellows Replacement Tool List Qty Needle Nose...

Page 56: ...tap carefully with socket and hammer to start seal straight in bore Drive seal fully into bore until it stops and wipe clean of any excess grease Attach rack and pinion unit to front axle See the Rack...

Page 57: ...ing ears of the unit Disassemble rack and pinion unit 1 by first removing screw 13 and tensioner 2 to relieve pressure on rack 3 and pinion 4 Ref Figure 18 Loosen jam nut 5 and remove rack ball joint...

Page 58: ...ck nuts 18 securing rack and pinion unit to front axle and discard nuts The rack and pinion unit can now be removed from vehicle Retain washers 19 spacers 20 and the two bolts 16 for assembly Replace...

Page 59: ...g wheel first turn wheels straight ahead To prevent damage to the clipboard or steering wheel cover perform the following removal procedure Do not use a screwdriver to push or pry the retaining tabs F...

Page 60: ...oosen front wheels Lift and support front of vehicle per SAFETY section and remove front wheels Remove the bolt 1 and washer 2 that secures the inter mediate shaft 3 to the steering shaft 4 Remove the...

Page 61: ...this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 43 Repair and Service Manual 699324 Figure 24 Small Retaining Ring Orientation Install wi...

Page 62: ...Repair and Service Manual FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 6993...

Page 63: ...hicle by overcoming the resistance of the accelerator return spring Ref Fig 1 As the accelerator pedal moves the parking brake is released the micro switch closes and activates the starter generator T...

Page 64: ...Torque Wrench in lbs 1 Torque Wrench ft lbs 1 Drill 1 4 1 Drill Bit 3 16 1 Pop Rivet Tool 1 Remove the negative battery cable at the battery to prevent the vehicle moving and the possible personal inj...

Page 65: ...o governor levers and rotate lower gover nor lever 19 counter clockwise until the throttle plate is fully open and rotate upper governor lever 20 counter clockwise until it stops then tighten bolt tha...

Page 66: ...et Making sure the setscrew in the cam does not contact the micro switch actuator Tighten the setscrew 9 and the jam nut 12 to the specified torque Be sure the accelerator pedal moves smoothly and the...

Page 67: ...49 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers SPEED CONTROL 699324...

Page 68: ...50 Repair and Service Manual SPEED CONTROL Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 69: ...range as indicated on the dip stick Do not operate vehicle if oil level is below the safe area indicated on the dipstick Oil should be added to bring the level into the safe oper ating range Remember...

Page 70: ...e first oil change small metal chips and lint may be found This is normal resulting from the break in period Inspect the filter at every oil change The presence of large metal chips could indicate pos...

Page 71: ...st collector Inspect the air filter element 3 and replace it in accordance with the SCEDULED MAINTENANCE CHART section Install the air filter element 3 and replace the cover 2 Be sure the cover is pro...

Page 72: ...e upper jam nut 12 against it the lower nut to the specified torque value See Fig 11 Fig 11 Adjusting the Belt Tension Using a socket and open end wrench tighten the starter generator pivot bolts 13 a...

Page 73: ...et or damp weather or overly fresh cut grass may result in a variety of debris accumulating and adhering to the internal shroud and fins of the cooling system SPARK PLUG Tool List Qty Spark Plug Socke...

Page 74: ...apter 2 and insert firmly into the plug hole Fig 16 Compression Gauge Place the spark plug cap 3 on the removed spark plug 4 and ground the spark plug to the engine To prevent possibility of personal...

Page 75: ...feeler gauge 7 measure the valve clearance between the rocker arm 8 and the valve stem end Valve Clearance when cold Inlet Exhaust 0 10 0 15 mm 0 004 0 006 in Fig 18 Measure Valve Clearance If the va...

Page 76: ...rotating clutch toward rear of vehicle when the belt is slipped off the top of the clutch Remove belt from vehicle 5 Disconnect the DF wire from the starter using 8mm wrench lay harness out of the wa...

Page 77: ...ssembly using standard torque specifications DRIVE CLUTCH REMOVAL To prevent the possibility of per sonal injury use only impact sock ets when using an impact wrench Insert a clutch puller bolt p n 60...

Page 78: ...60 Repair and Service Manual ENGINE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 79: ...attention to Notices Cautions Warnings and Dangers 61 Repair and Service Manual 699324 FUEL SYSTEM Fig 1 Fuel System Fuel Pump Front of Vehicle Fuel Injector 14 12 18 16 20 24 17 18 19 15 17 17 18 18...

Page 80: ...er than 10 Do not mix oil with gasoline NOTICE Some fuels called oxygenated or reformu lated gasoline are gasoline blended with alcohols or ethers Excessive amounts of these blends can damage the fuel...

Page 81: ...ne complete assembly See Fig 4 If any of these components fail the complete assembly must be replaced 1 Remove the fuel tank See Fuel Tank Removal on page 62 2 Remove the pump assembly 3 by removing t...

Page 82: ...IL 1 Lock the vehicle s direction selector in Neutral 2 View the MIL by removing the front seat bottom 3 Turn the key switch to the ON position 4 Observe the sequence of flashes Each code is sep arate...

Page 83: ...ion Module with LED indica tors on bottom right The LED Indicators PWR White Indicates Battery Power to the Mod ule USB Green Indicates connected to the PC USB CON Yellow Indicates they key switch is...

Page 84: ...data from the ECM Parameters for Viewing The following is a list of parameters available for viewing along with a short description of what each parameter represents Battery Voltage Shows the battery...

Page 85: ...oves across the plot Hint calculating a time difference is best accomplished by referring to the Key on Time variable instead of the time of day 12 Green and red squares may appear on the time scale a...

Page 86: ...RIS tool Update ECM tab window will start showing pro gramming progress The yellow LED on the USB Communication module will pulse during pro gramming Fig 17 IRIS Update ECM Window d A message will pop...

Page 87: ...how to read codes from the MIL is found in the vehicle owner s manual and ser vice manual Note that the MIL will not operate when the diagnostic dongle is connected to the vehicle In this case the fau...

Page 88: ...s in the ON position the software is connected and streaming is active 2 Navigate to the Diagnostics Trouble Codes sec tion as shown Fig 24 Trouble Codes Tab 3 Note the condition of the Kill Active li...

Page 89: ...ast 1 0 amp of current is available Use jumper wire with in line 5 amp fuse to connect the fuel pump to the battery positive terminal 3 Verify that there is sufficient fuel in the fuel tank 4 Verify t...

Page 90: ...B 72 Repair and Service Manual FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699324...

Page 91: ...73 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers FUEL SYSTEM 699324...

Page 92: ...74 Repair and Service Manual FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 93: ...begins to rotate As the engine speed continues to increase the primary clutch sheave continues to move inwards forcing the transmission belt to the outer diameter of the primary clutch sheaves which i...

Page 94: ...in ground speed Equilibrium The CVT functions because the primary and secondary clutches maintain equilibrium The clutch sets are adjusted to the vehicle that they are designed to operate Changes in...

Page 95: ...the power train to drop so that the clutch puller bolt clears the spring hanger 5 Remove the front eye bolt from the spring hanger 6 Install the clutch puller bolt using the impact tool and universal...

Page 96: ...d conical washer 8 from the second ary clutch 5 Install the clutch puller bolt until it bottoms out 6 Remove the clutch then remove the clutch puller bolt and slide the clutch from the rear axle input...

Page 97: ...ir and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers CONTINUOUSLY VARIABLE TRANSMISSION CVT...

Page 98: ...ir and Service Manual CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 99: ...SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 81 Repair and Service Manual 699324 Figure 1 Direction Selector 11 10 9 3 2 1...

Page 100: ...e switch to the assembly 6 Tighten hardware to 8 11 in lbs 0 7 0 9 Nm torque Shift Cable Adjustment The shift cable is sealed and does not require lubrication Adjust the threaded fitting 9 at the forw...

Page 101: ...83 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers DIRECTION SELECTOR 699324...

Page 102: ...84 Repair and Service Manual DIRECTION SELECTOR Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 103: ...OR When the engine is running the starter generator func tions as a generator This is used for charging the battery and for the ignition system Generated output is con trolled by the voltage regulator...

Page 104: ...or 13 Engine Disable 08 Igni on 01 O 2 GND VR Signal 06 07 Open 09 Open 12 Open 12V 15A Igni on Switch Igni on Switch MIL MIL Reverse Switch Reverse Buzzer Reverse Buzzer Fuel Pump Fuel Pump 16 Relay...

Page 105: ...ked by substituting them with good ones 4 Replace the plug if necessary Gap the spark plug 028 030 71 76 mm using a wire type spark plug gauge T Fig 2 Resistance Between B A and B C A normal reading w...

Page 106: ...1 If the battery charge is inadequate less than 11 VDC proceed as follows a Check the battery voltage and inspect for loose or corroded terminal posts and connections Check electro lyte level b Check...

Page 107: ...knowledge and equipment to overhaul the unit Some checks and repairs however can be accom plished by a skilled mechanic Make your own eval uation of the equipment and skills available before starting...

Page 108: ...d to the positive battery terminal The voltage reading obtained should be 12 volts or above If the reading is below 12 volts the battery requires either charging or replacement Hydrogen gas formed dur...

Page 109: ...n the point where no voltage is detected and the last place that voltage was detected In circuits where no voltage is expected the same procedure may be used except that the DVOM is set to continuity...

Page 110: ...ing that there is power to the fuse panel and the fuse is good continue checking the circuit using the procedures previously used to check the power sup ply i e loose or rusted connections bare wires...

Page 111: ...S PUSH ON 19 PUSH ON 23 FUSE BRAKE TSIG LTS PUSH ON 22 HORN FUSE PUSH ON 21 H L FUSE PUSH ON 20 12V FUSE PUSH ON 9 OIL PRESSURE SENSOR PUSH ON 26 SOL CONN6 FUEL SENDING UNIT CONN7 FUEL GAUGE CONN2 TUR...

Page 112: ...94 Repair and Service Manual ELECTRICAL Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 113: ...wheel brake will not be adequate The self adjusting mechanism in the wheel brakes requires enough cable travel at the wheel brake to work reliably When the brake is released there must be slack in th...

Page 114: ...sed while the vehicle is moving Fig ure 2 It is very important that the brake cables permit the brake levers to release fully when the brake pedal is in the released position Figure 2 Wheel Brake Adju...

Page 115: ...pressed until the stop tube within the spring is engaged and the linkage becomes solid Figure 4 The brake compensator assembly applies a spring load to the parking brake system and insures that the pa...

Page 116: ...roviding free travel is correctly adjusted the clevis pins will not be under tension by the brake cables Test Result Fails 2 out of 3 Fails 2 out of 3 Perform the Periodic Brake Performance Test PBPT...

Page 117: ...o this by first verifying that some braking function exists Then drive vehicle at slow speed and apply the brakes aggressively As the brakes adjust and stop the vehicle more effectively start driving...

Page 118: ...sticky or damaged System not adjusted properly Check and adjust per manual Wheel brake failure due to severely worn or damaged components Replace all severely worn or damaged com ponents Neither wheel...

Page 119: ...are described in detail under MAINTENANCE AND REPAIRS Satisfactory brake performance does not eliminate the need for rou tine brake testing and inspection as shown in the SCHEDULED MAINTENANCE CHART...

Page 120: ...ust brake pedal free travel as described in MAINTE NANCE AND REPAIRS if required 4 Inspect the brake cables Inspect for damage to the outer cable fraying of the inner cable or lack of free motion when...

Page 121: ...lting from operating a vehicle with improperly operating brake system the braking system must be properly main tained All driving brake tests must be done in a safe location with regard for the safety...

Page 122: ...for failure Aggressive Stop Test To prevent serious injury or death all brake tests must be done in a safe location with regard for the safety of all personnel Always conduct a visual inspection and...

Page 123: ...ction of the rear of the vehicle and hold in position Operate the brake lever Observe the brake adjuster arm and note if the arm engages the star wheel and attempts to rotate it Fig ure 13 Figure 13 A...

Page 124: ...el brake 12 Check adjust brake pedal free travel Whenever the brake system is serviced or requires a parts replacement the brake pedal free travel must be checked and adjusted Adjusting Brake Pedal Fr...

Page 125: ...system components The brake system may not be effective for the first few applications of the brake pedal Pre adjust service brake pedal free travel to the correct setting by loosening the jam nut and...

Page 126: ...he star wheel to retract the brake shoes and remove the brake drum NOTICE Pay particular attention to the location of the inner brake drum washer 6 inside the brake drum which may be on the axle shaft...

Page 127: ...shoes or the friction surface of the brake drum Use only recommended lubricants Lubricate the backing plate friction points of the shoes and moving anchor with Multi Purpose Grease MPG lubricant Figur...

Page 128: ...ster spring Figure 22 Hold the shoe clamp pin 4 and com press and rotate the shoe clamp 5 90 to release it from the shoe clamp pin Remove the brake shoes adjuster and remaining components Clean the ba...

Page 129: ...Inspect the hardware and replace if needed Remove the brake cable and equalizer assembly and discard Figure 24 Brake Cable Equalizer and Compensator Slide the equalizer link of the new assembly over...

Page 130: ...rdness characteristics A new part must be used Remove the two bolts 1 and nuts 2 which secure the catch bracket Replace the catch bracket with a new one replace and tighten the hardware to 85 95 in lb...

Page 131: ...just the kick off cam 6 Parking Brake Kick Off Cam Removal Replacement and Installation on same page Parking Brake Kick Off Cam Removal Replacement and Installation Disconnect the parking brake releas...

Page 132: ...114 Repair and Service Manual BRAKES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 133: ...securing the brake actuator assembly housing cover and remove cover The clevis pin joining the brake cylinder clevis and the upper actuator pivot must be removed by removing the cotter pin and discar...

Page 134: ...or serviced the caliper and pads must be swung out of the way to gain access to the rotor See Brake Pad Replacement The disc hub rotor can be serviced in the same manner as the hub on non front disc...

Page 135: ...e of the braking system Dispose of in accor dance with Federal state and local codes Attach a short length of clear hose to the caliper bleed valve and insert the other end into a suitable clean con t...

Page 136: ...118 Repair and Service Manual BRAKES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 137: ...ion is in the reverse order of disassembly except that the shock absorber nuts 30 must be tightened until the shock absorber bushings 29 expand to the diameter of the shock absorber washer 28 Rear Spr...

Page 138: ...l of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699324 Fig 1 Rear Suspension Front of Vehicle 1 30 28 29 10 13 12 11 29 3...

Page 139: ...ing the differ ential to the engine frame 5 Remove the U bolts 21 securing the axle to the engine frame 6 Remove the drive belt and driven clutch see CLUTCHES section 7 Remove the F R shifter bracket...

Page 140: ...122 Repair and Service Manual REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 141: ...er towards the area between F and R During that motion the pin will snap into the hole in the direction selector mounting bracket prevent ing any movement of the lever When in this position the direct...

Page 142: ...new one regardless of mileage Always wipe the seals and O rings with a light oil before installing To reduce the possibility of per sonal injury follow the lifting proce dure in SAFETY section of this...

Page 143: ...e of axle tube at the sealing area 5 Replace the seal by lightly tapping around the cir cumference with a plastic faced hammer Tighten bolts 4 to 26 31 ft lbs 35 42 Nm torque Axle Shaft Replacement 1...

Page 144: ...126 Repair and Service Manual REAR AXLE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 145: ...Installation Tap end caps item 7 into top of the rear support items 1 and 2 with plastic faced mallet Ref Fig 1 See Detail A At driver side align holes in the rear support item 1 with holes in seat b...

Page 146: ...empting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699324 Fig 1 Sun Top Driver Side Rear Shown Front Of Vehicle D B A C 36 Driver Side Shown Front Of Vehicle A 3 4...

Page 147: ...tighten or squeeze grommet Place bottom section of windshield on rubber grommets and press the sash starting at the bottom onto the front strut so that it snaps into place See Details B and C Repeat f...

Page 148: ...130 Repair and Service Manual WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 149: ...e Field coils are open Replace fields Armature coil is open Replace armature STARTER TURNS SLOWLY Terminals are loose or corroded Tighten or clean Weak battery Charge battery Leads are nearly broken o...

Page 150: ...r Wash or replace as required Plugged muffler or pipe Repair or replace Low compression in engine Check and repair ENGINE RUNS ROUGH OR LOSS OF POWER Dirty or clogged air filter element Replace as req...

Page 151: ...djust Faulty governor adjustment Check and adjust POOR MIDRANGE OR HIGH SPEED PERFORMANCE Spark plug fouled Clean or replace Incorrect or plugged main jet Check size for appropriate altitude Clean Dir...

Page 152: ...jet for conditions FLOODED ENGINE Fuel contamination Clean fuel system Clogged air filter element Clean or replace EXCESSIVE SMOKING Wrong oil weight Replace with recommended oil Dirty oil Change Cra...

Page 153: ...Make sure fuel vent tubes are venting MECHANICAL Faulty Ignition system Check ignition output per the service man ual Low or unbalanced compression Perform compression or leak down test Refer to the s...

Page 154: ...ace with fresh fuel LOSS OF POWER INSUFFICIENT FUEL Faulty fuel pump Replace fuel pump Dirt in fuel tank or hoses Clean Clogged fuel filter Replace fuel filter Air leak in system Check mounting hardwa...

Page 155: ...regulator ground connection Repair Open or short circuit Repair or replace Faulty starter generator Repair starter generator Condition Possible Cause Correction Condition Possible Cause Correction UNE...

Page 156: ...k brake cable and replace if sticky or damaged Brake shoes severely worn Replace Brake shoes glazed Sand shoes with emery cloth provided that shoes have 06 1 5 mm min material System not adjusted prop...

Page 157: ...of wheel that is not locking Sticky dragging cable Check for brake lever return Check that brake levers return at equal rate Indication of dragging cable Cracked brake drum Replace Brake shoes wet or...

Page 158: ...140 Repair and Service Manual FAULT TESTING Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 159: ...trical System Starter Generator Solid State Regulator Battery 12 Volt Maintenance Free 525 CCA 85 minute reserve Key or Pedal Start Pedal Air Cleaner Replaceable Dry Cartridge Lubrication Pressurized...

Page 160: ...with DuraShieldTM powder coat Front Body and Finish Injection Molded TPO Rear Body and Finish Injection Molded TPO Standard Color Flame Red Black Noise Sound pressure continued A weighted equal to or...

Page 161: ...143 Repair and Service Manual Notes Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers GENERAL SPECIFICATIONS 699324...

Page 162: ...144 Repair and Service Manual GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 163: ...for loose or missing hardware Fuel and engine oil level Pre ride Check for correct level 147 Air filter Pre ride Inspect Clean or replace as needed 53 Headlights and tail lights Pre ride Check operat...

Page 164: ...Months Inspect for unusual tire wear align if necessary S Battery 125 6 Months Inspect terminals Clean as needed King pins 125 6 Months Check for excessive play and tightness of retaining nuts Rear a...

Page 165: ...Replace fluid Item Interval perform at interval that comes first Remarks Page Hours Calendar Item Capacity Lubricants Fluids Notes Engine oil 1 3 qt 1 25 L 10W 30 Light duty use engines 10W 30 Heavy d...

Page 166: ...148 Repair and Service Manual SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 699324...

Page 167: ...re should be considered potentially hazardous Use extreme care when working on any vehicle When diagnosing removing or replacing any components that are not operating correctly take time to consider t...

Page 168: ...gusta GA USA 30909 3852 Dealer 800 296 4804 Consumer 877 394 6772 www trackeroffroad com Owner s Manuals and Repair Manuals are available from the manufacturer Copyrighted Material This manual may not...

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