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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.

699322

Parts Replacement vs. Repair

Some maintenance or repair tasks can take considerable

labor to do correctly. Assessment of the condition of worn

components is critical to the operation of the brake sys-

tem. In some cases, component replacement may be

more cost effective than the removal, cleaning, inspection

and reassembly of the component(s).

Adjusting Brake Pedal Free Travel

Brake pedal free travel MUST be

checked and adjusted any time that

the brake system is serviced or

when parts are replaced.

Brake pedal free travel is the distance the pedal travels

from rest to the point at which the brake cables start to

move the brake levers. This should not be confused with

the light resistance that is felt as the brake pedal is

pressed enough to remove slack from the compensator

and cables. Correct adjustment of free travel is essential

to proper brake function. Too much pedal free travel will

limit braking capability. Too little pedal free travel may

cause the brakes to drag (not fully released). Either con-

dition can prevent the brakes from adjusting properly.

This procedure is intended to adjust

the brakes and seat brake system

components. The brake system may

not be effective for the first few applications of the

brake pedal.

Pre-adjust service 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

The brake pedal free travel should be set to 7/8" - 1

1/8" (2.2 - 2.9 cm).

Press the brake pedal aggressively 4 - 6 times to

establish known free travel.

All brake tests must be done in a

safe location with regard for the

safety of all personnel.

In a safe location free from people and vehicles,

drive the vehicle at reduced speed and apply the

brakes aggressively. As the brakes adjust and stop

the vehicle, start driving at maximum speed and

brake aggressively 10 times.

At the spherical nut, adjust the free travel as noted

above.

Drive again and brake aggressively 10 times.

Repeat the previous step(s) until the pedal free travel

does not change during the aggressive braking.

Check to see that the clevis pins attaching the brake

cables to the brake levers are loose (Figure 18). If

they are not loose, inspect system again and correct

as required.

If the clevis pins are loose, tighten jam nut to 10 - 11

ft. lbs. (14 - 15 Nm) at the spherical nut.

Figure 18 Check Clevis Pins

10. The parking brake latching force can be checked as

verification after setting brake pedal free travel. To

check parking brake latching force, place a ‘bath-

room’ scale on the service and parking brake pedals.

Using both feet press the scale down against the

parking brake pedal until it latches. The parking

brake should latch between 65 and 75 lbs. (29 - 34

kg) indicated on the scale (Figure 19).

Spherical Nut

Jam Nut

7/8" - 1 1/8" (2.2 - 2.9 cm)

Check for loose
clevis pin

Содержание LS2 2020

Страница 1: ...REPAIR AND SERVICE MANUAL 699322 A Issued May 2019 653635 B...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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