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Related Manuals for Tracker Off-Road XTR1000
Summary of Contents for Tracker Off-Road XTR1000
- Page 1 O P E R A T O R ’ S MA N U A L A c t u a l v e h i c l e a p p e a r a n c e m a y v a r y p / n : 2 2 6 2 - 7 7 7 X T R 1 0 0 0...
- Page 2 This vehicle can be hazardous to operate. A collision or rollover can occur quickly, even during what you think are routine maneuvers such as driving or turning on flat terrain, driving on hills, or crossing obstacles, if you fail to take proper precautions. For your safety, understand and fol- low all the warnings contained in this Operator’s Manual and on the labels on this vehicle.
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Page 3: Foreword
Foreword Congratulations and thank you for pur- Division II of this manual covers opera- chasing a Tracker Off Road vehicle. tor-related maintenance, operating Built with American engineering and instructions, and storage instructions. If manufacturing know-how, it is designed major repair or service is ever required, to provide superior ride, comfort, utility, contact an authorized dealer for profes- and dependable service. -
Page 4: Table Of Contents
Table of Contents Foreword ..........1 Checking/Adjusting Ride Height..40 Compression Damping Adjustment...41 Parts and Accessories ......1 General Lubrication ......43 Division I — Safety Hydraulic Brake .........46 Safety Alert..........4 Fuel Hoses ........46 Hangtags ..........5-6 Protective Rubber Boots ....46 Important Safety Information....7 Battery ..........47 Warning Labels ........8-9 Spark Plugs ........50... -
Page 5: Division I - Safety
Division I — Safety This vehicle is not a toy and can be hazardous to operate. • Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating this vehicle. •... -
Page 6: Safety Alert
Safety Alert You should be aware that THIS VEHI- * Never consume alcohol or drugs CLE IS NOT A TOY AND CAN BE before or while operating this vehi- cle. HAZARDOUS TO OPERATE. This vehicle handles differently from other * Never operate this vehicle at exces- vehicles, including motorcycles and cars. -
Page 7: Hangtags
Hangtags This vehicle comes with hangtags containing important safety information. Anyone who operates the ROV should read and understand this information before riding. Indicates a hazardous situation which, if not ! WARNING avoided, could result in death or serious injury. - Page 8 Hangtags Indicates a hazardous situation which, if not ! WARNING avoided, could result in death or serious injury.
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Page 9: Important Safety Information
Important Safety Information Anyone who operates the ROV should read and understand this information before operating this vehicle. Indicates a hazardous situation which, if not ! WARNING avoided, could result in death or serious injury. -
Page 10: Warning Labels
Warning Labels NOTES: SAMPLE DECAL APPROVED ARCTIC CA T RELEASE 78511 02-18-11 ENGINEERING GRAPHIC STYLIST PRIOR ST ART PRODUCTION RUN. COLORS MA TERIALS MUST U.V . ST ABLE. DECAL SUPPLIED WITH KISSCUT "T AB" WITH P ART NUMBER REVISION LEVEL PRINTED "T AB"... - Page 11 Warning Labels XX138D 6411-481 6411-482 Indicates a hazardous situation which, if not ! WARNING avoided, could result in death or serious injury.
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Page 12: Location Of Parts And Controls
Location of Parts and Controls 1. Battery 2. Headlights 3. Passenger Grab Handle 4. Seat Lock Lever 5. Glove Box 6. Brake Pedal XX463D 7. Fuses 8. Ignition/Start Switch 9. Shift Lever 10. DC Power Outlet 11. Accelerator Pedal 12. Taillight/Brake Light 13. -
Page 13: Warnings
Warnings ! WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate this vehicle properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD All operators of this vehicle must read and understand this Operator’s Manual and all warning and instruction labels prior to operating this vehicle. - Page 14 ! WARNING POTENTIAL HAZARD Operating or riding this vehicle without wearing an approved helmet, goggles, and protective clothing. WHAT CAN HAPPEN Operating or riding without an approved helmet increases your chances of a serious head injury or death in the event of an accident. Operating or riding without goggles can result in an accident and increases your chances of a serious injury in the event of an accident.
- Page 15 ! WARNING POTENTIAL HAZARD Operating or riding in the vehicle without doors properly latched. WHAT CAN HAPPEN Serious injury or death. Occupants or their body parts can strike objects outside the vehicle, be crushed by the vehicle, or fall out of the vehicle during maneuvers or in the event of an accident.
- Page 16 ! WARNING POTENTIAL HAZARD Attempting abrupt maneuvers, sideways sliding, skidding, fishtailing, or donuts. WHAT CAN HAPPEN Increases the chance of an accident including a rollover. HOW TO AVOID THE HAZARD Never attempt abrupt maneuvers, sideways sliding, skidding, fishtailing, or donuts. Don’t try to show off.
- Page 17 ! WARNING POTENTIAL HAZARD Failing to use care in turns; turning too sharply or aggressively. WHAT CAN HAPPEN The vehicle could go out of control causing a collision, tip over, or rollover. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Operator’s Man- ual.
- Page 18 ! WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Operator’s Manual. Always check the terrain carefully before you start up any hill. Never climb hills with slippery or loose surfaces.
- Page 19 ! WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the vehicle to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in this Operator’s Manual.
- Page 20 ! WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this vehicle in fast-flowing water or in water deeper than the floorboard. Remember that wet brakes may have reduced stopping capability.
- Page 21 ! WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces. WHAT CAN HAPPEN The vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control.
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Page 22: Division Ii - Operation/Maintenance
Division II — Operation/Maintenance Specifications ENGINE Type 4-cycle, 3-cylinder, liquid cooled, DOHC Bore x Stroke 80 mm x 66.2 mm (3.14 x 2.60 in.) Displacement 998 cc (60.9 cu. in.) Spark Plug Type NGK CR9EB Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.) Alternator 65 Amps Stator... -
Page 23: Vehicle Operation
Vehicle Operation Pre-Start/Pre-Operation Checklist Item Remarks Brake System Pedal firm — near top of travel. Fluid at proper level. Check for fluid leaks. Controls Steering free — no binding — no excessive free-play. Shift lever in park. Accelerator free — no binding — returns to idle position. Fluids Check coolant level. - Page 24 3. To select reverse gear from park, CAUTION move the shift lever rearward one position until the letter “R” is dis- Do not run the starter motor for more played on the digital gauge. than eight seconds per starting attempt. The starter motor may over- 4.
- Page 25 Situation Operator Guideline Engine/belt insufficiently warmed up Before operating, place the transmission in Neutral (including low temperatures) (keep brake applied) and vary engine RPM several times. Allow the engine to warm up for a minimum of two minutes. Operate under 30 mph (48 km/h) for the first two miles or the first five miles when temperature is below freezing.
- Page 26 Driving Uphill ! WARNING Always drive straight up the hill and Use only approved brake fluid. Never always avoid hills that are very steep. substitute or mix different types or 1. Keep both hands on the wheel. grades of brake fluid. Brake loss can result.
- Page 27 Crossing Obstacles 1. Turn the steering wheel into the direc- tion of the slide. Crossing obstacles can be hazardous. There is always the possibility of the vehicle tip- 2. Keep your foot off the brake until ping. If you cannot go around an obstacle, you’re out of the skid.
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Page 28: General Information
General Information Control Locations and Functions Ignition Switch Key Two keys come with this vehicle. Keep the spare key in a safe place. An identifying number is stamped on each key. Use this number when ordering a replacement key. Ignition Switch The ignition switch has three positions. - Page 29 Headlight Switch CAUTION Do not attempt to either engage or disengage the front differential lock while the vehicle is moving. NOTE: When the differential lock is engaged, the LOCK icon will be illuminated on the digital gauge. NOTE: The differential lock is intended for use where minimum traction is available.
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Page 30: Doors
2. To lock the seat into position, place 2. Push the latch-plate into the buckle the front of the seat into the seat slot until it “clicks” and latches retainers and push down firmly on the securely. The belt will retract when rear of seat. -
Page 31: Power Steering
Code Fault Description Power Steering C1320 Incorrect Vehicle Speed-to-RPM This vehicle was produced with an Elec- Ratio tronic Power Steering (EPS) system to C1321 Vehicle Speed Erratic reduce steering effort and driver fatigue C1322 Engine RPM Lost over a broad range of operating conditions. C1323 "EPS OFF"... -
Page 32: Digital Gauge
Digital Gauge CAUTION If the indicator is illuminated, stop the engine immediately and allow it to cool down. If unable to either determine or remedy the problem, take the vehicle to an authorized dealer for service. If not under warranty, this service is at the dis- cretion and expense of the vehicle owner. - Page 33 Press and hold the Upper Button on the NOTE: The clock can only be dis- side of the digital gauge displaying RPM played in this position if it is not to view the maximum RPM achieved. already being displayed in the main This value is reset each time the ignition right screen.
- Page 34 Diagnostic Trouble Display Fault Description Codes (DTC) P0219 Engine Over-Speed Condition P0222 Throttle Position Sensor #2 Circuit Diagnostic trouble codes are activated by Low/SG/Open the ECM and may be displayed on the P0223 Throttle Position Sensor #2 Circuit digital gauge for a number of reasons. High If a code is displayed while the engine is P0261 Cylinder #1 Fuel Injector Circuit Low/...
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Page 35: Oil Level Stick
Display Fault Description Display Fault Description P0630 VIN Not Programmed or Incompatible P2127 Pedal Position Sensor #2 Circuit Low/Open/SG P0641 Sensor Reference Voltage #1 Circuit Low/Open P2128 Pedal Position Sensor #2 Circuit High/SP P0643 Sensor Reference Voltage #1 Circuit High P2135 Throttle Position Sensor Plausibility Error P0651 Sensor Reference Voltage #2 Circuit... -
Page 36: Load Capacity Ratings Chart
Load Capacity Ratings 4. Unscrew the oil tank stick and remove. Wipe off and reinsert into the oil tank Chart (DO NOT screw the dipstick back into This vehicle must always be loaded in the oil tank). accordance with the Load Capacity Ratings chart. -
Page 37: Gasoline-Oil-Lubricant
Recommended Gasoline NOTE: Suitable hold-down straps are available from your authorized dealer. The recommended gasoline to use in this Ordinary rope is not recommended vehicle is regular unleaded gasoline with because it can stretch under load. a pump octane number (PON) of 86 or higher, or research octane number (RON) CAUTION of 91 or higher. -
Page 38: Engine Break-In
Recommended Front During the first 10 hours of operation, Differential and Transaxle always use less than 1/2 throttle. Varying Lubricants the engine RPM during the break-in period allows the components to “load” NOTE: The manufacturer recom- (aiding the engine/transmission compo- mends the use of genuine lubri- nent mating process) and then “unload”... -
Page 39: General Maintenance
General Maintenance NOTE: Proper maintenance of the vehicle is important for optimum per- formance. Follow the Maintenance Schedule and all ensuing maintenance and care instructions/information. NOTE: Proper maintenance procedures for each item can be found on the corresponding page indicated. If, at any time, abnormal noises, vibrations, or improper functioning of any compo- nent of this vehicle is detected, DO NOT OPERATE THE VEHICLE. -
Page 40: Maintenance Schedule
Maintenance Schedule Item Interval Maintenance Schedule Remarks Page Engine oil/filter Initial Replace oil and filter between the first 12 and 25 43/20 hours or 250 miles Front differential Initial Replace oil between the first 12 and 25 hours or 44/20 250 miles Transaxle Initial... -
Page 41: Rear Cargo Tray Removal/Install
Rear Cargo Tray Removal/Install NOTE: Removal of the rear cargo tray is required for some mainte- nance procedures. 1. Remove fasteners from cargo tray by turning counter clockwise. XX127 Liquid Cooling System NOTE: Debris in the engine com- partment or packed between the cool- ing fins of the radiator can reduce cooling capability. -
Page 42: Shock Absorbers
When filling the cooling system, use a mixture of 60% antifreeze/40% water. The coolant system pressure cap is located under the front hood, behind the radiator. Fill the cooling system to the FULL COLD line. XX129 NOTE: When the vehicle is oper- ated in extremely cold weather (-23°... -
Page 43: Compression Damping Adjustment
1. Measure from the ground to the bot- 3. On the rear, measure from the ground tom of the frame tube in the location to the bottom of the skid plate. Mea- shown behind the front lower A-arms. surement should be 14 inches. Measurement should be 14 inches. - Page 44 Maintenance frequency vary depending on the number of hours the vehicle is driven and the conditions under which it is ridden. Heat, violent impacts, dust, mud and adjustment settings are all factors that need to be taken into consid- eration in determining the frequency of basic maintenance and oil changes.
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Page 45: General Lubrication
Task After each use End of each season Annually Clean under the bottom-out bumper Clean shock absorber exterior Check the assembly for Inspect Inspect Inspect leaks or loose components Check the shaft for Inspect Inspect Inspect damage or rust Check the seal head for Inspect Inspect/Replace* Inspect/Replace*... - Page 46 10. Start the engine (while the vehicle is outside on level ground) and allow it to idle until at least one of the radiator fans cycles on and off. Check for any leaking oil. If oil is leaking, immedi- ately stop the engine and correct the cause of the leak before proceeding.
- Page 47 XX116 XX113 2. Drain the oil into a drain pan by 2. Drain the oil into a drain pan by removing the drain plug. Clean away removing the drain plug. Clean away any debris that may have accumu- any debris that may have accumu- lated onto the magnetic end of the lated onto the magnetic end of the plug.
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Page 48: Hydraulic Brake
Hydraulic Brake Brake Hoses Carefully inspect the hydraulic brake hoses ! WARNING for cracks or other damage. If found, take the vehicle to an authorized dealer to have Be sure to inspect the brakes before the brake hoses replaced. each use. Always maintain brakes according to the Maintenance Schedule. -
Page 49: Battery
Spherical Ball Joints 2. Remove both front wheels. (Upper and Lower/Right 3. Inspect the four tie rod boots for and Left) cracks, tears, or perforations. 4. Check the free-play of the four tie rod ends by grasping the tie rod near the end and attempting to move it up and down, back and forth. - Page 50 XX124 800A NOTE: When charging a battery in the vehicle, be sure the ignition switch is in the OFF position. 1. Clean the battery terminals with a solution of baking soda and water. NOTE: The sealing strip should NOT be removed and NO fluid should be added.
- Page 51 Jump-Starting NOTE: Jump-starting a vehicle with a dead battery is not recom- mended. Instead, remove the battery, service it, and correctly charge it ; however, in an emergency, it may be necessary to jump-start a vehicle. If so, use the following procedure to carefully and safely complete this procedure.
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Page 52: Spark Plugs
3. Inspect the vehicle to be used for 7. Attach one clamp of the negative jump-starting to determine if voltage (black) jumper cable to the negative (-) and ground polarity are compatible. terminal (3) of the good battery (B); The vehicle must have a 12-volt DC, then attach the other clamp of the nega- negative ground electrical system. -
Page 53: Air Filter/Housing Drain
NOTE: The air filter is located above the engine and can be accessed by removing the rear cargo tray. 1. Remove dirt and debris from around the filter housing. 2. Pull the release tab out away from the filter housing. ATV-0051 Before removing the spark plug, be sure to clean the area around the spark plug. -
Page 54: Draining V-Belt Cover
NOTE: Once the filter has been removed, lightly tap the filter to remove any dust particles or con- taminants from the filter. If the filter is excessively covered in dust parti- cles and contaminants, it must be replaced. XX055B 7. -
Page 55: Tires
Tires Wheels 1. Park the vehicle on level ground, shift ! WARNING into park, and engage the differential lock. Always use the size and type of tires as specified. Refer to the specifica- 2. Loosen the lug nuts on the wheel to tions chart for proper tire inflation be removed. -
Page 56: Headlight Bulb Replacement
Headlight Assembly Replacement NOTE: The LED strips in the headlight assembly are not individ- ually replaceable. The entire assem- must replaced component. To replace the headlight assembly, use the following procedure: WC929 1. Remove hood. NOTE: If the screen is damaged in 2. - Page 57 5. Remove headlight from rear housing of headlight assembly by turning counterclockwise. XX071 8. Install the wiring harness connectors XX072A 6. Install headlight bulb from rear of headlight assembly by turning clock- wise. XX070B 9. Install the headlight retaining knob. XX072 7.
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Page 58: Checking/Adjusting Headlight Aim
5. Observe each headlight beam aim. Proper aim is when the most intense beam is 5 cm (2 in.) below the hori- zontal mark on the aiming surface. 6. Adjust each headlight until correct aim is obtained by loosening (counterclock- wise) the retaining knob located under- neath the hood in front of the radiator, then pivoting the assembly up or down. -
Page 59: Electrical Output Terminals
Glove Box/Tools This vehicle has a glove box in the dashboard. A basic tool kit (located under the hood) is provided with this vehicle. Maintain the tool kit with the vehicle at all times. Seat Belts 6411-051 CAUTION Inspect the seat belts for frayed or torn edges. Check that the belts extend and retract Always replace a blown fuse with a fuse of smoothly and fully without binding or catch-... -
Page 60: Preparation For Storage
Preparation for Storage The manufacturer recommends the follow- 7. Tighten all nuts, bolts, cap screws, and ing procedure to prepare the vehicle for screws. Make sure rivets holding com- ponents together are tight. Replace all storage: loose rivets. Care must be taken that all CAUTION calibrated nuts, cap screws, and bolts are tightened to specifications. -
Page 61: Preparation After Storage
Preparation after Storage Taking this vehicle out of storage and cor- 8. Check the entire brake systems (fluid rectly preparing it will ensure many miles and level, pads, hoses, etc.), all controls, hours of trouble-free riding. The manufacturer headlights, taillight, brake light, and recommends the following procedure: headlight aim;... -
Page 62: Warranty Procedure/Owner Responsibility
Warranty Procedure/Owner Responsibility At the time of sale, an ROV Rider Training Certificate and Owner Registration form is to be completed by the selling dealer and consumer. The receipt of the form by Tracker Off Road is a condition precedent to warranty coverage. It is the selling dealer’s responsibility to retain and/or submit appropriate copies of the form to the appropriate place(s) to initiate warranty coverage. -
Page 63: U.s. Epa Emission Control Statement
U.S. EPA Emission Control Statement/ Warranty Coverage (U.S. Only) STATEMENT/WARRANTY Tracker Off Road warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA-certified Tracker Off Road vehicles are designed, built, and equipped to conform to all U.S. EPA Emission Control Regulations. -
Page 64: Maintenance Record
Maintenance Record DATE MILEAGE SERVICE PERFORMED/NOTES... -
Page 65: Change Of Address, Ownership, Or Warranty Transfer
Change of Address, Ownership, or Warranty Transfer Tracker Off Road keeps on file the current name and address of the owner of this vehicle. This allows us to reach the current owner with any important safety information which may be necessary to protect customers from personal injury or property damage. - Page 66 Fold Back Place Stamp CHANGE OF ADDRESS/OWNERSHIP Here TRACKER OFF ROAD 1451 MARVIN GRIFFIN RD AUGUSTA GA 30906-3852...
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Page 67: Identification Numbers Record
Identification Numbers Record This vehicle has two identification numbers: Vehicle Identification Number (VIN) and Engine Serial Number (ESN). These numbers are required by the dealer to com- plete warranty claims properly. No warranty will be allowed if the VIN or ESN is removed or mutilated in any way. - Page 68 NOTES...
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