Tracker Off-Road 800SX Service Manual Download Page 64

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MOD546

7. Remove the two cap screws securing the engine to

the transaxle. Account for the spacers and washers

between the engine and transaxle.

MOD543

MOD554

8. Remove the two cap screws securing the starter to

the engine backplate; then remove the starter; then

remove the two cap screws securing the driver-side

backplate to the front mount; then remove the four

cap screws for the engine backplate and remove the

engine backplate.

MOD563A

MOD544

MOD544A

9. Remove the air intake to the engine.

MOD545

10. With tape or other suitable means, plug the intake for

the engine to prevent foreign debris from entering.

Summary of Contents for 800SX

Page 1: ...800SX SERVICE MANUAL p n 2263 005 9 20...

Page 2: ......

Page 3: ...ox Panel 56 Seat Base 58 Troubleshooting 59 Engine 60 Removing Engine 60 Cylinder Head and Related Components 65 Removing Cylinder Head and Related Components 65 Servicing Left Side Components 84 Engi...

Page 4: ...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 m...

Page 5: ...Part Bolted to Torque ft lb N m STEERING COMPONENTS cont Bracket Rack Mount Frame with weld nut 45 61 2 Bracket Rack Mount Frame with nut 16 21 8 Intermediate Shaft Rack Pinion 45 61 2 Steering Shaft...

Page 6: ...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 Cr...

Page 7: ...the gas in the gas tank 3 Clean the interior of the air filter housing 4 Plug the hole in the exhaust system with steel wool 5 Apply light oil to the upper steering shaft bushing and plungers of the...

Page 8: ...6 Charge the battery then install 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 br...

Page 9: ...nlet clean and inspect 3 Install the snorkel to the air inlet and tighten the clamp securely Reinstall the left side access panel Engine Air Filter Primary Air Filter Safety Filter Clean out Valve The...

Page 10: ...element for damage or dirt If damaged the filter must be replaced 6 A dust trail anywhere inside of the air filter housing inlet tube or on the safety filter is a telltale sign of a leak Leaks should...

Page 11: ...ousing for the air filter housing cover to fit properly MOD091A MOD092 2 Install the air filter housing cover with the clean out valve at the 5 o clock position then turn the air filter housing cover...

Page 12: ...until the highest section of the cam shaft lobes A of the valves to be checked are pointing directly away from the valve bucket B MF039A MF078A 4 Using a suitable feeler gauge check clearance between...

Page 13: ...on deposits from the screen taking care not to damage the screen NOTE If the screen is damaged in any way it must be replaced 3 Install the spark arrester assembly and secure with the cap screw Tighte...

Page 14: ...the vehicle is outside on level ground and allow it to idle for a few minutes 9 Turn the engine off and wait approximately one min ute Recheck the oil level 10 Inspect the area around the drain plug a...

Page 15: ...teral movement free play B Coupling cracked damaged or worn Headlight Taillight Brake Light Light Bulb Replacement NOTE The bulb portion of the headlight is fragile HANDLE WITH CARE When replacing the...

Page 16: ...D096 To replace the taillight brake light assembly use the fol lowing procedure 1 Remove the four screws from the inner cargo box side panel two rear tie down screws and one tailgate latch bail screw...

Page 17: ...arness MOD112 5 Install screw A first then flex the cargo box fender away from the cargo box to access and install screw B MOD117A MOD113 6 Position the outer cargo box side panel behind the two tabs...

Page 18: ...he distance from the floor to the midpoint of each headlight 3 Using the measurements obtained in step 2 make horizontal marks on the aiming surface 4 Make vertical marks which intersect the horizonta...

Page 19: ...nuts A and B and adjust the cable housing until the measurements on each side of the upper tilt steering wheel adjuster bracket are the same MOD297 4 Tighten the nuts A and B to 20 ft lb 27 2 N m 5 C...

Page 20: ...ire hydraulic brake system to ensure all hose connections are tight the bleed screws are tight the protective caps are installed and no leakage is present INSPECTING HOSES Carefully inspect the hydrau...

Page 21: ...l brake pads are properly burnished 1 Choose an area large enough to safely accelerate the vehicle to 30 mph 48 km h and to brake to a stop 2 Accelerate to 30 mph 48 km h then release the accelerator...

Page 22: ...the belt for any abnormal wear Measure across the top of the drive belt in multiple locations using a Vernier caliper Do not squeeze the belt as doing so may produce an inaccurate measurement The dri...

Page 23: ...81 6 N m while holding the driven clutch with the Drive and Driven Clutch Holder Tool 6 The belt should be as shown on the driven sheave MOD219 7 Install the clutch cover making sure the gasket is com...

Page 24: ...pokes 2 Inspect the splines for wear 3 Check that the steering wheel is not bent INSTALLING 1 Install the steering wheel aligning the two match marks then apply a drop of red Loctite 271 to the thread...

Page 25: ...e way MOD272 5 Remove the two cap screws on the occupant side and the one cap screw in the front left inner fender secur ing the EPS then gently remove the EPS taking note that the output shaft should...

Page 26: ...OD272 4 Reinstall the input shaft cap screw and new lock nut to the EPS then reinstall the output shaft cap screw and new lock nut of the EPS Tighten both to 24 ft lb 32 6 N m MOD270A MOD271 5 Reconne...

Page 27: ...s from the knuckles MOD315 MOD316 3 Remove the cap screw and lock nut securing the U joint to the rack and pinion Discard lock nut Inspect cap screw and replace if damaged MOD317 4 Remove the four cap...

Page 28: ...install the rack and pinion then line up marks on the U joint with the rack and pinion then connect the U joint to the rack and pin ion Install the bolt and new lock nut securing the U joint to the ra...

Page 29: ...between shoulder of the tie rod shaft and the tie rod MOD323 4 Using a wrench loosen the lock nut B while hold ing the tie rod at the location indicated C then remove the tie rod with a wrench at the...

Page 30: ...E RODS 1 Remove the rack and pinion from the vehicle see Removing Rack and Pinion section MOD322 2 Remove the inner boot clamp A and outer boot clamp B of the side being removed then slide the boot to...

Page 31: ...the two cap screws securing the ball joints in the knuckle Discard lock nuts Inspect cap screws and replace if damaged NOTE Turn the cap screws and not the lock nuts The lock nuts are held in place b...

Page 32: ...r pin and spread the pin 4 Apply a small amount of molybdenum grease to the hub splines MOD328 5 Install the hub assembly onto the splines of the shaft MOD329 6 Using Hub Retaining Wrench secure the h...

Page 33: ...then tighten to 8 ft lb 10 9 N m then con nect the connector to the accelerator pedal MOD535 MOD534 Throttle Cable This ROV UTV is equipped with an Electronic Throttle Control ETC that does not have a...

Page 34: ...r ing housing then install two the cap screws Tighten to 24 in lb 2 72 N m MOD306 3 Position the shift cable to the shift lever using the existing cap screw and a new lock nut Tighten to 6 ft lb 8 2 N...

Page 35: ...ut securing the shift cable to the shift lever Discard lock nut Inspect cap screw and replace if damaged MOD304 3 Loosen the lock nut securing the shift cable under neath the dashboard Slide the shift...

Page 36: ...o 20 ft lb 27 2 N m XX382 MOD304 MOD303 4 Fasten the shift cable to the chassis with the previ ously noted cable tie locations 5 Shift the transmission through all positions making sure the each gear...

Page 37: ...stments must be made with the vehicle unloaded steering rack aligned with marks steering wheel as shown at mid tilt and both wheels straight PR087A MOD162 Mark the centerline of the front tires at the...

Page 38: ...d water 2 Inspect the hood for cracks 3 Inspect for any missing decals INSTALLING Place the hood into position on the vehicle making sure the front tabs are in place then secure the hood with the 1 4...

Page 39: ...d longer thread for fastening through multiple panels MOD044C MOD133A 2 There are four cap screws per side that secure the bottom of the front fascia 3 Remove the three T20 cap screws securing the out...

Page 40: ...rough the A fender B fender flare and headlight bracket not identified into C front fascia grille then install the remaining T20 cap screw securing the front fascia to the lower grille Repeat for oppo...

Page 41: ...3 Remove the lower fascia to grille cap screw on each side MOD511 INSTALLING 1 Position the lower fascia into place then install the lower fascia to grille cap screw on each side MOD511 2 Position the...

Page 42: ...houldered cap screws from the bottom of the side cover MOD262 3 Gently pull on the front portion of the side panel then remove the cap screw securing the fender to the frame NOTE A 1 4 in driver bit i...

Page 43: ...g fender flare start at step 1 If installing fender start at step 2 1 With the fender removed from the vehicle install the fender flare onto the fender taking note of the four tabs on the fender flare...

Page 44: ...crews from the top of the side cover and the two shouldered cap screws from the bottom of the side cover MOD262 7 Located in the front of the inner fender install the two cap screws securing the fende...

Page 45: ...n the cargo box into the up position then rein stall the cap screws behind the rear ROPS mounting point MOD190 2 Reinstall the three cap screws from inside the behind the seat storage box panel MOD191...

Page 46: ...card lock nuts Inspect cap screws and replace if damaged MOD691 MOD692 3 Position roof onto the ROPS of the vehicle then hook the rear brackets under the rear ROPS tube then loosely secure the four re...

Page 47: ...d new lock nuts per side on the lower portion of the front bumper Tighten all fasteners securely Rear Bumper Optional REMOVING INSTALLING 1 Remove the four cap screws and lock nuts then remove bumper...

Page 48: ...he rearmost corner of the floor on each side MOD290 6 Remove the seven cap screws securing the floor to frame MOD291 MOD292 7 Gently lift the rear of the floor up and lift the floor out of the vehicle...

Page 49: ...r the front tires securing the splash panel to floor on each side MOD289A 4 Install the six fasteners on the occupant side securing the splash panel to floor MOD287 MOD288 5 Install the three fastener...

Page 50: ...each side that must be lifted vertically at an angle MODC061 4 From behind the dashboard disconnect the LCD gauge A and DC power outlets B C Note the orientation of the connectors for installing purp...

Page 51: ...e the three cap screws on each fender MOD592 2 Remove the lower steering adjuster cap screw With a suitable strap secure the steering wheel tilt assem bly up and out of the way MOD263 MOD264A CAUTION...

Page 52: ...the tabs on each side of the lower dashboard Install the five cap screws along the bottom of the lower dashboard MOD267 MOD268A 2 Reinstall the key switch into the key switch cut out then secure by t...

Page 53: ...adjust doors as needed MOD592 Splash Panel REMOVING 1 Remove the mid upper dashboard lower dashboard side panels seats seat base EPS lower steering adjuster cap screw and floor 2 Disconnect the maste...

Page 54: ...t cap screws and replace if damaged MOD231 2 Lift the muffler assembly upward to clear the three holders underneath the muffler assembly MOD232 INSPECTING 1 Inspect muffler externally for cracks holes...

Page 55: ...ng 4 Inspect the cargo box gate latches for smooth operation INSTALLING 1 Lightly grease the hinge points then with the help of an assistant or an adequate lift set the cargo box into position on the...

Page 56: ...t to the passenger seat backrest frame then remove the passenger seat backrest from the passenger seat backrest frame MOD521 2 Remove the five flange nuts securing the passenger seat backrest to the p...

Page 57: ...the driver seat rails MOD227 2 Lift the seat adjustment lever then move the seat assembly toward the front of the vehicle to clear the rear mounting channel MOD228 DISASSEMBLING 1 Remove the four cap...

Page 58: ...seat assembly by lifting up on the seat adjustment lever then move the seat assembly toward the rear of the vehicle to hook into the rear mounting channels MOD228A 2 Install the six cap screws undern...

Page 59: ...then remove the behind the seat storage box panel NOTE When removing the behind the seat storage box panel it might be necessary to gently pull down on the top of the panel to clear the metal channel...

Page 60: ...s then both side panels then both rear inner fenders Seat Base REMOVING 1 Remove the seats then remove the rear inner fenders and side panels then remove the behind the seat stor age box panel 2 Remov...

Page 61: ...s worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Steering impaired Condition R...

Page 62: ...Operators Manual SPECIAL TOOLS A number of special tools must be available to the techni cian when performing service procedures in this section Refer to the current Special Tools Catalog for the appr...

Page 63: ...MOD392 MOD393 4 Disconnect the battery connections then disconnect the starter wire A and start relay wire B MOD538 5 Remove the flywheel cover then remove the PTO stub shaft then remove the crank pos...

Page 64: ...rter to the engine backplate then remove the starter then remove the two cap screws securing the driver side backplate to the front mount then remove the four cap screws for the engine backplate and r...

Page 65: ...ap screws at the front of the engine below the engine oil filter MOD550 13 Using suitable clamps clamp the areas indicated to minimize coolant leakage MOD551 MOD552 NOTE Coolant will come out when rem...

Page 66: ...emove the wires going to the alternator then remove the temperature manifold absolute pressure TMAP sensor connector from the temperature manifold absolute pressure TMAP sensor MOD558 MOD559 17 Discon...

Page 67: ...rom the battery 2 Disconnect the crankcase breather hose from the valve cover then remove oil fill cap and six machine screws securing spark plug cover to valve cover MF031 MOD536 3 Remove spark plug...

Page 68: ...lug wires spark plug cover oil fill cap and breather hose MOD537 MOD536 CHECKING VALVE CLEARANCE See Periodic Maintenance Tune Up section REMOVING AND INSTALLING CAMSHAFT DRIVE BELT 1 Disconnect the n...

Page 69: ...ng contaminated with oil or coolant 5 Inspect the cogged pulleys for excessive wear bro ken or missing cogs or build up of dirt and debris between the cogs Replace if cracked worn exces sively or cogs...

Page 70: ...en install the lower and upper timing belt drive covers MF161A 13 Install the water pump pulley and tighten to 7 7 ft lb 10 N m then install the crankshaft drive pulley then tighten the crankshaft bol...

Page 71: ...the water pump onto the engine and secure with the three cap screws Tighten to 14 8 ft lb 20 N m MOD591 MOD590 3 Install the water pump pulley Tighten to 5 9 ft lb 8 N m MOD589 4 Install the timing be...

Page 72: ...camshaft lobe of the valve to be adjusted points directly down toward the valve bucket B fully opening the valve then insert the Valve Adjust Tool in position between the camshaft and the valve bucket...

Page 73: ...g Shim to Install To calculate the desired shim to install proceed as fol lows 1 Add the thickness of the removed shim to the mea sured valve clearance then subtract the desired valve clearance to fin...

Page 74: ...IVE BELT in this section NOTE Valve clearance must be measured and recorded prior to step 2 2 Rotate the camshaft drive pulley until the camshafts unload camshaft lobes relaxed from valve buck ets MF0...

Page 75: ...in several increments to allow the camshafts to be evenly seated in the camshaft bearings MF098B MF108A 8 Apply a thin bead of high temperature silicone seal ant to the cylinder head as shown then in...

Page 76: ...tine belt and tighten as required MF079 15 Install the valve cover and tighten to specifications REMOVING AND INSTALLING CAMSHAFTS VALVE BUCKETS NOTE The engine does not need to be removed from the ve...

Page 77: ...removal 6 Remove the end plug from the intake camshaft and the oil seal from the drive end of the exhaust cam shaft MF096B 7 Make sure the cap screw from step 4 is properly installed then carefully l...

Page 78: ...f damaged or worn beyond limits camshafts will have to be replaced MF101A 11 Inspect the camshaft drive gears for excessive wear chipped or missing teeth and security to the cam shafts Replace as requ...

Page 79: ...h other then apply a thin bead of high temperature sil icone sealant to the cylinder head as shown MF126A MF125A 17 Install the camshaft drive end bearing cap and cam shaft end plug then install the f...

Page 80: ...curing the exhaust pipe to the exhaust manifold and separate the exhaust pipe from the manifold Account for the gasket MOD549 7 Disconnect the fuel hose connector from the fuel rail then remove the P...

Page 81: ...emove camshafts see REMOVING AND INSTALLING CAMSHAFTS in this section 13 Remove the eight head bolts securing the cylinder head to the cylinder block in the sequence shown Account for the hardened was...

Page 82: ...ft wire brush to clean carbon deposits from combustion chambers and from around valve heads 3 Use a suitable valve spring compressor compress the valve spring A then depress the sleeve B to release th...

Page 83: ...e of the valve The lap ring H should be at or very near the center of the valve face I If not within suitable tol erance valves and seats must be replaced MF150A 11 Place the valve spring seat washer...

Page 84: ...ll and secure with attaching nuts seven intake and six exhaust and tighten to specifi cations Install the heat shield onto the exhaust mani fold 3 Wipe all surfaces clean of lint liquids or other con...

Page 85: ...MSHAFT DRIVE BELT in this section 7 Connect the exhaust pipe to the exhaust manifold and secure with the cap screws and nuts tightened securely MOD549 8 Install the fuel rail and injectors and secure...

Page 86: ...ddressed and to service only those components The technician should use discretion and sound judgment NOTE The engine does not have to be removed from the frame for this procedure CLUTCHES Removing 1...

Page 87: ...shaft place the Drive and Driven Clutch Holder Tool on the drive and driven clutch to hold the drive clutch in place then with a Torx T 60 drive remove the cap screw securing the drive clutch Account...

Page 88: ...er off all components dry with com pressed air 2 Remove any drive belt dust accumulation from the stationary sheave movable sheave and bushings using parts cleaning solvent only 3 Inspect the cover fo...

Page 89: ...ompressing the driven clutch then mark the cam and driven clutch then remove the four cap screws securing the cam to the driven clutch MOD459 2 Gently release the suitable compressor then remove the c...

Page 90: ...or bends 5 Inspect the bushing in the movable sheave and sta tionary sheave for wear damage or cracks 6 Inspect the spring for cracking or twisting 7 Inspect the cam for grooves 8 Check the bearings f...

Page 91: ...r and hand tighten Apply a light coat of grease to the inner most splines of the transaxle input shaft then place the driven clutch onto the input shaft of the transaxle then secure the drive and driv...

Page 92: ...0 ft lb 81 6 N m while holding the driven clutch with the Drive and Driven Clutch Holder Tool 8 The belt should be as shown on the driven sheave MOD219 9 Install the clutch cover making sure the gaske...

Page 93: ...Near the engine PTO remove the retaining ring securing the inner clutch cover to the engine then near the transaxle input shaft remove the four cap screws securing the inner clutch cover to the tran s...

Page 94: ...42A MOD540 2 Install the crankshaft position sensor to the crank shaft position sensor bracket and tighten the cap screw to 8 ft lb 10 9 N m then spray a light film of alcohol on the crankshaft positi...

Page 95: ...nvert the oil pan on a flat surface and check for irregularities in the perime ter of the oil pan Straighten as required MF237A 4 Apply a thin line of high temperature silicone sealant around the seal...

Page 96: ...trip seals install the oil pump assembly onto the crankshaft and secure to the engine block with the cap screws Tighten to specifi cations MF186B MF180A 2 Using a suitable seal driver drive a new cran...

Page 97: ...apply black RTV silicone to the engine in the areas indicated then position the engine backplate into place then install the four cap screws securing the engine backplate to the engine and tighten to...

Page 98: ...nuts securing the exhaust to the exhaust mani fold Tighten to 45 ft lb 61 2 N m 7 Remove the tape or other suitable means that was used to plug the intake for the engine MOD548 8 Install the air intak...

Page 99: ...ighten cap screws securely MOD541A MOD540 MOD539 11 Connect the gas line to the injector rail then connect each injector connector to the injector then connect the electronic throttle control ETC conn...

Page 100: ...ngine then install the coolant hose above the starter then install the coolant hose near the engine intake MOD551B MOD553A MOD555A 15 Remove the suitable clamps that were used to mini mize coolant lea...

Page 101: ...5 Spark plug wire s open shorted 1 Clean replace plug 2 Clean dry plug 3 Replace ECM 4 Replace ignition coil 5 Replace spark plug wire s Problem Engine will not start or is hard to start No fuel reach...

Page 102: ...ace service rings cylinder 3 Replace guides 4 Replace bore engine block 5 Replace valves 6 Replace seals 7 Clean replace element Problem Engine lacks power Condition Remedy 1 Valve clearance incorrect...

Page 103: ...el fuel 1 Remove the seats seat backs seat base behind the seat storage box panel and side panels then remove the floor 2 Disconnect the vent hose A fuel hose B and fuel pump gas level sensor connecto...

Page 104: ...ear excessively or break and whenever oil is contami nated the oil pump should be replaced The oil pump is only serviceable as an assembly TESTING OIL PUMP PRESSURE NOTE The engine must be warmed up t...

Page 105: ...g System While the cooling system is being filled air pockets may develop therefore make sure the cooling system is prop erly bled with no trapped air in the system 1 Slowly loosen the plug from the t...

Page 106: ...upper hoses MOD476 MOD475 4 Remove the two cap screws and lock nuts securing the radiator bracket to the frame then remove the radiator bracket from the vehicle then disconnect the radiator fan elect...

Page 107: ...he clamp securing the lower radiator hose to the radiator then connect the upper radiator hoses to the radiator then remove the suitable clamps to minimize coolant leakage then loosen and slide the ra...

Page 108: ...n wear or spring damage 2 Using 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 temperat...

Page 109: ...stem in this section MOD551B COOLING FAN Removing 1 Disconnect the radiator fan electrical connection MOD474 2 Remove the four cap screws securing the fan to the radiator fan bracket then remove the f...

Page 110: ...ting impaired Condition Remedy 1 Gas contaminated 1 Drain gas tank and fill with clean gas Problem Idling or low speed impaired Condition Remedy 1 Throttle body out of sync 1 Diagnose throttle body Pe...

Page 111: ...st then disconnect the positive cable MOD010B After being in service batteries require regular cleaning and recharging in order to deliver peak performance and maximum service life The following proce...

Page 112: ...hen key ON C1359 Torque Sensor Communication EPS internal torque sensor condition has been detected Internal EPS condition check for EPS software updates before replacing the EPS unit Correct the inte...

Page 113: ...OTE When the starter is engaged battery voltage will be approximately 10 5 DC volts Ignition Coils The ignition coils are located on the driver side of the cylinder head above the thermostat housing V...

Page 114: ...e ON position then set the meter selector to the DC Voltage position NOTE There are three black terminals and three orange black terminals that are connected to their respective colors 2 Connect the r...

Page 115: ...corporated into the assembly 1 Remove the driver s seat and the center passenger seat base 2 Remove the cap screw and lock nut securing the buckle cable to the frame Discard lock nut and cap screw MOD...

Page 116: ...then repeat for other brake switch NOTE If the meter shows more than 1 ohm of resis tance replace the switch DRIVE SELECT Resistance 1 Remove the switch assembly from the dash then dis connect the ha...

Page 117: ...the black wire C then connect the red meter lead to the white wire B then turn the key switch to the ON position and turn the light switch to LO BEAM Voltage must be pres ent If no voltage is present...

Page 118: ...t the black tester lead to the black wire 3 With the brake applied the meter must show battery voltage NOTE If the meter shows no voltage inspect the 10 amp lights fuse brake light switch wiring harne...

Page 119: ...d left for a minimum of 15 seconds without starting the engine The full verification process is completed when the throttle body stops making noise NOTE The throttle body will not go through the full...

Page 120: ...65 75 F or 18 24 C or inaccurate read ings will occur 1 Tilt the cargo box up 2 Disconnect the oxygen sensor that is located on the front side of the engine MOD583 3 Set the meter selector to the OHM...

Page 121: ...tion then connect the red tester lead to the pin inside the switch and the black tester lead to a ground The switch should have less than 1 ohm of resistance 3 Start the engine The switch should now b...

Page 122: ...ery voltage is indicated and the fuel pump does not run replace the pump assembly If no battery voltage is indicated check the ECM fuel relay fuse and the vehicle tilt sensor Removing Fuel Pump Assemb...

Page 123: ...clean alcohol and retest If still not correct replace the fuel pump assembly Replacing Fuel Level Sensor To replace the fuel level sensor use the following proce dure 1 Cut the two blue wires A in the...

Page 124: ...nd con nect the red tester lead to the orange wire C and the black tester lead to the pink black wire A MOD490 MOD491 2 Turn the ignition switch to the ON position The multimeter should read battery v...

Page 125: ...up Winch NOTE The winch is only serviceable as an assembly REMOVING 1 Disconnect the battery then remove the front bumper 2 Remove the four cap screws securing the winch to the winch bracket then remo...

Page 126: ...e starter Secure with two cap screws Tighten to 14 8 ft lb 20 N m MOD570 MOD571 2 Secure the positive cable to the starter with the nut then secure the start relay wire to the terminal MOD569 3 Instal...

Page 127: ...the START position while observing the multime ter The multimeter should drop to 0 volts and a click should be heard from the relay NOTE If a click is heard and more than 1 volt is indicated by the m...

Page 128: ...o a maxi mum of 15 5 DC volts NOTE If voltage rises above 15 5 DC volts the reg ulator is faulty or a battery connection is loose or cor roded Clean and tighten battery connections or replace the alte...

Page 129: ...an be cleared by following the procedures located in the Gauge Diagnostic Menu sub section in this section Gauge Diagnostic Menu DIGITAL GAUGE The digital gauge has a diagnostic menu that can be used...

Page 130: ...perature Manifold Absolute Pressure TMAP sensor DTC P0112 P0113 P0114 Usage Monitor intake air temperature to verify the fol lowing 1 Intake air temperature sensor signal Air Pressure AIR PRESS MOD57...

Page 131: ...nd EPS Fuel Sensor FUEL MOD238 Display Fuel level signal from the fuel level sensor DTC C1400 Usage Check output of the fuel level sensor 1 Full fuel is indicated by a reading of 0 5 ohms 2 Empty is i...

Page 132: ...rconnect harness is shorted to battery power Correct condition P0068 Throttle Position Sensor MAP Plausibility Check for a vacuum leak or a plugged air filter Correct condition P0107 MAP Sensor Circui...

Page 133: ...ge Control Valve Circuit Open The EVAP system purge control valve is disconnected or its interconnect harness is open Correct condition P0458 EVAP System Purge Control Valve Circuit Low SG The EVAP sy...

Page 134: ...CM detected an internal condition Correct condition P2107 Electronic Throttle Control Driver Over Temperature The ECM detected an internal condition Correct condition P210C Throttle Actuator 2 Control...

Page 135: ...r its interconnect harness is intermittent or has failed Correct condition U0155 LCD Gauge to ECM CAN Communication Lost The LCD gauge CAN circuit or its interconnect harness is intermittent or has fa...

Page 136: ...RG VLT BLK ORG B9 ROTOR WHT YEL ORG BLK D11 B2 BLK BLU D3 YEL BLK BRN RED PLUG A2 RED ORG BLU GRN ORG GRY 10AMP LIGHTS FUSE BLK RED BLK RED BLK RED PLUG 20AMP LIGHTS RELAY ORG BLU GRY D10 YEL GRN 90 R...

Page 137: ...does not engage Condition Remedy 1 Battery charge low 2 Switch contacts defective 3 Start relay defective 4 Starter relay defective 5 Wiring connections loose disconnected 6 Key switch defective 1 Rec...

Page 138: ...de of the front differential input housing With the engine stopped and the ignition switch in the ON position a momentary whirring sound can be heard each time the 2WD 4WD drive select switch is shift...

Page 139: ...all the front differential then connect the electrical plug to the main harness then secure the electrical plug 6 Turn the ignition switch to the ON position and check the operation by shifting the dr...

Page 140: ...rd the inner CV joint housing B to release the plunge coupler then while the axle shaft and the inner CV joint housing are pushed together remove the axle from the differ ential then account for the O...

Page 141: ...MOD363 13 From the passenger side remove the front differential from the vehicle Disassembling Input Shaft 1 Remove the front differential then remove the actua tor on the front differential then usin...

Page 142: ...uring the input shaft bear ing then place the pinion housing in a press and remove the bearing GC011 XR350 XR351 Assembling Input Shaft 1 Place the pinion housing in a press and install the input shaf...

Page 143: ...housing XR352A XR354 5 Place the dowel pin into the differential housing then install a new gasket Place the coupler onto the shift fork then simultaneously engage the shift fork to the shuttle shaft...

Page 144: ...3 Using a plastic mallet tap lightly to remove the dif ferential cover Account for an O ring A and note the location of any shims MOD360 NOTE If the cover is difficult to remove pry on the cover in m...

Page 145: ...a propane torch heat the gear case housing to approximately 200 F then install the pinion assem bly 4 Install the internal snap ring with the sharp side directed away from the bearing WC429 Shimming...

Page 146: ...into the splines of the ring gear and install a dial indicator making sure it con tacts the gauge at a 90 angle and on the index mark GC040 GC039A 5 Zero the dial indicator then while holding the pini...

Page 147: ...red side toward the gear onto the cover side of the ring gear GC036B NOTE The spider and ring gear assembly must be replaced as a complete unit 3 Apply a liberal coat of grease to the O ring then inst...

Page 148: ...seal apply High Per formance 2 Molybdenum Disulfide grease to the seal outside diameter 2 Using Gear Case Seal Installer Tool evenly press the seal into the cover bore until properly seated GC060 3 Re...

Page 149: ...en the lower differential mounting cap screws to 16 ft lb 21 8 N m MOD345 MOD347 5 Remove the fill plug and pour the recommended amount of lubricant into the differential then install the fill plug Ti...

Page 150: ...ort stand Drive Axles REMOVING REAR DRIVE AXLE 1 Remove the hubs see Hub Brake Disc in this sec tion 2 Remove the cap screw and lock nut securing the knuckle to the upper A arm Discard lock nut Inspec...

Page 151: ...e axles if any other component is worn or damaged the axle must be replaced 1 Using CV Boot Clamp Tool remove and retain both clamps for assembly purposes MOD514 2 Use a suitable form of protection on...

Page 152: ...of grease from the pack in the bear ing housing INSTALLING REAR DRIVE AXLE NOTE It is recommended to apply grease on the splines for the rear drive axles going into the tran saxle Prior to installing...

Page 153: ...d a new lock nut Tighten to 45 ft lb 61 2 N m 3 Install the hubs see Hub Brake Disc in this section 4 Install the wheels and using a crisscross pattern tighten the wheel nuts in 20 ft lb 27 2 N m incr...

Page 154: ...then remove a rear wheel and axle 2 Using an awl and a mallet pry the seal from the case taking care not to damage the seal bore TA118 3 Wipe any oil or dirt from the seal area of the tran saxle 4 Usi...

Page 155: ...TA129 TA130 Pinion Plug NOTE The transaxle does not need to be removed for this procedure 1 Support the vehicle on an appropriate stand then remove the left rear wheel and axle 2 Using an awl and a m...

Page 156: ...al mount then remove the upper differential mount Discard lock nut Inspect cap screws and replace if damaged MOD345 MOD346 3 Remove the drive belt drive and driven clutches then remove the clutch cove...

Page 157: ...er then remove the two cap screws securing the engine backplate to the front engine mount then remove the four cap screws securing the engine backplate then remove the engine backplate MOD563A MOD544...

Page 158: ...t any remaining fluid NOTE Install the drain plug and tighten to 18 ft lb 2 Lay the transaxle flat on the bench then remove the 19 mm detent gold plug near the gear position switch Account for the spr...

Page 159: ...4 Lift on the shift rail assembly to disengage the rail assembly from the case and rotate the rail away from the shift drum then remove the shift drum assembly NOTE Spread the shift forks while remov...

Page 160: ...outer snap ring and shim securing the ball bearing then using an appropriate tool remove the bearing TA013 TA127 SERVICING COMPONENTS NOTE If any bearing is removed install a new bearing using a suita...

Page 161: ...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 162: ...nt star A and shift drum gear B for nicks cracks chips or signs of wear If any are pres ent the detent star must be replaced TA057A 5 Install the spring into the shift drum TA121 6 Rotate the cam cloc...

Page 163: ...55 2 Inspect the gear teeth for nicks cracks chips or signs of wear If any are present the gear must be replaced TA049 TA050 TA051 3 Inspect the shaft gear teeth for nicks cracks chips or signs of wea...

Page 164: ...If any are present the shaft must be replaced TA045 I Pinion Assembly Inspect the teeth of the pinion gear and front output shaft If any chipping nicks wear or damage are observed the pinion assembly...

Page 165: ...ring installer install a new bearing into the housing TA132 7 Install the large outer snap ring with the shim TA086 8 Install the gear into the housing TA077 9 Install the small inner snap ring with s...

Page 166: ...7 2 N m TA025A NOTE To determine the appropriate shim proceed to step 3 3 Using an appropriate tool lock the pinion gear in place TA124A 4 Mount a dial indicator so the tip is contacting a tooth on th...

Page 167: ...afts completely into the case at this time TA056 2 With the aid of an assistant and with the gear forks in position install the input shaft and reverse shaft with chain as an assembly TA058 TA059 NOTE...

Page 168: ...he appropriate splines of the drum with the gear 8 Install the shift shaft gear onto the shift shaft with the timing marks facing up then install into the case with the gear aligning with the shift dr...

Page 169: ...the cap screws and tighten to 20 ft lb 27 2 N m 13 Install the detent gold plug with spring and O ring Tighten to 20 ft lb 27 2 N m MOD385 14 Align the shaft and the alignment pin on the gear positio...

Page 170: ...screws with new lock nuts B then tighten to 45 ft lb 61 2 N m then gently slide the transaxle toward the rear of the vehicle then install the rear transaxle mount to frame cap screws with new lock nut...

Page 171: ...nd install the two cap screws securing the starter to engine backplate then tighten to 14 8 ft lb 20 N m MOD544 MOD563A 6 Install the spacers for the transaxle to engine mount then install the two cap...

Page 172: ...lock nut for the front differential Tighten to 45 ft lb 61 2 N m MOD346 MOD345 11 Install the two cap screws underneath the front dif ferential then tighten to 16 ft lb 21 8 N m then install the carg...

Page 173: ...ing fixture 2 Drive the damaged stud out of the hub then place the new stud into the hub and thread on an appropriate nut MOD343 3 Using a socket and ratchet handle tighten the nut until the stud is f...

Page 174: ...er Brake fluid readily absorbs moisture from the air significantly lowering the boiling point This increases the chance of vapor lock reducing braking power and increasing stopping distance 3 Remove t...

Page 175: ...pads see Periodic Maintenance Tune Up Hydraulic Brake System 3 Inspect the brake caliper housings for signs of corro sion or discoloration 4 Inspect the piston surface for scoring discoloration or ev...

Page 176: ...g 1 Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the other end into a con tainer Remove the reservoir cover then open the bleeder valve Allow the brake fluid to dra...

Page 177: ...fittings Installing 1 Secure the master cylinder assembly to the frame with two cap screws and two flange nuts Tighten to 16 ft lb 21 8 N m 2 Using new crush washers secure the banjo fittings to the m...

Page 178: ...ars noisy Noise seems to come from transaxle Condition Remedy 1 Gears worn chipped 2 Splines worn 3 Primary gears worn chipped 4 Bearings worn 5 Bushing worn 1 Replace gears 2 Replace shaft s 3 Replac...

Page 179: ...cate the shock is in need of replacement cracks or breaks in the lower case or a bent shock rod If any one of these conditions is detected replacement is necessary NOTE When the vehicle is operated in...

Page 180: ...pressor tool CLEANING AND INSPECTING 1 Clean all shock absorber components in parts cleaning solvent 2 Inspect each shock rod for nicks pits rust bends and oily residue 3 Inspect all springs spring re...

Page 181: ...od end to the knuckle then remove the tie rod end from the knuckle MOD129 4 Remove the cap screws securing the ball joints to the knuckle MOD130 5 Tap the ball joints out of the knuckle then remove th...

Page 182: ...to the entire outside diame ter of the ball joint Install the ball joint into the A arm and secure with the snap ring MOD337 2 Install the A arm assemblies into the frame mounts and secure with the ca...

Page 183: ...lock cap screws Tighten to 45 ft lb 61 2 N m MOD130A 10 Install the wheels and using a crisscross pattern tighten the wheel nuts in 20 ft lb 27 2 N m incre ments to a final torque of 100 ft lb 136 N...

Page 184: ...reads exposed on the upper sway bar link and 5 6 threads exposed on the lower sway bar link Repeat for other side MOD504 MOD503 3 Remove the vehicle from the secure support stand Rear A Arms REMOVING...

Page 185: ...AND INSPECTING 1 Clean all A arm components in parts cleaning sol vent 2 Inspect the A arm for bends cracks and worn bush ings 3 Inspect the frame mounts for signs of damage wear or weldment damage I...

Page 186: ...out of the knuckle Discard bearing 5 If bushings E need to be replaced Remove dust seals F then push collar G out of upper knuckle bushings Press the upper and lower bushings out of knuckle Discard b...

Page 187: ...hten the wheel nuts in 20 ft lb 27 2 N m increments to a final torque of 100 ft lb 136 N m CHECKING INFLATING 1 Using an air pressure gauge measure the air pressure in each tire Adjust the air pressur...

Page 188: ...1 Tighten cap screws 2 Replace sway bar bushings Problem Vehicle pulling or steering erratic Condition Remedy 1 Vehicle steering is erratic on dry level surface 2 Vehicle pulls left or right on dry l...

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Summary of Contents for 800SX

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Tracker Off-Road 800SX, Service Manual

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Summary of Contents for 800SX

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