Tracker Off-Road 2262-827 Service Manual Download

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VOR-518

45. Install the spark plugs. Tighten to 9.4 ft-lb (12.8 N-m).

Install the ignition coils over the spark plugs making

sure they are fully seated. Secure using existing cap

screws. Tighten to 8 ft-lb (10.9 N-m).

VOR-519

Summary of Contents for 2262-827

Page 1: ...XTR1000 SERVICE MANUAL p n 2262 827 7 19...

Page 2: ...ng 51 Assembly Schematic 59 Troubleshooting 61 Servicing Clutch Components 62 Fuel Lubrication Cooling 69 Gas Tank 69 Oil Pump 70 Fuel Pump 70 Fuel Vent Hoses 70 Liquid Cooling System 70 Radiator 71 T...

Page 3: ...and are not designed to depict actual conditions Because products are constantly refined and improved no retroactive obligation is incurred All materials and specifications are subject to change with...

Page 4: ...OMPONENTS Manifold Engine 16 22 Muffler Transaxle Bracket 16 22 Spark Arrester Muffler 72 in lb 8 O2 Sensor Manifold 20 27 BRAKE COMPONENTS Brake Disc Hub 16 22 Brake Hose Caliper 20 27 Brake Hose Mas...

Page 5: ...an Radiator Shroud 6 8 Shroud Assembly Radiator 8 11 CLUTCH ASSEMBLY Drive Clutch Engine 60 81 Drive Clutch Fan Drive Clutch 60 in lb 7 Cam Arm Drive Clutch 50 in lb 6 Spider Stationary Sheave 250 339...

Page 6: ...Clean the vehicle thoroughly by washing dirt oil grass and other foreign matter from the entire vehi cle Allow the vehicle to dry thoroughly DO NOT get water into any part of the engine or air intake...

Page 7: ...ll Connect the battery cables making sure to connect the positive cable first 7 Check the entire brake systems fluid level pads etc all controls headlights taillight brake light and headlight aim adju...

Page 8: ...m around the filter hous ing 2 Pull the release tab out away from the filter housing XX227 3 Rotate the end of the housing approximately 1 16 of a turn counterclockwise to release the cover from the a...

Page 9: ...gine should be warm operating tem perature and the battery fully charged for an accu rate compression test NOTE The rear cargo tray must be removed for this procedure 1 Remove spark plugs See spark pl...

Page 10: ...new spark plug should be tightened 1 2 turn once the washer contacts the cylinder head A used spark plug should be tightened 1 8 1 4 turn once the washer contacts the cylinder head Engine Oil Filter...

Page 11: ...thetic oil into the oil tank Install the dipstick Install the fill plug on top of the valve cover 10 Start the engine while the vehicle is outside on level ground and allow it to idle until at least...

Page 12: ...lated onto the magnetic end of the plug XX114 3 After the fluid has been drained install the drain plug and tighten to 10 22 ft lb 14 30 N m 4 Add Synthetic Transaxle Fluid with EP into the fill plug...

Page 13: ...mbly toward the rear of the vehi cle to release from the channel 5 Remove headlight from rear housing of headlight assembly by turning counterclockwise XX072A INSTALLING HEADLIGHT ASSEMBLY 1 Install h...

Page 14: ...ng the taillight to the fascia XX073 INSTALLING TAILLIGHT BRAKE LIGHT 1 Install screws to the fascia Connect the wiring har ness connector XX073 CHECKING ADJUSTING HEADLIGHT AIM The headlights can be...

Page 15: ...r with DOT 4 brake fluid B Install and secure the cover then slowly press the brake pedal several times C Install one end of a clear hose onto the bleed screw farthest from the cylinder right rear and...

Page 16: ...e pads see Burnishing Brake Pads in this section BRAKE DISC Using a micrometer measure the thickness of the brake disc in the contact surface If thickness is 0 125 in or less the disc must be replaced...

Page 17: ...n clutch by turning clockwise Install the drive belt starting from the bottom of the driven clutch making sure the directional arrows on the belt are aligned with engine rotation 2 Remove the Belt Rem...

Page 18: ...ay Grille REMOVING INSTALLING HOOD 1 Turn the two 1 4 turn fasteners counterclockwise and remove hood VOR 471 2 Insert the tabs on the rear of hood into the rear por tion of the front body panels Lay...

Page 19: ...nnected to the taillights Taillight removal is not required to remove rear fas cia 3 Remove the cap screws securing the rear fascia Remove rear fascia VOR 475 REMOVING REAR FENDERS 1 Remove rear cargo...

Page 20: ...ep 6 When removing left side remove rear lower fender XX085B1 XX091 XX092 XX093 6 When removing right rear fenders loosen the gas tank filler hose clamp behind the passenger seat XX083 7 Remove the pa...

Page 21: ...right rear fender install filler hose onto fender Tighten hose clamp on gas tank filler hose XX083 2 Install the rear lower fender Secure with cap screws XX085B1 XX093 XX091 XX092 3 Install the rear...

Page 22: ...then remove the panel Front and or rear fender removal will make side panel removal easier XX098 INSTALLING SIDE PANELS Front and or rear fender removal will make side panel installation easier Insta...

Page 23: ...fender XX099 XX476 2 Remove hood see Removing Installing Hood in this section 3 Remove fender fasteners Lift slightly on the front and pull toward front of vehicle XX100 INSTALLING FRONT FENDERS 1 Al...

Page 24: ...1 8 1 4 in greater than the rear measurement toe out XX463C To adjust the wheel alignment use the following proce dure NOTE The tie rod threads are reverse thread 1 Center the steering rack then usin...

Page 25: ...to the shift lever then secure the shift lever to the frame and the bracket using the existing shoulder screw and new nut Tighten to 8 ft lb 11 N m 2 Secure the shift cable to the bottom of the shift...

Page 26: ...With the transmission in neutral loosen the jam nut A and adjust the cable until there is a small amount of free play in the shift lever moving forward and backward while still in neutral XX240 2 Onc...

Page 27: ...st heat shield to the frame then remove the heat shield assembly rearward and out of the vehicle XX261 6 Remove the six nuts attaching the exhaust header to engine then disconnect the oxygen sensor fr...

Page 28: ...ws and new nuts Tighten to 35 ft lb 48 N m 7 Install the skid plate and the rear cargo tray Seats REMOVING INSTALLING DRIVER S SEAT 1 To remove seat pull the seat lock lever up Raise the rear of the s...

Page 29: ...d near the floor in front of the seat frame XX102 Doors REMOVING Inspect the doors for broken or bent tubes hinges or latches Make sure the latches engage and lock securely 1 Remove cap screws securin...

Page 30: ...o the clamps at each corner of the ROPS then tighten all four straps at each corner of the ROPS 4 Fasten the strap on the front portion of the ROPS Front Bumper REMOVING INSTALLING 1 Remove the four c...

Page 31: ...flated unequally 2 Front wheel alignment incorrect 3 Wheel hub bearings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replac...

Page 32: ...rming service procedures in this section Refer to the current Special Tools Catalog for the appro priate tool description NOTE When indicated for use each special tool will be identified by its specif...

Page 33: ...axle into a position where you can access it with a 4 mm Allen wrench XX269 11 Turn the set screw a 1 4 turn counterclockwise to unlock the pin Do not turn it more than1 4 turn 12 Firmly grasp the in...

Page 34: ...Oil Filter sub section in the Periodic Maintenance Tune Up section and the cooling system see the Liquid Cooling System sec tion 21 Remove all coolant hoses and oil hoses from the engine 22 Disconnect...

Page 35: ...motor XX378 30 Remove the four cap screws securing the engine cra dle to the front of the engine VOR 515 31 Remove the two cap screws securing the rear of the engine to the mid transaxle mount then ca...

Page 36: ...ll the belt around the pulley on the engine and the alternator then apply tension to the belt using the alternator Secure using the cap screw Tighten to 25 ft lb 34 N m XX308 7 Using a suitable lift p...

Page 37: ...he coils and the injectors Press the white push mounts into the injector rail Cable tie wires as needed XX284 16 Position the air cleaner bracket onto the intake mani fold Secure using the two screws...

Page 38: ...ver housing install the CVT cover starting from the rear of the vehicle 23 Latch the clamps securing the CVT cover 24 Connect the cooling duct to the CVT cover install and tighten the clamp securing t...

Page 39: ...b section has been organized to show a progression for servicing of the engine For consistency purposes this sub section shows a complete and thor ough progression however for efficiency it may be pre...

Page 40: ...he camshaft lobes for cylinder 3 MAG side are turned away from each other NOTE At this point if the technician s objective is to service the valves proceed to Servicing Compo nents Valves in this sub...

Page 41: ...the flywheel from the crankshaft Account for the key in the crankshaft YM 206 YM 207 11 Thread the primary sheave bolt into the end of the crankshaft and pull the output shaft assembly from the engine...

Page 42: ...l pins that may still be connected to the camshaft caps NOTE To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap screws in stages and in a crisscross pattern work...

Page 43: ...ws securing the oil pump to the crankcase Account for two dowel pins one insert and two O rings YM 020A 22 Loosen the cap screws in decreasing numerical order of the embossed numbers on the crankcase...

Page 44: ...l dif ficult to remove remove it with the Piston Pin Puller SNO 869 26 Straighten the locking tabs securing the cap screws that secure the balancer shaft then remove both cap screws and both balancer...

Page 45: ...the following procedure Clearance 0 028 0 062 mm 0 0011 0 0024 in 1 Install the camshaft into the cylinder head without the dowel pins and the camshaft caps installed 2 Position a strip of Plastigauge...

Page 46: ...or servicing 1 Install the drive clutch then using a Drive Clutch Spanner Wrench rotate the engine two full revolu tions 2 Rotate the engine until the camshaft lobe of the valve being measured is dire...

Page 47: ...pin to big end bearing clearance and prevent engine damage the big end bearings must be installed in their original positions 1 Clean the big end bearings crankshaft pins and bearing portions of the c...

Page 48: ...ase Place the upper crankcase upside down on a bench 2 Install the journal bearings into the upper engine case NOTE Make sure the tabs of the bearings are prop erly seated to the notches in the upper...

Page 49: ...olerance they must be replaced Cleaning Inspecting Piston 1 Using a non metallic carbon removal tool remove any carbon buildup from the dome of the piston 2 Inspect the piston for cracks in the piston...

Page 50: ...peci fications If clearance is out of specification replace pis ton SNO 288 Measuring Piston Skirt Cylinder Clearance 1 Measure the cylinder bore using a gauge by taking side to side and front to back...

Page 51: ...he manufacturer marks A face up 2 Rotate the rings until the ring end gaps are 120 from one another SNO 294A CRANKSHAFT RUNOUT 1 Support the crankshaft using a set of V Blocks use a dial indicator to...

Page 52: ...A 2 Install the water pump drive gear A by aligning the punch mark B on the water pump gear with the shorter spline C on the balancer shaft end SNO 386A 3 Install the right balancer weight A onto the...

Page 53: ...ston assem blies into the cylinder using Ring Compressor and a soft hammer SNO 297 9 Rotate the engine to the upside down position for installing the crankshaft 10 With the proper bearings selected in...

Page 54: ...connecting rod cap screw Tighten the connecting rod cap screw further to reach the speci fied angle 115 125 SNO 859 NOTE Rotate the crankshaft one revolution to ver ify free movement 15 Using Three Bo...

Page 55: ...to the specified angle 20 Tighten cap screws 9 24 in order of the embossed numbers on the crankcase Tighten cap screws 9 12 to 17 ft lb 23 1 N m and cap screws 13 24 to 8 7 ft lb 11 8 N m SNO 304 NOT...

Page 56: ...the crankshaft aligning with the key on the crankshaft until it is fully seated Using a rubber hammer tap the rotor onto the crankshaft 27 Apply Three Bond Sealant to the stator grommet then place th...

Page 57: ...s with the hole C in cylinder 3 cam facing up When installing the timing chain start with the intake camshaft and be sure to keep the timing chain as tight as possible on the intake side Make sure the...

Page 58: ...timing chain tensioner housing is aligned with the timing chain tensioner clip D and that the timing chain ten sioner rod is locked in position SNO 628A 42 Install the chain tensioner assembly and se...

Page 59: ...8 45 Install the spark plugs Tighten to 9 4 ft lb 12 8 N m Install the ignition coils over the spark plugs making sure they are fully seated Secure using existing cap screws Tighten to 8 ft lb 10 9 N...

Page 60: ...59 Assembly Schematic XX998cc_18_2 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10...

Page 61: ...60 XX998cc_18_1...

Page 62: ...ine Does Not Start Fuel Does Not Ignite Condition Remedy 1 ECM Check Engine light failed 2 Spark absent 3 Compression low 4 Engine flooded 5 Gasoline contaminated 1 Check codes repair as necessary 2 C...

Page 63: ...k drive belt adjusted incorrectly worn 4 Rings grooves carboned 5 Exhaust obstructed 6 Compression low absent 7 Water pump thermostat damaged faulty 1 Add coolant 2 Remove obstructions 3 Troubleshoot...

Page 64: ...and lock washer from the cover then while firmly holding the cover and movable sheave together remove the three remain ing screws equally 3 Remove the cover and spring VOR 509 4 Remove the shoulder sc...

Page 65: ...Tighten to 60 in lb 6 8 N m VOR 508 DRIVEN CLUTCH Disassembling 1 Place the movable sheave on the Driven Clutch Compressor Tool with the torque bracket facing up then install the compressor flange and...

Page 66: ...nto the groove of the spider shaft Assembling 1 Place the movable sheave onto the Driven Clutch Compressor Tool then install the spring into the sheave making sure the tab is placed XM384 2 Install th...

Page 67: ...absorber was removed install the rear shock absorber and secure with the cap screws Tighten the upper cap screw to the recommended torque and the lower cap screw to the recommended torque Checking Clu...

Page 68: ...tch Alignment Bar should only contact the outer portions of the driven clutch as indicated XX456 9 While holding the Clutch Alignment Bar against the driven clutch as indicated in step 8 position the...

Page 69: ...annel along the whole CVT cover housing install the CVT cover starting from the rear of the vehicle 12 Latch the clamps securing the CVT cover 13 Connect the cooling duct to the CVT cover install and...

Page 70: ...cess panel Disconnect battery cables from battery 2 Disconnect the fuel filler hose from the fender Seal off the hose to prevent objects from entering the hose XX084 3 Disconnect the gas tank vent hos...

Page 71: ...the engine and install cap screw with a new crush washer Securely tighten the cap screw with washer 6 Install the cargo box NOTE If oil pressure is lower than specified check for an oil leak clogged o...

Page 72: ...bleeder valve open for at least 15 minutes XX455 2 Close the bleeder valve then start the engine then check for any leaks and monitor the temperature of the vehicle via the diagnostic menu Run the ve...

Page 73: ...XX449 7 Remove the radiator fan assembly from the vehicle by lifting vertically NOTE If the radiator is to be replaced transfer the cooling fans coolant hoses coil and attaching hard ware to the repl...

Page 74: ...the following procedure inspect the thermo stat for proper operation A Suspend the thermostat in a container filled with water B Heat the water and monitor the temperature with a thermometer C The the...

Page 75: ...he H mark is shown turn the crankshaft 180 until the I mark without the H mark is shown SNO 863 5 Disconnect all hoses from the water pump then remove the Allen head screws securing the water pump ass...

Page 76: ...er damper B onto the impeller shaft SNO 378A 4 Using a straight edge make sure the impeller is flush with the damper SNO 379 5 Install the impeller assembly into the housing and secure using the exist...

Page 77: ...and fill with clean gas Problem Idling or low speed impaired Condition Remedy 1 Gas contaminated 2 Throttle body dirty 1 Drain gas tank and fill with clean gas 2 Clean throttle body Problem Medium or...

Page 78: ...is component using the diagnostic mode on the LCD gauge see Gauge Diagnostic Menu in this section The battery is located in a compartment between the seats NOTE To access the battery remove the driver...

Page 79: ...water solution NOTE The sealing strip should NOT be removed and NO fluid should be added 2 Be sure the charger and battery are in a well venti lated area Be sure the charger is unplugged from the 110...

Page 80: ...t voltage regulator intermittent ACG stator wires EPS will auto recover when engine RPM signal drops below the maximum RPM specification C1314 Engine RPM Low Engine RPM signal received by the EPS sudd...

Page 81: ...show battery voltage NOTE If the meter shows no battery voltage trou bleshoot the main 30 amp fuse the battery or the main wiring harness 4 Connect the red meter lead to the brown black wire then wit...

Page 82: ...tor or the main wiring harness VOLTAGE Constant 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the red white wire then connect the black tester lead to ground 3 T...

Page 83: ...inder The frontmost brake switch is a 12 volt DC circuit switch and is connected to the front brakes The rearmost brake switch is a switch to ground cir cuit and is connected to the rear brakes Voltag...

Page 84: ...rformed on this component using the diagnostic mode on the LCD gauge see Gauge Diagnostic Menu in this section NOTE To determine if the fan motors are good connect the red wire from the fan connector...

Page 85: ...ghts NOTE The HI LO bulb connector uses a three pin connector with the corresponding color codes white yellow black and black 1 Behind the headlight remove the inner most connec tor from the headlight...

Page 86: ...e ON position and either the lights high beam or low beam selected on the light switch 1 Set the meter selector to the DC Voltage position 2 Connect the black tester lead to the black wire then connec...

Page 87: ...6411 051 This vehicle uses automotive style see through fuses The fuses can be visually inspected replace fuse if link is open NOTE Make sure the fuses are returned to their proper position according...

Page 88: ...must be approximately 200 ohms OXYGEN O2 SENSOR The oxygen sensor O2 sensor is located in the exhaust pipe NOTE When testing the resistance of the sensor s heater the engine exhaust pipe must be at r...

Page 89: ...s are not approximately as indicated the sensor must be replaced 4 Install the sensor and tighten securely then connect the connector to the sensor 5 Fill the cooling system as necessary ENGINE OIL PR...

Page 90: ...e passenger seat then disconnect the fuel pump electrical connector A then disconnect the fuel hose B from the fuel pump then install the EFI Fuel Pressure Test kit XX342 3 Reconnect the fuel pump ele...

Page 91: ...ohms at empty fuel position D ATV2116 NOTE If readings are erratic clean the resistor wiper and resistor with clean alcohol and retest If still not correct replace the fuel pump assembly Replacing Fue...

Page 92: ...leaks TILT SENSOR Supply Voltage 1 The tilt sensor A is located underneath the battery access cover behind the battery B Disconnect the three wire connector from the sensor then select DC Voltage on t...

Page 93: ...defective it must be replaced REMOVING 1 Disconnect the battery then remove the rear skid plate and engine cover 2 Remove the nut A securing the positive cable to the starter then remove the cable fr...

Page 94: ...should be heard from the relay NOTE If a click is heard and more than one volt is indicated by the multimeter replace the starter relay If no click is heard and the multimeter con tinues to indicate...

Page 95: ...onnections or replace the alternator If voltage does not rise check all battery connections the battery wire on the alter nator and the voltage regulator wire If all are nor mal replace the alternator...

Page 96: ...inimal electrical compo nents on accessories fans etc The maximum volts can be up to 15 5 DC volts NOTE If voltage rises above 15 5 DC volts the regula tor is faulty or a battery connection is loose o...

Page 97: ...OTE The gauge can be utilized dynamically engine running vehicle moving or statically engine vehicle stopped DIAGNOSTIC MODES Battery BATTERY VOLTS XX343 Display System DC voltage DTC P0562 P0563 Usag...

Page 98: ...rom the throttle body DTC P0068 P0122 P0123 P0222 P0223 P1120 P1121 P1122 P1123 P1124 P1125 P1126 P2135 Usage Monitor throttle percentage to verify the follow ing while the vehicle is running 1 Thrott...

Page 99: ...1 CPS crankshaft position sensor to ECM 2 ECM CAN signal to gauge tachometer 3 ECM CAN signal to EPS Speedometer MPH KMH XX351A Display Vehicle speed signal On the right screen on every diagnostic sc...

Page 100: ...sensor or its interconnect harness is shorted to chassis ground Correct condition P0113 Intake Air Temp Sensor Circuit High OpenThe intake air temp sensor or its interconnect harness is open or short...

Page 101: ...Correct condition P0504 Brake Switch Priority Brake pressure switch 1 or its interconnect is open or shorted to chassis ground Correct condition P0562 System Voltage Low The battery charge condition i...

Page 102: ...ct condition P2118 Throttle Actuator Control Motor Range Error The electronic throttle control actuator wires or its interconnect harness are shorted together Correct condition P2119 Throttle Control...

Page 103: ...sembly 4 Replace stator regulator rectifier Problem Starter does not engage Condition Remedy 1 Battery charge low 2 Switch contacts defective 3 Start relay defective 4 Starter relay defective 5 Wiring...

Page 104: ...al It is meant to serve as a weak point to protect the front differential and transaxle from extreme loads It can be replaced independent from the drive shaft and differential REMOVING 1 Lift and supp...

Page 105: ...frame XX392 13 Lower the subframe until there is enough clearance to remove the coupler Do not lower any more than needed 14 Remove the clamp for the boot then the coupler Inspect the boot for damage...

Page 106: ...lower mounts Tighten to 35 ft lb 47 6 N m NOTE The spacers go between the mounting brackets and the front differential on both sides of both lower mounts XX388 XX389 7 Using a new lock nut install the...

Page 107: ...nuckles brakes and axles Disconnect the shocks from the lower A arms dis connect the sway bar link on both sides 3 Using a suitable strap swing the upper A arm and shock absorber upward then secure th...

Page 108: ...subframe and differential while moving it forward slightly to release the rear of the subframe from the frame Removing the Actuator 1 Remove the black rubber cover from the side of the actuator XX400...

Page 109: ...ntire unit XX404 Installing the Actuator 1 Carefully slide the actuator over the shift shaft A needle nose pliers or similar tool may be needed to hold the shaft in place Take care not to damage the s...

Page 110: ...rench or one that is worn Make sure the wrench is properly seated in the cap screw Failure to do so will cause damage to the cap screw XX407 5 Use an awl or similar tool to hold the slider shaft while...

Page 111: ...Shaft 1 Side the input shaft into the housing Secure with the snap ring XX411 2 Slide the shift assembly along with the coupler into the housing XX414 3 Place the small spring on the shaft Using an a...

Page 112: ...ove the differential assembly from the case or cover Inspect for damage Replace if necessary XX417 5 Inspect the O ring for damage Replace if necessary XX418 6 To remove the pinion gear remove the sna...

Page 113: ...ear must be removed in order to remove the differential lock assembly 1 Remove the two cap screws for the differential lock housing Account for the spring under the housing XX422 2 Remove the E clip X...

Page 114: ...ke care not to damage the seals 5 Using a Torx T 40 wrench and green Loctite 270 install the eight cap screws that secure the cover to the case Tighten in a crisscross pattern to 22 ft lb 29 9 N m XX4...

Page 115: ...lower mounts Tighten to 35 ft lb 47 6 N m NOTE The spacers go between the mounting brackets and the front differential on both sides of both lower mounts XX388 XX389 4 Using a new lock nut install the...

Page 116: ...out and release the pressure on the C ring There are two Allen set screws used in the lock The more recessed set screw with no shoulder as shown in Fig 1 should not be turned for any reason Tightenin...

Page 117: ...d move it to the shown position XX154A 7 With the cup still compressed lower the swing arm while simultaneously moving the axle out of the chassis INSTALLING REAR DRIVE AXLE 1 To install reverse the s...

Page 118: ...allation XX155A When installing an axle make sure the opening on the c clip does not land on one of the lock pins XX156A REMOVING FRONT DRIVE AXLE 1 Lift and support the vehicle with a support stand t...

Page 119: ...the knuckle rotate it upward and secure the upper A arm to the knuckle using a new patch lock cap screw Tighten to 75 ft lb 102 N m XX197 3 Install the tie rod end using a new cap screw Tighten to 42...

Page 120: ...ly the boots are serviceable on the axles if any other component is worn or damaged the axle must be replaced NOTE The rear axle inner CV joint does NOT sep arate If the rear axle inner boot needs to...

Page 121: ...eds to be replaced the rear axle outer CV joint must be separated and the rear axle outer boot must be removed to allow access Transaxle REPLACING SEALS Output Axle Seals NOTE The transaxle does not n...

Page 122: ...appropriate seal installer install the front output seal approximately 1 5 2 0 mm 0 6 0 8 in deep TA129 TA130 Pinion Plug NOTE The transaxle does not need to be removed for this procedure 1 Support th...

Page 123: ...screws that secure the skid plate to the frame Then remove the four Allen head cap screws two on each side that secure the subframe to the frame XX373 6 Remove the four Allen head cap screws two on ea...

Page 124: ...ring and O ring XX294 3 Remove and discard the lock nut securing the bell crank then remove the bell crank from the shift shaft A screwdriver or similar tool may be used to aid in removal XX295 4 Remo...

Page 125: ...case and rotate the rail away from the shift drum then remove the shift drum assembly NOTE Spread the shift forks while removing XX302 6 Remove the drive gear A and the idler shaft B together Then rem...

Page 126: ...outer snap ring and shim securing the ball bearing then using an appropriate tool remove the bearing TA013 XX306 SERVICING COMPONENTS NOTE If any bearing is removed install a new bearing using a suita...

Page 127: ...ks chips or signs of wear If any are present the forks must be replaced TA041 2 Inspect the rail for nicks cracks chips or signs of wear If any are present the rail must be replaced D Shift Shaft Insp...

Page 128: ...are pres ent the detent star must be replaced XX311 5 Install the spring into the shift drum TA121 6 Rotate the cam clockwise so the tab of the spring installs into the shift drum groove Install the...

Page 129: ...present the gear must be replaced TA049 TA050 TA051 3 Inspect the shaft gear teeth for nicks cracks chips or signs of wear If any are present the shaft must be replaced TA052 TA053 4 Inspect the dogs...

Page 130: ...ket teeth for nicks cracks chips or signs of wear If any are present the sprocket must be replaced J Pinion Assembly Inspect the teeth of the pinion gear and front output shaft If any chipping nicks w...

Page 131: ...e secure with the snap ring TA073 NOTE To determine the appropriate shim start with the thickest shim and install the snap ring If the snap ring will not fit in the groove remove the shim and install...

Page 132: ...e existing shim and install a new thicker shim from shim kit TA102 8 If backlash measurement is more than specified remove the existing shim and install a thinner shim NOTE Continue to remove measure...

Page 133: ...the installer NOTE Engage all four shafts before seating them simultaneously into the case NOTE The shift shaft rail should remain unseated at this point XX356 4 Install the shift drum into the case t...

Page 134: ...the reverse idler gear XX361 11 Apply a coat of Loctite 5699 to the case then ensuring the shift shaft O ring lightly coated with grease and shift rail are correctly seated install the cover XX362 NO...

Page 135: ...nsaxle Tighten to 35 ft lb 47 6 N m 2 Carefully lift the transaxle into the chassis while moving it forward to join the transaxle and the drive shaft 3 Using new lock nuts secure the transaxle to the...

Page 136: ...l the cargo box tray both rear wheels and axles driver side rear shock inner clutch cover both clutches and the outer clutch cover 11 Remove from the vehicle from the support stand Driveshaft Carrier...

Page 137: ...he boot from the driveshaft will aid in removing the driveshaft 6 Slide the boot toward the bearing to expose the joint XX434 7 Remove and discard the four cap screws that secure the coupler to the di...

Page 138: ...n XX438 12 Remove the axle from the vehicle through the driver side of the cockpit NOTE At this point no further disassembling is required to replace the driveshaft If the technician s objective is to...

Page 139: ...le from the driver side of the cockpit 5 Install the coupler and secure the boot with the exist ing clamp XX438 6 Apply molybdenum grease to the splines on the driveshaft and connect the two sections...

Page 140: ...or repaired where brake fluid is exposed to air drain all fluid and replace with new DOT 4 brake fluid from an unopened container Brake fluid readily absorbs moisture from the air sig nificantly lower...

Page 141: ...ke fluid Do not wipe dry 2 Inspect the brake pads for damage and excessive wear NOTE For measuring brake pads see Periodic Maintenance Tune Up 3 Inspect the brake caliper housings for signs of corro s...

Page 142: ...t brake caliper bleeder valve and direct the other end into a container Remove the master cylinder cover then open the bleeder valve Allow the brake fluid to drain until the reservoir is empty 2 Remov...

Page 143: ...en con nect the spring 3 Using four new crush washers installed on both sides of the banjo fitting secure the banjo bolts into the master cyl inder Tighten to 20 ft lb 27 2 N m XX397 4 Connect the wir...

Page 144: ...t improper 3 Bearing damaged 4 Gears worn chipped 5 Splines worn 1 Adjust backlash 2 Adjust contact 3 Replace bearing 4 Replace gears 5 Replace shaft s Problem Braking poor Condition Remedy 1 Pad worn...

Page 145: ...t tires and 22 psi 151 7 kPa for the rear tires This is for an average operating load in the vehicle NOTE Before attempting to adjust the suspension clean dirt and debris from the sleeve and remove lo...

Page 146: ...mally set for a wide variety of riding conditions However if additional adjustments are necessary always make your adjustments in small increments until the desired ride is achieved Be sure to also re...

Page 147: ...ve the cable tie that secures the brakeline to the A arm A XX188 9 Account for the bushing B and the seals A on the A arm mount XX189 10 Remove the two cap screws that secure the upper A arm to the ch...

Page 148: ...241 2 Remove the snap ring securing the ball joint in the A arm Remove ball joint XX191 3 Remove the bearing with a suitable press 4 Press a new bearing into place and secure with the C clip NOTE Remo...

Page 149: ...suitable press Press the new bearing in place and secure with the snap ring XX196 13 Install the knuckle on the lower ball joint using the existing cap screw and a new nut Finger tighten only at this...

Page 150: ...Lift and support the vehicle on a support stand that allows access to the rear suspension with the rear tires off the floor Remove the wheel s 2 Support the trailing arm at full drop height with the s...

Page 151: ...ink to the trailing arm XX208 9 Remove the cap screws securing the trailing arm to the frame Remove the trailing arm XX209 NOTE The drive axle does not need to be removed for this procedure CLEANING A...

Page 152: ...me Torque the nut to 170 lb ft 230 N m Install rod end mounting cap screw but do not install the nut XX214 6 Install the shock absorber into the trailing arm mount and tighten to 65 lb ft 88 N m Insta...

Page 153: ...er distance is reached XX220 13 When the correct distance is reached tighten the jam nut to secure the rod end to the trailing arm Note the orientation of the rod end It should be parallel to or sligh...

Page 154: ...s There should be approx 1 4 of movement of the axle shaft at full suspension drop XX224 22 If there is not 1 4 of movement check the swing arm alignment Adjust the swing arm until 1 4 of movement is...

Page 155: ...ctors The textured side goes to the front of the vehicle Secure to the frame with zip ties Rear Sway Bar REMOVING NOTE The vehicle does not need to be lifted off the ground to service the sway bar How...

Page 156: ...res for damage wear or punctures NOTE If repair is needed follow the instructions found on the tire repair kit or replace the tire Troubleshooting WARNING Use only approved tires when replacing tires...

Page 157: ......

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