Tracker LS2 2020 Repair And Service Manual
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Tracker LS2 2020 Repair And Service Manual

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653635-B
REPAIR AND SERVICE MANUAL
699322- A
Issued May 2019

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  • Page 1 653635-B REPAIR AND SERVICE MANUAL 699322- A Issued May 2019...
  • Page 2 SA FETY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. The following symbols appear throughout this manual and on your vehicle. Your safety is involved when these symbols are used.
  • Page 3 SERVICE AND REPAIR MANUAL GASOLINE POWERED GOLF CAR TRACKER LS2 Starting Model Year 2020 Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specifications. Such modifications can cause serious personal injury or death. The manufacturer prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
  • Page 4 This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.

  • Page 5: Safety Information

    SAFETY INFORMATION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY INFORMATION This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer.
  • Page 6 SAFETY INFORMATION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment.
  • Page 7 SAFETY INFORMATION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring.
  • Page 8 SAFETY INFORMATION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...

  • Page 9: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION GENERAL INFORMATION AND ROUTINE MAINTENANCE SERIAL NUMBER PLATE ....................1 STARTING THE VEHICLE WITH A DISCHARGED BATTERY ....................... 1 SERVICING THE VEHICLE....................1 FUEL ..........................2 FUEL TANK ........................2 TOWING ........................... 2 ROUTINE MAINTENANCE....................3 POWERTRAIN MAINTENANCE..................
  • Page 10 TABLE OF CONTENTS Rocker Panel Replacement ................16 Body Replacement ....................16 Rear Bumper Replacement ................17 PAINTING ........................17 Minor Scratches ....................17 Larger Scratches ....................17 Complete Panel Repair ..................18 WHEELS AND TIRES TIRE REPAIR ........................21 Tire Replacement ....................21 WHEEL ..........................21 Wheel Removal ....................22 Wheel Installation ....................22 BRAKE SYSTEM...
  • Page 11 TABLE OF CONTENTS Brake Shoe Removal ..................41 Brake Shoe Installation ..................42 Brake Cable and Equalizer Assembly Removal and Installation ......43 Compensator Assembly, Removal and Installation ..........44 Brake Pedal Removal and Installation ............... 44 Parking Brake Catch Bracket Removal and Installation ........44 Parking Brake Pedal Removal and Installation ..........
  • Page 12 TABLE OF CONTENTS REAR AXLE NEUTRAL LOCK ......................69 Checking the Lubricant Level ................69 REAR AXLE DISASSEMBLY ..................70 Axle Shaft Removal and Disassembly ..............70 Axle Shaft Seal Removal and Replacement ............71 ENGINE POWERTRAIN MAINTENANCE ..................73 Checking the Oil Level ..................73 Changing the Oil ....................73 AIR FILTER INSPECTION/REPLACEMENT..............
  • Page 13 TABLE OF CONTENTS Accelerator Cable Removal at Governor ............84 Accelerator Cable Removal at Pedal Box ............84 Accelerator Cable Installation ................85 Accelerator Cable Adjustment (Ref. Fig. 2) ............85 Throttle Rod Removal ..................85 Throttle Rod Adjustment ..................85 PEDAL BOX ADJUSTMENTS ..................
  • Page 14 TABLE OF CONTENTS Other ........................99 DIRECTION SELECTOR Direction Selector Removal ................104 Replacing a Micro Switch ..................104 Shift Cable Adjustment ..................104 Neutral Lock Operation ..................104 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) GENERAL........................107 CLUTCHES........................107 Primary Clutch ....................107 Secondary Clutch ....................107 Increased Load ....................108 Equilibrium ......................108 Removing the Transmission Belt ..............108 Transmission Belt Service ................108...
  • Page 15 TABLE OF CONTENTS BATTERY VOLTAGE TEST ..................118 STORAGE OF BATTERY ..................... 118 DVOM (DIGITAL VOLT OHM METER)................. 118 TROUBLESHOOTING ....................119 POWER SUPPLY ......................119 ACCESSORY WIRING ....................120 WEATHER PROTECTION SUN TOP AND WINDSHIELD ..................123 Transporting Vehicle ..................123 SUN TOP ........................
  • Page 16 TABLE OF CONTENTS Repair and Service Manual 655827...
  • Page 17 TABLE OF CONTENTS 655827 Repair and Service Manual...
  • Page 18 TABLE OF CONTENTS Repair and Service Manual 655827...

  • Page 19: 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. GENERAL INFORMATION AND ROUTINE MAINTENANCE SERIAL NUMBER PLATE SERVICING THE VEHICLE To prevent severe injury or death, Two serial number and manufacture date code labels are resulting from improper servicing on the vehicle.

  • Page 20: Fuel

    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. FUEL TANK injury should an unforeseen dangerous situation occur. Always use the appropriate tools listed in the tool list and The fuel tank is located under the seat, on the passenger wear approved safety equipment.

  • Page 21: Routine Maintenance

    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. To operate neutral lock: NOTICE: Some maintenance items must be serviced more frequently on vehicles used under severe driv- Turn the key switch to the OFF position.

  • Page 22: Brakes

    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. BRAKES and gum in the fuel system and corrosion in the engine. Place the direction selector in the neutral position and After the vehicle has been put into service, it is recom- engage the neutral lock (Ref.

  • Page 23: Vehicle Care Products

    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. NOTICE: If the engine does not start or runs • Multi-purpose Hand Cleaner is an industrial strength improperly after washing, remove the spark plug cleaner containing no harsh solvents, yet gently lifts wire (by pulling the spark plug boots, never the...

  • Page 24: Recommended Fault Tests

    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. RECOMMENDED FAULT TESTS Fuel Pump Turn the key to the ON position. Ignition System Within 10 seconds, measure the voltage between terminal #1 at the fuel pump connection and the bat- Disconnect the two pin connection from the ignition tery ground.
  • Page 25 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. Notes: 699322 Repair and Service Manual...
  • Page 26 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. Notes: Repair and Service Manual 699322...

  • Page 27: Safety

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY NOTICE, CAUTIONS AND WARNINGS GENERAL MAINTENANCE Throughout this manual, the following NOTICE, When any maintenance procedure or inspection is per- CAUTIONS, WARNINGS and DANGERS are used.

  • Page 28: Battery Removal And Installation

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Removal and Installation the hot exhaust system. Never work on an engine that is hot. Tool List Qty. Never test the ignition system without Insulated Wrench, 1/2"..........1 either connecting the spark plug lead to a...

  • Page 29: Lifting The Vehicle

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LIFTING THE VEHICLE Lower the jack and test the stability of the vehicle on the two jack stands. Tool List Qty.
  • Page 30 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...

  • Page 31: Body

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY Figure 1 Body Components (Front) 699322 Repair and Service Manual...
  • Page 32 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 2 Body Components (Rear) Repair and Service Manual 699322...

  • Page 33: Body Component Replacement

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY COMPONENT REPLACEMENT NOTICE: In the following text, there are references to removing/installing bolts, etc. Additional hard- ware (nuts, washers, etc.) that are removed must The body components can be replaced by removing the always be installed in their original positions unless securing hardware, replacing the component and secur-...

  • Page 34: Cowl Replacement

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cowl Replacement Rocker Panel Replacement Tool List Qty. Tool List Qty. Electric/air drill ............1 Phillips screwdriver ............1 Drill bit, 7/32" ............... 1 Wrench, 7/16"...

  • Page 35: Rear Bumper Replacement

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PAINTING ing a battery. As extra protection, it is recommended that a protective piece of sheet metal be placed between the battery and the rivet.

  • Page 36: Complete Panel Repair

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. automotive grade) to renew gloss and to further blend and transition newly painted surface. Clean with alcohol and dry. (Optional but recommended) Follow this process with clear coat to renew and protect depth of finish.
  • Page 37 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699322 Repair and Service Manual...
  • Page 38 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...

  • Page 39: Wheels And Tires

    WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHEELS AND TIRES Follow the tire maintenance procedures as instructed in the small tires, over inflation can occur in seconds. Never exceed the tire inflation pressure rating on this manual and on the labels on the vehicle.

  • Page 40: Wheel Removal

    WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Installation To decrease the risk of component damage, do not tighten the lug nuts NOTICE: To decrease the to more than the torque specified Lug Nut Tightening Pattern risk of component dam-...
  • Page 41 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 Repair and Service Manual...
  • Page 42 WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...

  • Page 43: Brake System

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKE SYSTEM Torsion Springs Park Brake Pedal Push Nut Identification Hinge Pin Hole* Service Brake Pedal Pedal Latch Arm Spacer Catch Bracket Cap Screw Kick Off Cam...

  • Page 44: Equalizer Link

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. shoe contacts the brake drum, it can no longer move rear- ward. Additional pedal (and cable) travel causes the actu- ator bracket (moving anchor) to move and applies force to the front shoe, pushing it against the brake drum.

  • Page 45: Compensator Assembly

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Compensator Assembly The compensator assembly contains a spring, which is compressed until the stop tube within the spring is engaged and the linkage becomes solid (Figure 3).

  • Page 46: Fault Test Flowchart

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FAULT TEST FLOWCHART Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Condition of: Replace Includes...
  • Page 47 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjuster Tries Disassemble Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure. Replace Free Movement of Torque Lug Nuts.

  • Page 48: Fault Test Table

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FAULT TEST TABLE (PBPT), and Aggressive Stop Test is performed (Figure Refer to the following fault test table only after the thor- ough visual inspection, Periodic Brake Performance Test Figure 6 Fault Test Table Condition...
  • Page 49 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 6 Fault Test Table Condition Possible Cause Correction Neither wheel locks when park brake is Incorrect compensator spring adjust- Return to factory specification latched.

  • Page 50: Fault Testing And Inspection

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FAULT TESTING AND INSPECTION New Vehicles A new vehicle will undergo an initial break-in of compo- nents including brake cables and brake shoes. In this break-in period, it is not uncommon for the brake pedal free travel (and the effort required to latch the parking brake) to change.
  • Page 51 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Not enough pedal free travel may indicate improper 6. Inspect the brake cable equalizer linkage. adjustment of the wheel brake or the brake linkage. Inspect for signs of corrosion, damage, wear or exces- Either condition can prevent the brakes from adjusting sive misalignment (Figure 10).

  • Page 52: Periodic Brake Performance Test (Pbpt)

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pedal Latch Arm Hinge Torsion Springs Cam Must Be Against Latch Arm At This Point 0.0" Gap Push (0.0 mm) Catch Screw Bracket...

  • Page 53: Aggressive Stop Test

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. vehicle stopping distance from the point at which the brakes were latched. The vehicle should stop within the “normal” range of stopping distances. If the vehicle stops more than 4 ft.

  • Page 54: Wheel Brake Inspection

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Brake Inspection Observe the brake adjuster arm and note if the arm engages the star wheel and attempts to rotate it (Fig- Wear a dust mask and eye protec- ure 14).

  • Page 55: Maintenance And Repairs

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. springs and brake adjusters be replaced when install- ing new brake shoes. 10. Inspect the brake shoe springs. Be sure that they are not broken or damaged and are correctly installed.

  • Page 56: Parts Replacement Vs. Repair

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parts Replacement vs. Repair All brake tests must be done in a safe location with regard for the Some maintenance or repair tasks can take considerable safety of all personnel.

  • Page 57: Brake Drum Removal And Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use care when raising the adjuster arm. Too much force will damage the adjuster and require that both Use a 'bathroom' scale wheel brake assemblies be replaced.

  • Page 58: Backing Plate/Entire Wheel Brake Assembly Removal And Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wear eye protection and a mask sand the friction surfaces lightly with emery cloth to when cleaning brake components. remove any foreign material.

  • Page 59: Brake Shoe Removal

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Shoe Removal NOTICE: It is recommended that when brake shoes are replaced, the adjusters and springs also be replaced.

  • Page 60: Brake Shoe Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Shoe Installation The brake shoe end is pointed and engages the backside of the adjuster.There is a 17L stamped into brake shoe (Figure 23).

  • Page 61: Brake Cable And Equalizer Assembly Removal And Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TOP PULL ADJUSTER ASSEMBLY Figure 25 Brake Shoes and Springs Brake Cable and Equalizer Assembly Removal and Installation Cotter Clevis Compensator Spherical...

  • Page 62: Compensator Assembly, Removal And Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. cables to the brake levers using new clevis pins and new cotter pins. Adjust the brake pedal free travel. See the Adjusting Brake Pedal Free Travel.

  • Page 63: Parking Brake Pedal Removal And Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parking Brake Release Linkage Removal and Replacement Pedal Latch Arm Remove the cotter pin (2), washers (3) and bushings (4) .03"...
  • Page 64 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...

  • Page 65: Front Suspension And Steering

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT SUSPENSION AND STEERING Part of Frame Wave Washer Bearing Intermediate Outer Snap Ring Rack & Pinion Shaft with Inner Snap Ring Unit U-Joints Rack Extension...

  • Page 66: Maintenance

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE Wheel Bearing and King Pin Bushing Inspection NOTICE: In the following text, there are references to removing/installing bolts etc.

  • Page 67: Wheel Bearing Adjustment

    SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. of the rollers until the entire bearing is saturated in grease. Assemble the hub and install on the spindle. See the Hub Replacement on page 53 NOTICE: Once hub is placed onto spindle and before outer wheel bearing is installed, fill the area...
  • Page 68 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. alignment is achieved. Tighten jam nuts to 36 - 40 ft. lbs. (49 - 54 Nm) torque. Test drive the vehicle and confirm the steering wheel Rear is correctly centered.

  • Page 69: Front Shock Absorber Replacement

    SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Part of Frame Part of Frame *NOTE: Tie Rod Not Shown for Clarity Fig. 6 Front Suspension Components Front Shock Absorber Replacement Remove the shock absorber.

  • Page 70: Front Axle Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front Axle Replacement the springs with the hardware (20 - 23) installed in its original location (Ref. Fig. 6). Tool List Qty.

  • Page 71: Hub Replacement

    SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the two 1 3/4" long bolts (18) and lock nuts (19) securing driver side spring to axle and discard lock nuts (19).

  • Page 72: Wheel Bearing And Race Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Bearing and Race Replacement Tool List Qty. Non-ferrous Punch............1 Ball Peen Hammer............1 Front of Vehicle Bearing Driver ..............1 Remove hub (1) from spindle (Ref.
  • Page 73 SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Flat Section Fig. 11 Steering Components Rack Ball Joint Replacement Remove the cotter pin (2) and loosen the castellated nut (3) until rack ball joint (1) threads are protected.

  • Page 74: Tie Rod Inspection/Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Grasp the tie rod (8) at ball joints (6) and check for any vertical motion which would indicate a worn con- dition and require replacement (Ref.

  • Page 75: Bellows Replacement

    SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. tightening as required in order to insert a new cotter Install jam nut (3) and rack ball joint (2) on rack pin.

  • Page 76: Spindle Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. apply pressure to ball joint and tap nut with plastic faced hammer to release tie rod from spindle arm (4).

  • Page 77: Rack And Pinion Unit Disassembly And Inspection

    SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rack and Pinion Unit Disassembly and Inspection Tool List Qty. Vice ................1 Socket, 3/8" ..............1 Ratchet ................

  • Page 78: Rack And Pinion Unit Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rack and Pinion Unit Replacement 11. Check front wheel alignment and adjust if necessary. See the Wheel Alignment on page 49. Tool List Qty.

  • Page 79: Steering Wheel Replacement

    SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Approximately 1/8" Thick Washer Step 1 Step 2 Figure 20 Clipboard Removal Figure 19 Checking Gap Adjust, using a 1/8"...

  • Page 80: Steering Shaft And Column Replacement

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. shaft. Tighten the steering wheel nut (6) to 15 - 20 ft. lbs. (20 - 27 Nm) torque. Inspect the four retaining tabs on the clipboard (5) for white stress lines (Ref.
  • Page 81 SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 14. Press the steering shaft and bearing assembly into the column base. Secure with the large retaining ring making sure it is fully seated in the groove of the col- umn.
  • Page 82 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: Repair and Service Manual 699322...

  • Page 83: Rear Suspension

    REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR SUSPENSION Rear Spring Removal NOTICE: In the following text, there are references to removing/installing bolts etc. Additional hard- To reduce the possibility of per- ware (nuts, washers etc.) that are removed must sonal injury, follow the lifting proce-...
  • Page 84 REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Vinyl Cap Front of the Vehicle Fig. 1 Rear Suspension Repair and Service Manual 699322...

  • Page 85: Rear Axle Removal

    REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE REMOVAL 12. Remove the clevis pin from both brake cables where they attach to the wheel brake levers. Tool List Qty.
  • Page 86 REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...

  • Page 87: Rear Axle

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE Checking the Lubricant Level The rear axle is provided with a lubricant level check plug located on the driver side at the rear of the housing (Ref. Tool List Qty.

  • Page 88: Rear Axle Disassembly

    REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE DISASSEMBLY The rear axle is a precision assem- bly, and therefore any repair or replacement of parts must be done with extreme care in a clean environment.

  • Page 89: Axle Shaft Seal Removal And Replacement

    REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Axle Shaft Seal Removal and Replacement Tools List Qty. Internal Snap Ring Pliers ..........1 Seal Puller ..............1 Plastic Faced Hammer ..........1 Ratchet ................1 Torque Wrench, ft.
  • Page 90 REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...

  • Page 91: Engine

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ENGINE For further engine information, see Engine Shop Rebuild The engine can be operated safely as long as oil is within and Service Parts Manual.
  • Page 92 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: If vehicle is to be stored over winter At the first oil change, small metal chips and lint may be months, it can be stored with old oil left in engine.

  • Page 93: Air Filter Inspection/Replacement

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do NOT overfill engine. Too much If the element is in acceptable condition, loose dirt may oil may cause smoking or allow oil be removed by tapping the filter lightly.

  • Page 94: Adjusting The Belt

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 3/8" (1 cm) Maximum Deflection (New Belt) 1/2" (1.3 cm) Maximum Deflection (Existing Belt) Fig. 10 Checking Belt Tension with Finger Re-tighten an existing belt to 17 - 18 lbs.

  • Page 95: Cooling System Cleaning

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. can be removed from the drive clutch. Remove the Operation in wet or damp weather or overly fresh cut starter/generator pivot bolts (13) and lift starter/generator grass may result in a variety of debris accumulating and from the vehicle.

  • Page 96: Four Cycle Engine

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FOUR CYCLE ENGINE Engine Specifications Engine Model ..........FJ400-D Type........Four Cycle, Overhead Valve Number Of Cylinders ........... 1 Displacement............

  • Page 97: Rocker Cover Removal

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 2. Condition of the valve seating. 3. Valve clearance. 4. Piston/cylinder wear, piston seizure. 5. Piston ring, piston ring groove. Rocker Cover Removal Tool List Qty.

  • Page 98: Engine Removal

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ENGINE REMOVAL 7. Disconnect the F2 power cable from the top of the starter. Tool List Qty. 8. Starter/Generator (See Starter/Generator Replace- Socket, 10 mm.............

  • Page 99: Engine Installation

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. DRIVE CLUTCH REMOVAL Engine Installation It is important to follow the assem- To prevent the possibility of per- bly sequence recommended for sonal injury, use only impact sock- mounting hardware.
  • Page 100 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...

  • Page 101: Speed Control

    SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPEED CONTROL Accelerator Cable Governor Lever - Upper Governor Lever - Lower Governor Spring Accelerator Compression Spring Fig. 1 Accelerator and Speed Control System released, the micro switch closes and activates the NOTICE: The linkages that control the accelerator starter-generator.

  • Page 102: Troubleshooting

    SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Driving above governed speed could cause a loss of vehicle con- trol and possible injury or death. Tampering with or adjusting the governor or other speed control components will void the warranty.

  • Page 103: Accelerator Cable Installation

    SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Accelerator Cable Installation To install the accelerator cable, proceed in reverse order. (Ref. Fig. 2)(Ref. Fig. 3)(Ref. Fig. 4) Accelerator Cable Adjustment (Ref.

  • Page 104: Micro Switch Adjustment

    SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: Note that the factory applies a thread seal- switch (11) clicks. Measure the distance at the top of the ant to the accelerator rod threads before threading pedal with the pedal arm contacting the pedal bracket.
  • Page 105 SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699322 Repair and Service Manual...
  • Page 106 SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...
  • Page 107 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FUEL SYSTEM Carbon Vent Line Canister Front of Vehicle Fuel Pump Fuel Injector Terminal Fuel Line Fuel Pump Fuel Cap Fuel Tank Fig.

  • Page 108: Fuel System

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL the fuel/vapor. Never permit smoking or an open flame in an area that contains fuel/vapor. Clean up NOTICE: Hardware that is removed must always be all fuel spills immediately.

  • Page 109: Fuel Pump Assembly

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pull the fuel pump assembly up and out of the fuel tank. Fuel Line Fuel Pump With the fuel pump assembly removed, inspect the Connector Wire hold-down ring seal (4) for damage.

  • Page 110: Malfunction Indicator Light (Mil)

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CARBON CANISTER front seat. A series of flashes indicates each fault code. A description of how to read codes from the MIL is detailed Tool List Qty.

  • Page 111: Walbro Iris Tsv Service Tool Efi Diagnostics

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MIL Flash Fault Recovery Steps Code 1. Verify that the air filter is not clogged. Engine Running Rich / Lean 2.

  • Page 112: Connect To Vehicle

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Connect to Vehicle Plug the USB cable into your computer’s USB port. Click the “Connect” button at the top left of the IRIS Prepare the vehicle: tool.

  • Page 113: Update Ecm

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. sometimes stops moving at certain points. This is Update ECM normal. Before starting the update proce- An empty plot will appear. To show data traces, right- dure: click in the tan plot area and select a channel from the “Available Data”...

  • Page 114: Troubleshooting

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Click “OK” to load the map. Communication module will pulse during pro- gramming. Fig. 14 Completion of ECM Map Loading Stop streaming (Data Stream tab).

  • Page 115: Fault Check

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fault Check The Walbro EFI system uses Diagnostic Trouble Codes to report issues. Both active and stored faults are reported by the ECM.

  • Page 116: Pedal Kill Check

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. time. However, if the throttle-body/ECM assembly is With the pedal in the resting (“up”) position, the kill replaced, the hour count will be restarted from zero. indicator should display “Active”.

  • Page 117: Fuel Pump

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Verify that there is sufficient fuel in the fuel tank. Verify that the fuel filter is not contaminated with debris.
  • Page 118 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 699322...
  • Page 119 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699322 Repair and Service Manual...
  • Page 120 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...
  • Page 121 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 1 Direction Selector 699322 Repair and Service Manual...

  • Page 122: Direction Selector Removal

    DIRECTION SELECTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. DIRECTION SELECTOR Before removing a suspected faulty micro switch, ensure the ‘FORWARD’ stop. If further adjustment is necessary, the electrical wires are firmly attached and the wire is in adjust the threaded fitting (10) at the rear axle cable good condition.
  • Page 123 DIRECTION SELECTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699322 Repair and Service Manual...
  • Page 124 DIRECTION SELECTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...

  • Page 125: Continuously Variable Transmission (Cvt)

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Secondary Clutch Transmission Belt Primary Clutch Fig. 1 Continuously Variable Transmission System (CVT) GENERAL transmission belt to the outer diameter of the primary clutch sheaves, which increases the speed of the belt.

  • Page 126: Increased Load

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. increases and the belt starts to climb the sheaves, the secondary clutch responds by being forced open in order to permit the belt to ride lower in the secondary clutch sheaves.
  • Page 127 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the CVT belt (1) (Ref. Fig. 3). Remove the clutch puller bolt. Remove the Starter/Generator belt (Refer to Starter/ NOTICE: In some case the clutch can not separate Generator Removal in ENGINE section).

  • Page 128: Primary Clutch Installation

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Primary Clutch Installation Remove the clutch, then remove the clutch puller bolt and slide the clutch from the rear axle input To decrease the risk of damage to shaft.
  • Page 129 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: 699322 Repair and Service Manual...
  • Page 130 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: Repair and Service Manual 699322...

  • Page 131: Electrical System

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRICAL SYSTEM WIRING The electrical system is a 12 volt negative ground system (Ref. Fig. 1) consisting of a: Before performing any test of wir- •...
  • Page 132 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 1 Electrical System Wiring Diagram Repair and Service Manual 699322...

  • Page 133: Testing Starting Circuit

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do not arc spark plug wire to A normal reading with the negative lead on C and the ground. Connect to a known good positive lead on B would be: 10 - 30 K...

  • Page 134: Testing Charging Circuit

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. probe on the other terminal. The reading on the meter 2) With the engine off, measure the voltage at the should be “0”...

  • Page 135: Starter/Generator

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 6 Starter/Generator STARTER/GENERATOR NOTICE: In general, starter/generator service is best performed by trained motor technicians who have the knowledge and equipment to overhaul the unit. Starter/Generator Removal Some checks and repairs however, can be accom- See ENGINE section.

  • Page 136: Repair And Replacement

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • 14 mm - torque to 33 - 40 ft. lbs. (45 - 55 Nm) Brush Tighten terminal nuts to the following torques: Spring •...

  • Page 137: Troubleshooting

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. negative battery terminal. Move the positive (+) probe to COVER each wire termination starting at the battery and working out to the device that is not working.

  • Page 138: Accessory Wiring

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. battery voltage indicates that the power wire is in good condition. NOTICE: The power wire supplies power to the entire fuse block.
  • Page 139 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 699322 Repair and Service Manual...
  • Page 140 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...

  • Page 141: Weather Protection

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WEATHER PROTECTION SUN TOP AND WINDSHIELD Place washer (7) onto bolt (6) and insert bolt through the top hole in the seat back support (3 - 4 The top does not provide protec- threads).
  • Page 142 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Rear of Vehicle DETAIL C (FRONT) Driver Side DETAIL D (REAR) DETAIL A DETAIL B Fig.

  • Page 143: Spilt Windshield

    WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPILT WINDSHIELD Insert bolt (4) through washer (5), rubber grommet (6) and existing hole in front strut. Secure with Tool List Qty.
  • Page 144 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 655827...
  • Page 145 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FAULT TESTING Condition Possible Cause Correction STARTER DOES NOT TURN Weak or bad battery Recharge or replace as necessary Terminals are loose or corroded Clean and tighten Poor wiring connections Repair or replace wire and/or connections...

  • Page 146: Fault Testing

    FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction Fuel pump faulty Repair or replace Fuel line clogged or clamp loose Clean or replace if required Cracked or broken fuel line Replace with new hose Throttle lever motion restricted...
  • Page 147 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction POOR LOW SPEED Plugged gas tank vent Clean or repair PERFORMANCE Clutches not shifting out Replace clutch/clutches Fuel pump faulty Repair or replace...
  • Page 148 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction REPEATED SPARK PLUG Wrong spark plug type Replace with correct spark plug FOULING Wrong spark plug gap Check and adjust if required Excessive ring blow by Check/replace rings...
  • Page 149 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction ERRATIC, SURGING, OR SUDDEN Damaged governor spring Replace CHANGE IN GOVERNED SPEED Problem with adjustment of accelerator, Adjust governor and linkage Bent governor arm...

  • Page 150: Starter / Generator

    FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction POOR HIGH SPEED OPERATION Fuel pump faulty Replace fuel pump Dirt in fuel tank or hoses Clean Clogged fuel filter Clean fuel filter...

  • Page 151: Suspension And Steering

    FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction RECTIFICATION IS IMPERFECT Load exceeds specification Adjust load to specification Armature bent Repair or replace if necessary Brushes are worn beyond limits Replace Commutator is excessively rough...

  • Page 152: Brake System

    FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction STEERING PULLS TO ONE SIDE Incorrect tire pressure Inflate to recommended pressure Dragging wheel brakes Service brake system Suspension component failure Repair...
  • Page 153 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction NEITHER WHEEL LOCKS WHEN Incorrect cable adjustment Return to factory specification PARK BRAKE IS LATCHED. (NOTE: Excessive brake pedal free travel Adjust per manual AT FULL SPEED THE WHEELS MAY...
  • Page 154 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...

  • Page 155: General Specifications

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL SPECIFICATIONS Item Specification Overall Length 91in (231cm) Overall Width 47 in (119 cm) Overall Height (No Canopy) 46.5 in (118 cm) Overall Height (With Canopy) 68 in (173 cm)
  • Page 156 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front and Rear Tires K500 20 x 10 - 10 (6 ply rated) Frame Welded steel with DuraShield powder coat Body and Finish Injection Molded TPO...
  • Page 157 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699322 Repair and Service Manual...
  • Page 158 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...

  • Page 159: Scheduled Maintenance Chart

    SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SCHEDULED MAINTENANCE CHART Perform all services at the maintenance interval reached E –Indicates emission-related services (Failure to do this first.
  • Page 160 SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Interval (perform at interval Item Remarks Page that comes first) Hours Calendar Engine Monthly Check for unusual noise, vibration, acceleration, oil leaks. Rear axle Monthly Check for leakage;...

  • Page 161: Recommended Lubricants And Fluids

    SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Interval (perform at interval Item Remarks Page that comes first) Hours Calendar Cylinder head and 5 years Check valve seats for carbon buildup; clean if necessary. piston Rear axle 5 years...
  • Page 162 SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699322...
  • Page 163 NOTICE:Notice: Read the following warnings before attempting to operate the vehicle: To prevent personal injury or death, observe the following: When vehicle is to be left unattended, engage parking brake, move direction selector to ‘F’ (forward) position, turn key to ‘OFF’ position and remove key. Drive vehicle only as fast as terrain and safety considerations allow.
  • Page 164 MANUFACTURER INFORMATION Textron Specialized Vehicles Inc. 1451 Marvin Griffin Road Augusta, 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 be reproduced in whole or in part without the express permission of the manufacturer.

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