Tracker Off-Road 800SX, Service Manual

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4
* w/Blue Loctite #243 ** w/Red Loctite #271
Torque Conversions
(ft-lb/N-m)
Gasoline — Oil — Lubricant
FILLING GAS TANK
Since gasoline expands as its temperature rises, the tank must
be filled to its specified capacity only. Expansion room must
be maintained in the tank particularly if the tank is filled with
cold gas and then moved to a warm area.
Tighten the gas tank cap securely after filling the tank.
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates are added to
the gasoline. Oxygenated gasolines containing up to 10%
ethanol or 5% methanol are acceptable gasolines.
Part Part Bolted to
Torque
ft-lb N-m
DRIVE TRAIN COMPONENTS
Top Differential Mount Frame 16 21.8
Frame Lower Differential Mount 16 21.8
Differential Top Differential Mount 45 61.2
Differential Bottom Differential Mount 45 61.2
Drain Plug Front Differential 45 in-
lb
5.09
Oil Inspection Plug Front Differential 45 in-
lb
5.09
Fill Plug Front Differential 16 21.8
Rear Transaxle Mount Bracket Transaxle 45 61.2
Engine Backplate/Transaxle* Engine/Transaxle Bracket 75 102
Transaxle Mount Bracket* Engine 55 74.8
Rear Transaxle Mount Bracket Rear Rubber Mounts 45 61.2
Rear Rubber Mounts Frame 45 61.2
Driven Clutch Transaxle 60 81.6
Drive Clutch Engine 60 81.6
Speed Sensor Transaxle 10 13.6
Drain Plug Transaxle 16 21.8
Fill Plug Transaxle 16 21.8
Wheel Hub (20 ft-lb increments) 100 136
CVT Inlet/Exhaust Tubes Hose Clamp 15 in-
lb
1.70
CVT Exhaust Tube CVT Exhaust Support
Bracket
17 in-
lb
1.92
Inner Clutch Cover Transaxle 8 10.9
Driven Cam Driven Clutch 47 in-
lb
5.3
Drive Clutch Cover Drive Clutch 110
in-lb
12.4
Drive Clutch Cam Arms Drive Clutch 50 in-
lb
5.6
Flywheel Engine Crankshaft 51.7 70
PTO Stub Shaft Flywheel 36.9 50
ENGINE ASSEMBLY
Drain Plug Oil Pan 36.9 50
Front Engine Mount Engine 55 74.8
Front Engine Mount Backplate 20 27.2
Crankshaft Sensor Bracket Backplate 8 10.9
Crankshaft Sensor Crankshaft Sensor Bracket 8 10.9
Connecting Rod Cap Connecting Rod (4 Steps) 29.5 40
Main Bearing Cap Engine Block (6 Steps) 51.7 70
Camshaft Caps Cylinder Head 6.7 9
Cylinder Head Cylinder (5 steps) 51.7 70
Oil Pump Engine Block 14.8 20
Serpentine/Timing Belt Pulley Crankshaft 73.8 100
Camshaft Timing Belt Pulley Camshaft 73.8 100
Timing Belt Idler Nut Engine Block 18.5 25
Timing Belt Cover Engine 4.5 6
Oil Pan Crankcase 7.4 10
Crankshaft Seal/Flange Engine Block 14.8 20
Thermostat Housing Cylinder Head 14.8 20
Water Pump Engine Block 14.8 20
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
1 1.4 26 35.4 51 69.4 76 103.4
2 2.7 27 36.7 52 70.7 77 104.7
3 4.1 28 38.1 53 72.1 78 106.1
4 5.4 29 39.4 54 73.4 79 107.4
5 6.8 30 40.8 55 74.8 80 108.8
6 8.2 31 42.2 56 76.2 81 110.2
7 9.5 32 43.5 57 77.5 82 111.5
8 10.9 33 44.9 58 78.9 83 112.9
9 12.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
! WARNING
Always fill the gas tank in a well-ventilated area. Never add
gas to the tank near any open flames or with the engine run-
ning. DO NOT SMOKE while filling the tank.
! WARNING
Do not overflow gasoline when filling the tank. A fire
hazard could materialize. Always allow the engine to
cool before filling the gas tank.
! WARNING
Do not over-fill the gas tank.