Tracker 90 Operator's Manual
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Tracker 90 Operator's Manual

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Summary of Contents for Tracker 90

  • Page 2 Your ATV can be hazardous to operate. The Safety Alert Symbol means A collision or rollover can occur quickly, even during routine maneu- ATTENTION! BE ALERT! YOUR vers such as turning and driving on hills or over obstacles, if you fail to SAFETY IS INVOLVED.

  • Page 3: Foreword

    Manual is available through your authorized dealer. • Respect your ATV, • Respect the environment, and Tracker Off Road and the ATV Safety Institute (U.S.) recommend that • You will gain the respect of others. We also advise you to strictly follow the recommended maintenance pro- all ATV operators ride the appropriate-sized ATV according to age.

  • Page 4: Table Of Contents

    Table of Contents General Information ................33-38 Control Locations and Functions............33 Foreword ......................1 Shift Lever ....................35 Parts and Accessories ...................1 Carburetor Float Bowl Drain..............35 Division I — Rider Awareness/Responsibility Oil Level Stick..................35 Seat Lock .....................36 ATV Safety Alert....................5 Safety Flag/Bracket ................36 Rider Training Course ..................6 Transporting ATV .................36 Hangtags ......................7...

  • Page 5: Division I - Rider Awareness/Responsibility

    Division I — Rider Awareness/ • Never operate an ATV without wearing an approved helmet that fits prop- erly. You should also wear eye protection (goggles or face shield), gloves, Responsibility boots, long-sleeved shirt or jacket, and long pants. • Never consume alcohol or drugs before or while operating this ATV. AN ATV IS NOT A TOY AND CAN BE •...
  • Page 6 AN ATV IS NOT A TOY AND CAN BE • Always use the size and type tires specified in this manual. Always main- HAZARDOUS TO OPERATE. tain proper tire pressure as described in this manual. • Never improperly install or improperly use accessories on your ATV. •...

  • Page 7: Atv Safety Alert

    ATV Safety Alert * EVERY TRACKER OFF ROAD BRAND ATV IS DESIGNED FOR A CERTAIN AGE GROUP. NEVER RIDE AN ATV THAT IS The U.S. Consumer Product Safety Commission has concluded that NOT DESIGNED FOR YOUR AGE GROUP. THE OPERATOR’S...

  • Page 8: Rider Training Course

    Rider Training Course T he manufacturer sponsors a free Rider Training Course to teach ATV riding skills or to reinforce current riding skills. First-time purchasers without any previous ATV riding experience will receive a $100.00 cou- pon from the manufacturer through the Specialty Vehicle Institute of America/ATV Safety Institute after completing the training course (U.S.

  • Page 9: Hangtags

    Hangtags This vehicle comes with hangtags containing important safety informa- tion. Anyone who rides the vehicle should read and understand this information before riding. ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 10: Warning Labels

    Warning Labels This vehicle comes with several labels containing important safety information. Anyone who rides the vehicle should read and understand this information before riding. The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes KM960A hard to read, contact your autho- rized dealer for a replacement.

  • Page 11: Warnings

    Warnings ! WARNING ! WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating this ATV without proper instruction and supervision. Carrying a passenger on this ATV. WHAT CAN HAPPEN WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not Greatly reduces your ability to balance know how to operate the ATV properly in different situations and on and control this ATV.
  • Page 12 ! WARNING ! WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating this ATV on public streets, Operating this ATV without wearing an roads, or highways. approved motorcycle helmet, eye protec- tion, and protective clothing. WHAT CAN HAPPEN WHAT CAN HAPPEN You can collide with another vehicle. Operating without an approved helmet HOW TO AVOID THE increases your chances of a severe head...
  • Page 13 ! WARNING ! WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating this ATV at excessive speeds or removing the speed limit- Failure to inspect the ATV before operating. ing device from the ATV. Failure to properly maintain the ATV. WHAT CAN HAPPEN WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result Increases the possibility of an accident or equipment damage.
  • Page 14 ! WARNING ! WARNING POTENTIAL HAZARD POTENTIAL HAZARD Turning improperly. Removing hands from handlebar or feet from footrests during opera- WHAT CAN HAPPEN tion. WHAT CAN HAPPEN ATV could go out of control, causing a collision or rollover. HOW TO AVOID THE HAZARD Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV.
  • Page 15 ! WARNING ! WARNING POTENTIAL HAZARD POTENTIAL HAZARD Climbing hills improperly. Going down a hill improperly. WHAT CAN HAPPEN WHAT CAN HAPPEN Could cause loss of control or Could cause loss of control or cause the cause the ATV to overturn. ATV to overturn.
  • Page 16 ! WARNING ! WARNING POTENTIAL HAZARD POTENTIAL HAZARD Stalling, rolling backwards, or improp- Operating the ATV with improper tires or with improper or uneven tire erly dismounting while climbing a hill. pressure. WHAT CAN HAPPEN WHAT CAN HAPPEN Could result in the ATV overturning. Use of improper tires on the ATV, or operation of the ATV with HOW TO AVOID THE improper or uneven tire pressure, may cause loss of control increas-...
  • Page 17 ! WARNING ! WARNING POTENTIAL HAZARD POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. Could cause loss of control or a collision. Could cause the ATV to HOW TO AVOID THE overturn.
  • Page 18 California Proposition 65 ! WARNING The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 19: Prevention

    Prevention Helmet There are several types of helmets on the Overview Helmets should have market, but make sure you wear a helmet When using an ATV, prevention is the name of the game. “Had you only one of these: that complies with the current standards known”...

  • Page 20: Condition Of The Atv

    Gloves While checking the tire pressure, inspect the tread and sidewalls of the tires for cracks, cuts, or other damage that could indicate they need to be Your hands are targets for flying objects and branches. Along with pro- replaced. viding skin protection, gloves will shield your hands from harsh weather.

  • Page 21: First Aid And Survival

    4. Oil and Fuel For rides that are longer in duration and distance, the following addi- Check: Start with a full tank of gas and check engine tional items are recommended: 1. Gas oil before every ride. Don’t forget to check •...
  • Page 22 Emergency Kit with Flashlight and First Aid Kit You’ll need several items in your emergency Carry these items: kit including a flashlight. The matches will come in handy if you need to start a fire to stay 1. Flashlight warm. Flares are appropriate for signaling help. 2.

  • Page 23: Active Riding

    Active Riding Overview “Active Riding” is the second part of “P.A.S.S.” It involves an under- standing of how your body weight, balance, gravity, and physical forces affect the handling of the ATV. Knowing how to shift your weight is necessary to avoid rolling or flipping the ATV. For complete operating instructions, see ATV OPERATION section in this manual.

  • Page 24: Sound Judgment

    Sound Judgment Weather You need to consider the weather. It is dangerous to ride your ATV Those Around You when the weather is bad or potentially bad. Keep abreast with weather forecasts. People do all kinds of things that you can’t predict or control. Terrain Riding Companions Always pay close attention to the terrain you’re on even if it is familiar...

  • Page 25: Equipment

    Load Capacity Ratings Chart It also helps to know which trails you can legally ride and who else might be on those same trails. These are signs currently used in some areas to designate trail types and restrictions. Item Specifications (lb) (kg) Trail Signs...
  • Page 26 Laws and Regulations Group Behavior Any police officer will tell you that ignorance of the law is no defense. When riding in a group, it is human nature to try to keep up with or out- Your best defense is to check out your local, state, or provincial ATV do those around you.

  • Page 27: Supervision

    Supervision Remember that regardless of experience, you should never let anyone under the age of 12 operate your ATV . Overview The manufacturer and the ATV Safety Institute (U.S.) recommend that You’re responsible for supervising those who ride your ATV. Your wis- all ATV operators ride the appropriate-sized ATV according to age.

  • Page 28: Division Ii - Operation/Maintenance

    Reserve Capacity 1.3 L (0.34 U.S. gal.)  The ATV you have NOTE: Transmission Lubricant (Recommended) SAE 80W-90 Hypoid purchased may differ slightly Transmission Lubricant Capacity 250 ml (8.4 fl oz) from those shown in the fig- Engine Oil Capacity (Approx) 0.8 L (0.84 U.S.

  • Page 29: Atv Operation

    ATV Operation CAUTION Basic Operating Maneuvers Do not run the starter motor for more than eight seconds per Active riding and basic maneuvers are the foundation of your ATV ride. starting attempt. The starter motor may overheat causing severe Without basic skills, it’s impossible to execute active riding. These are starter motor damage.

  • Page 30: Handling The Atv (Active Riding Techniques)

    2. Compress the left-hand brake lever; then press on the starter button. 3. Never “ride” the brakes. Even maintaining minimal pressure on a brake lever will cause the brake shoes to drag on the drums and CAUTION overheat the brake system. Parking Do not run the starter motor for more than eight seconds per starting attempt.

  • Page 31: Tips

    K-Turns Tips Use K-turns if you accidentally stall while riding uphill; you need to Safe riding techniques include: take action before the ATV rolls backward down the hill. • Riding • Riding Downhill • Leaning, Weight Shift, and Balance • Wide Turns •...
  • Page 32 Riding Uphill Sidehilling/Traversing Many accidents happen while riding on hills and as a result of the ATV Sidehilling is considered an advanced skill; it’s really tricky and unpre- rolling or flipping. So, obviously, use extreme caution and follow this dictable. So, whether your skills are advanced or not, try to avoid this method for riding uphill.
  • Page 33 1. Shift your body weight as far back on the seat as possible. 2. Use the principles of leaning, weight shifting, and balancing - shift your body weight to the inside of the turn. 2. Lightly apply the brakes and ease up on the throttle. 3.
  • Page 34 Crossing Roads 7. Keep your body loose to absorb any shock. 8. If the ATV starts tipping, shift your weight to keep it in balance. Crossing roads on your ATV is also a bad idea, so avoid it. If you can’t: To clear a single-track (only one tire contacts) obstacle, follow the same 1.

  • Page 35: General Information

    General Information Parking Brake Control Locations and Functions To engage and release the parking brake, use the following procedure: Ignition Switch Key 1. Rotate the parking brake lever Two keys come with the ATV. Keep the spare key in a safe place. to the left to engage the brake.
  • Page 36 Emergency Stop Switch Throttle Limiter Screw This switch will stop the engine. The engine can be started again by Throttle lever travel may be limited by adjusting the throttle limiter screw. pressing the starter button. The throttle limiter should be adjusted according to the operator’s skill and experience.

  • Page 37: Shift Lever

    Shift Lever ! WARNING 1. To shift into forward gear, pull out and upward on the shift Always come to a complete stop with the engine at idle before lever until the transmission moving the shift lever. Changing gears while moving or shift- engages in the forward gear.

  • Page 38: Seat Lock

    Safety Flag/Bracket 2. Install the oil level stick completely into the engine crankcase.  A bracket is provided for mounting a flag at the rear of the ATV. The NOTE: The oil level stick flag should be displayed to make the ATV more visible. should be threaded into the engine crankcase for checking Transporting ATV...

  • Page 39: Gasoline - Oil - Lubricant

    Gasoline — Oil — Lubricant CAUTION Filling Gas Tank Do not use white gas. Only approved gasoline additives should ! WARNING be used. Recommended Engine Oil Always fill the gas tank in a well-ventilated area. Never add gasoline to the ATV gas tank near any open flames or with the CAUTION engine running or hot.

  • Page 40: Engine Break-In

    “unload” (allowing components to cool). Although it is essential to place some stress on the engine components during break-in, care The recommended transmission lubricant to use is SAE 80W-90 hypoid. should be taken not to overload the engine too often.

  • Page 41: General Maintenance

    General Maintenance Maintenance Schedule  Initial NOTE: Proper maintenance of the ATV is important for opti- Service mum performance. Follow the Maintenance Schedule and all Item Page Monthly Quarterly Annually (100 ensuing maintenance and care instructions/information. Miles)  Air filter NOTE: Proper maintenance procedures for each item can be found on the corresponding page indicated.

  • Page 42: Shock Absorbers

    Shock Absorbers Engine Oil Rear Each shock absorber should be visibly Change the engine oil at the scheduled checked weekly for excessive fluid leak- intervals. The engine should always be age (some seal leakage may be observed warm so the oil will drain easily and but it does not indicate the shock is in completely.

  • Page 43: Hand Brake System

    7. Shut the engine off; then allow 5. Remove the level plug and verify oil is at the plug threads. Install oil to drain into the crankcase the level plug and tighten to 16 ft-lb. for approximately three min- 6. Inspect the area around the drain plug for leaks. utes.

  • Page 44: Gas/Vent Hoses

    Checking/Adjusting Rear Wheel Hydraulic Adjusting Parking Brake Brake System  NOTE: The parking brake The rear wheel hydraulic brake system should be checked for proper lever must be in the off position operation before every time the ATV is ridden. when adjusting the parking brake cable.

  • Page 45: Battery

    4. Check the bushing for free-play Loss of battery charge may be caused by ambient temperature, ignition by grasping the steering knuckle OFF current draw, corroded terminals, self discharge, frequent start/ and turning it from side to side stops, and short engine run times. Frequent winch usage, snowplowing, and up and down.
  • Page 46  6. Once the battery has reached full charge, unplug the charger from NOTE: Optional battery charging adapters are available the 110-volt electrical outlet. from your authorized dealer to connect directly to your vehi- cle from the recommended chargers to simplify the mainte- ...
  • Page 47 2. Inspect the battery for any signs of electrolyte leaks, loose termi- 6. Attach one clamp of the positive (red) jumper cable to the positive nals, or bulging sides. Leaking or bulging battery cases may indi- (+) terminal (1) of the dead battery (C) being careful not to touch cate a frozen or shorted battery.

  • Page 48: Spark Plug

    Engine Idle RPM Adjustment 10. Remove the jumper cables in opposite order of hook-up (4, 3, 2, 1). Be careful not to short cables against bare metal. To properly adjust the idle, a tachometer is necessary. If one is not avail- ...

  • Page 49: Throttle Cable Adjustment

    Throttle Cable Adjustment 1. Remove the seat; then remove the five screws securing the air filter The throttle has been adjusted at housing cover. the factory, and no adjustment 2. Remove the air filter housing should be necessary. cover; then pull the filter out. 1.

  • Page 50: Tires

    Tires Tubeless Tire Repair Should a leak or flat tire occur due to a puncture, the tire may be repaired ! WARNING using a plug-type repair. If the damage is from a cut or if the puncture cannot be repaired using a plug, the tire must be replaced. When operating the ATV Always use the size and type of tires as specified.

  • Page 51: Fuse

     Fuse NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, do not touch The main (7 amp) fuse is located in a the glass portion of the bulb. If the glass is touched, it must fuse holder near the battery under the be cleaned with a dry cloth before installing.

  • Page 52: Preparation For Storage

    Preparation for Storage 7. Apply light oil to the upper steering post bushing and plungers of the shock absorbers. CAUTION 8. Tighten all nuts, bolts, cap screws, and screws. Make sure rivets holding components together are tight. Replace all loose rivets. Prior to storing the ATV, it must be properly serviced to prevent Care must be taken that all calibrated nuts, cap screws, and bolts rusting and component deterioration.

  • Page 53: Preparation After Storage

    Preparation after Storage 6. Connect the battery cables making sure to connect the positive cable first. Taking the ATV out of storage and correctly preparing it will ensure many miles and hours of trouble-free riding. Use the following proce- 7. Check the entire brake system (cables, shoes, etc.), all controls, and dure: brake light;...

  • Page 54: Limited Warranty

    Limited Warranty Tracker Off Road (the Company) extends a limited warranty as described below on each The following will VOID the warranty: new vehicle it assembles and on each genuine part and accessory assembled and sold 1. Failure to perform the proper break-in procedure and all related maintenance, by an authorized dealer.

  • Page 55: Warranty Procedure/Owner Responsibility

    Warranty Procedure/Owner Responsibility At the time of sale, an ATV Rider Training Certificate and Owner Registration form is The authorized dealer will examine the vehicle or part to determine if, in his opinion, a to be completed by the selling dealer and consumer. The receipt of the form by the warrantable condition exists.

  • Page 56: Epa Emission Control Statement/Warranty Coverage (U.s. Only)

    Tracker Off Road warrants to the original retail purchaser, and each subsequent I. For exhaust emissions, emission-related components include any engine parts related purchaser, that all U.S. EPA-certified Tracker Off Road vehicles are designed, built, and to the following systems: equipped to conform to all U.S.

  • Page 57: Maintenance Record

    Maintenance Record DATE SERVICE PERFORMED/NOTES...
  • Page 58 Maintenance Record DATE SERVICE PERFORMED/NOTES...

  • Page 61: Identification Numbers Record

    Identification Numbers Record 1. VEHICLE IDENTIFICATION NUMBER: This ATV has two identification numbers: Vehicle Identification Num- ber (VIN) and Engine Serial Number (ESN) These numbers are required by the dealer to complete warranty claims The VIN is located on the horizontal frame bar on the front fender properly.

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