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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.

699322

Front and Rear Tires

K500 20 x 10 - 10 (6 ply rated)

Frame

Welded steel with DuraShield

TM

powder coat

Body and Finish

Injection Molded TPO

Standard Color

Black

Noise

Sound pressure; continued A-weighted equal to or less than 74 db(A)

Vibration, WBV

Highest RMS value of weighted acceleration is less than 2.5 m/s².

Vibration, HAV

Highest RMS value of weighted acceleration is less than 2.5 m/s².
The uncertainty of measurement is 1.07 m/s².
Measurement methods were applied per the ISO 2631 and ISO 5349 standards
under conditions of typical vehicle surfaces.

Some items shown may be optional equipment

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Summary of Contents for LS2 2020

Page 1: ...REPAIR AND SERVICE MANUAL 699322 A Issued May 2019 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: ...es the right to incorporate engineering and design changes to products in this manual without obligation to include these changes on units sold previously The information contained in this manual may...

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 699322...

Page 9: ...ING THE VEHICLE 4 WINTER OR PROLONGED STORAGE 4 CARE AND CLEANING OF THE VEHICLE 4 VEHICLE CARE PRODUCTS 5 HARDWARE 5 TORQUE SPECIFICATIONS 5 RECOMMENDED FAULT TESTS 6 Ignition System 6 Fuel Pump 6 SA...

Page 10: ...Link 26 Automatic Adjuster Mechanism 26 How the Parking Brake Works 26 Compensator Assembly 27 FAULT TEST FLOWCHART 28 FAULT TEST TABLE 30 FAULT TESTING AND INSPECTION 32 New Vehicles 32 Fault Testin...

Page 11: ...brication 48 Wheel Bearing and King Pin Bushing Inspection 48 Wheel Bearing Packing 48 Wheel Bearing Adjustment 49 Wheel Alignment 49 Front Shock Absorber Replacement 51 Front Axle Replacement 52 Fron...

Page 12: ...lement 75 STARTER GENERATOR BELT TENSION 75 Adjusting the Belt 76 STARTER GENERATOR REPLACEMENT REF FIG 12 76 COOLING SYSTEM CLEANING 77 SPARK PLUG 77 FOUR CYCLE ENGINE 78 Engine Specifications 78 Eng...

Page 13: ...t 86 Road Test 86 FUEL SYSTEM GENERAL 90 FUEL 90 FUEL SYSTEM SERVICE 90 Fuel Tank Removal 90 Fuel Pump Assembly 91 FUEL INJECTOR REMOVAL 91 MALFUNCTION INDICATOR LIGHT MIL 92 WALBRO IRIS TSV SERVICE T...

Page 14: ...quilibrium 108 Removing the Transmission Belt 108 Transmission Belt Service 108 Primary Clutch Removal 108 Primary Clutch Installation 110 Secondary Clutch Removal 110 Secondary Clutch Repair 110 Seco...

Page 15: ...WEATHER PROTECTION SUN TOP AND WINDSHIELD 123 Transporting Vehicle 123 SUN TOP 123 Rear Struts Installation 123 Front Strut Installation 123 Sun Top Installation 123 SPILT WINDSHIELD 125 FAULT TESTIN...

Page 16: ...B xiv Repair and Service Manual TABLE OF CONTENTS 655827...

Page 17: ...B TABLE OF CONTENTS xv Repair and Service Manual 655827...

Page 18: ...B xvi Repair and Service Manual TABLE OF CONTENTS 655827...

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: ...8 at the ECM 3 Measure the spark plug gap Make sure the gap is correct 4 Replace the spark plug 5 Replace the spark plug cap 6 Reconnect the high tension lead the ignition coil and the spark plug cap...

Page 25: ...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 INFORMATION AND ROUTINE MAINTENAN...

Page 26: ...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 27: ...t will change 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 dea...

Page 28: ...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 29: ...process 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 jac...

Page 30: ...12 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 699322...

Page 31: ...fore attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 13 Repair and Service Manual 699322 BODY Figure 1 Body Components Front 10 19 18 15 11 55 16 11 20 17 6...

Page 32: ...ce Manual BODY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699322 Figure 2 Body Components Rear 28 33 34 30 31...

Page 33: ...iately behind the rivet The best way to prevent this from occurring is to use a sharp drill bit that requires very little pressure to cut successfully and to place a piece of protective sheet metal be...

Page 34: ...brace 28 is damaged remove bolts 29 26 and nuts 27 securing it to the frame and shield bracket 25 after removing the front Fascia 22 6 Install replacement front Fascia in reverse order of disassembly...

Page 35: ...nd install new rivets PAINTING Follow the paint manufacturer s recommendations for specific painting procedures and information All painting must be done in an area with adequate ventilation to safely...

Page 36: ...not recommended In such cases pro fessional painting or panel replacement is called for The manufacturer suggests body panel replacement be con sidered as a cost effective alternative to painting If t...

Page 37: ...19 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 699322...

Page 38: ...20 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 699322...

Page 39: ...owner s manual Do not over inflate the tires Excess pressure can cause the tire to separate from the wheel or cause a tire explosion Tire Pressure Maintaining correct tire inflation pressure is essen...

Page 40: ...NG THE VEHICLE on page 11 2 Remove the lug nuts 3 Remove the tire from the vehicle Wheel Installation NOTICE To decrease the risk of component dam age do not tighten the lug nuts to more than the spec...

Page 41: ...23 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 699322...

Page 42: ...24 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 699322...

Page 43: ...quate 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 the system so the brakes will...

Page 44: ...e wear and eliminate the need for manual brake shoe adjustment The brake adjuster is activated by movement of the lever attached to the brake cable How the Parking Brake Works The parking brake is ope...

Page 45: ...tube within the spring is engaged and the linkage becomes solid Figure 3 The brake compensator assembly applies a spring load to the parking brake system and insures that the parking brake remains un...

Page 46: ...ding 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 3 Ti...

Page 47: ...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 a...

Page 48: ...worn Replace Brake shoes glazed Sand shoes with emery cloth provided that shoes have 06 1 5 mm min material System not adjusted properly Check and adjust per manual End of brake cable loose from ancho...

Page 49: ...ed Check again when shoes are dry Rusted or sticky brake pivot hardware Replace Neither wheel locks Brake system requires complete adjustment Adjust entire system Brake pedal not returning Check for b...

Page 50: ...ting and inspection as shown in the SCEDULED MAINTENANCE CHART section Continued proper brake operation depends on periodic maintenance Brake Pedal and Linkage Inspection 1 Inspect brake pedal return...

Page 51: ...is applied and released Inspect the brake cable sup ports to be sure the cables are properly secured If any of these conditions are found replace both cables and equalizer as a set 5 Check the clevis...

Page 52: ...event severe injury or death resulting 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 lo...

Page 53: ...s remove from service and refer to Wheel Brake Inspection to evaluate the rea son for failure Aggressive Stop Test To prevent serious injury or death all brake tests must be done in a safe location wi...

Page 54: ...ced 6 Visually check the condition and operation of the adjuster mechanism Inspect the brake lever for damage or wear Test the adjuster function as follows Push the front brake shoe in the direction o...

Page 55: ...eplacement the brake pedal free travel must be checked and adjusted See the Adjusting Brake Pedal Free Travel This includes all linkage and wheel brake components Figure 15 Brake Shoe Wear r Figure 16...

Page 56: ...ice brake pedal free travel to the cor rect setting by loosening the jam nut and adjusting the spherical nut Figure 17 Tighten the jam nut to 10 11 ft lbs 14 15 Nm Figure 17 Free Travel Adjustment 2 T...

Page 57: ...hed to the rear of the drum hub This washer must be rein stalled when the brake is reassembled 7 To install the brake drum clean the axle shaft and the splines on the brake drum to remove dirt grease...

Page 58: ...not to be replaced sand the friction surfaces lightly with emery cloth to remove any foreign material Be sure that the adjusting screw is screwed into the star wheel nut until only 1 2 threads are ex...

Page 59: ...and away from the back mounting plate This will release the tension in the brake springs 4 Remove the brake springs and remove the brake shoes Figure 25 3 Inspect brake shoes If a brake shoe has less...

Page 60: ...brake shoe return springs Figure 24 Brake Shoe 17T 2 Clean the axle shaft to remove grease dirt and all foreign matter 3 Insert a straight blade screwdriver between the adjusting lever and the adjust...

Page 61: ...their brackets at the axle rear of cable and at the frame front of cable Loosen and remove the jam nut and the spherical nut on the equalizer link Figure 26 Inspect the hardware and replace if needed...

Page 62: ...t 5 the shoulder bolt 6 and remove the brake pedal Inspect the shoulder bolt for corrosion that could cause binding This bolt and both bushings 7 must be replaced with new ones if corrosion or wear is...

Page 63: ...Figure 29 Pedal Bumper Adjustment Parking Brake Release Linkage Removal and Replacement Remove the cotter pin 2 washers 3 and bushings 4 from linkage rod 1 Remove the linkage rod Figure 30 Inspect th...

Page 64: ...46 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 699322...

Page 65: ...47 Repair and Service Manual 699322 FRONT SUSPENSION AND STEERING Fig 1 Steering and Front Suspension Part of Frame Part of Frame Wave Washer Bearing Outer Snap Ring Inner Snap Ring Intermediate Shaft...

Page 66: ...cedure Always place chocks in front and behind the wheels not being raised Use extreme care since the vehicle is extremely unstable during the lifting process 1 Lift the front of the vehicle and suppo...

Page 67: ...elt If the cotter pin hole in the spindle 5 aligns with a slot in the castellated nut insert a new cotter pin 2 If the hole does not align the castellated nut must be loosened to align with the closes...

Page 68: ...ional right hand threads 4 To adjust the wheel alignment loosen the tie rod jam nuts 1 and turn the tie rod 2 until the correct alignment is achieved Tighten jam nuts to 36 40 ft lbs 49 54 Nm torque 5...

Page 69: ...front axle 3 Ref Fig 6 2 Compress shock absorber to clear the mounting bracket 3 Loosen the nut securing the top of the shock absorber to the vehicle frame and then rotate the shock absorber while hol...

Page 70: ...of washer 22 and remove it from end of bolt Remove nut 21 3 1 2 long bolt 20 spring plate 24 and spacer 23 and retain them for assembly at their original locations To prevent stress and possible damag...

Page 71: ...t of plastic trim retainer and away from floor Locate and remove hardware 25 27 securing rear of spring 17 to vehicle frame and discard lock nuts 27 12 Using new lock nuts 19 27 install passenger side...

Page 72: ...indle Ref Figure 10 See the Hub Replacement on page 53 2 Remove the grease seal 3 inner wheel bearing 4 and bearing races 5 by tapping through the other side of hub the bearing race using a hammer and...

Page 73: ...heel and lift and support front of vehicle per SAFETY section Ref Fig 11 2 Remove passenger side front wheel and turn steer ing wheel fully to the left 3 Remove the cotter pin 2 and loosen the castell...

Page 74: ...nd check for any vertical motion which would indicate a worn con dition and require replacement Ref Fig 11 2 To remove tie rod loosen wheel s and lift and sup port front of vehicle per SAFETY section...

Page 75: ...ave large end loose until rack extension to rack and pinion unit clearance is checked or adjusted 5 Install jam nut 3 and rack ball joint 2 on rack extension 4 and reattach to spindle arm See the Rack...

Page 76: ...ift and support front of vehicle per the SAFETY section and remove front wheel 2 Remove cotter pin 1 and loosen castellated nut 2 until tie rod ball joint 3 threads are protected Ref Figure 16 Using a...

Page 77: ...and Pinion Unit Disassembly 3 Clean rack pinion and housing Inspect gear teeth bearing surfaces and grease seal surfaces of rack and pinion for excessive wear or damage If any is found the rack and p...

Page 78: ...5 215 in lbs 180 250 kg cm torque After replacing or servicing steering components always verify that an 1 8 gap exists between large hex of rack extension and rack and pinion unit when steer ing is t...

Page 79: ...h from behind the steering wheel with fingertips to first pull down and then push up to release the two top clip board retaining tabs Ref Figure 20 Figure 20 Clipboard Removal Figure 21 Steering Wheel...

Page 80: ...e front wheels 4 Remove the bolt 1 and washer 2 that secures the intermediate shaft 3 to the steering shaft 4 Figure 22 Small Retaining Ring Orientation Figure 23 Steering Shaft and Column 5 Remove th...

Page 81: ...with the large retaining ring making sure it is fully seated in the groove of the col umn 15 Place the steering column on the vehicle and tighten the column mounting bolts 5 to 29 ft lbs 39 Nm torque...

Page 82: ...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 83: ...remove the top shock absorber nut 3 4 Remove the shock absorber 5 Shock absorber installation is in the reverse order of disassembly except that the shock absorber nuts 1 3 must be tightened until th...

Page 84: ...NSION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699322 Fig 1 Rear Suspension Front of the Vehicle Vinyl Cap...

Page 85: ...supporting the differ ential to the engine frame 5 Remove the U bolts holding axle to engine frame 6 Remove the drive belt and driven clutch see CLUTCHES section 7 Remove the F R shifter bracket nut a...

Page 86: ...68 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 699322...

Page 87: ...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 88: ...ew 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 89: ...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 C...

Page 90: ...72 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 699322...

Page 91: ...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 92: ...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 93: ...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 94: ...e upper jam nut 12 against it the lower nut to the specified torque value Ref Fig 11 Fig 11 Adjusting the Belt Tension Using a socket and open end wrench tighten the starter generator pivot bolts 13 a...

Page 95: ...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 96: ...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 97: ...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 98: ...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 way...

Page 99: ...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 100: ...82 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 699322...

Page 101: ...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 102: ...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 injury th...

Page 103: ...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 104: ...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 105: ...87 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 699322...

Page 106: ...88 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 699322...

Page 107: ...attention to Notices Cautions Warnings and Dangers 89 Repair and Service Manual 699322 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 108: ...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 109: ...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 90 2 Remove the pump assembly 3 by removing t...

Page 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...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 117: ...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 118: ...B 100 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 699322...

Page 119: ...101 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 699322...

Page 120: ...102 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 699322...

Page 121: ...SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 103 Repair and Service Manual 699322 Figure 1 Direction Selector 11 10 9 3 2...

Page 122: ...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 123: ...105 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 699322...

Page 124: ...106 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 699322...

Page 125: ...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...

Page 126: ...e 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 127: ...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 128: ...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 129: ...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 130: ...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 131: ...TOR 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 regulato...

Page 132: ...tor 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 133: ...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 134: ...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 135: ...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 136: ...ed 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 du...

Page 137: ...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 138: ...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 139: ...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 140: ...122 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 699322...

Page 141: ...ap end caps 5 into the top of the rear struts 3 4 Ref Fig 1 See Detail B and D 2 Place washer 7 onto bolt 6 and insert bolt through the top hole in the seat back support 3 4 threads Place the teflon w...

Page 142: ...efore attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 699322 Fig 1 Sun Top D B C A DETAIL A DETAIL B DETAIL D REAR Driver Side DETAIL C FRONT Front of Vehicl...

Page 143: ...indshield firmly into lower latches See Detail B 4 Insert bolt 4 through washer 5 rubber grommet 6 and existing hole in front strut Secure with washer 5 5 and lock nut 7 See Detail B Do not over tight...

Page 144: ...126 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 655827...

Page 145: ...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 146: ...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 147: ...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 148: ...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 149: ...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 150: ...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 151: ...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 152: ...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 153: ...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 154: ...136 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 699322...

Page 155: ...Valvetrain Single Cylinder OHV Electrical 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...

Page 156: ...t Body and Finish Injection Molded TPO Standard Color Black Noise Sound pressure continued A weighted equal to or less than 74 db A Vibration WBV Highest RMS value of weighted acceleration is less tha...

Page 157: ...139 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 699322...

Page 158: ...140 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 699322...

Page 159: ...for loose or missing Fuel and engine oil level Pre ride Check for correct level 143 Air filter Pre ride Inspect Clean or replace as needed 75 Headlights and tail lights Pre ride Check operation Repla...

Page 160: ...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 161: ...0 5 years 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...

Page 162: ...144 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 699322...

Page 163: ...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 164: ...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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