Tracker Off-Road 2262-827, Service Manual

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General
Information/Foreword
This Service Manual contains service, maintenance, and
troubleshooting information for the 2020 XTR1000 model.
The complete manual is designed to aid service personnel
in service-oriented applications.
This manual is divided into sections. Each section covers a
specific vehicle component or system and, in addition to
the standard service procedures, includes disassembling,
inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as
to how much disassembly is needed to correct any given
condition.
This service manual is designed primarily for use by a
basic level technician. The procedures found in this man-
ual are of varying difficulty, and certain service proce-
dures in this manual require one or more special tools to
be completed. The technician should use sound judgment
when determining which procedures can be completed
based on their skill level and access to appropriate special
tools.

NOTE: Whenever a part is worn excessively, cracked,
or damaged in any way, replacement is necessary.
When replacement of parts is necessary, use only genuine
parts. They are precision-made to ensure high quality and
correct fit. Refer to the appropriate Illustrated Parts Manual
for the correct part number, quantity, and description.
All publications and decals display the words Warning,
Caution, Note, and At This Point to emphasize important
information. The symbol
! WARNING
identifies
personal safety-related information. Be sure to follow the
directive because it deals with the possibility of serious
personal injury or even death. A
CAUTION
identifies
unsafe practices which may result in vehicle-related dam-
age. Follow the directive because it deals with the possi-
bility of damaging part or parts of the vehicle. The
symbol  NOTE: identifies supplementary information
worthy of particular attention. The symbol

AT
THIS POINT
directs the technician to certain and
specific procedures to promote efficiency and to improve
clarity.
At the time of publication, all information, photographs,
and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes
only 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-
out notice.
Specifications

NOTE: Specifications subject to change without notice.
* Visible at plug threads.
CHASSIS
Dry Weight (approx) 821 kg (1812 lb)
ROPS Tested Curb Weight 1179.4 kg (2600 lb)
Length (overall) 345.4 cm (136 in.)
Height (overall) 172.7 cm (68 in.)
Width (overall) 162.6 cm (64 in.)
Tire Size 30 x 10-15 — front
30 x 10-15 — rear
Tire Inflation Pressure 14 psi (96.5 kPa) — front
22 psi (151.7 kPa) — rear
MISCELLANEOUS
Spark Plug Type NGK CR9EB
Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)
Gas Tank Capacity 37.85 L (10 U.S. gal)
Coolant Capacity (60% Antifreeze/40%
Water Mixture) 9.5 L (2.5 U.S. gal)
Front Differential Capacity 400 ml (13.5 fl oz)*
Transaxle Capacity 1.2 L (40.5 fl oz)
Engine Oil Capacity
(Approx. Capacity at oil change)
2.55 L (2.70 U.S. qt)
Compression Ratio 11.3:1
Gasoline (recommended) Regular gas 86 PON, 91 RON or
higher/ethanol content not to
exceed 10%
Engine Oil (recommended) ACX All Weather (Synthetic)
Front Differential Lubricant SAE-Approved 80W-90 Hypoid
Transaxle Lubricant Synthetic Transaxle Fluid with EP
Belt Width 38.4 mm
Brake Fluid DOT 4
Taillight/Brake Light LED
Headlight Halogen H13 with LED
Electric Starter Type Constant Mesh
COOLING SYSTEM
Cooling Fan 1 On 194° F (90° C)
Cooling Fan 1 Off 185° F (85° C)
Cooling Fan 2 On 203° F (95° C)
Cooling Fan 2 Off 194° F (90° C)
Thermostat Opening Temperature 156.2-163.4° F (69-73° C)
ELECTRICAL SYSTEM
Ignition Coil Resistance (primary)
(secondary)
1.40 ohm ± 15%
10,000 ohm ± 15%
Ignition Coil Primary Voltage Battery Voltage
Stator Coil Resistance 0.19 ohm ± 20%
Pickup Coil Resistance 495 ohm ± 20%
AC Magnetos Output 14 volts, 39 A @ 5000 RPM
Alternator Output 65 amps
Ignition Timing 8° BTDC @ 1500 RPM
Intake Air Temperature Sensor 315 ohm @ 176° F (80° C)
Coolant Temperature Sensor 5,740 ohm @32° F (0° C)
310-326 ohm @ 176° F (80° C)
183.6 ohm @ 212° F (100° C)
VALVES AND GUIDES
Valve Head Diameter (intake)
(exhaust)
30.90-31.10 mm
25.90-26.10 mm
Valve/Tappet Clearance (intake)
(cold engine) (max) (exhaust)
0.16 mm
0.22 mm
Valve Guide/Stem (intake)
Clearance (max) (exhaust)
0.08 mm
0.10 mm
Valve Guide Inside Diameter (max) 4.550 mm
Valve Head Thickness (min) 2.3 mm
Valve Seat Angle 45° +15’/+30’
Valve Spring Free Length (min) 37.59 mm
Valve Spring Tension @ 34.6 mm 112.30-129.30 N (25.25-29 lb)